Kval Edge-SS, Operation Manual

Page 1: ...Innovation Quality Honesty Operation Manual Published October 14 2020 Edge SS System Operation Manual Edge SS System ...

Page 2: ...registered trademark of Microsoft Corporation All other products are trademarks or registered trademarks of their respective holders all rights reserved Reference to these products is not intended to imply affiliation with or sponsorship of Incorporated Contacting Customer Service For further information about this manual or other Incorporated products contact the Customer Support Department Maili...

Page 3: ...your user experience with our product that is the manual the machinery the software etc What was easy or difficult to use or to learn If you could change something about the design what would it be Please email your comments and suggestions for improve ment to userexperience inc com NOTE This is not a customer support email link For that please refer to the Customer Service contact information abo...

Page 4: ...KVAL Edge SS System Operation Manual ...

Page 5: ... in the content generated through the KvalCAM Software are also the property of the Licensor and are protected by applicable law 1 Definitions a KvalCAM Software means the KvalCAM computer application installed in the Machinery and written documentation and materials provided to you as well as any revisions or updates of such computer application and documentation b Install means storing of the Kv...

Page 6: ...KVAL Edge SS System Operation Manual ...

Page 7: ...agout Air Supply 1 11 Start Maintenance 1 11 Post Maintenance Steps 1 11 Zero Energy to Start Up 1 12 Getting Help from KVAL 1 14 KVAL Return and Warranty Policy 1 15 Send the Item 1 15 Acceptance of Return 1 15 Refund Turnaround Time 1 15 Kval Errors 1 15 Customer Errors 1 16 Shipper Errors 1 16 Warranty Replacement Parts 1 16 How to Download the Service Application 1 17 On Line Help 1 17 Downloa...

Page 8: ...Job Library 2 14 Revisions at the Door Data Library 2 15 Revisions at the Door Feature Group Library 2 15 About Door Job Creation 2 17 About the Job Name Menu 2 18 About the Door Data Menu 2 18 About the Feature Tree Menu 2 19 Breakdown of a Feature Group and Features 2 19 About the Feature Tree Menu 2 20 About the Selected Feature Details Menu 2 21 About the Selected Feature Details Menu Child Le...

Page 9: ...S Process 3 2 How to Position a Door for Cutting 3 3 Top and Bottom Cuts 3 3 Edge Cuts 3 3 Summary of the Controls on the Machine Line 3 4 Operators Station 3 4 Main Machine Controls 3 4 Foot Pedal Control 3 4 Indicator Light 3 5 Initial Powering Operations for the Edge SS 3 6 How to Power Up the Vision Line 3 6 Home the Machine Line 3 7 How to Power Down the Machine 3 7 The Machine Start Summary ...

Page 10: ...ens 3 27 About the Status Screen 3 27 About the Log Screen 3 28 Description of the Light Tower 3 29 Chapter 4 Calibration of the Edge SS Line About Calibration 4 2 About the Calibration Menus and the Calibration Reference Cut 4 2 Before you Calibrate 4 2 About the Calibration Tabs 4 3 Access to the Calibration Adjustments 4 3 Unlock the Calibration Option 4 4 Enter a Positive or Negative Number 4 ...

Page 11: ... Machine Controls 5 8 Foot Pedal Control 5 8 Indicator Light 5 9 Assemblies on the Main Cutter Head 5 10 Option 3 Routers and 1 Point to Point Drill 5 11 About the Probes 5 12 About Door Length Probe 5 12 About Door Thickness Probe 5 13 About Door Depth Probe 5 13 Laser Safety Scanners 5 14 About Sensors 5 14 Servo Motor and Valve Bank Locations 5 15 Servo Motor Locations 5 15 Valve Bank Locations...

Page 12: ...KVAL Edge SS Manual Table of Contents ...

Page 13: ...First IMPORTANT safety information is described in this section page 1 5 Lockout Tagout Guidelines Procedures describing Lockout Tagout page 1 9 Zero Energy to Start Up Procedure to power up your machine for the first time page 1 12 Getting Help from KVAL This section describes the method to con tact the KVAL Service Center for help The section includes how to get information from the specificatio...

Page 14: ...he Edge SS AC servomotors precision rack and pinion and ball screw drives are used for X Y and Z travel The X axis travel is 130 the Y axis travel is 20 and Z axis travel is 9 1 2 For control our ergo nomically located electrical panel contains an industrial Windows compatible computer con Examples of diverse cuts hinge pockets T strikes concealed closures flush bolts leaf and Euro pean hinges end...

Page 15: ...rs the middle and far end stops are used for rails and stiles This makes it easy to machine top and bottom flush bolts and a T strike without turning the door over In operation the operator can enter the details for the next door while the current door is being processed so no time is lost between jobs The screen and switches are used to select door thick ness position of machining and left or rig...

Page 16: ...bout KvalCAM Descriptions of the KvalCAM user interface 3 Operation Inter face Descriptions of how to power machine line and operator inter face user screens 4 Calibration Descriptions of Calibration Rou tines and how to use the interfaces 5 Tour of the Machine Descriptions the assemblies on the machine Chapter Title Description 1 Introduction Safety Information 2 System IT Admin istration Descrip...

Page 17: ...or illegible There are three types of warning labels or decals DANGER means if the danger is not avoided it will cause death or serious injury WARNING means if the warning is not heeded it can cause death or serious injury CAUTION means if the precaution is not taken it may cause minor or moderate injury Safety Guidelines In addition to the caution and warning labels affixed to this machine follow...

Page 18: ...ever perform any maintenance unless machine is at zero state Never clean the machine while it is running Never walk away from the machine while it is running When the Machine is ON The compressed air system connected to this machine should have a three way air valve for shut off and pressure relief All cylinders on machine are under high pressure and can be very dangerous when activated Before per...

Page 19: ...at different locations Before performing any repairs or mainte nance lockout and tagout must be installed at all locations All maintenance and repairs to electrical circuitry should only be per formed by a qualified electrician Still has power in OFF position Electrical Prior to performing any maintenance repairs cleaning or when clearing jammed debris you must disconnect tag out or lock out the e...

