Kval MLX Operation And Service Manual
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Kval MLX Operation And Service Manual

Multi-point lock router system with kvalcam
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Innovation, Quality & Honesty
MLX Multi-Point Lock Router System
®
With KvalCAM
Operation and Service Manual
Published: June 1, 2021

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  • Page 1 Operation and Service Manual Published: June 1, 2021 Innovation, Quality & Honesty MLX Multi-Point Lock Router System ® With KvalCAM...
  • Page 2 This Manual is confidential and contains proprietary information and intellectual property of Kval Inc., and is to be used solely by Customer as an operating manual for Kval Inc. machines. Neither this Manual nor any of the information contained herein may be reproduced or disclosed under any circumstances without the express written permission of Kval Inc.
  • Page 3 KVAL MLX Operation and Service 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 experience with our product - that is, the manual, the machinery, the software, etc.
  • Page 4 LICENSE. IF YOU DO NOT AGREE TO ALL OF THE TERMS OF THIS LICENSE, THEN DO NOT USE THE KVALCAM SOFTWARE. KVAL, Inc., is the owner of all rights in respect of the software and documentation (referred to as “Licensor”). You are the purchaser of KVAL Machinery operated by the KVALCAM Software are the “Licensee”.

  • Page 5: Table Of Contents

    Table of Contents Introduction to the MLX Chapter 1 Chapter 1 at a Glance................1-1 Overview of the MLX Multi-Point Lock Router ......1-2 Options Available ..................1-2 About this Manual .................1-3 Safety First!................1-4 Safety Sheet Sign-Off Sheet..............1-4 Safety Terminology of Labels..............1-4 Safety Guidelines..................1-4...
  • Page 6 Back Section..................2-5 Carriage Head ................. 2-6 Pre-Drill Option ..................2-7 Face Lock Router Option..............2-7 Operator’s Station and Controls on the MLX ......2-8 Operator’s Station.................2-8 Mechanical Controls on the Operator Station........2-9 About the Foot Pedal ................2-9 About Controls on the Machine ............2-10 About the Electrical Panels .............
  • Page 7 Door Face Axis Directions ..............3-6 How to Enter Calibration Data ..........3-7 About The Calibration Box..............3-7 About Restore Points................3-8 About the MLX Calibration Screen .......... 3-9 MLX Calibration Screen................3-9 Calibration Selections ................3-9 About Calibration Sequence ............ 3-10 Step 1: Calibrate the Carriage Stop......... 3-11 Procedure ...................3-12...
  • Page 8 Routers: How to Isolate and Calibrate a Specific Router..3-21 Example Of a Calibration Cut .............3-22 System IT Administration Chapter 4 System IT Administration ............4-2 About the MLX Computer ..............4-2 Connections on the PLC...............4-2 About Remote Connection to Kval Service...........4-3 Maintenance of MLX Chapter 5 Maintenance Schedule ............
  • Page 9 Flange Bearing Housings ..............5-14 Ball Rail Bearing .................5-14 Maintenance NO-GOES ............5-15 Grease Locations for the MLX ..........5-16 Locations of Bearings on the Carriage Head........5-16 Locations of Bearings on the Fence and Movable Stop .....5-17 About the Tool Kit and Tool Identification ......... 5-18 About the Tool Kit................5-18...
  • Page 10 Troubleshooting Electrical Problems ........6-17 If the Power Stops During Normal Operation ........6-17 Description of the Light Tower ..........6-19 Network System Overview............6-20 Connections to Servo Drives ..............6-20 Connections to VFD’s (High Freq Panel)..........6-20 MLX Operation and Service Manual...

  • Page 11: Chapter 1 At A Glance

    Getting Help from Kval for help. The section Kval Service Center includes how to get information from the specification plate tor provide to Kval, service center hours, and return procedures A record to track operators that are trained on page 1-20 Safety Sign-Off Sheet the machine.

  • Page 12: Overview Of The Mlx Multi-Point Lock Router

    Overview of the MLX Multi-Point Lock Router of a door for most types of The MLX is a computer controlled machine designed to rout the edge and face multi-point lock systems as well as standard cylinder locks, strike plates and simple top and bot- tom flush bolts.

  • Page 13: About This Manual

    Overview of the MLX Multi-Point Lock Router About this Manual This manual is part of a package delivered with the machine line. Integration Package includes the following: includes the following: Operation and Service Manual Chap- Title Description Introduction Descriptions of Machine Line and Safety Information.

  • Page 14: Safety First

    Training 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. KVAL MLX Operation/Service Manual...
  • Page 15 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 1-9. KVAL MLX Operation/Service Manual...
  • Page 16 This should be done in accordance with applicable state and/or federal code requirements. Laser Warnings On some machines, laser indicators are used to set boundaries. Follow the manufacturers safety precautions. KVAL MLX Operation/Service Manual...
  • Page 17 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. KVAL MLX Operation/Service Manual...

  • Page 18: Lockout-Tagout Guidelines

    O..OFF! Shut off all power sources and isolating devices P..Place lock and tag E..ENERGY: Release stored energy to a zero-energy state R ..Recheck controls and test to ensure they are in the “OFF” state KVAL MLX Operation/Service Manual...

