Related Manuals for PVA Carver PRO-S
Summary of Contents for PVA Carver PRO-S
- Page 1 ALL THE TOOLS YOU’LL NEED TO FABRICATE DEVICES IN-HOUSE. Carver PRO-S™ Operation Manual Revision B...
- Page 2 Carver PRO-S™ Manual 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.
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Page 3: Table Of Contents
Carver PRO-S™ Manual Table of Contents Introduction ......................5 PVA Contact Information ......................5 Document History ........................5 Safety ............................6 Getting Started ..................... 8 Unboxing ............................ 8 Initial Setup ..........................11 Tool Kit ..........................11 Mandrels ..........................12 Waste Bin Liners ......................... 12 Plugging into Ethernet and Power Connections ............ - Page 4 Best Practices ......................... 58 Appendix A ......................59 Carving Terminology ......................59 Appendix B ......................60 Carver PRO-S™ Dimensions ....................60 PVA Med Mandrel Dimensions ..................... 61 Spare Parts Kit ........................62 Technical Specifications and Warnings ................62 Table of Figures ....................63 Notes ........................
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Page 5: 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... -
Page 6: Safety
Carver PRO-S™ Manual 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. - Page 7 Carver PRO-S™ Manual 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.
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Page 8: Getting Started
Carver PRO-S™ Manual 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. -
Page 9: Figure 3: Metal Ramp Secured To The Wooden Pallet
Carver PRO-S™ Manual 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. -
Page 10: Figure 5: Raise And Lower The Feet
Carver PRO-S™ Manual 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. -
Page 11: Initial Setup
Carver PRO-S™ Manual 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 Toolbox Mallet... -
Page 12: Mandrels
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. -
Page 13: Plugging Into Ethernet And Power Connections
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. -
Page 14: Figure 11: Connected Power Cord On Carver Pro-S
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. -
Page 15: Connecting To The Network
Carver PRO-S™ Manual 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. -
Page 16: Figure 15: Mac Address Location
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. -
Page 17: Cutting Bit Installation
Carver PRO-S™ Manual 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. -
Page 18: Figure 18: Cutting Bit Removed From Collet
Carver PRO-S™ Manual 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. -
Page 19: Figure 20: Remove Bit Prompt
Carver PRO-S™ Manual 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. -
Page 20: Figure 22: Bit Resting On The Mandrel
Carver PRO-S™ Manual 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. -
Page 21: Deskproto
Carver PRO-S™ Manual DeskProto® 3.1 Installation and Setup 1. DeskProto® can be installed by running the DeskProto® Setup program. Users can download this setup program (DeskProto71.exe for Windows, DeskProto71.dmg for Mac, or DeskProto71.AppImage for Linux) from the download page on the DeskProto®... -
Page 22: Figure 25: Deskproto® Startup Screen
Carver PRO-S™ Manual Figure 25: DeskProto® Startup Screen 4. Click the OK button to apply the selections. Page 22 of 67 Revision B September 2022... -
Page 23: Activating A Deskproto® License
Carver PRO-S™ Manual Activating a DeskProto® License 1. Following the settings startup screen, select the Activate button to begin entering the information for a DeskProto® license. Figure 26: Activating a Current DeskProto® License 2. Copy the company name and key from the license file provided with the machine. -
Page 24: Figure 28: Entering A Deskproto® Key To Activate A License
Carver PRO-S™ Manual 3. In the license details section of the activation window, paste the previously copied company name in the Name box and the license key in the Key box. 4. Click the Activate button to activate the license. -
Page 25: Importing Machine Settings
