Kval EFX Operating instructions

Category
Grass trimmers
Type
Operating instructions
Innovation, Quality & Honesty
Operation Manual
Published: November 3, 2022
EFX Door Machining System
With KvalCAM®
Operation Manual EFX System
KVAL EFX System Operation Manual
Proprietary Notice
This Manual is confidential and contains proprietary information and intellectual property of
KVAL Inc., and is to be used solely by Customer as an operating manual for KVAL Inc.
machines. Neither this Manual nor any of the information contained herein may be reproduced
or disclosed under any circumstances without the express written permission of KVAL Inc. For
authorization to copy this information, please call Kval Customer Support at (800) 553-5825 or
fax (707) 762-0485.
Manual Name: EFX Operation Manual
Manual Revision: 229-MV100.2, 229-MV100.3
EFX is a trademark of Kval Incorporated.
KvalCAM® is a registered trademark of Kval Incorporated.
Copyright 2022 Kval Incorporated. All rights reserved.
Beckhoff®, TwinCAT, and EtherCat® are registered trademarks and are licensed by Beckhoff
Automation GmbH
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
Kval Incorporated.
Contacting KVAL
For further information about this manual or other Kval Incorporated products, please contact us.
Mailing address:
Kval Incorporated
825 Petaluma Boulevard South
Petaluma, CA 94952
Phone and Fax:
call: (800) 553-5825
fax: (707) 762-0485
General Office Business Hours
Mon-Thu:6:00 AM - 4:00 PM PST
Fri: 6:00 AM - 3:30 PM PST
Parts
Contact us for all parts related needs, from orders to inquiries. Call, email, contact us on our web-
site at the “Contact Us” page.
KVAL EFX System Operation Manual
KVAL EFX System Operation Manual
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For machinery support and troubleshooting. Call, email, contact us on our website at the “Contact
Us” page.
Mon-Fri:4:00 AM - 4:00 PM PST
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Contact Us” page.
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the “Contact Us” page.
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http://www.kvalinc.com
KVAL EFX System Operation Manual
NOTICE OF OWNERSHIP OF KvalCAM SOFTWARE AND LIMITED LICENSE TO
USE
READ THIS NOTICE CAREFULLY BEFORE USING THE KvalCAM SOFTWARE WHICH OPERATES
MACHINERY. THIS DOCUMENT CONSTITUTES NOTICE TO YOU THAT YOU HAVE A LIMITED
LICENSE TO USE THE KvalCAM SOFTWARE ON THE TERMS AND CONDITIONS APPEARING BELOW.
BY USING THE KvalCAM SOFTWARE YOU ARE CONSENTING TO BE BOUND BY THIS LIMITED
LICENSE. IF YOU DO NOT AGREE TO ALL OF THE TERMS OF THIS LICENSE, THEN DO NOT USE THE
KvalCAM SOFTWARE.
, Inc., is the owner of all rights in respect of the software and documentation (referred to as “Licensor”). You are the
purchaser of Machinery operated by the KvalCAM Software are the “Licensee”.
The computer program(s) and related documentation and materials (herein collectively referred to as “the KvalCAM
Software” and further defined herein) which are used in the operation of the Machinery are licensed, not sold, to you
for use only upon the limited terms of this license, and Licensor reserves any rights not expressly granted to you.
Licensor retains all ownership of the KvalCAM Software.
Title, ownership rights, and intellectual property rights in the KvalCAM Software shall remain with, Inc. The Kval-
CAM Software is protected by copyright laws and treaties. Title and related rights 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 KvalCAM Software in the computer component of the Machin-
ery.
c.“Use” means executing the KvalCAM Software for purpose of operating the Machinery and
use of the documentation for properly operating KvalCAM Software.
2. Grant of License.
a.Licensor hereby grants Licensee a non-exclusive, non-transferable license to Use the Kval-
CAM Software upon payment of all amounts due for the purchase of the related Machinery.
b.Licensee will make no copies of the KvalCAM Software or alter the KvalCAM Software in
any way. Title to the KvalCAM Software will remain vested in Licensor, and nothing in this
License will give or convey any right, title or interest therein to Licensee except as a licensee.
c.Licensee agrees that it will use the KvalCAM Software or related documentation directly or
indirectly for the benefit of Licensee, and only pursuant to the scope of the grant of the License
set forth herein.
d.Licensee will not decode, alter, decompile, reverse engineer, perform reverse analysis on or
disassemble the KvalCAM Software.
e.This License will terminate automatically if Licensee fails to comply with the limitations
described above.