  • Page 19: Lockout Tagout Procedure

    Turn Switch to the Lock and Tag out Insert Lock into hole. OFF position Note: When multiple people are working on the machine, each person needs to have a lock on the handle in the extra holes provided. KVAL MLX Operation/Service Manual...

  • Page 20: Lockout Tagout Air Supply

    The lock and tag can now be removed (only by the person(s) who placed them), and the machine can be re-energized. The tags must be destroyed and the locks and keys returned to the lockout center. KVAL MLX Operation/Service Manual 1-10...

  • Page 21: Zero-Energy To Start-Up

    Replace Guards Replace all equipment guards. If part of equipment cannot be properly adjusted after start-up with guard on, contact the Service team. See “Getting Help from Kval” Kval on page 1-13. Check Controls Confirm that all switches are in the “OFF” position. Please be advised that some com- ponents of the machine may start automatically when energy is restored.
  • Page 22 Be sure to follow the P-R-O- P-E-R lockout/tagout procedures, and that those around you do also. Close the Cage Gate Verify all cage gates are securely closed. Ensure all safety protocols are in effect. KVAL MLX Operation/Service Manual 1-12...

  • Page 23: Getting Help From Kval

    • Outside the U.S. and Canada, call (707) 762-7367 or fax (707) 762-0485 • Email address is service@Kvalinc.com • Hours: 6:00 AM to 4:00 PM Pacific Standard Time, Monday through Thursday 6:30 AM to 1:30 PM Pacific Standard Time, Friday KVAL MLX Operation/Service Manual 1-13...

  • Page 24: Kval Return And Warranty Policy

    We can only accept items for a return if they are still in their original packaging and in undam- aged, resalable condition. Returns are accepted within 45 days of purchase and with an RMA number issued by Kval Inc. Returns after 45 days of purchase or without a Kval Inc. issued RMA number will not be accepted.

  • Page 25: Customer Errors

    Kval provides a warranty to products that are deemed defective. Within 30 days of discovery of said defect, please notify Kval, but no more than one (1) year after delivery will the product be covered under Warranty. The repair, replacement, or payment in the manner described above shall be the exclusive remedy of Buyer for breach of Kval’s warranty or for claims based upon failure...

  • Page 26: How To Download The Service Application

    Kval tab. Follow the instruc- Support tions on the Support web page. Click the Download button to download the application that allows the technician to Kval have access to the operator sta- tion. KVAL MLX Operation/Service Manual 1-16...
  • Page 27 Sample of i.e Explorer: Located at the bottom of the screen. select the arrow and choose Save and Run A pop-up window is displayed. Accept the request to run the program. Note: Security settings may differ from plant to plant. If issues occur, con- tact your IT department. KVAL MLX Operation/Service Manual 1-17...
  • Page 28 Session code: An internal number to track this machine. It is auto filled. Your Name Field: Enter your name. The Kval techni- cian will use this field to identify this machine. Description: Enter machine Serial number and issue.
  • Page 29 How to Download the Service Application Page Intentionally Left Blank KVAL MLX Operation/Service Manual 1-19...

  • Page 30: Safety Sign-Off Sheet

    Note: It is recommended you make a copy of this sheet for new operators. If a copy is needed, you may download a PDF at the website (http:// Kval www.Kvalinc.com). You may also contact our Service Department at (800) 553-5825 or email at service@Kvalinc.com. KVAL MLX Operation/Service Manual 1-20...
  • Page 31 CHAPTER 2 This chapter describes components, assemblies, and the user interface of the machine. The con- tent is geared to help operators understand the basic operation of the MLX. Included are instruc- tions to process a door. Chapter 2 at a Glance...

  • Page 32: Operator's Tour

    The MLX is a computer controlled machine designed to rout the edge and face multi-point lock systems as well as standard cylinder locks, strike plates and simple top and bot- tom flush bolts. Below is a typical location of the MLX in a Door Processing Line. ON-3D: Feeds...

  • Page 33: Machine Components

    Machine Components. Components Descriptions Operator’s Station The operator’s station is a multi use station. It houses the MLX touchscreen, operation switches and other machine controls in the production line. Local Machine Controls The Local Machine Control is located on the front side of the...

  • Page 34: Identification Of Key Parts Of The Machine

    Start Sequence Emergency Stop Cut Area Carriage Head Router Counter Rotate Router Lock Drill Opt. Predrill Servo Motors Fixed Door Stop Foot Pedal Door Stop Electrical Panel Door Clamp Top View of the Machine FIGURE 2-1. KVAL MLX Operation/Service Manual...

  • Page 35: Front Section

    Carriage Head and face of the door. Retractable Back Fence Vertical Clamps Fixed Fence Precision Rails Carriage Head (Shown in the down position) Back View of Machine FIGURE 2-3. KVAL MLX Operation/Service Manual...

  • Page 36: Carriage Head

    Motor to drive the Head in the Up and Down direction Carriage Head Electrical Node: Connection box that delivers signals and voltages to the Head form the Electrical Box Carriage Head Side Views FIGURE 2-4. KVAL MLX Operation/Service Manual...