Page 20: ... you believe any part or operation of this machine is in violation of any health or safety regulation STOP pro duction It is your responsibility to immediately protect your employees against any such hazard Additional detailed safety guidelines are included in the operating instructions of this manual KVAL will be pleased to review with you any questions you may have regarding the safe operation o...

Page 21: ...tag on each disconnect Only each operator may remove their own lock and tag Important When many people are all working on the same machine you will need a multiple lockout device such as the one shown here Follow the P R O P E R lockout rule of thumb P Process shutdown R Recognize energy type electrical pneumatic mechanical etc O OFF Shut off all power sources and isolating devices P Place lock an...

Page 22: ...ply and pressure spring tension weight shifts etc 2 Inform all affected personnel of the eminent shutdown and the duration of the shutdown 3 Obtain locks keys and tags from your employer s lockout center 4 Turn off machine See Chapter 2 for power down and power up procedures 5 Turn the disconnect switches on ALL electrical and frequency panels to the OFF position Then push the red tab to pop it ou...

Page 23: ...completely removed and that all guards and safety devices are installed 10 Before removing the locks and tags the person who attached them shall inspect the equipment to ensure that the machine will not be put in an unsafe condition when re energized 11 The lock and tag can now be removed only by the person s who placed them and the machine can be re energized 12 The tags must be destroyed and the...

Page 24: ...en energy is restored Remove Locks Each operator must remove his or her own lock and tag This will ensure that all oper ators are in a safe place when the equipment is started Perform Visual Checks If the equipment is too large to see all around it station personnel around the area and sound the personnel alarm before starting the equipment If your operation is more complex your company s comprehe...

Page 25: ... to your lock Proper lockout tagout can save lives limbs and money Help make your work environment safe for you and your fellow workers Be sure to follow the P R O P E R lockout tagout procedures and that those around you do also Close the Cage Gate Verify all cage gates are securely closed Ensure all safety protocols are in effect ...

Page 26: ...d the serial number 3 phase volts electrical print number and air print number 2 Contact our customer support team In the U S and Canada call 800 553 5825 or fax 707 762 0485 Outside the U S and Canada call 707 762 7367 or fax 707 762 0485 Email address is service KVALinc com Hours 6 00 AM to 4 00 PM Pacific Standard Time Monday through Thursday 6 30 AM to 1 30 PM Pacific Standard Time Friday Air ...

Page 27: ... _______________ Send the Item Return the item to this address Kval Inc RMA ______ Kval Parts 825 Petaluma Blvd South Petaluma CA 94952 USA Acceptance of Return We can only accept items for a return if they are still in their original packaging and in undam aged resalable condition Returns are accepted within 45 days of purchase and with an RMA number issued by Kval Inc Returns after 45 days of pu...

Page 28: ...re than one 1 year after delivery will the product be covered under Warranty The repair replacement or payment in the manner described above shall be the exclusive remedy of Buyer for breach of Kval s warranty or for claims based upon failure of or defect in the products regardless of when the failure or defect arises and whether a claim however described is based upon contract warranty indemnity ...

Page 29: ... Windows 8 1 8 7 Vista XP and an internet connection our service team are able to connect run and troubleshoot your machine by way of the operator station Download Application 1 To download the application go the KVAL website http www KVALinc com 2 At the KVAL website select the Support tab Follow the instruc tions on the Support web page 3 Click the Download button to download the application tha...

Page 30: ...ams Below are samples of i e Explorer and Google web browsers Sample of Google Browser Located at the bot tom left of the screen Sample of i e Explorer Located at the bottom of the screen select the arrow and choose Save and Run 5 A pop up window is displayed Accept the request to run the program Note Security settings may differ from plant to plant If issues occur con tact your IT department ...

Page 31: ...our name The KVAL techni cian will use this field to identify this machine Description Enter machine Serial number and issue Indicator Green indicates there is a good connection to the service center If red there could be an issue with a LAN connection Check the connections in the plant 7 After the KVAL Support App is loaded and completed call the KVAL service center 1 800 553 5825 and have the te...

Page 32: ...How to Download the Service Application KVAL Operation Manual 1 20 Page Intentionally Left Blank ...

Page 33: ...my company s safety procedures I have read and understand these guidelines Machine Safety Concerns I have been given a tour of the machine and understand all the safety labels E Stops and the actions to take in case of an emergency I will make sure all guards are in place before operation I will turn off the compressed air before loading hardware staples screws etc I will turn off the electrical p...

Page 34: ... templates and verifying job creation page 2 2 About the Machine Line Screen Description of the Machine Line Screen Includes Line Control Buttons Queued Jobs and Machine Activity page 2 26 About Backing up Data Instruction to back up data page 2 30 Job Preview Examples Examples of Features in the Job Preview Window page 2 31 About Validation Example of Validation issues page 2 34 About LiteCutout ...

Page 35: ... downloaded remotely and created at the station The KvalCAM interface uses tabbed navigation to jump to desired screens Input Block Diagram KvalCAM has the versatility to connect with many types of inputs A Door Job is built from Door Data and Features The Door Job communicates with the Machine or Machine Line to process the door The figure below illustrates the multiple inputs that can be used by...

Page 36: ...reen is the boot up screen for KvalCAM View the entire process of the machine line queued jobs quantity and remaining doors and status of each machine Some line control is avail able Libraries The Libraries include three tabs the Door Job Library the Feature Group Library and the Door Data Library At each library screen files can be created edited cloned deleted and downloaded Each Library contain...

Page 37: ...ne has a distinct control screen KvalCAM is purpose built to allow all compatible machinery to communicate with one another Select the desired machine button to take control of that machine Note Information about the Machine Controls is located in the Machine Operation Manual ...

Page 38: ...es Lock editing capabilities and refresh tabs are also available Distinguish Between the Library Types The table below shows the details of the KvalCAM Libraries The Library Screens include The Door Job Library The Door Data Library The Feature Group Library Detail Door Job Door Data Feature Group Saves Cut Information Yes No Yes Saves Door Parameters Yes Yes No Number of Feature Groups Allowed Ma...

