Kval Edge Patriot Owner's manual

Innovation, Quality & Honesty

Standard

Auto Feed

System Reference

Published: 5/7/08

Edge Patriot & Edge STS

Proprietary Notice

This document contains confidential and trade secret information, which is proprietary to Kval, Inc.

(“Kval”), and is protected by laws pertaining to such materials. This document, the information in this

document, and all rights thereto are the sole and exclusive property of Kval, are intended for use by cus-

tomers and employees of Kval, and are not to be copied, used, or disclosed to anyone, in whole or in

part, without the express written permission of Kval. For authorization to copy this information, please

call Kval Customer Support at (800) 553-5825 or fax (707) 762-0485. Outside the U.S. and Canada, call

(707) 762-7367.

KVAL 2006 and DL-NCB are trademarks of Kval, Incorporated.

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

Customer Service: For further information about this manual or other Kval Incorporated products,

contact the Customer Support Department

• http://www.kvalinc.com/customer_service.html (lists all the representatives, including email

addresses and phone numbers)

• Mailing address:

Customer Support Department

Kval Incorporated

825 Petaluma Boulevard South

Petaluma, CA 94952

• 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

• Business hours:

Technical Support: 4:00 AM to 4:30 PM Pacific Standard Time, Monday through Friday

Parts & Service Sales: 6:30 AM to 4:30 PM Pacific Standard Time, Monday through Friday

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• Email: [email protected]

•

Your Feedback is Welcome: To help us design products that make your job easier and your business

more successful, we'd like to gain your perspective about 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 sugges-

tions for improvement to [email protected]. (NOTE: This is not a way to get customer sup-

port. For that, please refer to the Customer Service contact information above.) Thank you!

Edge Patriot & Edge STS a

Table of Contents

CHAPTER 1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Overview of the Edge Patriot & Edge STS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Safety First! . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

Lock Out Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

To lock out the Edge Patriot & Edge STS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

Lockout and Tagout Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6

Follow the P-R-O-P-E-R lockout rule of thumb. . . . . . . . . . . . . . . . . . . . . . . . . 1-6

CHAPTER 2 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Quick Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

Tour . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5

Control Panels: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5

Main Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5

Run Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5

Door Clamps: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6

Stop location: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6

How to position the door for cutting: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7

Top and bottom cuts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7

Edge cuts for doors less than 9.5’ in length. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7

Edge cuts for doors 9.5’ or greater in length. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8

KVAL 2006 User Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9

Launching the KVAL 2006 User Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9

KVAL 2006 User Interface Visual Tour . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9

Keystroke Shortcuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10

Entering Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10

Auto Feed (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11

Control Panel One . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11

Control Panel Two . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12

Powering Up the Edge Patriot & Edge STS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13

Powering up the system includes: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13

Powering Down the Edge Patriot & Edge STS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15

Powering down the system includes: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15

To Power Down the Edge Patriot & Edge STS . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15

Emergency Shutdown and Recovery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16

To Resume Normal Operation after an E-Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16

Running Pre-Defined (Saved) Door Files . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17

To Cut a Door Using a Saved Door File . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17

Homing the Edge Patriot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19

To Home the Edge Patriot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19

bEdge Patriot & Edge STS

CHAPTER 3 Advanced Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Creating a New Template from an Existing Template . . . . . . . . . . . . . . . . . . . . . . . . 3-3

To Create New Template Bases on Existing Template . . . . . . . . . . . . . . . . . . . . . . 3-3

Modifying (Permanently) an Existing Template . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

To Modify an Existing Template . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

Deleting Templates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5

To Delete a Template . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5

Creating and Saving a Permanent Door File . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6

Creating a New Permanent Door File . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7

Creating a Permanent Door File from an Existing Door File . . . . . . . . . . . . . . . . . . . 3-8

Modifying (Permanently) an Existing Door File . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9

To Make a Permanent Modification to an Existing Door File . . . . . . . . . . . . . . . . 3-9

Deleting a Door File . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10

To Delete a Door File . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10

Cylindrical Lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11

Creating and Saving a New Cylindrical Lock Template . . . . . . . . . . . . . . . . . . 3-11

To Create a New Cylindrical Lock Template . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12

More on Plate Radius . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13

For multiple plate corner radii: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13

Flushbolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15

Creating and Saving a New Flushbolt Template . . . . . . . . . . . . . . . . . . . . . . . . 3-15

To Create a New Flushbolt Template . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16

Deep Mortise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17

Creating and Saving a New Deep Mortise Template . . . . . . . . . . . . . . . . . . . . . 3-17

To Create a New Deep Mortise Template . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18

Auto Flushbolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19

Creating and Saving a New Auto Flushbolt Template . . . . . . . . . . . . . . . . . . . 3-19

To Create a New Auto Flushbolt Template . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20

