Kval Edge-SS User manual

Innovation, Quality & Honesty
Operation Manual
Published: October 14, 2020
Edge-SS System
Operation Manual Edge-SS System

KVAL Edge-SS System Operation Manual
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This Manual is confidential and contains proprietary information and intellectual
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Manual Part Number: DOC-175_1-OP
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KVAL Edge-SS System Operation Manual
KVAL Edge-SS System Operation Manual
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KVAL Edge-SS System Operation Manual

KVAL Edge-SS System Operation Manual
KVAL Edge-SS 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.

KVAL Edge-SS System Operation Manual

Table of Contents
KVAL Edge-SS 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..................................................................................1-5
Lockout-Tagout Guidelines...................................................... 1-9
Follow the P-R-O-P-E-R lockout rule of thumb.....................................1-9
Lockout Tagout Procedure....................................................... 1-10
Pre-Steps Before Lockout Tagout.......................................................1-10
Lockout Tagout Power........................................................................1-10
Lockout Tagout Air Supply..................................................................1-11
Start Maintenance...............................................................................1-11
Post Maintenance Steps.....................................................................1-11
Zero-Energy to Start-Up........................................................... 1-12
Getting Help from KVAL........................................................... 1-14
KVAL Return and Warranty Policy........................................... 1-15
Send the Item .....................................................................................1-15
Acceptance of Return.........................................................................1-15
Refund Turnaround Time....................................................................1-15
Kval Errors..........................................................................................1-15
Customer Errors .................................................................................1-16
Shipper Errors.....................................................................................1-16
Warranty Replacement Parts..............................................................1-16
How to Download the Service Application............................... 1-17
On-Line Help.......................................................................................1-17
Download Application.........................................................................1-17
Safety Sign-Off Sheet.............................................................. 1-21
A Note to the Operator........................................................................1-21
Chapter 2 About KvalCAM
About KvalCAM ....................................................................... 2-2
Summary of the KvalCAM Interface ........................................ 2-3
Machine Line ........................................................................................2-3
Libraries................................................................................................2-3
Machine Control....................................................................................2-4
About the Libraries................................................................... 2-5

KVAL Edge-SS Manual
Table of Contents
Distinguish Between the Library Types.................................................2-5
Around the Door Job Library Screen....................................................2-6
Around the Door Data Library Screen ..................................................2-6
Around the Feature Group Library Screen ...........................................2-7
Controls at the Library Screen................................................. 2-8
Using the Door File Table .....................................................................2-9
Using the Display Deleted Check Box (Recover a Door File)...............2-9
Using the File Control Buttons............................................................2-10
Using the Create Button .....................................................................2-10
Using the Edit/View Button.................................................................2-10
Using the Clone Button.......................................................................2-10
Using the Delete/Restore Button........................................................2-11
Using the Diff Button...........................................................................2-12
About the Database Icon....................................................................2-13
About Revisions....................................................................... 2-14
Principle and Diff.................................................................................2-14
Revisions at the Door Job Library.......................................................2-14
Revisions at the Door Data Library.....................................................2-15
Revisions at the Door Feature Group Library.....................................2-15
About Door Job Creation......................................................... 2-17
About the Job Name Menu.................................................................2-18
About the Door Data Menu.................................................................2-18
About the Feature Tree Menu.............................................................2-19
Breakdown of a Feature Group and Features....................................2-19
About the Feature Tree Menu.............................................................2-20
About the Selected Feature Details Menu..........................................2-21
About the Selected Feature Details Menu (Child Level).....................2-22
About the Control Buttons...................................................................2-23
About the Job Preview Screen (2D and 3D).......................................2-24
2 D Screen..........................................................................................2-24
3 D Screen..........................................................................................2-25
About the Machine Line Screen............................................... 2-26
Machine Line Screen..........................................................................2-26
About Backing up Data and Checking the Revision Status..... 2-30
Job Preview Examples ............................................................ 2-31
Door Face (Lock Preview)..................................................................2-31
Door Edge (Lock Preview)..................................................................2-32
Door Edge (Hinge Preview)................................................................2-33
About Validation....................................................................... 2-34
About the Validation Screen ...............................................................2-35
Outline ................................................................................................2-36