Carver PRO-S™ Manual Figure 29: Turning Off Startup Screen Importing Machine Settings 1. In DeskProto®, navigate to Options -> Library of Machines. Figure 30: Options Tab Page 25 of 67 Revision B September 2022... -
Page 26: Figure 31: Machine Library Warning Screen
Carver PRO-S™ Manual 2. Click the OK button on the warning screen. Uncheck the Always show this message box to avoid the message from showing again. Figure 31: Machine Library Warning Screen 3. In the Machines Library window, select the Open location button to open a new Windows Explorer window. -
Page 27: Figure 33: Machine Library Files
Figure 33: Machine Library Files Note: These files have been provided with the Carver PRO-S™ license file. They can also be downloaded as a zip folder from the PVA Med website on the Carver PRO-S™ product page. 5. Close the Windows Explorer window. -
Page 28: Figure 35: Advanced Settings Tab
Carver PRO-S™ Manual 7. In the Preferences window, navigate to Advanced -> Settings. 8. Select the Import Settings button. Figure 35: Advanced Settings Tab 9. Click the YES button on the warning screen to close the project and apply the changes. -
Page 29: Figure 37: Browse To A Settings File
Carver PRO-S™ Manual 10. Browse to and select the settings file named deskproto_7-1_settings V1.0.xml. Click the Open button to import the file into DeskProto®. Figure 37: Browse to a Settings File 11. A success message will be displayed to confirm that DeskProto® has enabled the new settings from the chosen file and the project is properly configured for use. -
Page 30: Workflow Template For Long And Short Mandrels
Carver PRO-S™ Manual 3.2 Workflow Template for Long and Short Mandrels Importing the Template Model 1. In DeskProto®, open the workflow template by selecting File -> Open Project. Figure 39: Opening a Project in DeskProto® 2. In the explorer window, browse to the template you would like to import and select the Open button. -
Page 31: Orienting The Model
Carver PRO-S™ Manual Figure 41: Changing the Name of a Project Orienting the Model 1. After import, the user will see the STL file and a representation of the mandrel. Figure 42: STL File and Mandrel Representation 2. To orient the model, double-click on the Project Name within the Project Tree. -
Page 32: Figure 44: Geometry Tab In Project Parameters
Carver PRO-S™ Manual 3. Within the Project Parameters popup, navigate to the Geometry tab. On the Geometry tab, select the Transform button. Figure 44: Geometry Tab in Project Parameters 4. The model will need to be oriented about the X axis. To achieve this, rotate the model by 90°... -
Page 33: Figure 46: Translation Tool
Carver PRO-S™ Manual 5. Use the Translation tool to change the location of the object in mm for X, Y, and Z so it is positioned on the mandrel. Use the Preview button to view changes as the values are entered. -
Page 34: Define Material Block
Carver PRO-S™ Manual Figure 48: Model After Translation 7. Once positioned, select the OK button in the Geometry Transformation window. 8. Select OK in the Project Paramater window. Define Material Block 1. To define parameters for the material block, double-click on the part in the Project Tree. -
Page 35: Figure 50: Material Tab In The Part Parameters Window
Carver PRO-S™ Manual Figure 50: Material Tab in the Part Parameters Window 3. In the pop-up window, the size of the CAD model will be displayed in Boundaries of CAD data section. The size of the material block will be displayed in the Material block of current part section. -
Page 36: Material Block Size Error
The R field and radius will be automatically calculated. Ensure that this number is less than the maximum work area of the Carver PRO-S™. 7. Select the OK button when finished with changes. Select the OK button in the Part Parameter window to return to the main screen. -
Page 37: Configuring Cutting Profiles
2. In the Geometry operation window, select the General tab. In the Precision section, enter in mm the desired distance between tool paths. The default pitch is set to 2.0 mm for the Carver PRO-S™. Figure 54: Adjusting the Distance Between Toolpaths Note: A smaller distance will create a better finish and finer detail but will result in a longer carve. -
Page 38: Calculating A Toolpath
Carver PRO-S™ Manual Figure 55: Use Material Block Above Rotation Axis Selection Note: If this step is not performed, a Move Outside of Machine Limits error will be displayed when the distal end is carved. Calculating a Toolpath 1. Select the Calculate Toolpaths icon. -