More on Plate Radius . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21

For multiple plate corner radii: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21

Flushbolt (Bottom Entry) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23

Creating and Saving a New Flushbolt (Bottom Entry) Template . . . . . . . . . . . 3-23

To Create a New Flushbolt (Bottom Entry) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24

SOSS Hinge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25

Creating and Saving a New SOSS Hinge Template . . . . . . . . . . . . . . . . . . . . . 3-25

To Create a New SOSS Hinge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26

Holder (Bottom Entry) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-27

Creating and Saving a New Holder (Bottom Entry) Template . . . . . . . . . . . . . 3-27

To Create a New Holder (Bottom Entry) Template . . . . . . . . . . . . . . . . . . . . . . . 3-28

Holder (Top Entry) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29

Creating and Saving a New Holder (Top Entry) Template . . . . . . . . . . . . . . . . 3-29

To Create a New Holder (Top Entry) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-30

Edge Patriot & Edge STS c

Hinge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-31

Creating and Saving a New Hinge Template . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-31

To Create a New Hinge Template . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-32

T-Strike . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-33

Creating and Saving a New T-Strike Template . . . . . . . . . . . . . . . . . . . . . . . . . 3-33

To Create a New T-Strike Template . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-34

Olive Hinge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-35

Creating and Saving a New Olive Hinge Template . . . . . . . . . . . . . . . . . . . . . . 3-35

To Create a New Olive Hinge Template . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-36

L-Pivot Hinge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-37

Creating and Saving a New L-Pivot Hinge Template . . . . . . . . . . . . . . . . . . . . 3-37

To Create a New L-Pivot Template . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-38

Point to Point Drill (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-39

To add a Point to Point Drill template to a Hinge or Plate template: . . . . . . . . . . 3-39

The Subnum.txt file . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-40

How to add or modify a Point to Point Drill template . . . . . . . . . . . . . . . . . . . . . 3-41

Command Reference: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-41

Plate Drill section of Subnum.txt file . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-43

Hinge Drill section of Subnum.txt file . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-44

CHAPTER 4 System IT Administration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

System Architecture . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

Backing up System Files . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

Network Integrated Door System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

Door files . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

File Propagation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

New Door File and Door Template file distribution . . . . . . . . . . . . . . . . . . . . . . . 4-4

Network ON/OFF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4

DoorNum.dbf file . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4

Barcode Reading and Parsing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5

Parsing: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5

L,Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5

Len: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6

M,Start,Stop: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6

R,Length: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6

How it all works together: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6

Remote Programming Station . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8

Set Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8

Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8

CHAPTER 5 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

Daily . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

Weekly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

dEdge Patriot & Edge STS

May and December Checkups . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3

Lubrication Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4

Linear Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4

Flange Bearing and Pillow Blocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4

Approved Lubrication Products for Lubricators . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4

Gear Motor Lubrication Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4

Ball Screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4

Adjusting the Air Line Lubricator (not available on all machines) . . . . . . . . . . . . 5-5

Grease Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6

X Axis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6

Back Section Grease Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7

Deep Mortise Collet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11

Tool Insertion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11

Collet Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11

Cutting Side Stops . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13

CHAPTER 6 Calibrating the Edge Patriot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

How to modify a Parameter: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2

Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4

Lock Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4

Lock Location RH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4

Loch Location LH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4

Stops . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5

Left Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5

Middle Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5

Right Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6

Left Outboard Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6

Right Outboard Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7

Deep mortise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7

DM Vertical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7

DM Diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8

Deep Mortise X: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8

Depth parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8

Plate Router . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9

Router Vert Offset (Vertical Offset) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9

Router Diam (Diameter) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9

Depth parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9

Counter Rotating Router . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10

Cnt Rout Vert, Cnt Rout Horiz (Vertical, Horizontal) . . . . . . . . . . . . . . . . . . . . . 6-10

Cnt Rout Diam (Counter Router Diameter) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10

Side Drills . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11

Chisels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11

Predrills . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12

Predrill 1 X offset and Predrill 1 vert offset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12

Edge Patriot & Edge STS e

Depth parameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12

CHAPTER 7 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

Troubleshooting the Air Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2

Adjusting Cylinder Extension Speed: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3

Adjusting Cylinder Retraction Speed: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3

Troubleshooting Electrical Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4

If the Power Stops During Normal Operation . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4

Troubleshooting with the Status Light Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5

Adjusting Limit Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8

Troubleshooting Photo Detectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9

Reference Bolt Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11

Limit - Switch Timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13

General process description: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13

KVAL2006 Limit - Switch Timing Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . 7-15

Axis Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-17

Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-17

Auto Feed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-18

Auto Feed System Description (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-19

Sequence of events: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-19

Cushion Stop Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-21

Getting Help from Kval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-23

Product Return Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-23

Part Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-25

Feed System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-25

Top View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-25

Bottom View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-26

Back View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-27

Back Section: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-29

Infeed View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-29

Point to Point Drill (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-30

Back View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-31

Outfeed View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-32

Top View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-33

Wiring Map . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-34

Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-35

fEdge Patriot & Edge STS

Edge Patriot & Edge STS 1-1

CHAPTER 1 Introduction

This chapter provides a description of the Edge Patriot & Edge STS product and identifies safety guide-

lines to ensure personnel safety and proper equipment use.