Table of Contents
KVAL Edge-SS Manual
About the LiteCutout Feature Detail (DL-NCD Only)............... 2-37
Process...............................................................................................2-37
About the LiteCutout Screen...............................................................2-41
About the Work Area Coordinates......................................................2-42
Sample Oval Cut.................................................................................2-43
Common Terms ....................................................................... 2-45
Door Job.............................................................................................2-45
Door Data ...........................................................................................2-45
Feature Group ....................................................................................2-46
Feature ...............................................................................................2-47
Revision..............................................................................................2-47
Ad Hoc................................................................................................2-47
Variant.................................................................................................2-48
Diff ......................................................................................................2-49
Axis.....................................................................................................2-49
Validation............................................................................................2-50
Validation Report ................................................................................2-50
Chapter 3 Operation of the Edge-SS Line
About the Edge-SS Process.................................................... 3-2
How to Position a Door for Cutting .......................................... 3-3
Top and Bottom Cuts............................................................................3-3
Edge Cuts.............................................................................................3-3
Summary of the Controls on the Machine Line........................ 3-4
Operators Station..................................................................................3-4
Main Machine Controls.........................................................................3-4
Foot Pedal Control................................................................................3-4
Indicator Light.......................................................................................3-5
Initial Powering Operations for the Edge-SS........................... 3-6
How to Power Up the Vision Line.........................................................3-6
Home the Machine Line........................................................................3-7
How to Power Down the Machine.........................................................3-7
The Machine Start Summary................................................... 3-8
Summary of the KvalCAM Interface ........................................ 3-11
Libraries and Machine Line Screens ..................................................3-11
Machine Control and Calibration Screens..........................................3-11
Status and Log Screens......................................................................3-12
About Machine Status Feedback............................................. 3-13
About the Edge-SS Interface Screens..................................... 3-14

KVAL Edge-SS Manual
Table of Contents
About the Edge-SS Main Screen........................................................3-14
Edge-SS Main Screen........................................................................3-15
About Speed Control ..........................................................................3-15
About the Edge SS Manual Servo Control Tab........................ 3-18
About the Tool Path Preview Test Tab..................................... 3-20
About the Tool Config Tabs...................................................... 3-21
General Operating Controls................................................................3-21
Unlock the Tool Slot Configuration......................................................3-22
About the Tool Pop-up Screens..........................................................3-22
About the Tool Pop-up Screens..........................................................3-22
About Tool Locations ..........................................................................3-23
About Chisel Locations.......................................................................3-24
About Using Tool Configuration..........................................................3-25
Measuring Tool Length .......................................................................3-25
About Entering Data into the Pop-up Menu........................................3-26
About the Status and Log Screens.......................................... 3-27
About the Status Screen....................................................................3-27
About the Log Screen.........................................................................3-28
Description of the Light Tower ................................................ 3-29
Chapter 4 Calibration of the Edge-SS Line
About Calibration..................................................................... 4-2
About the Calibration Menus and the Calibration Reference Cut.........4-2
Before you Calibrate.............................................................................4-2
About the Calibration Tabs....................................................... 4-3
Access to the Calibration Adjustments.................................................4-3
Unlock the Calibration (Option).............................................................4-4
Enter a Positive or Negative Number? .................................................4-4
Axis Direction for the Edge-SS Front Section.......................................4-5
How to Enter Calibration Data................................................. 4-6
About Restore Points............................................................................4-6
About the Edge-SS Calibration Screen ................................... 4-7
Edge-SS Calibration Screen................................................................4-7
Calibrating the Feelers............................................................. 4-8
Identify the Hinge and Lock Head Designations...................................4-9
Using the Carriage Axes Calibrations...................................................4-9
About Tools Calibration.......................................................................4-10
Tool Slot Identification.........................................................................4-11
Chisel Locations .................................................................................4-12