Table of Contents
KVAL EFX Manual
Chapter 1 Introduction to the EFX System
Overview of the EFX System................................................... 1-2
About this Manual.................................................................................1-4
Operation Manual .................................................................................1-4
Service Manual.....................................................................................1-4
KvalCAM Reference Manual ................................................................1-4
Safety First!.............................................................................. 1-5
Safety Sheet Sign-Off Sheet.................................................................1-5
Safety Terminology of Labels................................................................1-5
Safety Guidelines..................................................................... 1-6
Training.................................................................................................1-6
Protective Gear.....................................................................................1-6
When the Machine is Powered and Running........................................1-6
Compressed Air ....................................................................................1-7
Electrical ...............................................................................................1-7
Pinch Points..........................................................................................1-9
Before Conducting Maintenance ..........................................................1-9
Laser Warnings...................................................................................1-10
Compliance with Codes and Regulations...........................................1-10
Other Hazard Control Action...............................................................1-10
Follow Your Company’s Safety Procedures........................................1-10
Lockout Tagout Guidelines ...................................................... 1-11
Follow the P-R-O-P-E-R lockout rule of thumb...................................1-11
Lockout Tagout Procedure....................................................... 1-12
Pre-Steps Before Lockout Tagout.......................................................1-12
Lockout Tagout Power ........................................................................1-12
Lockout Tagout Air Supply ..................................................................1-13
Start Maintenance...............................................................................1-13
Post Maintenance Steps.....................................................................1-13
Zero-Energy to Start-Up .......................................................... 1-15
Inspect ................................................................................................1-15
Clean Up.............................................................................................1-15
Replace Guards..................................................................................1-15
Check Controls ...................................................................................1-15
Remove Locks....................................................................................1-15
Perform Visual Checks .......................................................................1-15
Close the Cage Gate ..........................................................................1-16
Getting Help from KVAL........................................................... 1-17
Kval Return and Warranty Policy............................................. 1-18
Send the Item .....................................................................................1-18
KVAL EFX Manual
Table of Contents
Acceptance of Return .........................................................................1-18
Refund Turnaround Time....................................................................1-18
Kval Errors..........................................................................................1-18
Customer Errors .................................................................................1-19
Shipper Errors.....................................................................................1-19
Warranty Replacement Parts..............................................................1-19
Safety Sign-Off Sheet .............................................................. 1-21
A Note to the Operator........................................................................1-21
Chapter 2 Operation of the EFX Line
About the EFX Process ........................................................... 2-2
How to Position a Door for Cutting .......................................... 2-3
Types of Cuts........................................................................................2-3
Summary of the Controls on the Machine Line........................ 2-4
Operators Station..................................................................................2-4
Main Machine Controls.........................................................................2-4
Foot Pedal Control................................................................................2-4
Initial Powering Operations for the EFX................................... 2-5
How to Power Up the Vision Line .........................................................2-5
.Home the Machine Line.......................................................................2-6
How to Power Down the Machine.........................................................2-6
About Emergency Stops.......................................................................2-7
To Resume Normal Operation after an E-Stop .....................................2-7
Other Safety Controls ...........................................................................2-7
The Machine Start Summary ................................................... 2-8
Summary of the KvalCAM Interface ........................................ 2-10
Libraries and Machine Line Screens ..................................................2-10
Machine Control and Calibration Screens ..........................................2-10
Status and Log Screens .....................................................................2-11
About Machine Status Feedback............................................. 2-12
About the EFX Interface Screens ............................................ 2-13
About the EFX Main Screen ...............................................................2-13
EFX Main Screen................................................................................2-14
About Speed Control ..........................................................................2-14
About the Edge SS Manual Servo Control Tab........................ 2-17
About the Tool Path Preview ................................................... 2-19
Tool Path Review Procedure ..............................................................2-20
Selected Path .....................................................................................2-20
Table of Contents
KVAL EFX Manual
Display Window ..................................................................................2-21
Instructions Tab...................................................................................2-22
Options Tab.........................................................................................2-22
Analysis Tab........................................................................................2-23
Json Tab .............................................................................................2-23
About the Tool Config Tabs...................................................... 2-24
Unlock the Tool Slot Configuration (Option)........................................2-24
About Using Tool Configuration ..........................................................2-24
