Kval EFX, Operation Manual

Page 1: ...Innovation Quality Honesty Operation Manual Published July 2 2020 EFX Door Machining System Operation Manual EFX System ...

Page 2: ...stered 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 Mailing a...

Page 3: ... 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 above T...

Page 4: ...ated 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 KvalCAM Software in the...

Page 5: ...t 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 Download Application 1 17 Safety Sign Off Sheet 1 21 A ...

Page 6: ...About Backing up Data and Checking the Revision Status 2 18 Definitions 2 19 Appendix Job Preview Examples 2 21 Door Face Lock Preview 2 21 Door Edge Lock Preview 2 22 Door Edge Hinge Preview 2 23 Appendix About Validation 2 24 About the Validation Screen 2 25 Outline 2 25 About the LiteCutout Feature Detail DL NCD Only 2 26 Process 2 26 About the LiteCutout Screen 2 30 About the Work Area Coordin...

Page 7: ...Path Preview Test Tab 3 19 About the Tool Config Tabs 3 20 General Operating Controls 3 20 Unlock the Tool Slot Configuration 3 21 About the Tool Pop up Screens 3 21 About the Tool Pop up Screens 3 21 Sample Drill Configuration Pop Ups 3 21 Sample Chisel Configuration Pop Ups 3 22 About Tool Locations 3 22 About Chisel Locations 3 23 About Using Tool Configuration 3 23 Measuring Tool Length 3 24 A...

Page 8: ...ength and Thickness 4 12 Step 3 Calibrate the Depth Feeler Option 4 14 Before Calibrating 4 14 Process to Calibrate the Probe Depth 4 15 Step 4 Calibrate the Face Axes 4 16 Process to Calibrate the Face Carriage 4 16 Face Axis Calibration Reference Cut 4 16 Step 5 Calibrate the Face Tools 4 18 Face Tool Locations 4 18 Process to Calibrate the Face Tools 4 18 Face Tools Calibration Reference Cut 4 ...

Page 9: ...ight 5 5 Assemblies on the Main Cutter Head 5 6 About Door Probes 5 7 About Encoders 5 7 About Length and Thickness Probes 5 7 Depth Probe 5 8 Laser Safety Scanners 5 9 About Sensors 5 9 Location of Servo Motors and Valve Bank Locations 5 10 Servo Motor Locations 5 10 Valve Bank Locations 5 10 About the Electrical Panels 5 11 EFX Main E Panel 5 11 EFX High Freq Panel 5 12 About the Nodes 5 13 Typi...

Page 10: ...KVAL EFX Manual Table of Contents ...

Page 11: ...t 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 specification pl...

Page 12: ...al Edge SS with an inverted bed of castors for door positioning The left side of the castor table extends towards the operator so doors can be clamped for rail work The software automatically extends the correct door reference stop for positioning based on door swing end work or face work The Kval EFX is a CNC door machining station designed to process all four door edges and door lock face holes ...

Page 13: ...AM based a single door file can be used by both machines for the same door with automatic data transfer Three additional spindles are mounted underneath the castor table two spindles are utilized for face routing to best suit individual cus tomer needs i e bit type the third 2HP spindle drill for lever lock screw holes Spindle movement is controlled via three additional ball screws and servo motor...

Page 14: ...ut 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 Descripti...

Page 15: ...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 16: ...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 17: ...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 18: ... 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 19: ...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 20: ...supply 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...

Page 21: ...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 22: ...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 23: ... 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 24: ...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 25: ... _______________ 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 26: ...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 27: ... 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 28: ...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 29: ...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 30: ...How to Download the Service Application KVAL Operation Manual 1 20 Page Intentionally Left Blank ...

Page 31: ...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 32: ...Safety Sign Off Sheet KVAL Operation Manual 1 22 ...

Page 33: ...ription of the KvalCAM interface page 2 2 About the Libraries Screen Description of Libraries Screen Includes job cre ation job editing loading templates and verifying job creation page 2 3 About the Machine Line Screen Description of the Machine Line Screen Includes Line Control Buttons Queued Jobs and Machine Activity page 2 14 About Backing up Data Instruction to back up data page 2 18 ...

Page 34: ...chine Line Screens Below are screen shots that show the programming and machine line program operations Machine Control For instructions to use the machine control interface see About the EFX Process on page 3 2 Libraries Includes two tabs the Door Job Library and the Feature Group Library Create edit clone delete and download door jobs and door templates Powerful and flexible database of door cut...