Table of Contents
KVAL Edge-SS Manual
Using the Tools Calibration...................................................... 4-13
Typical Adjustments............................................................................4-13
Chapter 5 Tour of the Edge-SS Line
About the Machine Line........................................................... 5-2
Top View of Edge-SS with Auto Feed-Out (Opt. Q)..............................5-3
Front View of the Edge-SS...................................................... 5-4
Front View of the Edge-SS with Auto Feed-Out (Opt. Q) .....................5-5
Edge-SS Fence, Clamps, Stops...........................................................5-6
Operator’s Station on the Edge-SS.......................................... 5-7
Operator’s Screen Layout.....................................................................5-7
Examples Door Placement (Left Side of Screen).................................5-7
Edge-SS Controls.................................................................... 5-8
Main Machine Controls.........................................................................5-8
Foot Pedal Control................................................................................5-8
Indicator Light.......................................................................................5-9
Assemblies on the Main Cutter Head...................................... 5-10
Option (3 Routers and 1 Point to Point Drill).......................................5-11
About the Probes..................................................................... 5-12
About Door Length Probe...................................................................5-12
About Door Thickness Probe..............................................................5-13
About Door Depth Probe ....................................................................5-13
Laser Safety Scanners ............................................................ 5-14
About Sensors....................................................................................5-14
Servo Motor and Valve Bank Locations................................... 5-15
Servo Motor Locations........................................................................5-15
Valve Bank Locations .........................................................................5-16
Typical Valve Bank Controls...............................................................5-16
About the Electrical Panels...................................................... 5-17
Main Electrical Panel..........................................................................5-17
The High Frequency Panel.................................................................5-18
About the Nodes...................................................................... 5-19
Typical Block Diagram of Network Connections.................................5-19
Graphical Sample of Node Connections and Power Distribution .......5-20

KVAL Edge-SS Manual
Table of Contents

1-1
KVAL Operation Manual
CHAPTER 1 Introduction to the Edge-SS 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 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 1-9
Zero-Energy to Start-Up Procedure to power up your machine for the
first time. page 1-12
Getting Help from KVAL This section describes the method to con-
tact the KVAL Service Center for help. The
section includes how to get informationfrom
the specification plate tor provide to KVAL,
service center hours, and return procedures
page 1-14
Safety Sign-Off Sheet A record to track operators that are trained
on the machine. page 1-21

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 cor-
rect router to eliminate chipping the door faces or edges. Maxi-
mum 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
1-3
KVAL Operation Manual
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.
2About KvalCAM Descriptions of the KvalCAM user
interface.
3Operation Inter- face Descriptions of how to power machine line, and operator inter-
face user screens.
4Calibration Descriptions of Calibration Rou-
tines and how to use the interfaces
5Tour 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.

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.
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.
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.
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.
Training

Safety First!
KVAL Operation Manual
1-6
Never operate the machine without proper eye and
ear protection.
Protective Gear
• 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.
• 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.
When the Machine is ON
The compressed air system connected to this
machine should have a three-way air valve
for shut-off and pressure relief.
All cylinders on machine are under high
pressure and can be very dangerous when
activated. Before performing any mainte-
nance or repairs on this machine turn off the
main air disconnect. Lockout and tagout
this connection.
See “Lockout Tagout Procedure” on
page 1-10.
Compressed Air

Safety First!
1-7
KVAL Operation Manual
Electrical circuitry on this
machine is protected by an
approved lockable disconnect
circuit. In addition to this equip-
ment, you must install an
approved disconnect for the
electrical power supplying this
machine.
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. Before performing any repairs or mainte-
nance, lockout and tagout must be installed at all locations
All maintenance and repairs to electrical circuitry should only be per-
formed by a qualified electrician.
Still has power
in OFF position
Electrical
Prior to performing any maintenance, repairs,
cleaning or when clearing jammed debris, you
must disconnect, tag out, or lock out the electrical
and air pressure systems. This should be done in
accordance with applicable state and/or federal
code requirements.
Before Conducting Maintenance
Laser Warnings
On some machines, laser indicators are used to set boundaries. Follow the
manufacturers safety precautions.

Safety First!
KVAL Operation Manual
1-8
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 regula-
tions which apply in your geographic area.
Compliance with Codes and Regulations
Other Hazard Control Action
Report a Hazard
Before You Report an Accident
If you believe any part or operation of this machine is in
violation of any health or safety regulation, STOP pro-
duction. It is your responsibility to immediately protect
your employees against any such hazard.
Additional detailed safety guidelines are included in the
operating instructions of this manual. KVAL will be
pleased to review with you any questions you may have
regarding the safe operation 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 proce-
dures to follow.