To Unlock the Configuration...............................................2-25
To Lock the Configuration ..................................................2-25
Enable or Disable Tool........................................................................2-25
About the Tool Parameters .................................................................2-26
Tool Config. Parameter Definitions .....................................................2-27
About Tool Locations ..........................................................................2-29
About Chisel Locations.......................................................................2-29
About Using Tool Configuration ..........................................................2-31
Measuring Tool Length .......................................................................2-31
About the Status and Log Screens.......................................... 2-32
About the Status Screen ....................................................................2-32
About the Log Screen.........................................................................2-33
Description of the Light Tower ................................................ 2-34
Chapter 3 Calibration of the Machine Line
About Calibration ..................................................................... 3-2
About the Calibration Menus and the Calibration Reference Cut.........3-2
Before you Calibrate.............................................................................3-2
About the Calibration Tabs....................................................... 3-3
Access to the Calibration Adjustments .................................................3-3
Unlock the Calibration (Option).............................................................3-4
Enter a Positive or Negative Number? .................................... 3-5
Door Edge Axis Directions ....................................................................3-5
Door Face Axis Directions ....................................................................3-6
How to Enter Calibration Data ................................................. 3-7
About The Calibration Box....................................................................3-7
About Restore Points............................................................................3-8
About the EFX Calibration Screen........................................... 3-9
EFX Calibration Screen ........................................................................3-9
Calibration Selections...........................................................................3-9
About Calibration Sequence .................................................... 3-10
KVAL EFX Manual
Table of Contents
Step 1: Calibrate the Carriage Stop......................................... 3-11
Procedure ...........................................................................................3-11
Step 2: Calibrate the Length and Thickness Feelers............... 3-12
Process to Calibrate the Length and Thickness .................................3-12
Step 3: Calibrate the Depth Feeler (Option) ............................ 3-14
Before Calibrating...............................................................................3-14
Process to Calibrate the Probe Depth ................................................3-15
Step 4: Calibrate the Face Axes .............................................. 3-16
Process to Calibrate the Face Carriage..............................................3-16
Face Axis Calibration Reference Cut..................................................3-16
Step 5: Calibrate the Face Tools.............................................. 3-18
Face Tool Locations............................................................................3-18
Process to Calibrate the Face Tools ...................................................3-18
Face Tools Calibration Reference Cut ................................................3-19
Step 6: Calibrate the Edge Carriage........................................ 3-20
Edge Axis Calibration Reference Cut .................................................3-20
Step 7: Calibrate the Edge Tools ............................................. 3-21
Edge Tool Locations ...........................................................................3-21
Chisel Locations .................................................................................3-22
Edge Axis Calibration Reference Cut .................................................3-22
Process to Calibrate the Edge Tools...................................................3-22
Edge Tools Calibration Reference Cut................................................3-23
Predrill.................................................................................................3-23
Routers ...............................................................................................3-23
Chisels................................................................................................3-23
Routers: How to Isolate and Calibrate a Specific Router......... 3-24
Chapter 4 Tour of the EFX Line
Front View of the EFX.............................................................. 4-2
Operator’s Station on the EFX................................................. 4-3
Operator’s Screen Layout.....................................................................4-3
Examples Door Placement (Left Side of Screen) .................................4-3
EFX Controls ........................................................................... 4-4
Main Machine Controls.........................................................................4-4
Foot Pedal Control................................................................................4-4
EFX Fence and Door Clamps...............................................................4-5
Description of the Light Tower .............................................................4-5
Assemblies on the Main Cutter Head ...................................... 4-6
Table of Contents
KVAL EFX Manual
About Door Probes .................................................................. 4-7
About Encoders ....................................................................................4-7
About Length and Thickness Probes....................................................4-7
Depth Probe..........................................................................................4-8
Laser Safety Scanners ............................................................ 4-9
About Sensors ......................................................................................4-9
Location of Servo Motors and Valve Bank Locations .............. 4-10
Servo Motor Locations........................................................................4-10
Valve Bank Locations .........................................................................4-10
About the Electrical Panels...................................................... 4-11
EFX Main E-Panel ..............................................................................4-11
EFX High Freq Panel..........................................................................4-12
About the Nodes ...................................................................... 4-13
Typical Block Diagram of Network Connections .................................4-13
Graphical Sample of Node Connections and Power Distribution .......4-14
KVAL EFX Manual
Table of Contents
1-1
KVAL Operation Manual
CHAPTER 1 Introduction to the EFX System
Chapter 1 at a Glance
The following information is available in this chapter:
TABLE 1- 1. Summary of Chapter
Section Name Summary Page
Overview of the EFX Door
System
This section provides an overview of the
machine. It includes a general description
and a table of available options
page 1-2
Safety First! IMPORTANT safety information is
described in this section
page 1-5
Lockout-Tagout Guidelines Procedures describing Lockout Tagout. page 1-11
Zero-Energy to Start-Up Procedure to power up your machine for the
first time.