Page 35: ...to jump to these screens Distinguish between the Door Job and Features Group Libraries One can describe the Features Group Library as a virtual scratch pad and the Door Job Library as the engine to run the door through the cutting process In the Features Group creation screen door cuts an be created and verified by way of the Job Pre view screen In the Door Job creation screen door cuts can be cre...

Page 36: ...ab then select Door Job Library or Features Group Library Tab depending on desired action Use the buttons at the bottom of the screen to create clone edit or delete jobs or Feature Groups Lock editing capabilities and refresh tabs are also available Note The Door Job and Features Group Library have the same layout and storage for mat ...

Page 37: ...ct a Template or Door Job Either Edit a known Job Template or use existing to run doors Jumps to the Job Creation Screen The Most Common Path way to start the door Machining Process Clone Button Select a Tem plate or Door Job from the list to copy and rename Delete Button Select a Tem plate or Door Job from the list to Delete Refresh Select to re read the data base Unlock Lock If Door jobs or Feat...

Page 38: ... at this screen Note Sample of face lock and hinge job creations are located in th appendix of this manual See Appendix Job Preview Examples on page 2 21 Note For a sample of validation errors see Appendix About Validation on page 2 24 FIGURE 2 1 Screen Shot of Job Creation To create a new Door Job or Template select the Create button at the bottom of the screen To edit or view a created Door Job ...

Page 39: ...it or create the door parameters to be processed Door Parameters Displays the basic parameters of the door being processed If creating a door enter the parameters Door Hand Select the Hand Ori entation of the Door From the drip down menu select Left Hand Right Hand Left Hand Reversed Right Hand Reversed Door Material Select type of material of the Face Hinge side and Lock side of the door Wood Fib...

Page 40: ...dd Group Select to create a new Group Features can be created in the Features Details Menu Add Child Select to create a new child to a group or child Add from Library Select to add a tem plate from the 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 Fac...

Page 41: ...this 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 ...

Page 42: ...the previous 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 LiteCutout See About the LiteCutout Feature Detail DL NCD Only on page 2 26 Door Side Select Door Side Bottom End Top End Hinge Edge ...

Page 43: ...About Validation on page 2 24 Save Select 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 Save as New Make adjustments to an existing cut pattern and save as another file Export to DXF Select the E...

Page 44: ...es see Appendix Job Preview Exam ples on page 2 21 Display Area Door Axis Axis changes per Preview Surface selections 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 mou...

Page 45: ...L Operation 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 46: ...elect the Machine Line Tab on the left side of the screen to jump to this screen This includes 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 47: ...hite 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 type...

Page 48: ...table can be sorted by 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 49: ...the machine 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...

Page 50: ...o send machine data to a text file The file may be sent to Service Support if any issues occur Notes may be added to describe the saved file Note Kval recommends backing up locally or to a isolated server Build Info Select to view upper level notes about the current build Exit Select to close the running KvalCAM program Backup Logs Select to save the to save all data from the machine operation Not...

Page 51: ...out All Feature Groups have their own L T and W location that is separate from the features contained inside This allows the user to quickly move templates to new locations or to duplicate templates in multiple locations by adding new locations to the group Feature Group Name This field is required when saving a new template Feature Features are created by adding children to a feature group All fe...

Page 52: ...only appears if the expression cannot be interpreted to a real number for validation while orange appears if the line cannot perform the cut Validation Report Validation Report identifies particular faults that would cause a feature to fail vali dation 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 provide...

Page 53: ...xample of a door 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 Lo...

Page 54: ...ght 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 S Lock Parameters and Locations ...

Page 55: ...light 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 and Locations ...

Page 56: ... errors in the 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 57: ...ns of parameter Shows the hierarchical outline of tested parameters Tile displays the dimensions of the Feature Group 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 desir...

Page 58: ... About the LiteCutout Screen on page 2 30 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 ...

Page 59: ...2 27 KVAL Operation 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 60: ...ure Detail DL NCD Only KVAL Operation Manual 2 28 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 61: ...About the LiteCutout Feature Detail DL NCD Only 2 29 KVAL Operation Manual 9 If finished with editing the Door Job run the door ...

Page 62: ...About the LiteCutout Feature Detail DL NCD Only KVAL Operation Manual 2 30 About the LiteCutout Screen This section describes selections on the LiteCutout Screen ...

Page 63: ...s all 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 ...

Page 64: ...ert Vertex 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 65: ...d background 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 Dele...

