Kval Edge-SS User manual

Innovation, Quality & Honesty

Service Manual

Published: March 8, 2023

Edge-SS System

Service Manual Edge-SS System

KVAL Edge-SS System Service 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 Technical Support at (800) 553-5825 or fax (707) 762-0485.

Manual Name: Edge-SS Service Manual

Manual Revision:

Edge-SS a trademark of Kval Incorporated.

KvalCAM® is a registered trademark of Kval Incorporated.

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.

email: [email protected]

KVAL Edge-SS System Service Manual

Technical Support

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

email: [email protected]

Field Service Support

For any other inquiries or to schedule on-site service. Call, email, contact us on our website at the

“Contact Us” page.

email: [email protected]

Sales Support

For machinery information, specifications, and quotes. Call, email, contact us on our website at

the “Contact Us” page.

email: [email protected]

KVAL Edge-SS System Service Manual

NOTICE OF OWNERSHIP OF KVALCAM SOFTWARE AND LIMITED LICENSE TO

USE

READ THIS NOTICE CAREFULLY BEFORE USING THE KVALCAM SOFTWARE WHICH OPERATES

KVAL 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.

KVAL, Inc., is the owner of all rights in respect of the software and documentation (referred to as “Licensor”). You

are the purchaser of KVAL 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 KVAL 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 KVAL, Inc. The

KVALCAM 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 KVAL

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 KVAL

Machinery.

c.“Use” means executing the KVALCAM Software for purpose of operating the KVAL

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 KVAL Machin-

ery.

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

Edge-SS Service Manual

Chapter 1 Introduction to the Edge-SS System

Overview of the Edge-SS System ........................................... 1-2

About this Manual.................................................................................1-4

Safety First!.............................................................................. 1-5

Safety Sheet Sign-Off Sheet.................................................................1-5

Safety Terminology of Labels................................................................1-5

Safety Guidelines..................................................................... 1-7

Training.................................................................................................1-7

Protective Gear.....................................................................................1-7

When the Machine is Powered and Running........................................1-7

Lockout Tagout Guidelines ...................................................... 1-8

Follow the P-R-O-P-E-R lockout rule of thumb.....................................1-8

Lockout Tagout Procedure....................................................... 1-9

Pre-Steps Before Lockout Tagout.........................................................1-9

Lockout Tagout Power ..........................................................................1-9

Lockout Tagout Air Supply ..................................................................1-10

Start Maintenance...............................................................................1-10

Post Maintenance Steps.....................................................................1-10

Zero-Energy to Start-Up .......................................................... 1-12

Inspect ................................................................................................1-12

Clean Up.............................................................................................1-12

Replace Guards..................................................................................1-12

Check Controls ...................................................................................1-12

Remove Locks....................................................................................1-12

Perform Visual Checks .......................................................................1-12

Close the Cage Gate ..........................................................................1-13

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

Safety Sign-Off Sheet .............................................................. 1-18

A Note to the Operator........................................................................1-18

Chapter 2 Maintenance of the Edge-SS

Edge-SS Service Manual

Table of Contents

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

300 Cycle Maintenance Steps ................................................. 2-4

Clean, Clean, Clean!.............................................................................2-4

600 Cycle Maintenance Steps ................................................. 2-5

Check Air Gauges and Inspect Water Traps.........................................2-5

Inspect Tooling......................................................................................2-5

Lubricate inside of Hopper (990-Series Only).......................................2-6

Empty Dust Collection Units .................................................................2-6

3,000 Cycle Maintenance Steps .............................................. 2-7

Inspect Feed Belts................................................................................2-7

Inspect Screw Drop Tubes on Six Shooter (990-Series Only)..............2-7

Inspect all Photo Eyes ..........................................................................2-8

Inspect Limit Switches ..........................................................................2-8

Inspect Screw Receiver Parts (990-Series Only) .................................2-8

Inspect Airlines......................................................................................2-9

Refill Lubricators...................................................................................2-9

Grease Ball Screw Bearings...............................................................2-10

Clean Bearing Shafts..........................................................................2-10

12,000 Cycle Maintenance Steps............................................ 2-11

Inspect Chains for Proper Tension......................................................2-11