  • Page 37: Pre-Drill Option

    FIGURE 2-5. Face Lock Router Option This option adds a Face Lock Router assembly to rout face locks. Lock Router (Option): Plunges through the door face to machine lock trim holes Face Lock Router Option FIGURE 2-6. KVAL MLX Operation/Service Manual...

  • Page 38: Operator's Station And Controls On The Mlx

    Operator’s Station and Controls on the MLX Operator’s Station and Controls on the MLX Machine controls include: • an operator station with the interface and mechanical controls. KvalCAM • local mechanical machine controls. • a foot pedal. Operator’s Station The Operator’s Station includes a touch screen and keyboard to run...

  • Page 39: Mechanical Controls On The Operator Station

    Operator’s Station and Controls on the MLX Mechanical Controls on the Operator Station The figure below describes the mechanical controls on the Operation Station Cut Type Indicator: Shows the type of cut being processed. (Lock or Hinge). ontrol Circuit: Powers up and down the entire machine.See “Powering Operations...

  • Page 40: About Controls On The Machine

    Operator’s Station and Controls on the MLX About Controls on the Machine are l coated at the front edge of the machine. The controls include: Machine Control • Starts the machining process. Start Sequence: • Press if an emergency occurs to stop the machine.

  • Page 41: About The Electrical Panels

    About the Electrical Panels About the Electrical Panels The MLX has a Main Electrical Panel, The figure below shows an overview of the location of assemblies in the panel Warning: High Voltage is present in this panel at the top of the Three Phase Input even with the disconnect off.

  • Page 42: Summary Of Machining A Door

    Step 1: Start the Process Ensure factory air is present at the machine and the main air supply valve is turned on. Power up the See “How to Power Up the MLX” on page 2-16. Select the shortcut. KvalCAM Home the See “See “Description of the Light Tower”...

  • Page 43: Step 3: Open The Main Mlx Screen

    Door Job Queued Jobs performed are displayed and pre-process streps can be made. For detailed descriptions of the interface screen, see “About the MLX Interface Screens” on page 2-20. MLX Main Screen FIGURE 2- 9. Step 4: Set the Movable Stop...

  • Page 44: Step 5: Load And Align The Door

    3. Firmly align After door is snug against the fence and door stop, press the pedal Door Clamp to secure the door for machining. KVAL MLX Operation/Service Manual 2-14...

  • Page 45: Step 6: Process The Door

    Start Sequence to start the machining process. Door Process The MLX will machine a hinge or lock depending on the active Door Job After machining is completed, either continue processing door or finish the process. To verify type of cut, check the illuminated lock or hinge indicator at the Note: See “Mechanical Controls on the Operator Station”...

  • Page 46: Powering Operations For The Mlx

    • Starting the Control Circuit Powering down the system includes: • Shutting down the control power • Removing power from the entire system How to Power Up the MLX Don t Forget Ensure factory air is applied to machine Air ON and main air supply is turned on.

  • Page 47: How To Power Down

    Switch the green switch to the OFF Control Circuit position. Kval also recommends that you turn the disconnect switch on the electrical cabinet to OFF; this helps reduce possible damage resulting from power surges from electrical storms. KVAL MLX Operation/Service Manual...

  • Page 48: About Emergency Stops

    Powering Operations for the MLX About Emergency Stops Important: Learn all safety precautionary controls on the machine. Depending on the model of machine, there are emergency shutdown (E- Stop) switches located at key points around the machine. The E-Stop switches are to be used when the machine is out of control or is about to damage personnel or equipment.

  • Page 49: About Machine Status Feedback

    This infor- mation can be used to troubleshoot any issues that may occur. When activated, the tab will highlight. At the top of the screen, the revision Note: of software is displayed. KVAL MLX Operation/Service Manual 2-19...

  • Page 50: About The Mlx Interface Screens

    KvalCAM Library: Load the cut parameters at the Door Job Screen. See the companion KvalCAM Refer- ence Manual. MLX Main Screen: Run the door cut at the Main Screen. MLX Operator Screens. Operator Screens contains the controls to operate the machine.

  • Page 51: About The Main Control Screen

    Main Control Tab is the most utilized screen. Information to machine a door is displayed Main Control Screen on this screen. The illustration below, displays a screen without a door loaded from the menu. Door Job KVAL MLX Operation/Service Manual 2-21...

  • Page 52: About The Sequence Control Section

    About the Main Control Screen About the MLX Main Control Section At this section control machine operations. Home Machine This button starts the home sequence on the machine, which scans to find a physical reference point on the frame. When this point is found, the position is stored and then used to calculate the location of all moves during the machine process.

  • Page 53: About The Stop And Clamp Control Section

    The value is determined by the KvalCAM Move the stop to the displayed Door Job. value.See “Step 4: Set the Movable Stop” on page 2-13. After the stop is moved, select button Confirm Door Stop Moved KVAL MLX Operation/Service Manual 2-23...

  • Page 54: About Speed Control

    About the Main Control Screen About Speed Control Adjust the speed of the cut. Press buttons to use the graduated speeds or select box and enter a desired speed. The speed can be changed during real time processing. KVAL MLX Operation/Service Manual 2-24...

  • Page 55: About The Manual Servo Control Screen

    Release the button to stop the move- ment. Select the to adjust Speed Percent box the speed of the Carriage Head. MLX Manual Control Screen FIGURE 2- 10. Y Forward X Forward Z Reverse X Reverse Z Forward Y Reverse Direction of the Carriage Head FIGURE 2-11.