Page 66: ...About the LiteCutout Feature Detail DL NCD Only KVAL Operation Manual 2 34 ...

Page 67: ...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 o...

Page 68: ... door accordingly 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 r...

Page 69: ...cutting a beveled door put the wide side 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 Follow the on screen instructions to position the door Use this position for Hinge Cuts Lock Cuts Face Cuts Use this position for Top Cuts Bottom Cuts ...

Page 70: ...tart Summary on page 3 8 Control Process See About the EFX Process on page 3 2 Machine Control Software See About the EFX Interface Screens on page 3 13 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 EFX Process on page 3 2 Full Definition See Main Machine Controls on page 5 6 Machine Start See...

Page 71: ...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 72: ...at 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 should light up Note To shut down and keep the compute...

Page 73: ...ine can be Homed using the Home Machine Line button located on the Machine Line Screen How to Power Down the Machine 1 Exit or shutdown all open programs 2 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 turned off in this order 3 For each machine sw...

Page 74: ...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 Double...

Page 75: ...ty 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 parameter to process first Check the position lights and use the toggle button to select the desired cut Note The cut sequence defaults to optimal usage Lock cuts are favored first Press the 1 DOOR STOP pedal accord ing to set up 2 Position t...

Page 76: ... to 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 EFX Main Screen on page 3 13 Manual Servo Control From this screen move the Cutting Head and Table See About the Edge SS Manual Serv...

Page 77: ...g process is displayed This function is primarily used by techni cians for troubleshooting See Chapter 3 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 25 Log Screen From this screen the feedback codes from the machine See About the Status and Log Screens on page 3 25 ...

Page 78: ...es is displayed The machines are constantly polled feeding back their state of operation This feedback is a great tool to instantly view the status of each machine This infor mation 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 79: ...th Preview Observe the path of the tool during machining process See page 3 19 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 23 Status For information see About the Status and Log Screens on page 3 25 Log For Information see About the Status and Log Screens on page 3 25 The EFX Operator...

Page 80: ...he 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 the button will ch...

Page 81: ...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 the...

Page 82: ...tops UP or DOWN This button is only available when a job is loaded in the machine Enable Feeler Adjusts Select 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 83: ...At this screen the Main Head and Face servo motors can be moved manually FIGURE 3 2 EFX Manual Control Screen About the EFX Face Servo Controls The manual controls are designated by Y and Z axises for the Face Tool Set Press and hold the button Forward or Reverse to move the tool set in the desired direction The X Axis is shared with the Carriage Head Y Forward Z Forward ...

Page 84: ...al 3 18 Position of Encoder About the EFX Main 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 Servo Feedback Y Forward X Axis Z Forward ...

Page 85: ...ry of the EFX 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 Step...

Page 86: ... 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 ente...

Page 87: ...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 88: ...fied by slots See the figures below for the locations and identifications Note Below are factory suggested locations Identification of the slots can be altered through this menu Chisel Pop up Sample Chisel Pop up Disabled Sample Main Plate Router Point to Point Counter Rotate Router Deep Mortise Face Router 2 Face Drill 1 Face Router 1 ...

Page 89: ...on of chisel can be altered through this menu About Using Tool Configuration 1 Identify the tool that needs replacement Measure tool dimensions and capture the data Use this information to populate the Drill or Router pop up screens 2 Select the Tool Slot from the desired assembly 3 Enter the data into the pop up screen Router or Drill Rectangle Orientation Lower Right Chisel Upper Right Chisel Up...

Page 90: ... to user defined descriptions Customize the tools to reflect the actual tool parameters making the most accurate cuts Ability to define cut operation 1 Measure the parameters listed below Total Tool Length The distance from the collet 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 ...

Page 91: ... 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 3 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 92: ...he 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 4 Log Scre...

Page 93: ...e Red Machine Error Solid General Error 1 Flash EtherCat Device not Ready to Run 2 Flashes VFD Servo or Motor Error 3 Flashes 24 VDC Power Error Yellow External Error Solid General Error 1 Flash 3 Phase Voltage Error 2 Flashes Low Air Error Blue Operator Status Solid Waiting for Operator 1 Flash Reposition Door Green Machine is Operational Safety OFF Clear Safety Project not Running Red Safety PLC...

Page 94: ...a from the machine operation Notes may be added to describe the saved file Backup and Export Click to send machine data to a text file The file may be sent to Service Support if any issues occur Notes may be added to describe the saved file Note recommends backing up locally and to a isolated server Build Info Click to view upper level notes about the cur rent build Release Notes Click to open a P...