Overview of the Edge Patriot & Edge STS

The Edge Patriot is a computer-controlled router designed to machine architectural doors for T-strikes,

concealed closures, flush bolts, leaf and European hinges, re-railing and re-stiling, end pivots, or other

mortises up to 3 inches deep that can be cut with a router bit. Also, an optional secondary mortising

unit makes it possible to machine deep-mortise locks up to 5-1/2 inches deep.

Design features include a heavy-duty 7-½ HP Perske router mounted to carriage that pivots for a 0-

degree or 3-degree bevel. Baldor servomotors and Thomson ball screws are used for X-, Y-, and Z-axis

travel. The X-axis travel is 96 inches, while the Y- and Z-axis travels are 2 inches each. The Edge

Patriot can be programmed for feed speeds up to 180 inches-per-minute.

The machine tabletop is L-shaped and consists of inverted caster wheels for easy door positioning. The

L-shape allows routing of either rails or stiles by rotating the door. Three doorstops are provided at 4-

foot intervals. The first stop at the corner of the L-table is used for both stile and rail routing, depending

on door orientation. The middle and far end stops are used to machine rails and stiles on opposite swing

doors. This makes it easy to machine top and bottom flush bolts and a T-strike without turning the door

over.

All machine programming is done from the Edge Patriot’s operator’s station, which featuring a touch-

screen interface. This interface allows the operator to begin working by choosing from an array of basic

door templates. The operator can then modify these templates to custom specifications by filling in a

few data fields in the program, such as hinge depth, locations, backset radius and bevel dimensions. For

example, a template’s graphic screen shows a drawing of a door stile with hinge pockets. The operator

fills in blank dimension fields, and the computer directs the machine to perform the cut. Templates can

be saved for future use.

Templates also exist for flush bolts, roller catches, T-strikes, dead bolt plates and mortise locks. The

software makes it simple to couple door templates with mortising location templates for continuous

machining. For example, the router could automatically machine a top manual flush bolt then move

down to machine a dead bolt plate, a T-strike, and then the bottom manual flush bolt.

For efficiency, the operator can enter the details for the next door while the current door is being pro-

cessed. The screen and switches are used to select door thickness, position of machining, and left- or

right-hand machining. For instance, while a door is being machined, the operator can program the next

door for a T-strike pattern called SCHLAGET at 44-½ inches. The operator selects SCHLAGET as the

pattern, enters 44-½ inches, and when the next door is clamped in position, the machine automatically

cuts for the T-strike as specified. If the following door is the same, the “Start” button can be pressed

again to repeat the pattern.

Introduction

1-2 Edge Patriot & Edge STS

Edge Patriot & Edge STS 1-3

Safety First!

The Edge Patriot & Edge STS 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 damage to

equipment and/or serious injury to personnel.

Safety Guidelines

In addition to the caution and warning labels affixed to the Edge Patriot & Edge STS system, follow the

guidelines below to help ensure the safety of equipment and personnel.

Guideline Description

Safety Training Ensure that all employees who operate this machine are aware of and adhere

to all safety precautions posted on the machine and are trained to operate this

machine in a safe manner.

Protective Gear Never operate the machine without proper eye and ear protection.

Entering the Safety

Cage When the machine is on:

• Never reach hands beyond safety cage. Servo motors can unexpectedly

move quickly and out of control.

• Do not clear slugs out of the machine while it is running.

• Never perform any maintenance while machine is running.

• Never clean the machine while running.

• Never walk away from the machine while running.

Compressed Air .

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 supplying this machine.

When opening the cabinet you must first turn off the dis-

connect switch. When the cabinet door is open there is

still power on the top side of the disconnect switch. All

maintenance and repairs to electrical circuitry should

only be performed by a qualified electrician.

Before Conduct-

ing 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 the state and/or fed-

eral code requirements.

Compliance with

Codes and Regula-

tions

KVAL Inc. 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.

The compressed air system connected to this machine should have a three-

way air valve for shut-off and pressure relief. The air supply providing the

pressure to this machine also has a three-way air valve for the

supply line. All cylinders on machine are under high pressure

and can be very dangerous when activated. Before performing

any maintenance or repairs on machine turn the main air discon-

nect off. Lock out and tag out this connection.

