Kval MLX Operation And Service Manual

Type
Operation And Service Manual
Innovation, Quality & Honesty
Operation and Service Manual
Published: June 1, 2021
MLX Multi-Point Lock Router System
With KvalCAM®
MLX Operation and Service Manual
KVAL MLX Operation and 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. Outside the U.S. and
Canada, call (707) 762-7367.
Manual Part Number: DOC-191-3-OPSRV
MLX is a trademark of Kval Incorporated.
KvalCAM® is a registered trademark of Kval Incorporated..
Copyright 2021 Kval Incorporated. All rights reserved.
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Contacting Kval
Customer Service: For further information about this manual or other Kval Incorpo-
rated products, contact the Customer Support Department
• Mailing address:
Customer Support Department
Kval Incorporated
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Petaluma, CA 94952
• Phone and Fax:
In the U.S and Canada, call (800) 553-5825 or fax (707) 762-0485
Outside the U.S. and Canada, call (707) 762-7367 or fax (707) 762-0485
• Business hours:
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(Other sales related inquiries: http://www.kvalinc.com)
KVAL MLX Operation and Service Manual
KVAL MLX Operation and Service Manual
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KVAL MLX Operation and Service Manual
NOTICE OF OWNERSHIP OF KvalCAM SOFTWARE AND LIMITED LICENSE TO
USE
READ THIS NOTICE CAREFULLY BEFORE USING THE KVALCAM SOFTWARE WHICH OPERATES
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1.
Definitions.
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Machinery and written documentation and materials provided to you, as well as any res or
updates of such computer application and documentation.
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above.
Table of Contents
MLX Operation and Service Manual
Chapter 1 Introduction to the MLX
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
Lockout-Tagout Guidelines ...................................................... 1-8
Follow the P-R-O-P-E-R lockout rule of thumb.....................................1-8
Lockout Tagout Procedure....................................................... 1-9
Pre-Steps Before Lockout Tagout.........................................................1-9
Lockout Tagout Power ..........................................................................1-9
Lockout Tagout Air Supply ..................................................................1-10
Start Maintenance...............................................................................1-10
Post Maintenance Steps.....................................................................1-10
Zero-Energy to Start-Up .......................................................... 1-11
Getting Help from Kval............................................................. 1-13
Kval Return and Warranty Policy............................................. 1-14
Send the Item .....................................................................................1-14
Acceptance of Return .........................................................................1-14
Refund Turnaround Time ....................................................................1-14
Kval Errors..........................................................................................1-14
Customer Errors .................................................................................1-15
Shipper Errors.....................................................................................1-15
Warranty Replacement Parts..............................................................1-15
How to Download the Service Application ............................... 1-16
On-Line Help.......................................................................................1-16
Download Application .........................................................................1-16
Safety Sign-Off Sheet .............................................................. 1-20
A Note to the Operator........................................................................1-20
Chapter 2 Operation of the MLX
Operator’s Tour ........................................................................ 2-2
Machine Components.............................................................. 2-3
Identification of Key Parts of the Machine ............................... 2-4
MLX Operation and Service Manual
Table of Contents
Top View ...............................................................................................2-4
Front Section ........................................................................................2-5
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 ..................................................... 2-11
Summary of Machining a Door ................................................ 2-12
Step 1: Start the Process....................................................................2-12
Step 2: Create or Load a Door Job.....................................................2-12
Step 3: Open the Main MLX Screen...................................................2-13
Step 4: Set the Movable Stop.............................................................2-13
Process to Move and Lock the Stop...................................................2-13
Step 5: Load and Align the Door.........................................................2-14
Step 6: Process the Door....................................................................2-15
Powering Operations for the MLX............................................ 2-16
How to Power Up the MLX .................................................................2-16
How to Power Down ...........................................................................2-17
About Emergency Stops.....................................................................2-18
To Resume Normal Operation after an E-Stop ...................................2-18
Other Safety Controls .........................................................................2-18
About the Computer Setting (Option) .................................................2-18
About Machine Status Feedback............................................. 2-19
About the MLX Interface Screens............................................ 2-20
MLX Operator Screens.......................................................................2-20
