Kval EFX User manual

Innovation, Quality & Honesty

Service Manual

Published: November 3, 2022

EFX Door Machining System

With KvalCAM®

Service Manual EFX System

KVAL EFX System Service Manual

Proprietary Notice

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. For

authorization to copy this information, please call Kval Customer Support at (800) 553-5825 or

fax (707) 762-0485.

Manual Name: EFX Service Manual

Manual Revision: 229-MV100.2, 229-MV100.3

EFX is a trademark of Kval Incorporated.

KvalCAM® is a registered trademark of Kval Incorporated.

Beckhoff®, TwinCAT, and EtherCat® are registered trademarks and are licensed by Beckhoff

Automation GmbH

All other products are trademarks or registered trademarks of their respective holders, all rights

reserved. Reference to these products is not intended to imply affiliation with or sponsorship of

Kval Incorporated.

Contacting KVAL

For further information about this manual or other Kval Incorporated products, please contact us.

Mailing address:

Kval Incorporated

825 Petaluma Boulevard South

Petaluma, CA 94952

Phone and Fax:

call: (800) 553-5825

fax: (707) 762-0485

General Office Business Hours

Mon-Thu:6:00 AM - 4:00 PM PST

Fri: 6:00 AM - 3:30 PM PST

Parts

Contact us for all parts related needs, from orders to inquiries. Call, email, contact us on our web-

site at the “Contact Us” page.

email: pa[email protected]

KVAL EFX System Service Manual

Technical Service Support

For machinery support and troubleshooting. Call, email, contact us on our website at the “Contact

Us” page.

Mon-Fri:4:00 AM - 4:00 PM PST

email: [email protected]

Field Service Support

For any other inquiries or to schedule on-site service. Call, email, contact us on our website at the

“Contact Us” page.

email: [email protected]

Sales Support

For machinery information, specifications, and quotes. Call, email, contact us on our website at

the “Contact Us” page.

email: [email protected]

Kval Website

Learn about Kval, order parts, get information on our array of machines (including new machine

releases), learn about our machine software solutions, download machine documentation, view

videos of our machines in action, contact all the departments.

http://www.kvalinc.com

KVAL EFX System Service 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

Operation Manual .................................................................................1-4

Service Manual.....................................................................................1-4

KvalCAM Reference Manual ................................................................1-4

Safety First!.............................................................................. 1-5

Safety Sheet Sign-Off Sheet.................................................................1-5

Safety Terminology of Labels................................................................1-5

Safety Guidelines..................................................................... 1-6

Training.................................................................................................1-6

Protective Gear.....................................................................................1-6

When the Machine is Powered and Running........................................1-6

Compressed Air ....................................................................................1-7

Electrical ...............................................................................................1-7

Pinch Points..........................................................................................1-9

Before Conducting Maintenance ..........................................................1-9

Laser Warnings...................................................................................1-10

Compliance with Codes and Regulations...........................................1-10

Other Hazard Control Action...............................................................1-10

Follow Your Company’s Safety Procedures........................................1-10

Lockout Tagout Guidelines ...................................................... 1-11

Follow the P-R-O-P-E-R lockout rule of thumb...................................1-11

Lockout Tagout Procedure....................................................... 1-12

Pre-Steps Before Lockout Tagout.......................................................1-12

Lockout Tagout Power ........................................................................1-12

Lockout Tagout Air Supply ..................................................................1-13

Start Maintenance...............................................................................1-13

Post Maintenance Steps.....................................................................1-13

Zero-Energy to Start-Up .......................................................... 1-15

Inspect ................................................................................................1-15

Clean Up.............................................................................................1-15

Replace Guards..................................................................................1-15

Check Controls ...................................................................................1-15

Remove Locks....................................................................................1-15

Perform Visual Checks .......................................................................1-15

Close the Cage Gate ..........................................................................1-16

Getting Help from KVAL........................................................... 1-17

Kval Return and Warranty Policy............................................. 1-18

Send the Item .....................................................................................1-18

KVAL EFX Manual

Table of Contents

Acceptance of Return .........................................................................1-18

Refund Turnaround Time ....................................................................1-18

Kval Errors..........................................................................................1-18

Customer Errors .................................................................................1-19