Page 95: ...Appendix About Backing up the Data 3 29 KVAL Operation Manual ...

Page 96: ... 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 7 About the Calibration Screen Descriptions of the calibration available page 4 9 ...

Page 97: ...ibration Reference Cut This chapter describes the Calibration Menus In the Calibration Menus offsets are entered to calibrate assemblies in the machine See About the Calibration Tabs on page 4 3 Before you Calibrate Before you start calibration check for the following common issues 1 Is the loaded setup correct for the current cut 2 Check tools for wear 3 Is the correct Calibration loaded 4 Are th...

Page 98: ... 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 KVAL Inc 1 800 553 5825 Have any error code that is displayed ready to give the KVAL representative This will aid in troubleshooting and shorten down time Access to the Calibration Adjustments Buttons to unlock access to calibration save a calibrat...

Page 99: ...ation Option Access to the calibration is password protected Optional 1 Select the Unlock button 2 At the Password pop up enter the password and select OK to continue 3 The calibration message will change from a red Calibration is Locked to a green Calibration is Unlocked ...

Page 100: ...e the Lock Side of the door as a reference Hold out the left hand with the first finger pointed at the door cut second finger and thumb at right angle to each other The first finger represents the positive direction of the Z Axis the thumb represents the positive direc tion of the Y Axis then second finger represents the positive the direction of the X Axis Stand at the Lock Side of Door point at ...

Page 101: ...Positive or Negative Number KVAL Operation Manual 4 6 Door Face Axis Directions X Y Z X Y Z Stand at the Lock Side of Door point down at the face of the door with the left hand rule to determine axis direction ...

Page 102: ...ions to perform a calibration 1 Check for deviations between the expected machining and the actual machining Determine the offset 2 Enter a positive or negative offset in the Offset box to adjust the servos in the X Y and Z directions Note Select the Combine Button to keep track of the offsets during the process 3 After every calibration change select the Save button to store the calibration Run a...

Page 103: ... a Restore Point 1 Select the Restore Points button 2 Select the Save Current button from the pop up window save current calibration 3 Name and enter to save To Load or Delete a Restore Point 1 Select the restore point from the menu 2 Select the Load button to use the calibration Select the Load button to load 3 Select the Delete button to delete the point ...

Page 104: ...libration Selections The table below describes the available calibration routine Calibration Adjustments Performed Carriage Axes Adjust the axis offsets for the Edge and Face Carriage Head Edge X axis Edge Z and Y axes at 3 degree bevel Edge Z and Y axes at 0 degree bevel Face X Y and Z axes Edge Tools Adjust each Tool Slot X Y Z axis and tool diameter offsets Adjust each Chisel offset Face Tools ...

Page 105: ...e settings in the order described in this section If the steps are not followed in the correct order all calibrations may suffer See Step 1 Calibrate the Carriage Stop on page 4 11 See Step 2 Calibrate the Length and Thickness Feelers on page 4 12 See Step 3 Calibrate the Depth Feeler Option on page 4 14 See Step 4 Calibrate the Face Axes on page 4 16 See Step 5 Calibrate the Face Tools on page 4 ...

Page 106: ...on the machine Always verify the carriage stop setting before continuing to cal ibrate Procedure After homing the machine measure the distance between edge of the cut area that is closest to the Operator s Station to the farthest Carriage Stop The distance should equal 20 inches Figure 4 6 below If not in specification adjust the location Repeat until specification is reached For polarity of value...

Page 107: ...known good door is sent through the machine multi ple times Process to Calibrate the Length and Thickness 1 Measure a known good door These measurements are used to compare feed back at the Log Screen a The door should be true and be considered a calibration reference b Door should be sturdy enough to survive multiple passes through machine c Measure the Length of the door and capture it d Measure...

Page 108: ...pturing the measure ments from the Log Viewer 10 To get the average add up all data collected from the Log Viewer and divide by the number of times the door was fed in 11 Compare the actual measured data with the calculated data 12 If the thickness measurement feedback is less that the actual measurement input a positive value 13 If the length measurement feedback is less that the actual measureme...

Page 109: ...ers to display the calibration menu Note For this calibration step a known good door is sent through the machine multi ple times Before Calibrating Before calibrating the Lock Probe depth Z Axis verify the X Axis and Y Axis This is a visual test Run a Door Job Check the Depth Probe Pad position as it touches the door edge Pad on probe should cover at least 50 of the door edge X Y X Y Probe Pad Pro...

