Kval EFX User manual

Innovation, Quality & Honesty
Operation Manual
Published: July 2, 2020
EFX Door Machining System
Operation Manual EFX System

KVAL EFX System Operation Manual
Proprietary Notice
This Manual is confidential and contains proprietary information and intellectual
property of Inc., and is to be used solely by Customer as an operating manual for Inc.
machines. Neither this Manual nor any of the information contained herein may be
reproduced or disclosed under any circumstances without the express written permis-
sion of Inc. For authorization to copy this information, please call Customer Support at
[phone] or fax [phone]. Outside the U.S. and Canada, call (707) 762-
7367.
Manual Part Number: DOC-229-1-OP
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Copyright 2020 Incorporated. All rights reserved.
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KVAL EFX System Operation Manual
KVAL EFX System Operation Manual
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
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For that, please refer to the Customer Service contact information above.) Thank you!
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KVAL EFX System Operation Manual
NOTICE OF OWNERSHIP OF KvalCAM SOFTWARE AND LIMITED LICENSE TO
USE
READ THIS NOTICE CAREFULLY BEFORE USING THE KvalCAM SOFTWARE WHICH OPERATES
MACHINERY. THIS DOCUMENT CONSTITUTES NOTICE TO YOU THAT YOU HAVE A LIMITED
LICENSE TO USE THE KvalCAM SOFTWARE ON THE TERMS AND CONDITIONS APPEARING BELOW.
BY USING THE KvalCAM SOFTWARE YOU ARE CONSENTING TO BE BOUND BY THIS LIMITED
LICENSE. IF YOU DO NOT AGREE TO ALL OF THE TERMS OF THIS LICENSE, THEN DO NOT USE THE
KvalCAM SOFTWARE.
, Inc., is the owner of all rights in respect of the software and documentation (referred to as “Licensor”). You are the
purchaser of Machinery operated by the KvalCAM Software are the “Licensee”.
The computer program(s) and related documentation and materials (herein collectively referred to as “the KvalCAM
Software” and further defined herein) which are used in the operation of the Machinery are licensed, not sold, to you
for use only upon the limited terms of this license, and Licensor reserves any rights not expressly granted to you.
Licensor retains all ownership of the KvalCAM Software.
Title, ownership rights, and intellectual property rights in the KvalCAM Software shall remain with, Inc. The Kval-
CAM Software is protected by copyright laws and treaties. Title and related rights in the content generated through
the KvalCAM Software are also the property of the Licensor and are protected by applicable law.
1. Definitions .
a.“KvalCAM Software” means the KvalCAM computer application installed in the Machinery
and written documentation and materials provided to you, as well as any revisions or updates of
such computer application and documentation.
b.“Install” means storing of the KvalCAM Software in the computer component of the Machin-
ery.
c.“Use” means executing the KvalCAM Software for purpose of operating the Machinery and
use of the documentation for properly operating KvalCAM Software.
2. Grant of License .
a.Licensor hereby grants Licensee a non-exclusive, non-transferable license to Use the Kval-
CAM Software upon payment of all amounts due for the purchase of the related Machinery.
b.Licensee will make no copies of the KvalCAM Software or alter the KvalCAM Software in
any way. Title to the KvalCAM Software will remain vested in Licensor, and nothing in this
License will give or convey any right, title or interest therein to Licensee except as a licensee.
c.Licensee agrees that it will use the KvalCAM Software or related documentation directly or
indirectly for the benefit of Licensee, and only pursuant to the scope of the grant of the License
set forth herein.
d.Licensee will not decode, alter, decompile, reverse engineer, perform reverse analysis on or
disassemble the KvalCAM Software.
e.This License will terminate automatically if Licensee fails to comply with the limitations
described above.

Table of Contents
KVAL EFX Manual
Chapter 1 Introduction to the EFX System
Overview of the EFX System................................................... 1-2
About this Manual.................................................................................1-4
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
Summary of the KvalCAM Interface ........................................ 2-2
Libraries and Machine Line Screens ....................................................2-2
Machine Control....................................................................................2-2
About the Libraries Screen...................................................... 2-3
Distinguish between the Door Job and Features Group Libraries........2-3
Library Screens.....................................................................................2-4

KVAL EFX Manual
Table of Contents
About the Feature Groups and Door Jobs............................................2-5
About the Library Buttons.....................................................................2-5
About Job Creation.................................................................. 2-6
About the Job Name Menu...................................................................2-7
About the Door Data Menu...................................................................2-7
About the Feature Tree Menu...............................................................2-8
About the Selected Feature Details Menu............................................2-9
About the Selected Feature Details Menu (Child Level).....................2-10
About the Control Buttons...................................................................2-11
About the Job Preview Screen (2D and 3D).......................................2-12
2 D Screen..........................................................................................2-12
3 D Screen..........................................................................................2-13
About the Machine Line Screen............................................... 2-14
Machine Line Screen..........................................................................2-14
About Backing up Data and Checking the Revision Status..... 2-18
Definitions................................................................................ 2-19
Appendix: Job Preview Examples ........................................... 2-21
Door Face (Lock Preview)..................................................................2-21
Door Edge (Lock Preview)..................................................................2-22
Door Edge (Hinge Preview)................................................................2-23
Appendix: About Validation...................................................... 2-24
About the Validation Screen ...............................................................2-25
Outline ................................................................................................2-25
About the LiteCutout Feature Detail (DL-NCD Only)............... 2-26
Process...............................................................................................2-26
About the LiteCutout Screen...............................................................2-30
About the Work Area Coordinates......................................................2-31
Sample Oval Cut.................................................................................2-32
Chapter 3 Operation of the EFX Line
About the EFX Process ........................................................... 3-2
How to Position a Door for Cutting .......................................... 3-3
Types of 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