  • Page 56: About The Tool Config Tabs

    • Change the rate of machining (feed-rate, spindle speed, plunge feed, entry feed, perimeter feed) • Parameters of the cut (depth, passes through material, overlaps, skin priority) Select Tab Unlock, Lock, and Save Data List of Tools Available Pop-Up Menus: enter tool data.(Routers,Drills,and Chisels) KVAL MLX Operation/Service Manual 2-26...

  • Page 57: Unlock The Tool Slot Configuration

    Below are samples of the pop-up windows Enable Check Box available About the Tool Pop-up Screens Drill Pop-up Drill Pop-up Disabled Sample Drill Configuration Pop-Ups Drill Pop-up Sample Drill Pop-up Disabled Sample KVAL MLX Operation/Service Manual 2-27...

  • Page 58: About Tool Locations

    Insert specifications of the tools being used to make the cuts. Ability to name the tools to user defined descriptions. Customize the tools to reflect the actual tool parameters, making the most accurate cuts. Ability to define cut operation. KVAL MLX Operation/Service Manual 2-28...
  • Page 59 About the Tool Config Tabs KVAL MLX Operation/Service Manual 2-29...

  • Page 60: About The Tool Path Preview Test Tab

    The figure below displays a sample of a good Deep Mortise Cut. Step 2 Step 1 Step 3 Center Circle represents the Point tool and the animation represents the path KVAL MLX Operation/Service Manual 2-30...

  • Page 61: About The Status Screen

    (idle, operation). The data can be filtered to observe certain aspects of the operation of the machine. This tool is great for troubleshooting to locate faulty assemblies. Filter Data List of Parameter of door in Process Status is listed by Location Status Screen FIGURE 2-12. KVAL MLX Operation/Service Manual 2-31...

  • Page 62: About The Log Screen

    Green = Report is a non-issue Yellow = Warning If the machine issue can not be resolved, call Kval Inc. (1-800-553-5825). Have any error code that is displayed, ready to give the Kval representative. This will aid in troubleshooting and shorten down time.

  • Page 63: Description Of The Light Tower

    Solid: General Error • Flashing: Not Ready to Re-Start (E-Sop Switch is Active) Green: Machine is Operational Off: No Control Power Control Power ON (Green): 24 VDC Control Power ON Ready to Work Light Tower Rev 2 KVAL MLX Operation/Service Manual 2-33...
  • Page 64 Description of the Light Tower KVAL MLX Operation/Service Manual 2-34...
  • Page 65 About the Calibration Tabs page 3-3 Descriptions of the Calibration Tabs. How to Enter Calibration Data page 3-7 Descriptions of how to use the calibration screens About the Calibration Screen page 3-9 Descriptions of the calibration available. KVAL Operation Manual...

  • Page 66: About Calibration

    Calibration is all about the confidence in the end results of your manufacturing process. Calibra- tion assures you that your cut parameters are accurate and within the specified limits. If slight discrepancies in the machining of a door are observed, the built in Kval calibration can adjust the tooling to fix the issue.

  • Page 67: About The Calibration Tabs

    Log Screens reporting. Finding errors from these screens will help localize problem areas. Note: If the machine issues can not be resolved, call Kval Inc. (1-800-553-5825). Have any error code that is displayed, ready to give the Kval representative. This will aid in troubleshooting and shorten down time.

  • Page 68: Unlock The Calibration (Option)

    Access to the calibration is password protected. (Optional) Select the button Unlock At the pop-up, enter Password the password and select OK to continue. The calibration message will change from a red ''Calibration is Locked '' to a green Calibration is Unlocked”. KVAL Operation Manual...

  • Page 69: Enter A Positive Or Negative Number

    X-Axis Y-Axis Positive movement Z-Axis Positive movement X-Axis Positive movement Door Edge Axis Directions Stand at the side of door, point at the edge of the door with the left hand rule to determine axis direction KVAL Operation Manual...

  • Page 70: Door Face Axis Directions

    Enter a Positive or Negative Number? Door Face Axis Directions is an optional add-on to the MLX. Using the Left-Hand rule, point at the cut at Lock Router the top to define the negative or positive offset. See the figure below for the offset direction.

  • Page 71: How To Enter Calibration Data

    Note: Maximum offset is 0.50 inches. If more than 0.50 inches of adjustment is needed, there is a high probability that another issue may be causing a problem. If issues can not be resolved, contact the Kval Service Center Kval Inc. (1-800- 553-5825).

  • Page 72: About Restore Points

    Name and enter to save To Load or Delete a Restore Point: Select the restore point from the menu Select the button to use the calibration. Select the button to load Load Load Select the button to delete the point. Delete KVAL Operation Manual...

  • Page 73: About The Mlx Calibration Screen

    About the MLX Calibration Screen About the MLX Calibration Screen contains a list of calibration adjustments. Select the located on Calibration Screen MLX Tab the left hand side of the machine, then select the to jump to this menu. Enter...