page 1-15
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 plate tor provide to KVAL,
service center hours, and return procedures
page 1-17
Safety Sign-Off Sheet A record to track operators that are trained
on the machine.
page 1-21
Overview of the EFX System
KVAL Operation Manual
1-2
Overview of the EFX System
All major electronic components including the on board PC, PLC, drives and servo motors are by
Beckhoff. Software is KvalCAM our latest CNC code generation software designed specifically to
simplify and manage nearly unlimited numbers of door hardware templates.
Machine files are created using a graphical interface. Once created, the software automatically
generates g-code to drive the machine movements. Spindle selection and tool path are combined
to efficiently process templates without tear-out in even delicate door edges and faces including
plastic laminates.
Note: Barcode or RFID scanning is available.
This machine is very similar in appearance to the standard Kval 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 or special shapes for card
locks.
The machine processes a wide range of door sizes up to 2-1/4” x 4’0” x
9’ with ability to complete virtually all marketable hardware sets,
including hinge preps, various multipoints, card locks and deep pocket
locks.
The machine’s L shaped inverted castor bed makes it simple to orient
doors for end work as well, so this machine is also ideal for overhead
closers, top and bottom pivots and manual or automatic flush bolts.
Many customers also use the edge detailing heads to rout out door rails
or stiles for cut-down doors.
Overview of the EFX System
1-3
KVAL Operation Manual
Edge detailing spindles are by Colombo and include a standard rotation 3HP, reverse rotation
3HP, 11HP deep mortise, and 2HP drill spindle for screw pilot holes. Four corner chisels are stan-
dard to square hinge pockets or lock face plates. The entire edge detailing tower automatically
pivots from zero to three degrees to match the door edge, including mid sequence for face plate
and deep pocket lock.
Consider the Kval FT-1 Door Flipper, or even better since it eliminates flipping completely, con-
sider the Kval DL-NCD or DL-NCX door light router as a companion machine with EFX. Either door
light router can process lock face holes from the top door face as well as door lights. Since they
are also KvalCAM 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 motors. It is inde-
pendent of the edge detailing tower. In operation,
the software will position the edge detailing
tower an appropriate distance away from the
face heads, and then a door reference stop will
project from the edge tower to position the
door for clamping (left or right). This makes
face hole or slot locations completely pro-
grammable as part of a lock file. The underside face spindles typically
cut all the way through the door, but for face details only half way through the
door from the top face – the door is flipped and processed in a second step.
Overview of the EFX System
KVAL Operation Manual
1-4
About this Manual
This manual is part of a package delivered with the machine line.
Operation Manual
Operation Manual includes the following:
Service Manual
Service Manual includes the following
KvalCAM Reference Manual
KvalCAM Reference Manual includes the following
Chapter Title Description
1Introduction Descriptions of Machine Line and
Safety Information.
2
Operation Inter-
face
Descriptions of how to power
machine line, and operator inter-
face user screens.
3Calibration Descriptions of Calibration Rou-
tines and how to use the interfaces
4Tour of EFX Identification and descriptions of
the EFX machine assemblies.
Chapter Title Description
1Introduction Safety Information.
2System IT Admin-
istration
Descriptions of the PLC system,
and computer system.
3Maintenance Maintenance steps for the
machine line
4Trouble Shooting Troubleshooting tips and theory of
operation.
Chapter Title Description
1KvalCAM reference Description of the Interface
2KvalCAM Examples Examples of Common Door Job
Features
3KvalCAM Common
Terms
Common terms associated with
KvalCAM
Safety First!
1-5
KVAL Operation Manual
Safety First!
Safety Sheet Sign-Off Sheet
At the end of this chapter, there is a safety sign-off sheet. It lists personnel and machine safety cri-
teria to understand before operating the machine. It is highly recommended that personnel operat-
ing, working on a machine meet the criteria listed in this sheet. It is recommended the sheet be
signed and kept for records. See “Safety Sign-Off Sheet” on page 1-21.
