PVA Carver PRO-S User manual

Carver PRO-S™
Operation Manual
Revision B
ALL THE TOOLS YOU’LL NEED TO
FABRICATE DEVICES IN-HOUSE.

Carver PRO-S™ Manual
Revision B /September 2022 Page 2 of 67
This document is based on information available at the time of its publication. While efforts
have been made to ensure the contents of this manual are accurate, the information
contained herein does not purport to cover all specific details or variations in hardware, or
to provide for every possible contingency in connection with installation, operation, or
maintenance. Features may be described herein which are not present in all hardware and
software systems. Precision Valve and Automation, Inc. assumes no obligation of notice to
holders of this document with respect to changes subsequently made.
Precision Valve and Automation, Inc. makes no representation or warranty, expressed,
implied, or statutory with respect to, and assumes no responsibility for the accuracy,
completeness, sufficiency, or usefulness of the information contained herein. No warranties
of merchantability or fitness for purpose shall apply.
This document, including the information contained herein, is the property of
Precision Valve and Automation, Inc. and is considered confidential and proprietary
information. It is delivered on the express condition that it not be used, disclosed, or
reproduced, in whole or in part, for any reason without prior written consent of
Precision Valve and Automation, Inc.
Copyright © 2022
Precision Valve and Automation, Inc.
All Rights Reserved.

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Table of Contents
Introduction...........................................................................................................5
1.1 PVA Contact Information........................................................................................................5
1.2 Document History.....................................................................................................................5
1.3 Safety ..........................................................................................................................................6
Getting Started .....................................................................................................8
2.1 Unboxing.................................................................................................................................... 8
2.2 Initial Setup ...............................................................................................................................11
Tool Kit ..................................................................................................................................11
Mandrels ..............................................................................................................................12
Waste Bin Liners.................................................................................................................12
Plugging into Ethernet and Power Connections ........................................................13
Connecting to the Network .............................................................................................15
Cutting Bit Installation ..................................................................................................... 17
DeskProto®.......................................................................................................... 21
3.1 Installation and Setup............................................................................................................ 21
Activating a DeskProto® License ................................................................................. 23
Importing Machine Settings........................................................................................... 25
3.2 Workflow Template for Long and Short Mandrels .......................................................... 30
Importing the Template Model....................................................................................... 30
Orienting the Model...........................................................................................................31
Define Material Block ....................................................................................................... 34
Material Block Size Error ................................................................................................. 36
Configuring Cutting Profiles ...........................................................................................37
Calculating a Toolpath..................................................................................................... 38
Saving a G-code................................................................................................................ 39
Operation............................................................................................................. 40

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4.1 Preparing for a Carve ............................................................................................................ 40
Adding a Foam Blank onto a Pre-Installed Mandrel...................................................41
Adding a Foam Blank to a Mandrel Before Installation ............................................ 43
4.2 Using G-code Files................................................................................................................. 44
Loading a G-code File from a microSD Card............................................................... 44
Loading a G-code File from an Internet Upload......................................................... 47
Accessing G-Code Files from the Web Interface....................................................... 49
4.3 Starting a Carve ..................................................................................................................... 50
Cleaning and Maintenance.................................................................................56
5.1 Ball Screw and Linear Guides.............................................................................................. 56
5.2 Cables and Drive Belt............................................................................................................ 56
5.3 Waste Bin ................................................................................................................................. 56
5.4 Best Practices......................................................................................................................... 58
Appendix A ...........................................................................................................59
6.1 Carving Terminology ............................................................................................................. 59
Appendix B .......................................................................................................... 60
7.1 Carver PRO-S™ Dimensions................................................................................................. 60
7.2 PVA Med Mandrel Dimensions .............................................................................................61
7.3 Spare Parts Kit........................................................................................................................ 62
7.4 Technical Specifications and Warnings ............................................................................ 62
Table of Figures ...................................................................................................63
Notes .....................................................................................................................66
Warranty ...............................................................................................................67