Page 39: ...se The Door Job files contains all the information to create a door Files support revisions Around the Door Data Library Screen Below is a list of highlights about this screen Selecting a file from the table leads into the Door Data Creation screen The Door Data Library contains the specifications about an unprocessed door No shape cutting information is at this screen Files can be saved and be at...

Page 40: ...ighlights about this screen Selecting a file from the table leads into the Door Feature Creation screen The Door Feature Library contains shape information There is one shape information per file Files can be saved and be attached to the many Door Job files Files support revisions Tracks variants ...

Page 41: ...cated at each Library Screen Select the Libraries Tab located at the upper left and then select the desired library Note The operations described here are common to all screens Note The Revision Display Panel is hidden Select the line to the right and drag to the left to display this pane FIGURE 2 1 Library Screen ...

Page 42: ...words to search by name or description Select the Display Deleted Check Box to view or recover deleted door files Tip Change the column widths by selecting the column border and dragging to the desired width Using the Display Deleted Check Box Recover a Door File Follow this procedure to recover a door file 1 Select the Display Deleted Check Box located in the upper right hand corner 2 Deleted fil...

Page 43: ...n an existing file to view or edit Edit or view a Door Job Door Feature or Door Data file 1 Select a file from the File Table 2 Select the Edit View Button to go the file screen Tip Double click the desired file in the table to go straight to the screen Using the Clone Button Use the Clone Button to create a copy of a door file To Clone a File 1 Select the file to be cloned from the table 2 Select...

Page 44: ...te Button turns into the Restore Button when the Display Deleted Check Box is selected To Delete a File 1 Select the file to be deleted from the table 2 Select the Delete Button 3 At the pop up window select Yes to delete the file Note To restore a file see Using the Display Deleted Check Box Recover a Door File on page 2 9 Clone Pop Up Screen ...

Page 45: ...e figure below shows two highlighted files to be compared Use the Diff Button to Compare Two Files 1 Select 2 files to compare 2 Select the Diff Button 3 In the popup window the differences are highlighted The top selected file is highlighted in red while the second file selected is highlighted in green ...

Page 46: ...SQL Text Box 3 Select the Connect Button 4 Select the Go to Libraries Button that is located at the bottom of the screen About the Database Screen Contents The database screen contains the following Data Source path PostgreSQL Status Information Connection State Tip If not connected verify path Server Multiple servers may be created Database This is the name assigned to the database User Assigned ...

Page 47: ...contains a Principle and Diff Button The Diff Button compares two files For information about using the Diff Button see Using the Diff Button on page 2 12 Using the Principle Button Normally the top file in the table is the principle However any revised file can be assigned as the principle using the Principle Button 1 From the revision table select to highlight the desired revision file 2 Select ...

Page 48: ... The Door Jobs that contain the selected Door Data File The Revision ID Revisions at the Door Feature Group Library In the upper panel the Door Feature file revisions may be compared and any file can be assigned as the principle The lower panel displays The Door Jobs that contain the selected Feature Group File The Revision ID Any Variant in the files For a Variant definition see Variant on page 2...

Page 49: ...About Revisions 2 16 KVAL Manual ...

Page 50: ... of face lock and hinge job creations are located in this manual See Job Preview Examples on page 2 31 Note For a definition of validation errors see Validation on page 2 50 FIGURE 2 2 Screen Shot of Job Creation To create a new Door Job select the Create button at the bottom of the screen To edit or view a created Door Job select the item from the table then select the Edit View button on the bot...

Page 51: ...ption Add an descrip tion of the Door Job About the Door Data Menu Door Parameters Displays the basic parameters of the door being processed Door Material Select type of material of the Face Hinge side and Lock side of the door Wood Fiber Glass or Steel Name and Description Add a file name and description Door Hand Select the Hand Ori entation of the Door From the drip down menu select Left Hand R...

Page 52: ...About Door Job Creation 2 19 KVAL Manual Breakdown of a Feature Group and Features Feature Groups and Features resemble an outline FIGURE 2 3 Feature Group Breakdown About the Feature Tree Menu ...

Page 53: ...es Add Child Select to create a new child to the Feature or Feature Group Add from Library Select to add a file from the Feature Library Delete Select to delete a Group or Child Notes Tips Color Coded Indicators next to the Child Features are color coded to reflect the location on the door Hinge Edge Lock Edge Hinge Pivot Face Oppo site Hinge Pivot Face Top End Bottom End Validation If a cut is no...

Page 54: ...is example the hinge locations are located 6 75 36 0 and 65 25 with a reference from the top of the door Coordinate References Set the reference in relation with the cut The reference option will be dis played in Job Preview T Thick Reference Hinge Pivot Face Key Face Opposite Key Face Opposite Hinge Pivot Face L Length Reference Bottom Top W Width Reference Lock Hinge Defined Properties Create a ...

Page 55: ...ous page The example below details the parameters of the hinge cut Predrill locations are also included in the example Feature Name Name of The Fea ture Under the Group Feature Type Select type of cut Circle FaceCircle FaceRectangle Hinge Rectangle TeeShape Face Profile LiteCutout See About the LiteCutout Feature Detail DL NCD Only on page 2 37 Door Side Select Door Side Bottom End Top End Hinge E...

Page 56: ...ct to Save all a new Door Job or save Edits to a Job Password Protected Add to Queue and Door Qty The first step of door processing Enter the quantity of doors to be pro cessed in the Door Qty Box then select the Add to Queue button to start the process See About the Machine Line Screen on page 2 26 Save as New Make adjustments to an existing cut pattern and save as another file Export to DXF Sele...

Page 57: ...ew Examples on page 2 31 Display Area Door Axis Axis changes per Preview Surface selections See Axis on page 2 49 Preview Surface Preview Surface Select from drop down list to view Bottom End Top End Hinge Edge Lock Edge Hinge Pivot Face Opposite Pivot Face Grid Lines in Change the size of the grid line Scale Percent Displays the mag nification value of the screen pre view Note May use the mouse w...

Page 58: ...2 25 KVAL Manual 3 D Screen Select the 3 D Tab to display a three dimensional view of the Door Job Right click the mouse to control the movement of the 3 D display The Preview Surfaces are color coded and listed on the display ...