Inspect Air Cylinders...........................................................................2-11

Inspect Hydraulic Lines.......................................................................2-11

Inspect Ball Rail Shafts.......................................................................2-12

Inspect Ball Screw Axle ......................................................................2-12

Clean and Lubricate Slides, Cylinder Rods and Bearing Shafts.........2-12

Clean inside Hopper ...........................................................................2-13

72,000 Cycle Maintenance Steps............................................ 2-14

Inspect Nuts and Bolts........................................................................2-14

Check Door Feeding Transition ..........................................................2-14

Electrical .............................................................................................2-14

Computer Backup...............................................................................2-14

Wash Filter and Lubricator Bowls .......................................................2-15

Maintenance NO-GOES .......................................................... 2-16

About Bearings ........................................................................ 2-17

About Pillow Block Bearing Housings.................................................2-17

About Flange Bearing Housings.........................................................2-18

About Ball Rail Bearings.....................................................................2-18

About Tapered Bearings .....................................................................2-19

Tapered Bearing Housings .................................................................2-19

Ball Screw Nut ....................................................................................2-20

Table of Contents

Edge-SS Service Manual

Ball Screw Drive Assembly .................................................................2-20

Pulley and Idler Shafts........................................................................2-21

Lubrication Schedule ............................................................... 2-22

Kval Lubrication Kit.............................................................................2-23

Sample of Grease Locations for Edge-SS............................... 2-24

Locations of Hub Bearings..................................................................2-25

Locations of Rail Bearings on the Carriage Heads.............................2-26

Deep Drill Bearing Locations (Option) ................................................2-27

Maintenance of Lift Drive Chains........................................................2-27

Description of Air Input System................................................ 2-28

Air Input with Lubrication ...................................................................2-28

Adjusting the Air Line Lubricator ........................................................2-28

Priming the Air Line Lubricator............................................................2-29

Air Line Without Lubricator .................................................................2-29

Identifying Edge-SS Tools........................................................ 2-30

Tool Location Edge-SS .......................................................................2-30

Edge-SS Tool Collet Wrench and Shaft Wrench List..........................2-31

How to Access the Tool Config Screen.................................... 2-32

Check the Tool Config.........................................................................2-32

Measure the Tool Length ....................................................................2-33

Remove and Replace the Router or Pre-Drill Bits .................. 2-34

About Chisels........................................................................... 2-36

Chisel Orientation on Machine............................................................2-36

Changing Chisels on a Machine.........................................................2-37

About the Self Lubricator Module ............................................ 2-38

How the Self Lubricator Works ...........................................................2-38

Replace the Lubricator Well................................................................2-38

Collet Torque Values................................................................ 2-40

Addition Collet Torque Values.............................................................2-41

Chapter 3 Troubleshooting the Edge-SS Line

Troubleshooting Basics ........................................................... 3-5

Before you Adjust..................................................................................3-5

Analyze the Sub Systems.....................................................................3-7

About Motion Control ............................................................... 3-8

Sequencing...........................................................................................3-8

Point to Point ........................................................................................3-8

Incremental...........................................................................................3-8

Edge-SS Service Manual

Table of Contents

Basic Control Circuit ................................................................ 3-9

About a Typical Contactor Control ........................................... 3-10

About Contactor Troubleshooting .......................................................3-11

About Typical VFD Motor Drive Control................................... 3-12

About the VFD ....................................................................................3-13

About VFD Troubleshooting................................................................3-14

About a Typical Pneumatic Circuit ........................................... 3-15

Typical Pneumatic Assembly ..............................................................3-16

About the Coil (Solenoid)....................................................................3-16

About Cylinder Operation ...................................................................3-17

How the Pneumatic System Works ....................................................3-17

Important Notice about Adjusting Cylinder Speed ..............................3-19

Adjusting Cylinder Extend Speed .......................................................3-20

Adjusting Cylinder Retraction Speed .................................................3-20

Valve Bank Locations .............................................................. 3-21

Location of Valve Banks on the Edge-SS ...........................................3-21

Network System Overview....................................................... 3-22

Connections to Servo Drives ..............................................................3-22

Edge-SS Servo Motor Locations ........................................................3-23

About Switches and Sensors................................................... 3-24

Using Sensors to Trouble Shoot .........................................................3-25

Description of the Light Tower ................................................ 3-26

1-1

CHAPTER 1 Introduction to the Edge-SS System

Chapter 1 at a Glance

The following information is available in this chapter.