About the Main Control Screen................................................ 2-21
About the Sequence Control Section .................................................2-22
About the Stop and Clamp Control Section .......................................2-23
About Speed Control ..........................................................................2-24
About the Manual Servo Control Screen ................................. 2-25
About the Tool Config Tabs...................................................... 2-26
General Operating Controls................................................................2-26
Unlock the Tool Slot Configuration......................................................2-27
About the Tool Pop-up Screens ..........................................................2-27
About the Tool Pop-up Screens ..........................................................2-27
Table of Contents
MLX Operation and Service Manual
Sample Drill Configuration Pop-Ups ...................................................2-27
About Tool Locations ..........................................................................2-28
About Using Tool Configuration ..........................................................2-28
Measuring Tool Length .......................................................................2-28
About Entering Data into the Pop-up Menu ........................................2-28
About the Tool Path Preview Test Tab ..................................... 2-30
About the Status Screen.......................................................... 2-31
About the Log Screen.............................................................. 2-32
Description of the Light Tower ................................................ 2-33
Chapter 3 Calibration of the Machine Line
About Calibration ..................................................................... 3-2
About the Calibration Menus and the Calibration Reference Cut .........3-2
Before you Calibrate.............................................................................3-2
About the Calibration Tabs....................................................... 3-3
Access to the Calibration Adjustments .................................................3-3
Unlock the Calibration (Option).............................................................3-4
Enter a Positive or Negative Number? .................................... 3-5
Door Edge Axis Directions ....................................................................3-5
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
Step 2: Calibrate the Carriage Axis.......................................... 3-13
Process to Calibrate the Carriage Head ............................................3-13
Face Carriage Axis Calibration Reference Cut (Option) .....................3-14
Step 3: Calibrate the Edge Tools ............................................. 3-16
Edge Tool Locations ...........................................................................3-16
Edge Axis Calibration Reference Cut .................................................3-17
Process to Calibrate the Edge Tools...................................................3-17
Predrill.................................................................................................3-18
MLX Operation and Service Manual
Table of Contents
Step 4: Calibrate the Face Tool ............................................... 3-19
Face Tool Locations............................................................................3-19
Process to Calibrate the Face Tools ...................................................3-19
Face Tools Calibration Reference Cut ................................................3-20
Routers: How to Isolate and Calibrate a Specific Router......... 3-21
Example Of a Calibration Cut .............................................................3-22
Chapter 4 System IT Administration
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
Chapter 5 Maintenance of MLX
Maintenance Schedule ............................................................ 5-2
300 Cycle Maintenance Steps ................................................. 5-4
Clean, Clean, Clean!.............................................................................5-4
600 Cycle Maintenance Steps ................................................. 5-5
Check Air Gauges and Inspect Water Traps.........................................5-5
Inspect Tooling......................................................................................5-5
Empty Dust Collection Units .................................................................5-6
3,000 Cycle Maintenance Steps .............................................. 5-7
Inspect all Photo Eyes ..........................................................................5-7
Inspect Limit Switches ..........................................................................5-7
Inspect Airlines......................................................................................5-7
Refill Lubricators...................................................................................5-8
Grease Ball Screw Bearings.................................................................5-8
Clean Bearing Shafts............................................................................5-8
12,000 Cycle Maintenance Steps............................................ 5-9
Inspect Air Cylinders .............................................................................5-9
Inspect Ball Rail Shafts and Ball Screws..............................................5-9
Clean and Lubricate Slides, Cylinder Rods and Bearing Shafts...........5-9
72,000 Cycle Maintenance Steps............................................ 5-10
Inspect Nuts and Bolts........................................................................5-10
Electrical .............................................................................................5-10
Computer Backup...............................................................................5-10
Wash Filter and Lubricator Bowls .......................................................5-10
Maintenance NO-GOES .......................................................... 5-11
Table of Contents
MLX Operation and Service Manual
Lubrication Schedule ............................................................... 5-12