Table of Contents
KVAL EFX Manual
Initial Powering Operations for the EFX................................... 3-6
How to Power Up the Vision Line.........................................................3-6
........................................................................Home the Machine Line3-7
How to Power Down the Machine.........................................................3-7
The Machine Start Summary................................................... 3-8
Summary of the KvalCAM Interface ........................................ 3-10
Libraries and Machine Line Screens ..................................................3-10
Machine Control and Calibration Screens..........................................3-10
Status and Log Screens......................................................................3-11
About Machine Status Feedback............................................. 3-12
About the EFX Interface Screens............................................ 3-13
About the EFX Main Screen...............................................................3-13
EFX Main Screen................................................................................3-14
About Speed Control ..........................................................................3-14
About the Edge SS Manual Servo Control Tab........................ 3-17
About the Tool Path Preview Test Tab..................................... 3-19
About the Tool Config Tabs...................................................... 3-20
General Operating Controls................................................................3-20
Unlock the Tool Slot Configuration......................................................3-21
About the Tool Pop-up Screens..........................................................3-21
About the Tool Pop-up Screens..........................................................3-21
Sample Drill Configuration Pop-Ups...................................................3-21
Sample Chisel Configuration Pop-Ups...............................................3-22
About Tool Locations ..........................................................................3-22
About Chisel Locations.......................................................................3-23
About Using Tool Configuration..........................................................3-23
Measuring Tool Length .......................................................................3-24
About Entering Data into the Pop-up Menu........................................3-24
About the Status and Log Screens.......................................... 3-25
About the Status Screen....................................................................3-25
About the Log Screen.........................................................................3-26
Description of the Light Tower ................................................ 3-27
Appendix: About Backing up the Data..................................... 3-28
Chapter 4 Calibration of the Machine Line
About Calibration..................................................................... 4-2
About the Calibration Menus and the Calibration Reference Cut.........4-2
Before you Calibrate.............................................................................4-2

KVAL EFX Manual
Table of Contents
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? .................................... 4-5
Door Edge Axis Directions....................................................................4-5
Door Face Axis Directions....................................................................4-6
How to Enter Calibration Data................................................. 4-7
About The Calibration Box....................................................................4-7
About Restore Points............................................................................4-8
About the EFX Calibration Screen........................................... 4-9
EFX Calibration Screen........................................................................4-9
Calibration Selections...........................................................................4-9
About Calibration Sequence.................................................... 4-10
Step 1: Calibrate the Carriage Stop......................................... 4-11
Procedure...........................................................................................4-11
Step 2: Calibrate the Length and Thickness Feelers............... 4-12
Process to Calibrate the Length and Thickness.................................4-12
Step 3: Calibrate the Depth Feeler (Option) ............................ 4-14
Before Calibrating...............................................................................4-14
Process to Calibrate the Probe Depth................................................4-15
Step 4: Calibrate the Face Axes.............................................. 4-16
Process to Calibrate the Face Carriage..............................................4-16
Face Axis Calibration Reference Cut..................................................4-16
Step 5: Calibrate the Face Tools.............................................. 4-18
Face Tool Locations............................................................................4-18
Process to Calibrate the Face Tools...................................................4-18
Face Tools Calibration Reference Cut................................................4-19
Step 6: Calibrate the Edge Carriage........................................ 4-20
Edge Axis Calibration Reference Cut.................................................4-20
Step 7: Calibrate the Edge Tools ............................................. 4-21
Edge Tool Locations ...........................................................................4-21
Chisel Locations .................................................................................4-22
Edge Axis Calibration Reference Cut.................................................4-22
Process to Calibrate the Edge Tools...................................................4-22
Edge Tools Calibration Reference Cut................................................4-23
Predrill.................................................................................................4-23
Routers...............................................................................................4-23
Chisels................................................................................................4-23
Routers: How to Isolate and Calibrate a Specific Router......... 4-24

Table of Contents
KVAL EFX Manual
Chapter 5 Tour of the EFX Line
Front View of the EFX.............................................................. 5-2
Operator’s Station on the EFX................................................. 5-3
Operator’s Screen Layout.....................................................................5-3
Examples Door Placement (Left Side of Screen).................................5-3
EFX Controls ........................................................................... 5-4
Main Machine Controls.........................................................................5-4
Foot Pedal Control................................................................................5-4
EFX Fence and Door Clamps...............................................................5-5
Indicator Light.......................................................................................5-5
Assemblies on the Main Cutter Head...................................... 5-6
About Door Probes.................................................................. 5-7
About Encoders....................................................................................5-7
About Length and Thickness Probes....................................................5-7
Depth Probe..........................................................................................5-8
Laser Safety Scanners ............................................................ 5-9
About Sensors......................................................................................5-9
Location of Servo Motors and Valve Bank Locations .............. 5-10
Servo Motor Locations........................................................................5-10
Valve Bank Locations .........................................................................5-10
About the Electrical Panels...................................................... 5-11
EFX Main E-Panel..............................................................................5-11
EFX High Freq Panel..........................................................................5-12
About the Nodes...................................................................... 5-13
Typical Block Diagram of Network Connections.................................5-13
Graphical Sample of Node Connections and Power Distribution .......5-14

KVAL EFX Manual
Table of Contents