Section Name Summary Page

Overview of the Edge-SS

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 1-7

Zero-Energy to Start-Up Procedure to power up your machine for the

first time.

page 1-11

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 1-13

Safety Sign-Off Sheet A record to track operators that are trained

on the machine.

page 1-17

Overview of the Edge-SS System

Kval Operation Manual

1-2

Overview of the Edge-SS System

The Edge-SS is a computer-controlled router designed to machine architectural doors for Edge

Cuts. Many customers also use the Edge for re-railing & re-stiling operations

.

A Door Touch-off system is used to automatically accurately determine the length of the door

from the '0' or the fixed stop on the left end of the Edge-SS. With this system, both left and right

hand doors are positioned against the same stop. The machining head automatically adjusts to the

correct position based on the door hand selection that is entered. This system also increases pro-

ductivity by eliminating extra door clamping steps and reduces the chance of positioning errors.

Note: Minimum sensing range for door touch off is 14". For doors less than 14" wide

the exact width will need to be manually measured and entered into the Edge -

SS

AC servomotors, precision rack and pinion and ball screw drives are used for X, Y and Z travel.

The X axis travel is 130", the Y axis travel is 20" and Z axis travel is 9-1/2". For control, our ergo-

nomically located electrical panel contains an industrial Windows compatible computer con-

Examples of diverse cuts:

• hinge pockets

• T-strikes

• concealed closures

• flush bolts, leaf and Euro-

pean hinges

• end pivots

• as well as edge work for

either cylindrical or deep

pocket locks

Design features include three heavy duty high frequency spindle

motors mounted to a carriage which pivots from 0 to 3 degrees to

match door bevel. Two of the motors are 7-1/2 HP, which rotate

in opposite directions. Kval software automatically chooses the

correct router to eliminate chipping the door faces or edges.

Maximum depth with these heads is 4-1/2” deep. The third head

is a 12HP motor with a 7/8” solid carbide bit to rout pockets or

drill holes up 5-1/2” deep. An optional 3HP motor is available

with a short shank for fast routing of face plates and hinges, and

this makes an ideal head for diamond tooling.

Overview of the Edge-SS System

Kval Operation Manual

1-3

nected to a solid state motion controller. The computer allows an almost limitless number of

routing patterns to be stored for instantaneous set-up.

The same method is used with other screens for flush bolts, roller catches, “T” strikes, dead bolt

plates and mortise locks. The software also makes it simple to put together combination program-

ming with fill in the blanks for mortising locations so continuous machining can be done. For

example, the router could automatically machine a top manual flush bolt then move down to

machine a dead bolt plate, a “T” strike, then and the bottom manual flush bolt.

The machine tabletop is “L” shaped and consists of inverted caster wheels so doors are easy to

position. The “L” shape allows routing of either rails or stiles by rotating the door. Doorstops are

provided at 4’ intervals. The first stop at the corner of the “L” table is used for both stile and rail

routing depending on door orientation. For opposite swing doors the middle and far end stops are

used for rails and stiles. This makes it easy to machine top and bottom flush bolts and a “T” strike

without turning the door over.

In operation, the operator can enter the details for the next door while the current door is being

processed, so no time is lost between jobs. The screen and switches are used to select door thick-

ness, position of machining and left or right hand machining.

For Example: a “T” strike pattern called SCHLAGET is specified at 44-1/2”, the operator selects

SCHLAGET as the pattern, enters 44-1/2” and when the next door is clamped in position, the

machine automatically machines the “T” as specified. If the next door gets the same treatment, the

“Start” button can be pressed again to repeat the pattern.

Edge: Programming has been developed to automatically generate the most common CNC pro-

gramming with graphics screens. For example, one graphic screen shows a drawing of a door

stile with hinge pockets. The operator just fills in blank dimensions for hinge depth, locations,

backset radius and bevel and the computer tells the machine what to do. If the pattern is a stan-

dard, it can be named “Ceco,” for example, and recalled without re-typing dimensions next-time.

