Kval Commander III Service Manual Download

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Overview of the Commander III System

KVAL Commander III Service Manual

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Overview of the Commander III System

The Commander III incorporates CNC movements on six axes and a Beckhoff touch screen to
automate setup for up to 12 different door specifications. Custom specifications can also be
entered directly at the touch screen for special doors.

An optional package for architectural door processing is also available including a PC interface
and Kval software that allows unlimited predefined set-ups for doors up to 2-1/4” thick and bar-
code scanner for program selection.

Standard features include:

Hinge Head –

dual spindle routers with counter rotation for clean entry and exit at hinge corners

(eliminates traditional chip-outs), programmable point to point drill for screw pilot holes, and cor-
ner square chisels for door and jamb. Full X, Y and Z axis programming is combined with preci-
sion ball screws and servo motors. Auto tilt between a three degree door edge and jamb clamped
in the square H blocks so both can be processed simultaneously, as well as auto detect for jamb
only and door only processing without wasted motions.

Hinge Centers –

no collar bars - automatic adjustment with precision encoder system combined

with a servo motor drive and position lock. The traditional chain and torque limiter are retained so
an operator can fasten the first hinge after the hinge head shifts to the second hinge location. A
couple of manual adjustments for H blocks and jamb clamps are still necessary, but a pointer and
setup mode reduce this to under two minutes and eliminates errors.

Lock Locations –

fully automatic positioning for lock locations from the door top, and up to three

locks can processed on one door. Program selection for lock hole backsets of 2-3/8” or 2-3/4” and
either 1” or 1-1/8” face plate width at zero or three degrees (two auto selections). Up to 5” backset
and up to 1-1/4” x 12” face plates can be manually adjusted. Option FC adds corner squaring and
full CNC control of face plate routing.

Door Reference Stops –

fully automatic positioning of off-feed door stop to match door length and

hinge off-set with a ball screw and servo motor. The in-feed stop is fixed and is the zero reference
for all other settings.

Additional features include:

• Efficient hinge and lock dust take-off connections
• Auto width adjust to match incoming door
• Door feed system with parallel non-marking belts and heavy duty AC drive for

smooth speed transitions at door reference stops.

• 5HP lock bore, and 3 HP latch bore with precision Accuflex collets and nuts
• Auto door clamp
• Air blow-off to clean the face as the door off-feeds.
• Door hand indicator light to speed processing in a companion 700C door framer.

Operators Interface:

The operator interface for the Commander III is simple and requires very minimal training to cre-
ate door specifications. Dimensions are entered at the amply sized 19” Beckhoff touch screen for
hinge layout from the door top, hinge reveal, hinge size, ¼”radius, 5/8”radis or square corners,