Shipper Errors.....................................................................................1-19

Warranty Replacement Parts..............................................................1-19

Safety Sign-Off Sheet .............................................................. 1-21

A Note to the Operator........................................................................1-21

................................................................................................. 1-23

Chapter 2 System IT Administration

System IT Administration ......................................................... 2-2

About the EFX Line Computer..............................................................2-2

Connections on the PLC.......................................................................2-2

About Remote Connection to KVAL Service............................ 2-3

Network Diagram..................................................................................2-3

Chapter 3 Maintenance of the EFX

Maintenance Schedule ............................................................ 3-2

300 Cycle Maintenance Steps ................................................. 3-4

Clean, Clean, Clean!.............................................................................3-4

600 Cycle Maintenance Steps ................................................. 3-5

Check Air Gauges and Inspect Water Traps.........................................3-5

Inspect Tooling......................................................................................3-5

Empty Dust Collection Units .................................................................3-5

3,000 Cycle Maintenance Steps .............................................. 3-7

Inspect Feed Belts (If Applicable) .........................................................3-7

Inspect all Photo Eyes ..........................................................................3-7

Inspect Limit Switches ..........................................................................3-7

Inspect Airlines......................................................................................3-8

Refill Lubricators...................................................................................3-8

Grease Ball Screw Bearings.................................................................3-9

Clean Bearing Shafts............................................................................3-9

12,000 Cycle Maintenance Steps............................................ 3-10

Inspect Chains for Proper Tension......................................................3-10

Inspect Air Cylinders...........................................................................3-10

Inspect Hydraulic Lines (If Applicable)................................................3-10

Inspect Ball Rail Shafts.......................................................................3-11

Table of Contents

KVAL EFX Manual

Clean and Lubricate Slides, Cylinder Rods and Bearing Shafts.........3-11

72,000 Cycle Maintenance Steps............................................ 3-12

Inspect Nuts and Bolts........................................................................3-12

Check Door Feeding Transition (If Applicable) ...................................3-12

Electrical .............................................................................................3-12

Computer Backup...............................................................................3-12

Wash Filter and Lubricator Bowls .......................................................3-12

Maintenance NO-GOES .......................................................... 3-13

Lubrication Schedule ............................................................... 3-14

Typical Lucubration Kit........................................................................3-14

Lubrication Requirements........................................................ 3-15

Pillow Block Bearing Housings ...........................................................3-15

Flange Bearing Housings ...................................................................3-16

Ball Rail Bearing .................................................................................3-16

About Taper Bearings .........................................................................3-17

Tapered Bearing Housings .................................................................3-17

Ball Screw Nut ....................................................................................3-18

Ball Screw Drive Assembly .................................................................3-18

Pulley and Idler Shafts (If Applicable) .................................................3-19

Grease Locations on the EFX.................................................. 3-20

Procedure to Grease the Hub Bearings..............................................3-20

Locations of Rail Bearings on the Carriage Head...............................3-21

Procedure to Grease the Carriage Head Bearings.............................3-21

Edge Cutting Section Lubrication .......................................................3-22

Face Cutting Section Lubrication........................................................3-23

Procedure to Grease the Stops and Probe Bearings .........................3-24

Procedure to Grease Pop Down Fence Bearings...............................3-25

Procedure to Grease Servo Assemblies.............................................3-26

Description of Air Input System................................................ 3-27

Air Input with Lubrication ...................................................................3-27

Air Line Without Lubricator .................................................................3-28

Identifying EFX Tools ............................................................... 3-29

Tool Information for the Edge Cutter...................................................3-29

Tool Information for the Face Cutter ...................................................3-30

About Chisels........................................................................... 3-31

Chisel Orientation on Machine............................................................3-31

Access the Tool Config Screen................................................ 3-32

Check the Tool Config.........................................................................3-32

Tool Length in Edge Cutter .................................................................3-33

Tool Length in Face Cutter..................................................................3-33

KVAL EFX Manual

Table of Contents

How to Access Tooling............................................................. 3-34

How to Access Edge Tooling ..............................................................3-34

How to Access the Face Tooling.........................................................3-35

Remove and Replace the Router or Pre-Drill Bits .................. 3-36

Before Changing the Tool Bits ............................................................3-36