  • Page 74: About Calibration Sequence

    • See “Step 1: Calibrate the Carriage Stop” on page 3-11 • See “Step 2: Calibrate the Carriage Axis” on page 3-13 • See “Step 3: Calibrate the Edge Tools” on page 3-16 • See “Step 4: Calibrate the Face Tool” on page 3-19 KVAL Operation Manual 3-10...

  • Page 75: Step 1: Calibrate The Carriage Stop

    For this calibration, make sure the distance from the cutting space to the first carriage stop is at 20 inches. Important: The is the starting reference for the calibrations on the Carriage Stop machine. Always verify the carriage stop setting before continuing to cal- ibrate. KVAL Operation Manual 3-11...

  • Page 76: Procedure

    See “Step 2: Calibrate the Carriage Axis” on page 3-13. Calibration. If not in specification, adjust the location. Repeat until specification is reached. For polarity of value to enter, see “Door Edge Axis Directions” on page 3-5. KVAL Operation Manual 3-12...

  • Page 77: Step 2: Calibrate The Carriage Axis

    Y-Axis adjusted. • If the plunge cut is out of specification, check the then verify Configuration Menu Z-Axis. If not in specification, adjust the location. Repeat until specification is reached. KVAL Operation Manual 3-13...

  • Page 78: Face Carriage Axis Calibration Reference Cut (Option)

    Y-Axis be adjusted. • If the plunge cut is out of specification, check the then verify Configuration Menu Z-Axis. If not in specification, adjust the location. Repeat until specification is reached. KVAL Operation Manual 3-14...
  • Page 79 Step 2: Calibrate the Carriage Axis Face Cut FIGURE 3-3. KVAL Operation Manual 3-15...

  • Page 80: Step 3: Calibrate The Edge Tools

    Standard Router, but pre- Head in the Left and Right vents tear-outs on the Direction edge of the door Z Axis Servo Motor: Pre- cision Motor to drive the Head in the IN and Out direction KVAL Operation Manual 3-16...

  • Page 81: Edge Axis Calibration Reference Cut

    Y-Axis • If the cut is out of specification, the needs to be adjusted. depth Z-Axis If not in specification, adjust the location. Repeat until specification is reached. KVAL Operation Manual 3-17...

  • Page 82: Predrill

    Step 3: Calibrate the Edge Tools Predrill Check location of the predrill cut. Measure and compare against the specifications. If needed, Door Job input the offset polarity as seen in the figure above. KVAL Operation Manual 3-18...

  • Page 83: Step 4: Calibrate The Face Tool

    ( ). This is a global calibration. Therefore, by calibrating, other Z-Axis tools may be out of calibration. For directions on how to use the configuration menus, See “About the Tool Config Tabs” on page 2-26 KVAL Operation Manual 3-19...

  • Page 84: Face Tools Calibration Reference Cut

    If not in specification, adjust the location. Repeat until specification is reached. Face Tools Calibration Reference Cut The figure below, shows a sample reference cut and the type of offset to input into the calibration menu. See “How to Enter Calibration Data” on page 3-7 KVAL Operation Manual 3-20...

  • Page 85: Routers: How To Isolate And Calibrate A Specific Router

    If it is a 1.0 inch diameter router then set the Width = 2.0*1.0 = 1.0 For Example: Set the depth deep enough to measure. • 0.15 inches). For Example: Feature Details and Tool Configuration FIGURE 3-5. KVAL Operation Manual 3-21...

  • Page 86: Example Of A Calibration Cut

    , and Diameter Z axis X axis axis by measuring from the edges of the rectangle to the edges of the door. Enter offsets to adjust the cut match the Door Job. X-Axis Y-Axis KVAL Operation Manual 3-22...
  • Page 87 This chapter describes the basic parts of the opera- page 4-2 System IT tion of the PLC in the machine. Such as Administration • About the PLC • Connections on the PLC • Backing up the Computer • About Remote Connection to Kval Service KVAL MLX Operation/Service Manual...

  • Page 88: About The Mlx Computer

    Intranet and help solve any port issues that may occur. Connection to the Intranet is achieved by interfacing with the MLX con- troller. The location of the Intranet connection is identified in the figure below (RJ45 to Intranet.) About the MLX Computer ®...

  • Page 89: About Remote Connection To Kval Service

    About Remote Connection to Kval Service Remote access is a powerful tool to help fix issues that occur with the MLX machine. With the remote access, our Kval Service Technician is able to observe your user screen in real time, read ®...
  • Page 90 System IT Administration KVAL MLX Operation/Service Manual...

  • Page 91: Chapter 5 Maintenance Of Mlx

    • Ball Screws • Description of Air Input System • Adjusting the Air Line Lubricator • Priming the Air Line Lubricator This section describes the methods to replace bits on the page 5-18 Replacing Bits machine. KVAL MLX Operation/Service Manual...

  • Page 92: Maintenance Schedule

    Inspect the label. (Adjust only if Trained in Maintenance) Inspect Air Filter Water Traps. Empty if necessary Inspect Inspect the Tooling for wear.(Drill Bits, Cutting Tools, Screw Driver Inspect Bits) Empty All Dust Collection Units Clean KVAL MLX Operation/Service Manual...
  • Page 93 Inspect all airlines for kinks or rubbing. Inspect Refill all lubricators. Replace fluid if milky or discolored. Use ab ISO 32 Lubricate standard hydraulic oil (Kval PN:SYS-LUBEG). Grease Ball Nut screw bearings (if applicable). Lubricate Clean all bearing shafts with clean, dry cloth.