Overview of the Edge-SS System

Kval Operation Manual

1-4

About this Manual

This manual is part of a package delivered with the machine line.

Integration Package includes the following:

Operation Manual includes the following:

Service 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 the

Machine

Descriptions the assemblies on the

machine.

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

4Troubleshooting Troubleshooting tips and theory of

operation.

KvalCAM Reference Manual Includes the follow-

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!

Kval Service Manual

1-5

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 1-17.

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 Service Manual

1-7

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 1-2shows 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.

• 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.

Lockout Tagout Guidelines

Kval Service Manual

1-8

Lockout Tagout Guidelines

Follow these Lockout Tagout guidelines,

• Place a tag on all padlocks. On the tag, each operator must put their own name and

date. (These locks are only to be removed by the person who signs the tag)

• If more than one person is working on the machine, each additional person places a

lock and 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 and tag

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

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

Lockout Tagout Procedure

Kval Service Manual

1-9

Lockout Tagout 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 this machine while it is

powered down. During a lockout, you disconnect all power and shut

off the air supply. Be sure to use the tagout guidelines noted below.

https://www.osha.gov/

Pre-Steps Before Lockout Tagout

1. Evaluate 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.

Lockout Tagout Power

Note: When multiple people are working on the machine, each person needs to have a

lock on the handle in the extra holes provided.

4. Turn the Main Power on ALL electrical panels to the OFF position.

a.Lever style Electrical Panels: ensure the lever is in the down position, insert

lock and tag into the lever hole making sure the lever cannot move, lock as per

the tagout guidelines. (see illustration below).

Lockout Tagout Procedure

Kval Service Manual

1-10

b.Disconnect style Electrical Panels: push the red tab to pop it out. Place a pad-

lock through the hole. Place your tag on the padlock, as per the tagout guide-

lines below. (see illustration below).

Lockout Tagout Air Supply

5. Turn all air valves to the OFF position and place a padlock through the hole (see

illustration below).

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

Start Maintenance

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.

7. Maintenance or repairs may started.

Post Maintenance Steps

8. After maintenance is completed, the person performing the work must ensure all

tools, spare parts, test equipment, etc., are completely removed and that all guards

and safety devices are installed.

Insert Lock into hole.

Turn Switch to the

OFF position

Lock and Tag out

Lockout Tagout Procedure

Kval Service Manual

1-11

9. 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.

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

and the machine can be re-energized.

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

Zero-Energy to Start-Up

Kval Service Manual

1-12

Zero-Energy to Start-Up

Starting the equipment properly is just as important as the lockout/tagout guidelines in terms of

safety.The following guidelines below should be followed to start the equipment.

Inspect

The equipment must be inspected for proper adjustment before starting equipment.

Clean Up

All materials and debris must be cleaned up. Any combustible materials or old parts used during

repairs must be cleaned up and/or properly disposed of.

Replace Guards

Replace all equipment guards. If part of equipment cannot be properly adjusted after start-up with

guard on, contact the Kval Technical Support. See “Getting Help from Kval” on page 1-13.

Check Controls

Confirm that all switches are in the “OFF” position. Please be advised that some components of

the machine may start automatically when energy is restored.

Remove Locks

Each operator must remove his or her own lock and tag. This will ensure that all operators 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 com-

pany’s comprehensive safety procedure may involve additional steps. You will need to ask your

supervisor about these procedures. The company’s lockout procedure should be posted at each

machine. On larger or long-term maintenance or installation projects, the company’s procedures

must be explained to all new operators and a copy of the company’s procedures should be posted

on-site for the duration of the work.

The Company’s procedures should also include provisions for safely handling shift changes and

changes in operators or new operators.Comprehensive lockout/tagout may use a gang box or other

system to ensure that locks are secure and not removed without authorization.

Remember, lockout/tagout procedures work because you are the only one with the key 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 proce-

dures, and that those around you do also.

Zero-Energy to Start-Up

Kval Service Manual

1-13

Close the Cage Gate

Verify all cage gates are securely closed. Ensure all safety protocols are in effect.Kval

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Kval Edge-SS User manual

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