Process to Remove Tooling ................................................................3-37

Inspect Collet......................................................................................3-37

Insert New the New Tool.....................................................................3-37

Changing Chisels on a Machine .............................................. 3-38

Replacing the Self Lubricator................................................... 3-39

Replace the Lubricator Well................................................................3-40

Collet Torque Values................................................................ 3-42

Addition Collet Torque Values.............................................................3-43

Chapter 4 Troubleshooting the EFX Line

Get Live Technical Help ........................................................... 4-2

Troubleshooting Basics ........................................................... 4-3

Before you Adjust..................................................................................4-3

Analyze the Sub Systems.....................................................................4-5

About Motion Control ............................................................... 4-6

Sequencing...........................................................................................4-6

Point to Point ........................................................................................4-6

Incremental...........................................................................................4-6

Basic Control Circuit ................................................................ 4-7

About a Typical Contactor Control ........................................... 4-8

About Contactor Troubleshooting .........................................................4-9

About Typical VFD Motor Drive Control................................... 4-10

About the VFD ....................................................................................4-11

About VFD Troubleshooting................................................................4-12

Error Checking on the Variable Frequency Drives..............................4-12

Using the Reset Buttons.....................................................................4-12

About a Typical Pneumatic Circuit ........................................... 4-13

Typical Pneumatic Assembly ..............................................................4-14

About the Coil (Solenoid)....................................................................4-14

About Cylinder Operation ...................................................................4-15

How the Pneumatic System Works ....................................................4-15

Important Notice about Adjusting Cylinder Speed ..............................4-17

Adjusting Cylinder Extend Speed .......................................................4-18

Table of Contents

KVAL EFX Manual

Adjusting Cylinder Retraction Speed .................................................4-18

Valve Bank Locations .............................................................. 4-19

Location of Valve Banks on the EFX ..................................................4-19

Network System Overview....................................................... 4-20

Connections to Servo Drives ..............................................................4-20

EFX Servo Motor Locations................................................................4-21

About Switches and Sensors................................................... 4-22

Using Sensors to Trouble Shoot .........................................................4-23

Troubleshooting Electrical Problems ....................................... 4-24

If the Power Stops During Normal Operation .....................................4-24

Description of the Light Tower ................................................ 4-26

KVAL EFX Manual

Table of Contents

1-1

KVAL Service Manual

CHAPTER 1 Introduction to the EFX System

Chapter 1 at a Glance

The following information is available in this chapter:

TABLE 1- 1. Summary of Chapter

Section Name Summary Page

Overview of the EFX Door

System

This section provides an overview of the

machine. It includes a general description

and a table of available options

page 1-2

Safety First! IMPORTANT safety information is

described in this section

page 1-5

Lockout-Tagout Guidelines Procedures describing Lockout Tagout. page 1-11

Zero-Energy to Start-Up Procedure to power up your machine for the

first time.

page 1-15

Getting Help from KVAL This section describes the method to con-

tact the KVAL Service Center for help. The

section includes how to get information from

the specification plate to provide to KVAL,

service center hours, and return procedures

page 1-17

Safety Sign-Off Sheet A record to track operators that are trained

on the machine.

page 1-21

Overview of the EFX System

KVAL Service Manual

1-2

Overview of the EFX System

All major electronic components including the on board PC, PLC, drives and Servo motors are by

Beckhoff. Software is KvalCAM® our latest CNC code generation software designed specifically

to simplify and manage nearly unlimited numbers of door hardware templates.

Machine files are created using a graphical interface. Once created, the software automatically

generates g-code to drive the machine movements. Spindle selection and tool path are combined

to efficiently process templates without tear-out in even delicate door edges and faces including

plastic laminates.

Note: Barcode or RFID scanning is available.

This machine is very similar in appearance to the standard Kval Edge SS with an inverted bed of

castors for door positioning. The left side of the castor table extends towards the operator so doors

can be clamped for rail work. The software automatically extends the correct door reference stop

for positioning based on door swing, end-work or face work.