Page 59: ... Select the Machine Line Tab on the left side of the screen to jump to this screen Machine Line Screen Menu Description A Machine Activity For each machine a table shows job name quantity of remain ing doors doors being processed and status of the machine B Queued Jobs Shows a list of the upcoming jobs C Line Controls Common operations to control the machine line ...

Page 60: ...ite Machine is idle Orange Machine is paused Machine Lists the machines in the line Status Lists the status of each machine Quantity Lists the quantity of doors at the start of the Door Job Job Lists the name of the Job being processed The Job name reflects the name assigned in the Door Job Library Remaining Lists remaining quantity of doors left in the Door Job Templates Descrip tion of the types...

Page 61: ... selecting the desired title Sortable Queue Order Lists the jobs that are going to be processed Commands Select the Remove Button to clear the Job from the list Creation Time List the time when the job is put in queue Job List the file name of the Job Quantity Lists the quantity of doors at the start of the Door Job Template List the File name of the Template ...

Page 62: ...achine between Auto Feed ON or Auto Feed OFF Auto Feed ON The door will automat ically feed through each machine Auto Feed OFF The feed status must be set the machine Operator s Screen Clear Queued Jobs Press to clear the entire list of Door Jobs in the Queued Job table Home the Machine Line Press to Home every machine in the line Reset the Machine Line Press to reset the every machine in the line...

Page 63: ...t the current build Exit Select to close the running KvalCAM program Release Notes Select to open a PDF of the history of release notes on this version o software Backup Select to save the to save all data from the machine operation Notes may be added to describe the saved file Licenses Select to see all third party licenses Kval Docs Website Select to go to a see Kval CAM documentation Must have ...

Page 64: ...or lock preview form the face viewpoint Highlight the item from the Feature Tree The Preview Screen will display the cut from the feature group point of view Note the Axis indicator Length and Width for a quick refer ence Note Errors will be indicated by an orange box around the parameter Note Change views by using the manual view buttons at he bottom of the screen Lock Parameters Lock Locations ...

Page 65: ...tem from the Feature Tree The Preview Screen will display the cut from the feature group point of view Note the Axis indicator Length and Width for a quick refer ence Note Errors will be indicated by an orange box around the parameter Note Change views by using the manual view buttons at he bottom of the screen S Lock Parameters and Locations ...

Page 66: ...item from the Feature Tree The Preview Screen will display the cut from the feature group point of view Note the Axis indicator Length and Width for a quick refer ence Note Errors will be indicated by an orange box around the parameter Note Change views by using the manual view buttons at he bottom of the screen Lock Parameters and Locations ...

Page 67: ... Door Job will be highlighted with instructions to fix the error This is a sample of an incorrect depth parameter Validation error is discovered when creat ing a Door Job 1 An Orange Box will highlight the group with an error In this sample the Lock Edge Child has an error 2 To investigate the error select the Vali dation Report button at the bottom of the display 1 2 ...

Page 68: ...KVAL Manual About the Validation Screen The Validation Screen displays a nested outline of the error cause Displays the definitions of an error and definitions of parameter Shows the hierarchical outline of tested parameters ...

Page 69: ...p Each child node is listed under the selected group In this case there is an error in the Lock Edge routine Either change the depth in the table of the Feature Table or select Commander 3 Tool Con fig Lock Tools and change the depth in the Depth Stop Z Loca tion field to match desired depth ...

Page 70: ...t the LiteCutout Screen on page 2 41 To add a new LiteCutout 1 If needed add a Feature Group 2 Add a Child to the Feature Tree 3 Select LiteCutout from the Feature Type drop down menu and add a Feature Name add a Feature Name 4 Select the Edit Button The LiteCutout is a Feature Type selection With this feature type DXF Drawing Exchange For mat files can be imported manipulated on a sep arate scree...

Page 71: ...Only 2 38 KVAL Manual 5 The LiteCutout working space is displayed 6 Select the Import DXF Button and select the desired file from your directory If needed manipulate the shape Add Group Select LiteCutout and Name Add Child Select the Edit Button ...

Page 72: ... Feature Detail DL NCD Only 2 39 KVAL Manual 7 Add the file into KvalCAM by selecting the OK Button 8 Input WLocation and LLocation to put the cut onto the door Import DXF file In this example an oval DXF file was imported ...

Page 73: ...About the LiteCutout Feature Detail DL NCD Only 2 40 KVAL Manual 9 If finished with editing the Door Job run the door ...

Page 74: ...About the LiteCutout Feature Detail DL NCD Only 2 41 KVAL Manual About the LiteCutout Screen This section describes selections on the LiteCutout Screen ...

Page 75: ... machines and doors About the Work Areas Zoom In and Out with Mouse Move shape vertically and horizontally with Slide Bars Select a vertex point on the cutting path and manipulate the shape Expand or collapse windows 0 0 origin point Referenced to the LLocation and WLo cation on the door Y Positive goes toward the Hinge Edge Y Negative goes toward the Lock Edge X Positive goes toward the Top of th...

Page 76: ...ertex Button in the bottom bar Cutting Path Width varies with the MaxToolDiameter size that is inputed Knockout Point Points may be added with the Insert Knock Out Point button located under LiteCutout Parameters menu Plunge Point Point may be adjusted with controls in the LiteCutout Parameter menu or moved manually with the mouse ...

Page 77: ...kground with error descriptions View Setting Control the display settings of the Work Area Selected Details Displays the details of a selected point on the DXF file The Shape may be manipulated with a mouse or by populating the designated input boxes OK Send to KvalCAM Cancel Stop work and go back to KvalCAM Insert Vertex Insert another Vertex point along the cutting path Delete Selected Delete an...

Page 78: ...ing blocks of a Door Job Job Door assigned file name Door Data Door slab specifications Feature Tree A collection of Feature Groups Selected Feature Details Shapes locations and cut information of the features that are part of the Feature Group FIGURE 2 4 Door Job Parts Door Data Door Data represents all the information for a door slab and or jamb Properties such as the door length width thickness...