Typical Lucubration Kit........................................................................5-12
Lubrication Requirements........................................................ 5-13
Pillow Block Bearing Housings ...........................................................5-13
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
Location of Tools in the Carriages .....................................................5-18
How to Access to Bit Assemblies............................................. 5-20
Changing a Tool Bit.............................................................................5-20
Remove and Replace the Router or Pre-Drill Bits .............................5-20
Remove and Replace the Router or Pre-Drill Bits ..............................5-22
Replacing the Self Lubricator................................................... 5-24
Replace the Lubricator Well................................................................5-24
Process to Change an Auto-Lubricator...............................................5-25
Collet Torque Values ................................................................ 5-26
Chapter 6 Troubleshooting the MLX
Get Live Technical Help ........................................................................6-1
About Motion Control ............................................................... 6-2
Basic Control Circuit .............................................................................6-3
About a Typical Contactor Control ........................................... 6-4
About Contactor Troubleshooting .........................................................6-5
About Typical VFD Motor Drive Control................................... 6-6
About the VFD ......................................................................................6-7
About VFD Troubleshooting..................................................................6-8
About a Typical Pneumatic Circuit ........................................... 6-9
Typical Pneumatic Assembly ..............................................................6-10
About the Coil (Solenoid)....................................................................6-10
About Cylinder Operation ...................................................................6-11
How the Pneumatic System Works ....................................................6-11
Important Notice about Adjusting Cylinder Speed ..............................6-14
Adjusting Cylinder Extend Speed .......................................................6-14
MLX Operation and Service Manual
Table of Contents
Adjusting Cylinder Retraction Speed .................................................6-14
About Switches and Sensors................................................... 6-15
Using Sensors to Trouble Shoot.........................................................6-16
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
1-1
KVAL MLX Operation/Service Manual
CHAPTER 1 Introduction to the MLX
This chapter provides an overview of the Kval MLX Multi-Point Lock Router. Included is important
safety Information and Lockout Tagout procedures.
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 MLX
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 1-4
Lockout-Tagout Guidelines Procedures describing Lockout Tagout. page 1-8
Zero-Energy to Start-Up Procedure to power up your machine for the
first time.
page 1-11
Getting Help from Kval This section describes the method to contact
the Kval Service Center for help. The section
includes how to get information from the
specification plate tor provide to Kval, service
center hours, and return procedures
page 1-13
Safety Sign-Off Sheet A record to track operators that are trained on
the machine.
page 1-20
Overview of the MLX Multi-Point Lock Router
KVAL MLX Operation/Service Manual
1-2
Overview of the MLX Multi-Point Lock Router
The MLX is a computer controlled machine designed to rout the edge and face of a door for most types of
multi-point lock systems as well as standard cylinder locks, strike plates and simple top and bot-
tom flush bolts. The counter rotating spindles also make it possible to rout through the door edge
or an attached astragle without tear-out. Standard G code programming is used to create template
programs that can be selected directly at the touch screen.
Two counter rotating horizontal spindles rout slots for connecting rods as well as pockets for
latches. Afterwards a vertical router/drill plunges through the door stile to machine for the lock
trim holes larger than 10mm (0.397"). Servo motors are used to move the cutting head horizon-
tally (X axis) vertically (Y axis), and depth of cut (Z axis) on the edge of the door. For the lock
face machining the location and shapes are also computer controlled. The feed table will use non-
marking plastic rolls that will allow the door to be rolled into and out of the machine.
Options Available
Option Title Description
Option A 2-1/4" Door
Capacity
Door clamp system will be set to accommodate doors up to 2-1/4"
thick.
Option B: Jamb Routing Adds Exterior Jamb routing for strikes and hinge pockets using the
door face router. Not for flat or clad jambs. Jamb profile must be
standard rebated style with a section approximately 1-1/4" thick
and thin section approx. 5/8" thick.
No limit to jamb width, but thin section no more than 2-3/8" wide.
Jamb clamps in place facing downward, with the moulded stop
edge against the door backstop, and thin section overhanging the
backstop.
Option includes a touch off probe and encoder to precisely register
jamb face for routing depth. Programming available for hinges and
strike plates, including ASA and multi point plates.
Special Option 1: Raised Moulding
and 4'0" width
Machine bed upgrade to width adjusting system with multiple
support wheels. Maximum door width 4'0".
Overview of the MLX Multi-Point Lock Router
1-3
KVAL MLX Operation/Service Manual
About this Manual
This manual is part of a package delivered with the machine line.
Integration Package includes the following:
Operation and Service Manual includes the following:
KvalCAM Reference Manual
Chap-
ter
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.
3
4Maintenance Maintenance steps for the machine
line
5Troubleshooting 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!