  • Page 94: 300 Cycle Maintenance Steps

    Use pressured air to blow off dust and debris on entire machine. Use a clean rag to clean areas not affected by pressurized air. Also blow out any dust collection units. Check vertical bearings for loose screws. Loose screws could cause bearing damage. Dust Collection Unit High Dust Accumulation Areas FIGURE 5- 1. KVAL MLX Operation/Service Manual...

  • Page 95: 600 Cycle Maintenance Steps

    Maintenance) Inspect Air Filter Water Traps. Empty trap if necessary Slide locking switch down to unlock twist trap to remove. Reverse action when installing trap. Inspect Tooling Inspect the Tooling for wear, (Drill Bits, Cutting Tools) KVAL MLX Operation/Service Manual...

  • Page 96: Empty Dust Collection Units

    Check and empty any dust collection units. Clean any dust filters. Dust collection systems vary from machine to machine. Follow manufacturers directions to empty dust collection units. Filters Dust Collection Con- tainers Typical Dust Collection Unit FIGURE 5- 2. KVAL MLX Operation/Service Manual...

  • Page 97: 3,000 Cycle Maintenance Steps

    Perform pull test on push on hose connectors. Check all airline connections, assem- blies, air valves, and hoses. Check from source to end assembly. Check Hoses for kinks and rubbing, manifold con- nections and Air Cylinder connections. KVAL MLX Operation/Service Manual...

  • Page 98: Refill Lubricators

    Grease ball screw bearings (if applicable). For a table of lubrication types to use, Lubrication Schedule. For locations to lubricate, See Grease Ball Screw Bearings Clean Bearing Shafts Clean all bearing shafts with clean, dry cloth.Spray shaft with silicone oil and clean build up grime and dirt. KVAL MLX Operation/Service Manual...

  • Page 99: 12,000 Cycle Maintenance Steps

    Example of a Pitted Ball Rail Inspect ball screws for pitting or abrasions. Example of a Pitted Ball Screw Clean and Lubricate Slides, Cylinder Rods and Bearing Shafts Clean and lubricate all slides and cylinder rods with dry silicone spray. KVAL MLX Operation/Service Manual...

  • Page 100: 72,000 Cycle Maintenance Steps

    Wash filter and lubricator bowls with soapy water. • Slide lock down to unlock. • Twist bowl to remove it. • Remove filter from Air filter assembly. Inspect and clean or replace if necessary. • Clean bowls and reas- semble. KVAL MLX Operation/Service Manual 5-10...

  • Page 101: Maintenance No-Goes

    • Do not adjust any and all flow controls from factory settings • Do not remove shim stock • Do not Change or Alter any safety assemblies (E-Stops, Gate Locks, etc) • Do not Change programs in PLC’s or PC’s • Do not Alter Electrical Components KVAL MLX Operation/Service Manual 5-11...

  • Page 102: Lubrication Schedule

    Lubrication Type Linear Bearing Pillow Block Bearing Every 250 Hours of Machine Operation Idler Shaft Dura-Lith Grease (KVAL P/N Lube EP-2) Flange Block Bearing Air Line Lubricator One drop of oil every 2 or 3 cycles Either lubricant listed below is approved to use.

  • Page 103: Lubrication Requirements

    Hub Style Opened Pillow Block parallel perpendicular mount Greasing Approximatively 1 Gram (one pump from grease gun) of Dura-Lith Grease (KVAL P/N: Lube EP-2). Every 250 hours of operation. Pillow Block Bearings FIGURE 5- 3. KVAL MLX Operation/Service Manual 5-13...

  • Page 104: Flange Bearing Housings

    Flange Greasing Housings Bearing Approximatively 1 Gram (one pump from grease gun) of Dura- Lith Grease (KVAL P/N: Lube EP-2). Every 250 hours of oper- ation. Flange Bearings FIGURE 5- 4. Ball Rail Bearing are linear bearings that are attached to positioning rails. In most cases, the bear- Ball Rail Bearings ings are attached to assemblies to move them in the X,Y, or Z direction.

  • Page 105: Maintenance No-Goes

    • Do not adjust any and all flow controls from factory settings • Do not remove shim stock • Do not Change or Alter any safety assemblies (E-Stops, Gate Locks, etc) • Do not Change programs in PLC’s or PC’s • Do not Alter Electrical Components KVAL MLX Operation/Service Manual 5-15...

  • Page 106: Grease Locations For The Mlx

    Grease Locations for the MLX Grease Locations for the MLX This machine is a powerful electro-mechanical Caution motion control system. If servicing this machine, fol- low the safety guidelines. Failure to do so can result in damage to equipment and/or serious injury to person- nel.

  • Page 107: Locations Of Bearings On The Fence And Movable Stop

    Grease Locations for the MLX Locations of Bearings on the Fence and Movable Stop For lubrication schedule information, see “Lubrication Schedule” on page 5-12. The figure below shows the bearings of the from the front section viewpoint. The bearings are color coded for Tools easy identification.