Page 79: ...tion of Features that describe the operations to be done Feature Groups can be created edited and saved in the Feature Group Library Feature Groups and it s associated Features may be added to a Door Job Figure 2 4 below shows a collection of Feature Groups in a Door Job More information about Feature Groups can be found at About the Feature Tree Menu on page 2 19 FIGURE 2 6 Feature Group Panel ...

Page 80: ...e Selected Feature Details Menu Child Level on page 2 22 FIGURE 2 7 Feature Details Example Revision After editing an existing Door Job Door Data or Feature Group in the KvalCAM library a revision is created Revisions represent a save point in the history of editing the Principle revision is the current save point in the case of Door Data or Feature Group In the case of a Door Job the Princi ple i...

Page 81: ...For example there may be a Feature Group that represents cuts for a particular lock but the loca tion of the lock varies between Door Jobs By adding the lock Feature Group to the Door Job then changing its location and saving the Door Job a modified Variant will be created When looking at the associated Door Jobs of that lock Revision all of the Door Jobs will be listed even if the location varies...

Page 82: ...ision The process to use the Diff function can be found at Using the Diff Button on page 2 12 Axis An axis icon is located on the Door Preview Screen to visually represent the door reference Figure 2 9 below shows the axis icons Note the icon relationship to the door graphic FIGURE 2 9 Axis Icons in Job Preview L Represents the Length axis W Represents the Width Axis T Represents the Thickness Axi...

Page 83: ...preted to a real number for validation while orange appears if the line cannot perform the cut FIGURE 2 10 Example of a Validation Error Indication Validation Report A Validation Report identifies particular faults that would cause a feature to fail validation Each feature has its own validation tests and will fail if the tests for a valid feature are not satisfied Clicking on a specific test will...

Page 84: ...Common Terms 2 51 KVAL Manual FIGURE 2 11 Example of a Validation Report ...

Page 85: ... Section Name Summary Page About the Machine Line A Summary of the entire machine line page 3 3 Summary of Controls on the Machine Line Overview of mechanical controls of the machine line page 3 4 Initial Power Operations Description of powering up the line from the off state Includes Power down description Six Light Panel and homing the machine line page 3 6 Machine Start Summary A quick summary ...

Page 86: ...ly 9 After all cuts are completed press the Blue Door Finished Button to feed the completed door into the next stage 3 Push the Door Stop Foot Pedal to pop up the stops 4 Position the door against the stop and fence according to the Operator s Screen 5 After the door is set press the Door Clamp Foot Pedal to secure the door Note If not clamped correctly press the clamp pedal again re set and press...

Page 87: ...e up in common cases Some factories pro cess the door with the narrow side up Verify the practice your company uses 3º 3º Up Door 1 Push Door against the back stop 2 Keeping Pressure against the back fence push the door against the appropriate stop Hinge Side Use this position for Left Hand Top and Right Hand Bottom Use this position for Left Hand Hinge and Right Hand Lock ...

Page 88: ...mary on page 3 8 Control Process See About the Edge SS Process on page 3 2 Machine Control Software See About the Edge SS Interface Screens on page 3 14 Full Definition See Operator s Station on the Edge SS on page 5 5 Machine Start See The Machine Start Summary on page 3 8 Control Process See About the Edge SS Process on page 3 2 Full Definition See Main Machine Controls on page 5 6 Machine Start...

Page 89: ...utine The visibility of the light allows observation of the progress of the machining in a factory environment TABLE 3 1 Indicator Light Descriptions Color Description of Process Red Machine in Error State Yellow Low Air Pressure X Axis Auto Greaser Empty Green Solid un Cutting Routine Blinking Ready to Start Blue No Remaining Work on the Door ...

Page 90: ...machine and main air supply is turned on 2 Check that all E Stop buttons are out and safety gates are closed Note A pop up is displayed on the user screen if an E Stop is pressed The pop up will indicate which E Stop has been activated 3 Make sure the electrical disconnect each electrical cabinet is turned to the ON position 4 Switch the green CONTROL CIRCUIT switches to the ON posi tions They sho...

Page 91: ...hine Line button located on the Machine Line Screen How to Power Down the Machine Step 1 1 Push the Stop button for each machine located on the Operator s Station 2 Exit or shutdown all open programs 3 Shut down the operating system by selecting Shutdown from the Window s Desktop Note Make sure Windows is shutdown com pletely before turning off the machine Hard drive or data may be damaged if not ...

Page 92: ...ve is on 2 Turn on the Red Power Lever at each Electrical Panel 3 Turn on each Green Control Transformer Lever on the Operators Station Press each Green Start Button on the Operators Station to boot up into Desktop environment After the computer is completed booting up the KvalCAM User Interface will start automatically However for instruction purposes below are manual steps to start the programs ...

Page 93: ...late Add the Quantity of Doors in the Door Qty box Select the Add to Queue button Select a Door Job Select Libraries Tab Select Edit Verify or Modify Job Enter Qty Select Add to Queue Choose which door edge to pro cess first Check the Edge posi tion lights and use the Edge toggle button to select the desired edge Note Edge cut sequence defaults to optimal usage and favors hinge cuts last Press the...

Page 94: ...wering Operations for the Edge SS on page 3 6 1 Press the Red Stop button located on the Operators Station 2 Shut down the operating system by selecting Shutdown from the Desktop 3 After computer has fully shutdown turn off the Green Control Transformer lever on the Operators Station 4 Turn OFF the Red Power lever the Electrical Panels ...

Page 95: ...o jump to desired screens Libraries and Machine Line Screens See Chapter 2 for information about KvalCAM Libraries and Machine Line Screens Machine Control and Calibration Screens Main Control Includes auto controls speed control and sequence controls See About the Edge SS Main Screen on page 3 14 Manual Servo Control From this screen move the Cutting Head and Table See About the Edge SS Manual Se...

Page 96: ...eens Status From this screen check the status of the assemblies on the machine See what state the assemblies are in See About the Status and Log Screens on page 3 27 Log Screen From this screen the feedback codes from the machine See About the Status and Log Screens on page 3 27 ...