KVAL MLX Operation/Service Manual
1-4
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 1-20.
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.
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.
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.
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.
Training
Safety First!
1-5
KVAL MLX Operation/Service Manual
Never operate the machine without proper eye and
ear protection.
Protective Gear
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.
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.
When the Machine is ON
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 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.
Compressed Air
Safety First!
KVAL MLX Operation/Service Manual
1-6
Electrical circuitry on this
machine is protected by an
approved lockable disconnect
circuit. In addition to this equip-
ment, you must install an
approved disconnect for the
electrical power supplying this
machine.
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. Before performing any repairs or mainte-
nance, lockout and tagout must be installed at all locations
All maintenance and repairs to electrical circuitry should only be per-
formed by a qualified electrician.
Still has power
in OFF position
Electrical
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.
Before Conducting Maintenance
Laser Warnings
On some machines, laser indicators are used to set boundaries. Follow the
manufacturers safety precautions.
Safety First!
1-7
KVAL MLX Operation/Service Manual
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 regula-
tions which apply in your geographic area.
Compliance with Codes and Regulations
Other Hazard Control Action
Report a Hazard
Before You Report an Accident
If you believe any part or operation of this machine is in
violation of any health or safety regulation, STOP pro-
duction. 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 proce-
dures to follow.
Lockout-Tagout Guidelines
KVAL MLX Operation/Service Manual
1-8
Lockout-Tagout Guidelines
• Place a tag on all padlocks. On the tag, each
operator must put their own name and date.
(These locks are only to be removed by the
person who signs the tag)
• If more than one person is working on the
machine, each additional person places a lock
and tag on each disconnect.
• Only each operator may remove their own
lock and tag.
Important: When many people are all working
on the same machine you will need a multiple
lockout device, such as the one shown here.
Follow the P-R-O-P-E-R lockout rule of thumb.
P...... Process shutdown
R ...... Recognize energy type (electrical, pneumatic, mechanical, etc.)
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
Lockout Tagout Procedure
1-9
KVAL MLX Operation/Service Manual
Lockout Tagout Procedure
This policy is required by OSHA regulation 1910.147 and Cal OSHA’S
SB198 ruling of July 1991.
Use the following lockout procedure to secure this machine while it is
powered down. During a lockout, you disconnect all power and shut
off the air supply. Be sure to use the tagout guidelines noted below.
Pre-Steps Before Lockout Tagout
Lockout Tagout Power
1. Evaluate the equipment to fully understand all energy sources (multiple electrical
supplies, air supply and pressure, spring tension, weight shifts, etc.).
2. Inform all affected personnel of the eminent shutdown, and the duration of the
shutdown.
3. Obtain locks, keys, and tags from your employer’s lockout center.
4. Turn off machine. See Chapter 2 for power down and power up procedures.
5. Turn the disconnect switches on ALL electrical and frequency panels to the OFF
position. Then push the red tab to pop it out. Place a padlock through the hole.
Place your tag on the padlock, as per the tagout guidelines below. (see illustration
below).
Note: When multiple people are working on the machine, each person needs to
have a lock on the handle in the extra holes provided.
Insert Lock into hole.
Turn Switch to the
OFF position
Lock and Tag out
Lockout Tagout Procedure
KVAL MLX Operation/Service Manual
1-10
Lockout Tagout Air Supply
Start Maintenance
7. Once the locks and tags are in place and all personnel are clear, attempt to operate
the machine to ensure equipment will not operate.
8. Maintenance or repairs may started.
Post Maintenance Steps
9. After maintenance is completed, the person performing the work must ensure all
tools, spare parts, test equipment, etc., are completely removed and that all guards
and safety devices are installed.
10. Before removing the locks and tags, the person who attached them shall inspect the
equipment to ensure that the machine will not be put in an unsafe condition when
re-energized.
11. The lock and tag can now be removed (only by the person(s) who placed them),
and the machine can be re-energized.
12. The tags must be destroyed and the locks and keys returned to the lockout center.
6. Turn all air valves to the OFF position and place a pad-
lock through the hole (see illustration below).
NOTE: Place your tag on the padlock, as per the
tagout guidelines.
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Kval MLX Operation And Service Manual

Type
Operation And Service Manual

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