Edge detailing spindles are by Colombo and include a standard rotation 3HP, reverse rotation

3HP, 11HP deep mortise, and 2HP drill spindle for screw pilot holes. Four corner chisels are stan-

dard to square hinge pockets or lock face plates. The entire edge detailing tower automatically

The Kval EFX is a CNC door machining station designed to process all

four door edges and door lock face holes or special shapes for card

locks.

The machine processes a wide range of door sizes up to 2-1/4” x 4’0” x

9’ with ability to complete virtually all marketable hardware sets,

including hinge preps, various multi points card locks and deep pocket

locks.

The machine’s L shaped inverted castor bed makes it simple to orient

doors for end work as well, so this machine is also ideal for overhead

closers, top and bottom pivots and manual or automatic flush bolts.

Many customers also use the edge detailing heads to rout out door rails

or stiles for cut-down doors.

Overview of the EFX System

1-3

KVAL Service Manual

pivots from zero to three degrees to match the door edge, including mid sequence for face plate

and deep pocket lock.

Consider the Kval FT-1 Door Flipper, or even better since it eliminates flipping completely, con-

sider the Kval DL-NCD or DL-NCX door light router as a companion machine with EFX. Either door

light router can process lock face holes from the top door face as well as door lights. Since they

are also KvalCAM based, a single door file can be used by both machines for the same door with

automatic data transfer

Three additional spindles are mounted underneath the castor table; two

spindles are utilized for face routing to best suit individual cus-

tomer needs (i.e bit type), the third 2HP spindle drill for lever

lock screw holes. Spindle movement is controlled via three

additional ball screws and servo motors. It is inde-

pendent of the edge detailing tower. In operation,

the software will position the edge detailing

tower an appropriate distance away from the

face heads, and then a door reference stop will

project from the edge tower to position the

door for clamping (left or right). This makes

face hole or slot locations completely pro-

grammable as part of a lock file. The underside face spindles typically

cut all the way through the door, but for face details only half way through the

door from the top face – the door is flipped and processed in a second step.

Overview of the EFX System

KVAL Service Manual

1-4

About this Manual

This manual is part of a package delivered with the machine line.

Operation Manual

Operation Manual includes the following:

Service Manual

Service Manual includes the following

KvalCAM Reference Manual

KvalCAM Reference Manual includes the following

Chapter Title Description

1Introduction Descriptions of Machine Line and

Safety Information.

2

Operation Inter-

face

Descriptions of how to power

machine line, and operator inter-

face user screens.

3Calibration Descriptions of Calibration Rou-

tines and how to use the interfaces

4Tour of EFX Identification and descriptions of

the EFX machine assemblies.

Chapter Title Description

1Introduction Safety Information.

2System IT Admin-

istration

Descriptions of the PLC system,

and computer system.

3Maintenance Maintenance steps for the

machine line

4Trouble Shooting Troubleshooting tips and theory of

operation.

Chapter Title Description

1KvalCAM reference Description of the Interface

2KvalCAM Examples Examples of Common Door Job

Features

3KvalCAM Common

Terms

Common terms associated with

KvalCAM

Safety First!

1-5

KVAL Service Manual

Safety First!

Safety Sheet Sign-Off Sheet

At the end of this chapter, there is a safety sign-off sheet. It lists personnel and machine safety cri-

teria to understand before operating the machine. It is highly recommended that personnel operat-

ing, working on a machine meet the criteria listed in this sheet. It is recommended the sheet be

signed and kept for records. See “Safety Sign-Off Sheet” on page 1-21.

Safety Terminology of Labels

In addition to the nameplate, KVAL machines may have other warning labels or decals that provide

safety information to operators. Safety labels should be clearly visible to the operator and must be

replaced if missing, damaged, or illegible.

There are three types of warning labels or decals:

• DANGER means if the danger is not avoided, it will cause death or serious injury.

• WARNING means if the warning is not heeded, it can cause death or serious

injury.

• CAUTION means if the precaution is not taken, it may cause minor or moderate

injury.

This machine is a powerful electro-mechanical motion control

system. You should test your motion system for safety under

all potential conditions. Failure to do so can result in dam-

age to equipment and/or serious injury to personnel.

Safety Guidelines

KVAL Service Manual

1-6

Safety Guidelines

In addition to the caution and warning labels affixed to this machine, follow the guidelines below

to help ensure the safety of equipment and personnel.