Page 39: Saving A G-Code
Carver PRO-S™ Manual lines shown in the Model View will represent the starting point and the lead in process of the carve. Figure 57: Model View Showing Cutting Path, Starting Point, and Lead In Process 3. Select OK to close the window. -
Page 40: Operation
Operation 4.1 Preparing for a Carve When preparing the Carver PRO-S™ for a carve, the foam blank being used can be either inserted onto a pre-installed mandrel or slid onto the mandrel before it is installed into the chuck of the machine. -
Page 41: Adding A Foam Blank Onto A Pre-Installed Mandrel
Carver PRO-S™ Manual Adding a Foam Blank onto a Pre-Installed Mandrel 1. Align the foam blank’s pilot hole with the end of the pre-inserted mandrel. Figure 60: Inserting the Mandrel into a Foam Blank 2. Gently tap end of the foam blank with the mallet from the supplied kit or by hand until the mandrel is fully inserted. -
Page 42: Figure 62: Properly Inserted Foam Blank And Mandrel
5. Tighten the chuck with the supplied square chuck key. Once the chuck is fully tightened, ensure the square key is removed from machine before operation. Figure 63: Tightening the Chuck 6. Close the door of the Carver PRO-S™. Page 42 of 67 Revision B... -
Page 43: Adding A Foam Blank To A Mandrel Before Installation
Carver PRO-S™ Manual Adding a Foam Blank to a Mandrel Before Installation 1. To ensure the foam blank is slid to the end of the mandrel and fully seated, the user can tap the end of the foam blank by hand or with a mallet. -
Page 44: Using G-Code Files
4. Close the door of the Carver PRO-S™. 4.2 Using G-code Files Once a user has acquired their desired G-code, the Carver PRO-S™ allows for G-codes to be loaded through either a microSD card or a network upload. Loading a G-code File from a microSD Card 1. -
Page 45: Figure 68: Inserting The Microsd Card
PRO-S™. Note: The microSD card must be inserted with the metallic contacts facing the center of the Carver PRO-S™. Figure 68: Inserting the MicroSD Card 4. Once the card is loaded, press the microSD card button on the home page of the carver’s HMI control screen, as seen in Figure 75. -
Page 46: Figure 70: Microsd Options Screen
Carver PRO-S™ Manual 5. In the microSD options screen, press the microSD card icon to switch between the onboard SD card (Card 0) and the secondary SD card on the top of the machine (Card 1). Figure 70: MicroSD Options Screen 6. -
Page 47: Loading A G-Code File From An Internet Upload
Figure 72: Print Screen for MicroSD Card Loading a G-code File from an Internet Upload 1. Connect to the Carver PRO-S ™ via the web interface, as seen in Figure 79, by typing the carver’s IP address into a web browser. -
Page 48: Figure 74: Select G-Code And Open
Carver PRO-S™ Manual 3. When prompted, select the desired G-code to print and click the Open button. Figure 74: Select G-code and Open 4. Once selected, the interface will begin uploading the G-code file and a status bar will show its progress as it is being transmitted over the network to the carver. This file will be saved on Card 0, which is the onboard SD card. -
Page 49: Accessing G-Code Files From The Web Interface
3. Users can also Rename, Delete, or Edit the selected G-code file in this section. Figure 77: Right Click Options for G-codes in the Web Interface Note: The file upload functionality in the web interface cannot be used while the Carver PRO-S™ is running. Page 49 of 67 Revision B... -
Page 50: Starting A Carve
Carver PRO-S™ Manual 4.3 Starting a Carve 1. After opening the file, the carver will automatically home all axes. 2. Once the homing process is complete, the spindle will move to the left side of the carver with Z axis fully retracted. -
Page 51: Figure 80: Jogging The X And U Axes On The Hmi
Carver PRO-S™ Manual 4. Using the buttons on the HMI or the web interface, users can jog the axis to move the spindle to the starting point for the X and the U axes. Figure 80: Jogging the X and U Axes on the HMI 5. -
Page 52: Figure 82: Axes Diagram
Carver PRO-S™ Manual Note: If the spindle is biased to the left edge of the foam, the material finished part will be short. If the spindle is biased to the right edge of the foam, there will be uncut material at the left side of the foam blank. -