Page 97: ...es is displayed The machines are constantly polled feeding back their state of operation This feed back is a great tool to instantly view the status of each machine This information can be used to troubleshoot any issues that may occur Select the tabs to jump to associated Operator s Screen The active screen will highlight with a green background ...

Page 98: ...Path Preview Observe the path of the tool during machining process See page 3 20 Calibration Description and instructions to fine tune the servo drives See Chapter 3 Tool Config Fine tune the tools parameters for an accurate cut See page 3 25 Status For information see About the Status and Log Screens on page 3 27 Log For Information see About the Status and Log Screens on page 3 27 The Edge SS Op...

Page 99: ...button will reset the machine to the start position Important Press the Home button after resetting the machine Setup Mode On Off Select Setup Mode to toggle on or off In the On mode a safe mode is active The machine will go through normal sequences except the cutting motors will be inactive Use this mode to check the machine operation without making a cut on the door With the setup mode set to on...

Page 100: ...s the flexibility to override the sequence and select the edge position This button also allows the opportunity to repeat the selected cut This control is also located at the machine control panel as a mechanical switch but ton Door Finished Clears the job if user wants to finish the job before completing all cuts or at the end of the job if Auto Feed out is disabled If the machine is working on t...

Page 101: ...r stops UP or DOWN This button is only available when a job is loaded in the machine Enable Feeler Adjust Press to Enable or Disable the Feelers A red background desig nates disabled A gray background designates enabled If this button is Disabled the door measurements will be derived from the Door Job specifications May be used to verify a door against the feeler measurement Note Toggle selections...

Page 102: ... an Optional Fea ture About the Edge SS Feeler Servo Controls These controls operate the Thickness Feeler The feeler uses encoder technology to accu rately measure the thickness of a door For information about the Feeler see About the Door Length Feeler on page 7 8 LengthFeelerEncoder Dis plays the Count Position of the Feeler Encoder Feeler Forward Press and Hold to move the feeler forward Toward...

Page 103: ...n Y Axis Forward Moves Heads Down Reverse Moves Heads Up Z Reverse Away from the Door Cut Z Forward Towards the Door Cut X Forward X Reverse To the Stacker Position of Encoder About the Edge SS Head Servo Controls The manual controls are designated by X Y and Z axises for the Main Head Press and hold the button Forward or Reverse to move the head in the desired direction ...

Page 104: ...y of the Edge SS can be viewed This sequence can be essential if troubleshooting calibrating or checking the wear of a tool Dis crepancies can be viewed before cutting into a door saving product and time The figure below displays a sample of a good Deep Mortise Cut 1 Select a G Code routine form the drop down menu 2 Select the Render Button 3 View the path of the tool on the screen Step 1 Step 2 S...

Page 105: ...e General Operating Controls The Tool Config Screen contains a sample of the following List of the available tools Pop up menus to enter information about each tool Specifications The ability to adjust the method of chisel operation during machining The ability to enable or disable specific tool slots The ability to name the tools to familiar names The ability to lock and unlock the ability to ent...

Page 106: ...ut the Tool Pop up Screens Each tool slot has versatility to choose between entering router or chisel information Click the Enable Check Box to clear the box and disable the tool Below are samples of the pop up windows available About the Tool Pop up Screens Sample Drill Configuration Pop Ups 1 Select Unlock 2 Enter Password Click OK 3 Ready to Enter Data Drill Pop up Drill Pop up Disabled Drill P...

Page 107: ...ations are identified by slots See the figures below for the locations and identifications Note Below are factory suggested locations Identification of Slots can be altered through this menu Chisel Pop up Sample Chisel Pop up Disabled Sample Tool Slot 4 Tool Slot 2 Tool Slot 3 Tool Slot 1 Tool Slot 6 Tool Slot 5 Edge SS ...

Page 108: ... by slots See the figures below for the locations and identifications Note Below are factory suggested locations Identification of Slot and location of chisel can be altered through this menu Rectangle Orientation Lower Left Chisel Lower Right Chisel Upper Left Chisel Upper Right Chisel Vertical Orientation ...

Page 109: ...st Each head tool should match in type and specifications 3 Enter the data into the pop up screen Router or Drill 1 Measure the parameters listed below Total Tool Length The distance from the col let face to the tool s tip Tool Cutting Length The distance from start of the cutting area to the tip of the bit Tool Point Length From the point where the point starts to the end of the bit 2 Update the ...

Page 110: ...ing Data into the Pop up Menu Insert specifications of the tools being used to make the cuts Ability to name the tools to user defined descriptions Customize the tools to reflect the actual tool parameters making the most accurate cuts Ability to define cut operation ...

Page 111: ...operation or a False flag if not in operation Also status can include data and motor states idle operation The data can be filtered to observe certain aspects of the operation of the machine This tool is great for troubleshooting to locate faulty assemblies FIGURE 3 13 Status Screen TIP Right Click the Icon at the Bottom of the screen Select Backup Logs to save all data from the machine operation ...

Page 112: ... the error code to machine sections or functions The top line will have the most current routine that is running The codes are color coded Red Error Green Report is a non issue Yellow Warning If the machine issue can not be resolved call Inc 1 800 553 5825 Have any error code that is displayed ready to give the representative This will aid in troubleshooting and shorten down time FIGURE 3 14 Log S...

Page 113: ...lash Waiting for all systems to initial ize Red Machine Error Solid General error 1 Flash EtherCat device not ready to run 2 Flashes VFD servo or motor fault 3 Flashes 24vdc power error over cur rent fault etc Yellow External Error Solid General error 1 Flash 3 phase voltage error 2 Flashes Low air Green Operational 2 Middle Safety Off Safety project not running Red Safety PLC error Blue Waiting f...

Page 114: ...tion Name Summary Page About Calibration Descriptions of the Calibration Menus Tips to look for before calibrating page 4 2 About the Calibration Tabs Descriptions of the Calibration Tabs page 4 3 How to Enter Calibration Data Descriptions of how to use the calibration screens page 4 5 About the Edge SS Calibration Screen Descriptions of the calibration available page 4 6 ...