Still has power

in OFF position

1-4 Edge Patriot & Edge STS

Other Hazard Con-

trol Action

If you believe any part or operation of this machine is in violation of any

health or safety regulation, it is your responsibility to immediately protect

your employees against any such hazard and bring the matter to our attention

for review and correction, if deemed advisable.

Additional detailed safety guidelines are included in the operating instruc-

tions of this manual. KVAL will be pleased to review with you any questions

you may have regarding the safe operation of this machine.

Edge Patriot & Edge STS 1-5

Lock Out Procedure

This policy is required by OSHA regulation 1910.147 and Cal OSHA’S SB198 ruling of July 1991.

Use the following lockout procedure to secure the Edge Patriot & Edge STS while it is powered down.

During a lockout, you disconnect all power and shut off the air supply. Be sure to use the tagout guide-

lines noted below.

To lock out the Edge Patriot & Edge STS

1.Assess the equipment to fully understand all energy sources (multiple electrical supplies, air 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.Disconnect power

a.Turn the disconnect switches on the main electrical panel to the OFF position. Then pull out

the red tab and place a padlock through the hole. Place your tag on the padlock, as per the tagout

guidelines below. (see example below)

b.Turn the disconnect switch on the larger high-frequency panel to the OFF position. Then pull

out the red tab and place a padlock through the hole. Place your tag on the padlock, as per the

tagout guidelines below

5.Turn the main air valve to the OFF position and place a padlock through the hole (see illustration.).

NOTE: Place your tag on the padlock, as per the tagout guidelines below.

When multiple people are

working on the machine, each

person needs to have a lock on

the handle in the extra holes

provided.

1-6 Edge Patriot & Edge STS

6.Once the locks and tags are in place and all personnel are clear, attempt to operate the machine to

ensure equipment will not operate. When maintenance or repairs are completed, the person who per-

formed the work must ensure all tools, spare parts, test equipment, etc., are completely removed and

that all guards and safety devices are installed.

7.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.

8.The lock and tag can now be removed (only by the person(s) who placed them), and the machine can

be re-energized.

9.The tags must be destroyed and the locks and keys returned to the lockout center.

Lockout and Tagout Guidelines

• Place a tag on all padlocks. On the tags, include your

name and date.

• These locks are only to be removed by the person on

the tag.

• If more than one person is working on the machine,

then each additional person places a lock and tag on

each disconnect. You may only remove your own lock

and tag.

• You may only remove your own lock and tag

Note: 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 and tag

E...... ENERGY: Release stored energy to a zero-energy state

R ...... Recheck controls and test to insure they are in the “OFF” state

Edge Patriot & Edge STS 2-1

CHAPTER 2 Operation

The following chapters explain normal operation of the Edge Patriot & Edge STS.

Operation

2-2 Edge Patriot & Edge STS

Quick Start

Edge Patriot & Edge STS 2-3

Quick Start

1.Apply power to the machine. See “Powering Up the Edge Patriot & Edge STS” on page 2-13.

2.Home the machine. See “Homing the Edge Patriot” on page 2-19.

3.Start the KVAL2006 program. See “Launching the KVAL 2006 User Interface” on page 2-9.

If the machine has auto feed it is now ready to process doors. See “Network Integrated Door Sys-

tem” on page 4-3 for more information.

4. Load door file. See “Running Pre-Defined (Saved) Door Files” on page 2-17

5.Enter the quantity of doors to be processed.

6.The Load light will illuminate. The Load light will stay on as long as the quantity entered in is

greater than 0.

7.Choose which door edge to process first. Check the Edge position lights, and use the Edge toggle but-

ton to select the desired edge.

Note: Edge cut sequence is determined by the order of templates in the door file.

8.Press the DOOR STOP pedal or START SEQUENCE button.

9.Select desired door clamps (See “Door Clamps:” on page 2-6.)

10.Position the door. (See “How to position the door for cutting:” on page 2-7.)

Note: If cutting a beveled door, put the wide side up.

3º 3º

Up

Door

11.Press DOOR CLAMP pedal or START SEQUENCE button

12.If START SEQUENCE button was pressed, the clamps will clamp and the cutting will start; if the

DOOR CLAMP pedal was pushed, press the START SEQUENCE button.

13.If the Auto Unclamp is ON, the clamp will un-clamp after the cuts have been completed. If Auto

Unclamp is OFF, press the DOOR CLAMP foot pedal to unclamp the door.

14.If there are no more cuts, remove the door.

15.If there are more cuts to be made, press the Edge Toggle button to move to the next cut.

16.Move the door to the position indicated by the edge indication light.

17.Go to step 4.

2-4 Edge Patriot & Edge STS

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Kval Edge Patriot Owner's manual

Kval Edge Patriot Owner's manual

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