Kval EFX User manual

EFX or Edge-SS QUICK STARTEFX or Edge-SS QUICK START
2. Ensure factoy air is applied to all ma-
chines.
3. Verify that all E-Stop butons are OUT
and Gates are CLOSED.
4. Turn the Electrical Disconnect to the ON
positions on each Electrical Cabinet in the
production line.
1. Verify the area of operation is clear
and safe to process doors
5. Turn the Control Circuit Switch to the ON
position. (Approximately 3 minute boot-
up)
6. Push the Machine Power Buton.
7. All Tower Lights Should be Green
See reverse side for Tower Light Description
Power-UP
Load Door Job from KvalCam
Edge SS/EFX Quick Ref rev 1
1. Select the Libraries Tab at the upper let side of the
screen
2. Select the Door Job Libray Tab at the upper center
screen
3. At the Door Job List double click the desired door job to
go to the Door Job screen
Verify Door Job
Add Doors to Queue
Verify the Door Job
speciications. Look for
validation errors.
Note: For more information about
Libraries, see the KvalCam Manual.
1. Enter the quantiy of door to be processed in the Door
Qy box at the botom of the screen
2. Select the Add to Queue Buton
Process a Door
Home the machine
(Impotant: Homing sets a
stating reference point for
the machine.)
1. Move the door into the Machine.
2. Initiate the Stops. Press the Door
Stop Foot Pedal.
3. Position the door against the
stops and fence according to the
Operator’s Screen.
Tips
* Torque the collet to recommended values, See the Sevice Manual for
torque values.
* Stay out of the Unsafe Zone when th cuting process begins. The ma-
chine will shut down
* For detailed information about the EFX or Edge-SS , see the Operation
Manual.
* If a door is not clamped correctly, toggle the clamp pedal until door is
secure.
4. Press the Edge Toggle Buton to
choose door parameter to pro-
cess.
5. Ater the door is set, press the
Door Clamp Foot Pedal to secure
the door.
6. To begin the process, press the
Stat Sequence Buton.
7. Follow the instructions on the
screen. Position the door accord-
ingly until all processing is com-
pleted.
8. Ater process is completed, press
the Blue Door Finished Buton.
9. Roll the door out for next pro-
cessing.
Pop-Up Stops
Position Door
Toggle to Door Edge
Clamp Door
Start Sequence
Process Door
Select Door Finished
Roll Out Door
Roll Door In

Machine Terminology
Electrical
Panels
Electrical Panels contain the brains and power for the machine. The Main Electrical Panel contains the
main PLC and sevo drivers to control the sevo motors. The High Frequency Panels contain the VFD’s to
drive the routers, width adjust, and feed motors.
Door Clamp The Door Clamp secures the door for stable routing and drilling.
Probes Probes are an option. Encoder based assemblies that measure door width ,lenth, or depth of a cut. Data
is fed back to the PLC to create exact measurements of the door. Check options of the machine to identify
installed probe ypes.
Door Stop The Door Stop sets a reference for the door to be in the correct position for processing.
Carriage The Carriage contains the Tool sets to mill the door. The Edge-SS contains the Edge Tools. The EFX con-
tains the Face and the Edge tools.
Edge Tools The Edge Router is an available option to rout the edge of the door.
Face Tools (EFX) Routers and a drill to mill the face of the door.
Sensors Sensors provide input to the PLC as pat of the automation of the door cuting process, including feed
through, door clamping, and door location. It is impotant to keep the sensors cleaned and aligned to keep
the door process running smoothly. There are wo classiications of sensors, Photo Electronic and Induc-
tive Proximiy Sensor.
Routers Routs hinge or lock pockets. On the EFX, routs the lock hole on the face of the door.
Drills Drills screw holes into door.
Chisels (Option) Chisels are located in the Cuter Head. The chisels square corners on a lock or face cut.
Tools
Operator’s
Station
The Operator’s Station is the inteface of operator to machine. It contains power controls and touch
screen inteface to control the cuting parameters of the door.
KvalCAM The KvalCAM soware includes a single User Inteface to control the entire machine line. Each machine
can also be controlled separately or as a collective. Door Jobs and Features from a libray can be download-
ed remotely and created at the station. The KvalCAM inteface uses tabbed navigation to jump to desired
screens.
Door Job In the Door Job creation screen, door cuts can be created, the door parameters stored and machining of
the door can be processed using this information.
Feature Group In the Features Group creation screen, door cuts can be created and veriied by way of the Job Preview
screen. Templates are stored to be called into the Door Job.
Categoy Desig. Descriptions
Machine Status
OFF (Clear): Machine not in operation.
White: Initializing
1 Flash: Waiting for all systems to initialize
Red: Machine Error
Solid: General Error
• 1 Flash: EtheCat Device not Ready to Run
• 2 Flashes: VFD, Sevo, or Motor Error
• 3 Flashes: 24 VDC Power Error
Yellow: External Error
Solid: General Error
• 1 Flash: 3 Phase Voltage Error
• 2 Flashes: Low Air Error
Blue: Operator Status
Solid: Waiting for Operator
• 1 Flash: Reposition Door
Green: Machine is Operational
Safey
OFF (Clear): Safey Project not Running
Red: Safey PLC Error
Blue: Waiting for Safey Re-Set
• Solid: General Error
• Flashing: Not Ready to Re-Stat (E-Sop Switch is Active)
Green: Machine is Operational
Control Power
O: No Control Power
ON (Green): 24 VDC Control Power ON
About the Light Tower
Machine
High Voltage may cause injury or death.
Troubleshooting checks must be performed
by a Qualied Electrical Technician.
The Light Tower indicates the working status of the system. The
Light Tower is mounted on top of the Electrical Boxes. Each light dis-
plays dierent colors and lashing codes to show the machine status.
The table below describes the dierent states of the Lght Tower.
Be Smat! Follow all Safey Precautions.
Operation
Remote Troubleshooting
Kval’s Suppot Team is able to work remotely with your maintenance sta or contractor to diagnose and troubleshoot machiney
issues. Call (800)- 553-5825 or stat a suppot ticket Online htps://www.kvalinc.com/suppot.
Tools Needed for machine hardware troubleshooting:
• Access to a broadband internet connection
• An iPhone or Android smat-phone (We use Apple FaceTime or
Google Duo for video)
• A DMM
• A standard tool set
For machine soware troubleshooting:
• Access to a broadband internet connection
• A computer running Windows
• Our remote suppot client
Allow Kval to Logon to the Machine
• Exit the KvalCAM program. On the
Windows Screen, select the KVAL
Sevice Icon