Page 115: ... Reference Cut delivers a calibration cut for the Hinge Heads and for the Lock Head Use the Calibration Menus to adjust the tool sets from information taken from the calibra tion cuts 1 Hinge Cut Performs a cut to verify the Predrill Hinge Router and the Counter Rotate Router 2 Lock Cut Performs a cut to verify the Predrill Counter Rotate Router Plunge Router Plate Router and the Deep Mortise Rout...

Page 116: ...Log Screens for error reporting Finding errors from these screens will help localize problem areas Note If the machine issues can not be resolved call Inc 1 800 553 5825 Have any error code that is displayed ready to give the representative This will aid in troubleshooting and shorten down time Access to the Calibration Adjustments Buttons to unlock access to calibration save a calibration and res...

Page 117: ...ht angle to each other The first finger represents the positive direction of the Z axis the thumb represents the positive direction of the Y axis then second finger rep resents the positive the direction of the X axis Axis Direction for the Edge SS Front Section FIGURE 4 16 Left Hand Rule Front Section 1 Select the Unlock button 2 At the Password pop up enter the password and select OK to continue...

Page 118: ...enter Inc 1 800 553 5825 6 Run a test door again to verify the offset correction was successful 7 Keep running a test door and adjusting the offset until satisfied with the result About Restore Points Restore Points can be created to store a calibration point for recall 2 Enter the offset positive or negative number in the white box below the Offset title to adjust the servos in the X Y and Z dire...

Page 119: ...list of calibration adjustments Select the Edge SS Tab located on the left hand side of the machine then select the Calibration Tab to jump to this menu Enter adjustments according to Axis Direction for the Edge SS Front Section on page 4 4 and How to Enter Calibration Data on page 4 5 Ensure Calibration is unlocked Edge SS Calibration Screen ...

Page 120: ...re the measurements a Run the door and re feed it at least 3 times Each time capturing the measure ments from the Log Screen b Reverse the door and re feed it at least 3 times Repeat data collection 6 Compute the averages of the fed back measurement 7 Enter the data derived from the averages a Go to the Edge SS Calibration select Feelers b Subtract measured data to adjust for the difference Door F...

Page 121: ... heads to match to the calibration list FIGURE 4 17 Carriage Designators Using the Carriage Axes Calibrations The Carriage Axes calibration treats the entire tool set within the carriage as one unit There fore if all parameters or a particular cut are out of specifications use this calibration adjustment Hinge Head 1 Identify the cut out of specification 2 Select Carriage A 3 Measure the cut and f...

Page 122: ...Calibrations A Positive X Offset will move the entire pocket as shown A Negative X Offset will move the entire pocket as shown A Positive Z Offset increases depth A Negative Z Offset decreases depth A Positive Y Offset will move the entire pocket in the up direction A Negative Y Offset will move the entire pocket n the down direction Y Offset X Offset Y Offset X Offset Note Reference is look ing d...

Page 123: ...y loaded Cutter Head Options may vary however the tool slot designators will have the same locations Tool Location Parameter Tool Slot 1 Axis Y Axis X Axis Z Diameter Offset Tool Slot 2 Tool Slot 3 Tool Slot 4 Tool Slot 5 Tool Slot 6 Axis Y Axis X Axis Z Chisels Axis Y Axis X and Axis Z of each discrete corner Tool Slot 4 Tool Slot 2 Tool Slot 3 Tool Slot 1 Tool Slot 6 ...

Page 124: ...Calibrating the Feelers 4 11 KVAL Operation Manual Chisel Locations Tool Slot 5 Rectangle Orientation Lower Left Chisel Lower Right Chisel Upper Left Chisel Upper Right Chisel Vertical Orientation ...

Page 125: ...ed examples of how the cut will change with calibration Y Offset X Offset In this case the router pocket is out of specifica tion Negative offsets should be entered into the Y and X axis calibration to bring into specifica tion If there are any issues with lip depth use the Z axis calibration positive number to increase depth negative number to decrease depth In this case a lock hole is out of spe...

Page 126: ...Using the Tools Calibration 4 13 KVAL Operation Manual The chisel calibrations adjust each corner of the square cut pocket For more information see Chisel Locations on page 4 11 ...

Page 127: ...S A tour of the Operators Side of the Machine page 5 4 The Main Cutter Descriptions of the tools located on the Cutting Head page 5 10 About the Probes Descriptions of the probes that collect parameters about the door page 5 12 About the Safety Scanners Description of the safety scanner page 5 14 Servo Motors and Valve Bank Locations Illustrates locations of the servo motors and the valve banks pa...

Page 128: ...inge pockets T strikes concealed closures flush bolts leaf and European hinges end pivots as well as edge work for either cylindrical or deep pocket locks Many customers also use the Edge for re railing re stiling operations Control Roll Table Operators Station Electrical Panel 2 Electrical Panel 1 Rails Door Clamps Main Cutter Head Door Path Clamps Door Feeler ...

Page 129: ... the caster bed lowers the door onto the door onto the rolls The door will automatically feed out only when the next machine is ready to receive the door A switch is included for the operator to enable the sequence when the door is clamped on the Last Edge Control Roll Table Operators Station 2 Electrical Panel 2 Electrical Panel 1 Rails Door Clamps Main Cutter Head Clamps Door Feeler OPT Q Pop up...

Page 130: ... Driven Tool Carriage to rout and drill the edge of a door Operator Station The Operator s Station includes a touch screen and keyboard to run the program that operates the machine Note Multiple machine controls may combined in one station Machine Combinations are Cus tomer Definable Foot Pedal Controls Door Stops Door Clamps Emergency Stop Fence Clamps The Fence acts like a reference to align the...

Page 131: ...t operates the machine Note Multiple machine controls may combined in one station Machine Combinations are Cus tomer Definable Foot Pedal Controls Door Stops Door Clamps Emergency Stop Fence Clamps The Fence acts like a reference to align the door The clamps hold the door in place in processing Stops Stops are located both sides of the table and are identified by software Auto Feed Out Table At th...

Page 132: ...w of the Edge SS KVAL Operation Manual 5 6 Edge SS Fence Clamps Stops The Door is pressed against the Fence and Stops After the door is secure clamp the door with the foot pedal Door Clamps Door Fence Door Stops ...