Page 110: ... Calibrate the Length and Thickness Feelers on page 4 12 Note The depth position of the probe will influence the depth of the cut for edge tools 1 Create a Door Job with edge work 2 Add the door to the Queue 3 Feed the door into the machine 4 Select the Log Tab and check the latest Edge Probe feedback located under the Mes sages Column 5 If a positive value is displayed enter a positive offset to ...

Page 111: ...figuration on page 3 23 2 Create a FaceRectangle Door Job of your choice 3 Add Door Job to the Queue 4 Once the cut has been made check the location of the cut 5 Perform the Left Hand Rule at the lock side of the door to determine axis direction See illustration below If the location is out of specification in the length of the door the X Axis needs to be adjusted If the location is out of specifi...

Page 112: ...Step 4 Calibrate the Face Axes KVAL Operation Manual 4 17 X Y Z X Y Z Y ...

Page 113: ...ocess until a satisfactory final cut is in specification Face Tool Locations Process to Calibrate the Face Tools Note It is recommended to verify the Tool Config settings before calibrating the plunge cut Z Axis This is a global calibration Therefore by calibrating other tools may be out of calibration For directions on how to use the configuration menus See About Using Tool Configuration on page ...

Page 114: ...e the length width and depth positions of the cut If the cut is not in the specification determine which tool and axis needs to be cali brated 4 Perform the Left Hand Rule pointed at the cut lock to determine axis direction See illustration below If diameters of the plunges are out of specification the Diameter Offset needs to be adjusted If the length of the cut is out of specification the X Axis...

Page 115: ...oor Job to the Queue 4 Once the cut has been made check the location of the cut 5 Perform the Left Hand Rule at the lock side of the door to determine axis direction See illustration below If the location is out of specification in the length of the door edge the X Axis needs to be adjusted If the location is out of specification in the width of the door edge4 the Y Axis needs to be adjusted If th...

Page 116: ...ons of the process until a satisfactory final cut is in specification Edge Tool Locations Zero Three Degree Cylinder Tog gles the Head for 3 and 0 degree cuts Deep Mortise Router Routs a deep pocket Standard Router Routs the edge pocket Counter Rotate Hinge Router Routs the hinge pocket providing a clean cut Point to Point Drills pilot holes on the door Chisels 4 Squares the corners of the edge cu...

Page 117: ... page 3 23To help identify tools that need to be calibrated view Tool Path Review See About the Tool Path Preview Test Tab on page 3 19 1 Create a Door Job of a Lock Cut of your choice 2 Add Door Job to the Queue 3 Once the cut is machined measure the length width and depth positions of the cut If the cut is not in the specification determine which tool and axis needs to be cali brated 4 Perform t...

Page 118: ... as seen in the figure above Check location and shape of the Router cuts Look for stair step cut Counter Rotate and Standard Router not aligned Check the Tool Path Review page to isolate routers Use Tool Config to turn routers on or off to isolate If needed input the offset polarity as seen in the figure above See Routers How to Isolate and Calibrate a Specific Router on page 4 24 Check location a...

Page 119: ...asure For Example 0 15 inches 5 Run the Door Job 6 Measure the width of the rectangle and offset the tool diameter calibration by half the difference between the expected width and actual width measured For Example Running a rectangle with Width set to 1 5 in KvalCAM and 1 6 is measured Adjust the tool diameter calibration by 1 5 1 6 2 0 05 If 1 45 was measured then adjust by 1 5 1 45 2 0 025 7 Re...

Page 120: ...ow to Isolate and Calibrate a Specific Router KVAL Operation Manual 4 25 Appendix Servo Motor Drive Assemblies Face Cutter Z Axis Face Cutter Y Axis Edge Cutter Y Axis Edge Face Cutter X Axis Edge Cutter Z Axis ...

Page 121: ...Routers How to Isolate and Calibrate a Specific Router KVAL Operation Manual 4 26 ...

Page 122: ...our of the Operators Side of the Machine page 5 2 The Main Cutter Descriptions of the tools located on the Cutting Head page 5 6 About the Probes Descriptions of the probes that collect parameters about the door page 5 7 About the Safety Scanners Description of the safety scanner page 5 9 Servo Motors and Valve Bank Locations Illustrates locations of the servo motors and the valve banks page 5 10 ...