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Introduction
Before you operate this system, read the operation and setup manual. This will help you to
become familiar with the product and ensure successful operation.
If any questions or problems arise, contact PVA’s Technical Support department.
1.1 PVA Contact Information
Main Office PVA Med
Six Corporate Drive
Halfmoon, NY 12065
Tel [phone]
Fax [phone]
Website: https://pvamed.net
Email: [e-mail]
Technical Support
Tel [phone]
Email: [e-mail]
1.2 Document History
Revision
Revision Date
Reason for Changes
REV B
September 2022
Workflow Replaced with Mandrel Template Workflow
REV A
June 2022
Initial Release
Note: All photographs and CAD model representations in this document are a
“general representation” of the system and its components. The actual appearance
of the system and its components can differ based upon customer specific
configuration.

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1.3 Safety
Certain warning symbols are affixed to the machine and correspond to notations in this
manual. Before operating the system, identify these warning labels and read the notices
described below. Not all labels may be used on any specific system.
Always wear approved safety glasses when you operate or work near the
workcell.
Before you operate the system, read and understand the manuals provided
with the unit.
Never put hands or tools in areas with this symbol when the machine is in
operation. A dangerous condition may exist.
Read and understand the manuals provided with the unit before any repairs
or maintenance is done. Only a qualified individual should do service.
Use caution when there are pressurized vessels. Find and repair any leaks
immediately. Always wear appropriate safety equipment when you work
with pressurized vessels or vessels that contain chemicals
Shear hazard from moving parts. Avoid contact.
Do not remove protective guarding.
In situations where inattention could cause either personal injury or damage
to equipment, a warning notice is used.

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Do not smoke near the machine. Always have a fire extinguisher available
for emergency use.
Before performing any repairs or maintenance to the system, turn off power
and lock out the power disconnect switch.
Warning notices are used to emphasize that hazardous voltages, current,
temperatures, or other conditions that could cause personal injury exist in
this equipment or may be associated with its use. Only qualified personnel
should enter areas designated with this symbol.
Laser light source present. Do not stare directly into the beam. Do not use in
the presence of highly reflective surfaces
Pinch hazard from moving parts. Avoid contact.
Hot surface. Avoid contact.
Warning, Ultraviolet (UV) light hazard. Do not look directly at the UV light
source.
This product meets EU standards for health, safety, and environmental
protection.
Warning, no open flames.
Electrostatic sensitive device warning. Observe precautions for handling.

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Getting Started
2.1 Unboxing
1. Remove the packaging straps from the shipping crate.
2. Open the shipping crate by first taking the lid off and then removing the sides.
3. Remove the plastic wrapping around the metal ramp and any additional items.
Figure 1: Remove Plastic Wrapping
4. Remove the waste bin access key tied to the handle on the front. Open the waste
bin access doors on the front of the machine and remove the lag screws in the four
metal brackets that are holding the carver in place around its wheels on the pallet.
Figure 2: Metal Brackets Inside Access Doors

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5. Secure the metal ramp to the wooden pallet on the side of the carver with the lag
screws from the previous step.
Figure 3: Metal Ramp Secured to the Wooden Pallet
6. Unload the carver using the metal ramp with at least two people – one person in
front of the machine and one person behind the machine.
Figure 4: Unloading the Carver Using the Metal Ramp

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7. Move the carver to its desired location and position the machine on level ground.
8. To level the carver, lower the feet by turning the red knob on each leg to stabilize it.
Turning the knob to the left lowers the foot and turning the knob to the right raises
the foot.
Figure 5: Raise and Lower the Feet

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2.2 Initial Setup
Tool Kit
Before starting the setup process, locate the Tool Kit that has been provided with your
Carver PRO-S™. The following items are included and shown below.
Figure 6: Carver Tool Kit
1. Toolbox 5. Mallet
2. Square Chuck Key 6. microSD Card and Converter
3. Crescent Wrench 7. Cleaning Brush
4. Collet Wrench