Page 133: ...ator s Screen contains the following Examples Door Placement Left Side of Screen Keyboard Enter data and interact with Touch Screen Touch Screen Interface Main Control of Entire Machine Line Download G code and Templates to set the specifications of door machining Manually control the door path and process through the line Machine diag nostics are included as well as internet sup port and connecti...

Page 134: ...e end of the job if Auto Feedout is disabled Edge Toggle Door edge selection This button adds the flexibility to over ride the sequence and select the edge position This button also allows the opportunity to repeat the selected cut Edge Position Lights Indicates the selected door edge The Foot Pedal is centrally located and controls the Door Stops and the Door Clamps Press the pedals once to engag...

Page 135: ...ibility of the light allows observation of the progress of the machining in a factory environment TABLE 5 1 Indicator Light Descriptions Color Description of Process Red Machine in Error State Yellow Low Air Pressure X Axis Auto Greaser Empty Green Solid un Cutting Routine Blinking Ready to Start Blue No Remaining Work on the Door ...

Page 136: ...tate Hinge Router Routs the hinge pocket providing a clean cut Cylinders drives tools In and Out the door Deep Drill Z Axis Servo Motor Plunge Router Routs the lock hole in the door Main Plate Router Routs the Face plate pocket Deep Mortise Router Routs a deep pocket Zero Three Degree Cylinder Toggles the Head for 3 and 0 degree cuts X Axis Servo Motor Y Axis Servo Motor Electronic Node Connection...

Page 137: ...ear and rail Electronic Node Connections from the Electrical Panel Opt Chisels X4 Cylinders Drives tools In and Out the door Counter Rotate Hinge Router Routs the hinge pocket providing a clean cut Main Plate Router Routs the Face plate pocket Deep Mortise Router Routs a deep pocket Y Axis Servo Motor Point to Point Drills pilot holes for insertion of screws on the door ...

Page 138: ...rma tion Incremental encoders can provide a once per revolution pulse often called index marker or reference that occurs at the same mechanical point of encoder shaft revolution This refer ence is used as a comparative point resulting in a highly accurate measurement The encoder assembly is identified as a Feeler Important If calibrating calibrate the Feelers first See Chapter 3 in this manual Typ...

Page 139: ... door has been fed in to the door stop and clamped the feelers lightly tap the face of the door Then the accurate width is calculated The feeler and encoder is located at the in feed of the machine This feeler and encoder are located on the Cutter Head After the door has been fed in to the door stop and clamped the feelers lightly tap the face of the door The feeler and encoder work with the drill...

Page 140: ...cess including feed through door clamping and door location It is important to keep the sen sors cleaned and aligned to keep the door process running smoothly There are two classifications of sensors on the Face SS Photo Electronic and Inductive Proximity Sensor FIGURE 5 4 Examples of Sensor FIGURE 5 5 If field is broken 1 Push the START MACHINE button on the operator s station 2 Home the Machine ...

Page 141: ...unction with the schematics to locate the assembly Servo Motor Locations Figure 5 6 shows the locations of the servo motors on the machine The motors interact with the Template PLC and servo drivers They are highly accurate in movement and position Servo motor positions may be calibrated See the calibration chapter for axis direction See the Vision System Service Manual for motor part numbers FIGU...

Page 142: ... the solenoids identify loads they control Typical Valve Bank Controls FIGURE 5 7 Location of Valve Banks The table below lists the typical loads controlled by the valve banks Note The values in this table are typical To verify check the labels on the solenoids and the air schematic TABLE 5 2 Valve Bank Descriptions Valve Bank Loads Cylinders Table Valve Bank 1 Extend and Retract Stops Feeler Dust...

Page 143: ...odes on the Cutter Head and the Frame This section is an overview of the electrical components Refer the machine s elec trical prints for in depth information Main Electrical Panel Supplies voltages to the machine Contains the PLC Programmable Logic Controller Contains servo drives to interact with the servo motors FIGURE 5 8 Main Panel PLC Edge SS 24 VDC and 110 VAC Terminals Relays 24V DC Suppli...

Page 144: ...lly connect Main PLC VFDs Variable Frequency Drives to interact with the cutter motors FIGURE 5 9 High Frequency 24 VDC and 110 VAC Terminals Relays 1 VFDs Plate Router Point to Point Feed 1 Feed 2 Plunge Router Counter Router Deep Mortise Deep Drill 1 VFD brands may vary High Voltage Input Fuses Edge SS High Freq Panel Power Outlet PLC Edge SS ...

Page 145: ...of PLC and power connec tions For example door sensors width adjusts and tool interfaces FIGURE 5 10 Sample of a Frame Node Typical Block Diagram of Network Connections FIGURE 5 11 Block Diagram of Network Connections PLC Interface Top Ethernet cable is PLC Bottom Ethernet goes to Cutter Node Inputs and Outputs Interconnect Bar ...

Page 146: ...ower Distribution FIGURE 5 12 Location of Nodes on the Edge SS Network Connections Main E Box Contains Servo Drives Network Connec tions power and Inputs Outputs originate this box and are connected to Nodes Frame Node Cutter Node Power Dis tributed to Points in the machine Power Power ...

Page 147: ...About the Nodes 5 21 KVAL Operation Manual ...

Page 148: ... inductive proximity sensor 14 L location of Door Length Feeler 12 lockout and tagout Guidelines 12 lockout procedure 10 log screen description 28 M manual operation interface 18 20 menu map 11 P power lock out procedure 10 powering up and down machine 6 preset selection description 16 R remote operation setting up machine for 17 reset machine button description user interface 15 Restore Points cr...

Page 149: ...Index Kval Edge SS clean up 12 inspect 12 ...

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Page 152: ...partment Kval Incorporated 825 Petaluma Boulevard South Petaluma CA 94952 Contacting KVAL Phone and Fax In the U S and Canada call 800 553 5825 or fax 707 762 0485 Outside the U S and Canada call 707 762 7367 or fax 707 762 0485 Email service kvalinc com http www kvalinc com ...