  • Page 108: About The Tool Kit And Tool Identification

    Location of Tools in the Carriages This section describes the steps to change the pre-drill bits, router bits, deep mortise and chisels. The next Figures show the locations of the tools on the Hinge Carriages.and the Lock Carriage. KVAL MLX Operation/Service Manual 5-18...
  • Page 109 Wrench PN Pre-Drill JLD1563 2.0 in. 59 ft lbs COLS55E389-1.5,2 COLER20-CW WRENCH22M Router 1 RB1010550-MISUC 3.75 in WRENCH24MM COLS73E478-3D COLER25-CW RBSC0808500-L Counter 4.25 in. 25 ft lbs Rotate Router 2 Lock Drill RB7076DR 2.75 in. Router KVAL MLX Operation/Service Manual 5-19...

  • Page 110: How To Access To Bit Assemblies

    Tool Point Length Remove and Replace the Router or Pre-Drill Bits After lockout tagout and access has been obtained to the assemblies, follow these instructions to remove and replace the router bit or the pre-drill bit. KVAL MLX Operation/Service Manual 5-20...
  • Page 111 Verify that there is no damage or blu- ing on the side of the collet Collet Assembly FIGURE 5- 2. Insert New Bit For a correct bit installation, follow the instructions in the Important: Tips Section on page 5-26 KVAL MLX Operation/Service Manual 5-21...

  • Page 112: Remove And Replace The Router Or Pre-Drill Bits

    Use a 17 mm shaft wrench and a 3/8 “collet wrench to remove the bit on the pre-drill or router assemblies. See Figure below. Removing Pre-Drill or Router Bit. FIGURE 5-3. Inspect and clean collet assembly. KVAL MLX Operation/Service Manual 5-22...
  • Page 113 Lightly tighten and torque to correct value. For torque values, See “Collet Torque Values” on page 5-26 Drill Depth Router Depth Set to 2.0” Set to 1 3/4 “ 1 3/4 ““ 2.0 “ Bit Depth Gauge (PN432C) KVAL MLX Operation/Service Manual 5-23...

  • Page 114: Replacing The Self Lubricator

    The lubricator kit part number is “Wit Lubricating Kit”. It contains, lubricator well, hose (with oil) and its connectors, bracket, and sensor. Follow the instructions on the next page. Well Hose Sensor Clamp Hose Connectors Wit Lubricating Kit FIGURE 5- 6. KVAL MLX Operation/Service Manual 5-24...

  • Page 115: Process To Change An Auto-Lubricator

    Verify the oil is being applied to the gear and there is no alert on the user screen. The lubricator well will have blinking light when in operation. Reattach grate and secure wires with a zip tie. KVAL MLX Operation/Service Manual 5-25...

  • Page 116: Collet Torque Values

    Collet Torque Values Collet Torque Values recommends torquing the collets. Torquing adds consistency is important for repeatable Kval machining. Follow the torque tool manufacturers method of torquing. KVAL MLX Operation/Service Manual 5-26...
  • Page 117 Collet Torque Values KVAL MLX Operation/Service Manual 5-27...
  • Page 118 Collet Torque Values KVAL MLX Operation/Service Manual 5-28...

  • Page 119: Get Live Technical Help

    Includes procedure to trouble shoot air cylin- page 6-9 Troubleshooting the ders,such as adjusting extension and retraction Air Cylinders speed. Includes basic information about the PLC control page 6-20 Network System wiring to different sections in the machine. Overview KVAL MLX Operation/Service Manual...

  • Page 120: About Motion Control

    Machinery. Kval Sequencing: Sequencing is a series of events executed in a predetermined order. Most Kval machines use a form of sequential motion control. A typical series of events for a Kval machine are: Move the door into position. Clamp the door.

  • Page 121: Basic Control Circuit

    • Moves the load. Examples: A motor or a pneumatic cylinder. The Position Feedback. • Provides location information to the controller. Examples: A limit switch, a photo eye, or ferrous eye, a resolver or an encoder KVAL MLX Operation/Service Manual...

  • Page 122: About A Typical Contactor Control

    Control Circuit Common DC - Control Coil for Thermal OverLoad 120 Vac. Should measure Line Voltage here Motor Schematic Drawing of Contactor and Thermal Overload Block Diagram of a Common Contactor Circuit FIGURE 6- 8. KVAL MLX Operation/Service Manual...

  • Page 123: About Contactor Troubleshooting

    Rerun the machine and verify that motor runs without tripping the circuit. If the same overload keeps tripping, verify condition. Follow circuit path using the E-Drawing as a reference. a.Common issues: Check for bad wire, bad motor, or if load is too great for cur- rent draw. KVAL MLX Operation/Service Manual...

  • Page 124: About Typical Vfd Motor Drive Control

    An adjustable-speed drive is used to control the motor speed and torque by varying motor input frequency and voltage. A variable-frequency drive (VFD) is used in Kval machinery to accu- rately drive motors for machining or moving product through the machine. The figure below shows a block diagram of a typical motor drive circuit.

  • Page 125: About The Vfd

    Figure 6- 10 on page 6- VFD models vary in Kval machines depending on where it is used, voltage requirements and type of PLC used. This is a general view on the VFD. See the machine’s Electrical Print for detailed information.