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Mandrels
One long through mandrel and one short mandrel are included with the Carver PRO-S™.
Dimensions for both mandrels are as follows:
•Length of long mandrel: 91.2 cm (35.9 in) in
•Length of short mandrel: 26.8 cm (10.5 in) in
•Diameter for both mandrels: 2.5 cm (1 in)
Figure 7: Long Mandrel and Short Mandrel
Refer to Section 7.2 for more information on the PVA Med mandrels.
Waste Bin Liners
One (1) roll of clear plastic waste bin liners has been included with the Carver PRO-S™. For
more information on accessing and emptying the waste bin, refer to Section 5.3.
Figure 8: Roll of Waste Bin Liners

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Plugging into Ethernet and Power Connections
1. Plug one end of the ethernet cable into a wall supply and the other end of the cable
into the back of the Carver PRO-S™.
Figure 9: Connecting the Ethernet Cable
2. Connect the supplied power cord into the 120/220V wall power supply. Refer to the
machine serial tag for more information.
Figure 10: Supplied Power Cord End
Note: The unit power is specified at time of purchase depending on outlet
country. The plug at the end of the cord will reflect these changes.

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3. Connect the other end of the power cord to the back of the carver. The power
connection is located directly below the ethernet connection.
Figure 11: Connected Power Cord on Carver PRO-S™
4. Turn the main power switch on the side of the carver clockwise to the ON position.
Figure 12: Main Power Switch

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Connecting to the Network
1. Upon powering up, the machine will be assigned an IP address by the user’s in-
house router.
2. To view the IP address, select the Setup tab on the bottom right corner of the HMI
screen.
Figure 13: IP Setup Tab Location on the HMI
3. On the bottom left corner in the Setup screen, the IP address that the network has
assigned to the machine will be shown.
Figure 14: IP Address Location

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4. This IP address can be entered into an internet browser to access the web interface
of the carver. Refer to Section 4.2.2 for more information on this interface.
5. On a new power cycle, the user’s network may assign an alternate IP address based
on the other devices connected. It is advised to assign a preset static IP address to
the Carver PRO-S™ to make the connection process easier. Consult any appropriate
router manual and/or IT group to assign an IP based on the unique MAC address for
the Carver PRO-S™.
6. To find the Carver PRO-S™ MAC address, select the Console tab. Enter M540 in the
terminal and the machine’s MAC address will be displayed.
Note: If the IP address is displaying as 000.000.00.00, ensure that the front door is
closed, and the E-stop is disengaged.
Figure 15: MAC Address Location

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Cutting Bit Installation
To install a cutting bit for the first time, or in the event that the cutting bit is damaged,
worn, or at the incorrect height and needs to be replaced with a new bit, perform the
following steps:
1. Place a crescent wrench on the spindle flats, as seen in Figure 16.
Figure 16: Crescent Wrench Holding the Spindle Flats
2. With the other hand, place a collet wrench on the collet nut, as seen in Figure 17.
Figure 17: Collet Wrench on the Collet Nut

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3. To prevent the spindle from rotating with the crescent wrench, turn the collet nut to
the left to loosen the collet until the bit can be fully removed from the collet.
Figure 18: Cutting Bit Removed from Collet
Note: If loosened too much, the bit may fall into the waste bin.
4. On the HMI, select the Move To Bit Load Position button.
Figure 19: Move to Bit Load Position

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5. The REMOVE BIT prompt will display. If a bit was previously installed, ensure it has
been removed and press the OK button to continue.
Figure 20: Remove Bit Prompt
6. The carver will then home and move to the preset position.
7. A prompt will display indicating to manually install the bit and slide the spindle over
the mandrel by hand.
Figure 21: Install Bit Prompt

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8. Place the bit in the collet and manually slide it over to the right side of the mandrel.
Allow the end of the bit to rest on the mandrel, as seen in Figure 22.
Figure 22: Bit Resting on the Mandrel
9. Secure the spindle with a crescent wrench, tightening the collet with the collet
wrench until snug.
10. Once properly tightened, there will be a slight gap between the end of the bit and
the top of mandrel, as seen in Figure 23.
Figure 23: Gap Between Bit and Mandrel
11. The end of the bit is now at the correct position to run a test carve to confirm
dimensional accuracy.