Page 53: Figure 83: Spindle And Z Axis Locations After A Finished Carve
Carver PRO-S™ Manual 10. After the sample carve is completed, the spindle will be turned off, the Z axis will lower, and the spindle will move to the right side of the machine. Figure 83: Spindle and Z Axis Locations After a Finished Carve 11. -
Page 54: Figure 85: Removing Finished Part From Mandrel
Carver PRO-S™ Manual 12. The door of the Carver PRO-S™ can now be opened and the finished carve can be removed from the mandrel. Figure 85: Removing Finished Part from Mandrel 13. Alternatively, the mandrel can be removed with the finished part still attached by opening the chuck with the square key. -
Page 55: Figure 87: Finished Cylindrical Extension Sample Carve Tolerance
Carver PRO-S™ Manual 14. Upon completion, the cylindrical extension on the left end of the sample carve should measure 75 mm (2.95 in), as seen in Figure 93. Figure 87: Finished Cylindrical Extension Sample Carve Tolerance Note: This measurement may fluctuate slightly if the foam becomes compressed. -
Page 56: Cleaning And Maintenance
5.3 Waste Bin Each Carver PRO-S™ includes a waste bin and a box of replacement waste bags for the bin. A key is provided to lock and unlock the enclosure doors to access the waste bin, as seen in Figure 94. -
Page 57: Figure 89: Removing The Waste Bin From Its Enclosure
Carver PRO-S™ Manual When the waste bin has reached capacity: 1. Unlock the doors using the provided key and slide the waste bin out of the enclosure. Figure 89: Removing the Waste Bin From its Enclosure 2. Remove the used bag and replace with a new bag. -
Page 58: Best Practices
Carver PRO-S™ Manual 5.4 Best Practices • Do not wear loose clothes or jewelry when operating the carver. • Do not touch the cutting bit while it is moving. • Immediately engage the Emergency Stop button if personnel is in danger. -
Page 59: Carving Terminology
CAD program, calculate CNC toolpaths, and then write NC program files. Rapid Plaster® PVA Med’s exclusive modification software designed specifically for lower extremity prosthetics. A file type common for 3D models. Has the file extension “.stl”. Page 59 of 67... -
Page 60: Carver Pro-S™ Dimensions
Carver PRO-S™ Manual Appendix B 7.1 Carver PRO-S™ Dimensions Figure 90: Carver PRO-S™ Dimensions Page 60 of 67 Revision B September 2022... -
Page 61: Pva Med Mandrel Dimensions
Carver PRO-S™ Manual 7.2 PVA Med Mandrel Dimensions Figure 91: PVA Med Mandrel Dimensions Page 61 of 67 Revision B September 2022... -
Page 62: Spare Parts Kit
Figure 92: Spare Parts Kit 7.4 Technical Specifications and Warnings • Do not use the Carver PRO-S™ if wires are frayed, connections are loose, or if unusual conditions are detected that could indicate a short. • This machine is made of machined metal which may retain sharp edges. Improper handling may result in property damage or personal injury. -
Page 63: Table Of Figures
Figure 9: Connecting the Ethernet Cable ..................13 Figure 10: Supplied Power Cord End ....................13 Figure 11: Connected Power Cord on Carver PRO-S™ ..............14 Figure 12: Main Power Switch ......................14 Figure 13: IP Setup Tab Location on the HMI ..................15 Figure 14: IP Address Location ...................... - Page 64 Figure 70: MicroSD Options Screen ....................46 Figure 71: Select G-code........................46 Figure 72: Print Screen for MicroSD Card ..................47 Figure 73: Carver PRO-S™ Web Interface Home Screen ............... 47 Figure 74: Select G-code and Open ....................48 Figure 75: Upload Complete ........................ 48 Figure 76: G-code Files in the Web Interface ...................
- Page 65 Figure 88: Accessing the Waste Bin ....................56 Figure 89: Removing the Waste Bin From its Enclosure ..............57 Figure 90: Carver PRO-S™ Dimensions ..................... 60 Figure 91: PVA Med Mandrel Dimensions................... 61 Figure 92: Spare Parts Kit ........................62...
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Page 66: Notes
Carver PRO-S™ Manual Notes Page 66 of 67 Revision B September 2022... -
Page 67: Warranty
Unauthorized repair or modification of the enclosed product, and/or the use of spare parts not directly obtained from PVA (or from factory authorized dealers) will void all warranties.
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