  • Page 126: About Vfd Troubleshooting

    Note: The number of reset buttons depends on the machine type and option. The fig- ure above shows a machine with 11 VFDs The VFD manuals are located in the Electrical Panels. On some machines, documentation can be found in the operation station in the documen- tation folder. KVAL MLX Operation/Service Manual...

  • Page 127: About A Typical Pneumatic Circuit

    Note: In this sample set-up, Port A is nor- mally open and Port B is nor- mally closed. If power is OFF, air should be on Port B. Block Diagram of a Pneumatic Circuit FIGURE 6- 13. KVAL MLX Operation/Service Manual...

  • Page 128: Typical Pneumatic Assembly

    About a Typical Pneumatic Circuit Typical Pneumatic Assembly Pneumatic assembly setups vary in Kval machines depending on where it is used and air require- ments.This is a general overview of a pneumatic assembly. See the machine’s Air Print for detailed information.

  • Page 129: About Cylinder Operation

    Router applies the control voltage to the which directs com- Control Valve pressed air to extend port of the Cylinder are extended deactivating the Cylinder Router Retract Sensor fully extends activating the Router Extend Sensor. KVAL MLX Operation/Service Manual 6-11...
  • Page 130 Control Valve Cylinder. retract deactivating the Cylinder Router Extend Sensor When the are fully retracted, the is activated. Cylinder Router Retract Sensor senses the voltage from the completing the process Retract Sensor KVAL MLX Operation/Service Manual 6-12...
  • Page 131 Router Assembly (Load) Retract Sensor Activated Air Pressure Retracts Cylinder Cylinder and Router Assembly Control Valve Air In Position Feedback Extended Sensor: Deactivated Translated Positioning Retracted Sensor: Force Instructions Activated Retracted 0 Volts Positioning Load System KVAL MLX Operation/Service Manual 6-13...

  • Page 132: Important Notice About Adjusting Cylinder Speed

    However, sometimes machine settling, mechanics be “broken in” may be cause to slightly adjust extend and retraction speed. If more than 1/2 turn on adjustment knobs are needed, call in a specialist or check with Kval customer service at 1-800-553-5825. Adjusting Cylinder Extend Speed Adjusting Cylinder Retraction Speed Tip: If Installing a new flow control assembly, shut down the flow control and back out 4 to 5 turns.

  • Page 133: About Switches And Sensors

    PLC. When the metal object leaves the sensing area, the sensor to returns to 24VDC and sends it to the PLC. • As a result, if a metal object is sensed, the output of the sensor equals 0VDC Sensors on Piston and Cylinder KVAL MLX Operation/Service Manual 6-15...

  • Page 134: Using Sensors To Trouble Shoot

    • Check the output voltages of the sensors in inactive mode.The voltage should effec- tively equal 24 VDC The distance from an eye to the door should be in range. Typically the range should be 3/4'' to 7/8'' from the top of all eyes to the door. KVAL MLX Operation/Service Manual 6-16...

  • Page 135: Troubleshooting Electrical Problems

    Refer to Air and Electrical Schematics provided with delivery of the machine. Schematics are located in the Electrical Panel. If copies NOTE: are unavailable, contact the Kval Service Department. Have model number and serial number of machine readily available. Warning The following checks require the electrical panel to be energized.
  • Page 136 Note: Most electrical problems are related to mechanical malfunction (e.g., stuck motors, jammed chain, blocked photo sensors etc.) Note: If a solenoid valve is suspected, and not cleared in the air checks section (see), it can be electrically jumped to check operation. KVAL MLX Operation/Service Manual 6-18...

  • Page 137: Description Of The Light Tower

    Solid: General Error • Flashing: Not Ready to Re-Start (E-Sop Switch is Active) Green: Machine is Operational Off: No Control Power Control Power ON (Green): 24 VDC Control Power ON Ready to Work Light Tower Rev 2 KVAL MLX Operation/Service Manual 6-19...

  • Page 138: Network System Overview

    The Servo Drives are located in the Main Electrical Panel. The outputs connect to the motors to drive assemblies such as: • Front Routers • Face Plate Router • Pre-Drills • Feeder • Width Adjust For detailed wiring information, see your machine’s electrical drawings. KVAL MLX Operation/Service Manual 6-20...
  • Page 139 16 drill bit main electrical panel replacing 18 description 11 dura-lith grease, bearing lube 12 manual operation DVI/USB module location 2 interface 30 electrical panels network system description 11 overview 20 EtherCat® smart power supply 2 terminals,location 2 Kval MLX...
  • Page 140 18 Safe Mode Enabled/Disabled 22 safety guidelines 4 Safety Sign Off Sheet Safety Concerns 20 sensors troubleshooing 16 types 15 voltage levels 15 service connecting your machine to KVAL Service 3 servo drives Kval MLX...
  • Page 144 Contacting KVAL Customer Service Phone and Fax: Mailing address: In the U.S and Canada, call (800) 553-5825 or fax Customer Support Department (707) 762-0485 Kval Incorporated Outside the U.S. and Canada, call (707) 762-7367 825 Petaluma Boulevard South or fax (707) 762-0485 Petaluma, CA 94952 Email: service@kvalinc.com...

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