Page 123: ...ine Controls See Operator s Station on the EFX on page 5 3 Note Multiple machine controls may com bined in one station Machine Combina tions are Customer Definable Stops Stops are located both sides of the table and are iden tified by software Foot Pedal Controls Door Stops Door Clamps See Foot Pedal Control on page 5 4 Fence Clamps The Fence acts like a reference to align the door The clamps hold...

Page 124: ... Placement Left Side of Screen Keyboard Enter data and interact with Touch Screen Touch Screen Interface Main Control of entire machine line Download KvalCAM Templates to set the specifications of door machining Manually control the door path and process through the machine Machine diagnostics is included as well as internet support and connectivity for remote support via Kval Service Support Mach...

Page 125: ...nes is homed Press the Start Sequence but ton to run the program 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 Control Circuit Activates the power from the Electrical Panels Emergency Stop Push to shut the machine down in emergency situations Machine Power Ap...

Page 126: ...ibility of the light allows observation of the progress of the machining in a factory environment Door Clamps After Door is set into position the clamps extend to secure the door Pop Down Fence Fence extends down to set a reference for the door Fence Door rests on this fence TABLE 5 1 Indicator Light Descriptions Color Description of Process Red Machine in Error State Yellow Low Air Pressure X Axi...

Page 127: ...d Router Routs the edge pocket Counter Rotate Hinge Router Routs the hinge pocket providing a clean cut Point to Point Drills pilot holes on the door Chisels 4 Squares the corners of the edge cut Edge Tools Y Axis Servo Motor Edge Z Axis Servo Motor Edge Face Cutter Box Face Tools Valve Bank Length Probe Assembly Electronic Node Connections from the Electrical Panel Edge Tools Valve Bank Y Axis Se...

Page 128: ...s The location of the stop and the encoder measurement is calculated to the exact length and thickness of the door This machine may be equipped with quadrature encoders Quadrature encoders provide high speed bi directional informa 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 revolu...

Page 129: ...fter the door has been fed in to the door stop and clamped the probe lightly taps the face of the door The feeler and encoder work with the drill location to provide an accurate depth Probe in action The probe actively measures the edge of the door during routing to achieve the accurate depth Depth Probe Assembly ...

Page 130: ...process including feed through door clamping and door location It is important to keep the sensors 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 3 Examples of Sensor If field is broken 1 Push the MACHINE POWER button on the operator s station 2 Home the Machine Photo Eye...

Page 131: ...e Assemblies on the Main Cutter Head on page 5 6 Valve Bank Locations Figure 5 4 shows the locations of the valve banks on the machine The valve banks include con trol valves solenoids that drive cylinders to move different loads in the machine The solenoid if controlled by the PLC by applying a high voltage or a low voltage to a control coil Controls for example are extending and retracting route...

Page 132: ...nd Nodes on the Cutter Head and the Frame This section is an overview of the electrical components Refer the machine s electrical prints for in depth information EFX Main E Panel The 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 5 Main Panel PLC EFX 24 VDC and 110 VAC Terminals ...

Page 133: ...s the PLC interface serially connect Main PLC VFDs Variable Frequency Drives to interact with the cutter motors FIGURE 5 6 High Frequency 24 VDC and 110 VAC Terminals Relays VFDs Face Router 1 Face Router 2 Face Drill Edge Router Edge Counter Router Edge Drill Deep Mortise With thermal Resistor High Voltage Input Fuses Power Outlet PLC EFX ...

Page 134: ... of PLC and power connec tions For example door sensors width adjusts and tool interfaces FIGURE 5 7 Sample of a Frame Node Typical Block Diagram of Network Connections FIGURE 5 8 Block Diagram of Network Connections PLC Interface Top Ethernet cable is PLC Bottom Ethernet goes to Cutter Node Inputs and Outputs Interconnect Bar ...

Page 135: ... and Power Distribution FIGURE 5 9 Location of Nodes on the EFX Power Network Connections Cutter Node Frame Node Main E Box Contains Servo Drives Network Connec tions power and Inputs Outputs originate this box and are connected to Nodes Power Dis tributed to Points in the machine ...

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Page 137: ... sensor 9 L lockout and tagout Guidelines 12 lockout procedure 10 log screen description 26 M main electrical panel description 11 manual operation interface 17 19 menu map 2 10 P power lock out procedure 10 powering up and down machine 6 preset selection description 15 R remote operation setting up machine for 17 reset machine button description user interface 14 Restore Points create load delete...

Page 138: ...Index 1 2 Kval EFX ...

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Page 140: ...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 ...