Safety Terminology of Labels
In addition to the nameplate, KVAL machines may have other warning labels or decals that provide
safety information to operators. Safety labels should be clearly visible to the operator and must be
replaced if missing, damaged, 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.
This machine is a powerful electro-mechanical motion control
system. You should test your motion system for safety under
all potential conditions. Failure to do so can result in dam-
age to equipment and/or serious injury to personnel.
Safety Guidelines
KVAL Operation Manual
1-6
Safety Guidelines
In addition to the caution and warning labels affixed to this machine, follow the guidelines below
to help ensure the safety of equipment and personnel.
Note: Different versions of the stickers may have been applied to the machine. The
intent of safety is the same.
Training
Ensure that all employees who operate this machine are aware of and adhere to all safety precau-
tions posted on the machine and are trained to operate this machine in a safe manner. Figure 1-1
shows a sample of safety labels addressing training.
Read the Manual
FIGURE 1-1. Read the Manual Labels
Protective Gear
Never operate the machine without proper eye and ear protection. Figure 1-2 shows a sample of
safety labels addressing safety gear.
FIGURE 1-2. protective Gear Labels
When the Machine is Powered and Running
Serious injury or death could occur if these general rules are not followed. Figure 1-3 shows a
sample of safety labels addressing machine safety.
Never reach hands beyond safety cage. Servo motors can unexpectedly move
quickly.
Never clear screws or hinges out of the machine while it is running.
Never reach into the router area to retrieve a hinge. The router may still be running
down after shut down.
Safety Guidelines
1-7
KVAL Operation Manual
Never 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.
Never operate the machine without the safety guards.
FIGURE 1-3. Machine Safety Labels
Compressed Air
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 performing any maintenance or repairs on this machine turn off the main air disconnect.
Lockout and tagout this connection.See “Lockout Tagout Procedure” on page 1-12.
Electrical
Electrical circuitry on this machine is protected by an approved lockable disconnect circuit. In
addition to this equipment, you must install an approved disconnect for the electrical power sup-
plying this machine
FIGURE 1- 4. Electrical Box Labels
Safety Guidelines
KVAL Operation Manual
1-8
Before performing any repairs or maintenance, lockout and tagout must be installed at all loca-
tions. See “Lockout Tagout Procedure” on page 1-12.
All maintenance and repairs to electrical circuitry should only be performed by a qualified electri-
cian.
Warning: Lever Style Electrical Panels: Lever style panels have a lock system that can
be unlocked to allow access to electrical penal that still has power applied.
High Voltage may cause injury or death. Do not open the cabinets with-
out High Voltage training or without permission from a supervisor.
Warning: Disconnect Style Panels: When opening the cabinet you must first turn off
the disconnect switch. When the cabinet door is open there is still power
on the top side of the disconnect switch. Some machines are powered by
more than one supply located at different locations. Do not open the cabi-
nets without High Voltage training or without permission from a
supervisor.
Still has power
in OFF position
Safety Guidelines
1-9
KVAL Operation Manual
Pinch Points
A pinch point is a mechanical point where a person or part of a person's body can be caught
between moving parts of a machine, between the moving and stationary parts of a machine, or
between product and any part of the machine.
Always be aware of the safety stickers on the machine
Note: Different versions of the stickers may have been applied to the machine. The
intent of safety is the same.
FIGURE 1-5. Pinch Point Warning Labels
Before Conducting Maintenance
Prior to performing any maintenance, repairs, cleaning or when clearing jammed debris, you must
disconnect, tag out, or lock out the electrical and air pressure systems. This should be done in
accordance with applicable state and/or federal code requirements
.
FIGURE 1-6. Maintenance Warning Labels
Safety Guidelines
KVAL Operation Manual
1-10
Laser Warnings
On some machines, laser indicators are used to set boundaries. Follow the laser manufacturers
safety precautions.
Compliance with Codes and Regulations
KVAL advises that you request an on-site state safety review of your installation of this machine.
This is to ensure conformance to any additional specific safety and health regulations which apply
in your geographic area.
Other Hazard Control Action
If you believe any part or operation of this machine is in violation of any health or safety regula-
tion, STOP production. 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
of this machine
Follow Your Company’s Safety Procedures
In addition to these safety guidelines. Your company should have on-site and machine specific
safety procedures to follow.
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Kval EFX Operating instructions

Category
Grass trimmers
Type
Operating instructions

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