Note: Different versions of the stickers may have been applied to the machine. The

intent of safety is the same.

Training

Ensure that all employees who operate this machine are aware of and adhere to all safety precau-

tions posted on the machine and are trained to operate this machine in a safe manner. Figure 1-1

shows a sample of safety labels addressing training.

Read the Manual

FIGURE 1-1. Read the Manual Labels

Protective Gear

Never operate the machine without proper eye and ear protection. Figure 1-2 shows a sample of

safety labels addressing safety gear.

FIGURE 1-2. protective Gear Labels

When the Machine is Powered and Running

Serious injury or death could occur if these general rules are not followed. Figure 1-3 shows a

sample of safety labels addressing machine safety.

• Never reach hands beyond safety cage. Servo motors can unexpectedly move

quickly.

• Never clear screws or hinges out of the machine while it is running.

• Never reach into the router area to retrieve a hinge. The router may still be running

down after shut down.

Safety Guidelines

1-7

KVAL Service Manual

• Never perform any maintenance unless machine is at zero state.

• Never clean the machine while it is running.

• Never walk away from the machine while it is running.

• Never operate the machine without the safety guards.

FIGURE 1-3. Machine Safety Labels

Compressed Air

The compressed air system connected to this machine should have a three-way air valve for shut-

off and pressure relief.

All cylinders on machine are under high pressure and can be very dangerous when activated.

Before performing any maintenance or repairs on this machine turn off the main air disconnect.

Lockout and tagout this connection.See “Lockout Tagout Procedure” on page 1-12.

Electrical

Electrical circuitry on this machine is protected by an approved lockable disconnect circuit. In

addition to this equipment, you must install an approved disconnect for the electrical power sup-

plying this machine

FIGURE 1- 4. Electrical Box Labels

Safety Guidelines

KVAL Service Manual

1-8

Before performing any repairs or maintenance, lockout and tagout must be installed at all loca-

tions. See “Lockout Tagout Procedure” on page 1-12.

All maintenance and repairs to electrical circuitry should only be performed by a qualified electri-

cian.

Warning: Lever Style Electrical Panels: Lever style panels have a lock system that can

be unlocked to allow access to electrical penal that still has power applied.

High Voltage may cause injury or death. Do not open the cabinets with-

out High Voltage training or without permission from a supervisor.

Warning: Disconnect Style Panels: When opening the cabinet you must first turn off

the disconnect switch. When the cabinet door is open there is still power

on the top side of the disconnect switch. Some machines are powered by

more than one supply located at different locations. Do not open the cabi-

nets without High Voltage training or without permission from a

supervisor.

Still has power

in OFF position

Safety Guidelines

1-9

KVAL Service Manual

Pinch Points

A pinch point is a mechanical point where a person or part of a person's body can be caught

between moving parts of a machine, between the moving and stationary parts of a machine, or

between product and any part of the machine.

Always be aware of the safety stickers on the machine

Note: Different versions of the stickers may have been applied to the machine. The

intent of safety is the same.

FIGURE 1-5. Pinch Point Warning Labels

Before Conducting Maintenance

Prior to performing any maintenance, repairs, cleaning or when clearing jammed debris, you must

disconnect, tag out, or lock out the electrical and air pressure systems. This should be done in

accordance with applicable state and/or federal code requirements

.

FIGURE 1-6. Maintenance Warning Labels

Safety Guidelines

KVAL Service Manual

1-10

Laser Warnings

On some machines, laser indicators are used to set boundaries. Follow the laser manufacturers

safety precautions.

Compliance with Codes and Regulations

KVAL advises that you request an on-site state safety review of your installation of this machine.

This is to ensure conformance to any additional specific safety and health regulations which apply

in your geographic area.

Other Hazard Control Action

If you believe any part or operation of this machine is in violation of any health or safety regula-

tion, STOP production. It is your responsibility to immediately protect your employees against

any such hazard.

Additional detailed safety guidelines are included in the operating instructions of this manual.

KVAL will be pleased to review with you any questions you may have regarding the safe operation

of this machine

Follow Your Company’s Safety Procedures

In addition to these safety guidelines. Your company should have on-site and machine specific

safety procedures to follow.

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Kval EFX User manual

Kval EFX User manual

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