Kval MLX User manual

Innovation, Quality & Honesty

Service Manual

Published: April 13, 2023

MLX Multi-Point Lock Router System

With KvalCAM®

MLX Service Manual

KVAL MLX 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 Technical Support at (800) 553-5825 or fax (707) 762-0485.

Manual Name: MLX Service Manual

Manual Revision: 191-MV100.2

MLX 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: [email protected]

KVAL MLX Service Manual

Technical 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]

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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 MLX Service Manual

NOTICE OF OWNERSHIP OF KvalCAM SOFTWARE AND LIMITED LICENSE TO

USE

READ THIS NOTICE CAREFULLY BEFORE USING THE KVALCAM SOFTWARE WHICH OPERATES

KVAL 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.

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”.

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 KVAL 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 KVAL, Inc. The

KVALCAM 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 KVAL

Machinery and written documentation and materials provided to you, as well as any res or

updates of such computer application and documentation.

b.“Install” means storing of the KVALCAM Software in the computer component of the KVAL

Machinery.

c.“Use” means executing the KVALCAM Software for purpose of operating the KVAL

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 KVAL Machin-

ery.

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.

This License will terminate automatically if Licensee fails to comply with the limitations described

above.

MLX Service Manual

Table of Contents

Chapter 1 Introduction to the MLX

Chapter 1 at a Glance...........................................................................1-1

Overview of the MLX Multi-Point Lock Router ......................... 1-3

Options Available ..................................................................................1-3

About this 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

Lockout/Tagout Guidelines ...................................................... 1-7

Follow the P-R-O-P-E-R lockout rule of thumb.....................................1-7

Lockout/Tagout Procedure....................................................... 1-8

Pre-Steps Before Lockout/Tagout.........................................................1-8

Lockout/Tagout Power ..........................................................................1-8

Lockout/Tagout Air Supply ....................................................................1-9

Start Maintenance.................................................................................1-9

Post Maintenance Steps.......................................................................1-9

Zero-Energy to Start-Up .......................................................... 1-11

Inspect ................................................................................................1-11

Clean Up.............................................................................................1-11

Replace Guards..................................................................................1-11

Check Controls ...................................................................................1-11

Remove Locks....................................................................................1-11

Perform Visual Checks .......................................................................1-11

Close the Cage Gate ..........................................................................1-12

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

Safety Sign-Off Sheet .............................................................. 1-17

A Note to the Operator........................................................................1-17

MLX Service Manual

Table of Contents

Chapter 2 Maintenance of MLX

Maintenance Schedule ............................................................ 2-1

Using Sensors to Trouble Shoot ...........................................................2-4

300 Cycle Maintenance Steps ................................................. 2-5

Clean, Clean, Clean!.............................................................................2-5

600 Cycle Maintenance Steps ................................................. 2-6

Check Air Gauges and Inspect Water Traps.........................................2-6

Inspect Tooling......................................................................................2-6

Lubricate inside of Hopper (990-Series Only).......................................2-7

Empty Dust Collection Units .................................................................2-7

3,000 Cycle Maintenance Steps .............................................. 2-8

Inspect Feed Belts................................................................................2-8

Inspect Screw Drop Tubes on Six Shooter (990-Series Only)..............2-8

Inspect all Photo Eyes ..........................................................................2-9

Inspect Limit Switches ..........................................................................2-9

Inspect Screw Receiver Parts (990-Series Only) .................................2-9

Inspect Airlines....................................................................................2-10

Refill Lubricators.................................................................................2-10

Grease Ball Screw Bearings...............................................................2-11

Clean Bearing Shafts..........................................................................2-11

12,000 Cycle Maintenance Steps............................................ 2-12

Inspect Chains for Proper Tension......................................................2-12

Inspect Air Cylinders...........................................................................2-12

Inspect Hydraulic Lines.......................................................................2-13

Inspect Ball Rail Shafts.......................................................................2-13

Inspect Ball Screw Axle ......................................................................2-13

Clean and Lubricate Slides, Cylinder Rods and Bearing Shafts.........2-14

Clean inside Hopper (990-Series Only)..............................................2-14

72,000 Cycle Maintenance Steps............................................ 2-15

Inspect Nuts and Bolts........................................................................2-15

Check Door Feeding Transition ..........................................................2-15

Electrical .............................................................................................2-15

Computer Backup...............................................................................2-15

Wash Filter and Lubricator Bowls .......................................................2-16

Maintenance NO-GOES .......................................................... 2-17

About Bearings ........................................................................ 2-18

About Pillow Block Bearing Housings.................................................2-18

About Flange Bearing Housings.........................................................2-19

About Ball Rail Bearings.....................................................................2-19

About Tapered Bearings .....................................................................2-20

MLX Service Manual

Table of Contents

Tapered Bearing Housings .................................................................2-20

Ball Screw Nut ....................................................................................2-21

Ball Screw Drive Assembly .................................................................2-21

Pulley and Idler Shafts........................................................................2-22

Lubrication Schedule ............................................................... 2-23

Kval Lubrication Kit.............................................................................2-24

Greasing the Lock Carriage Bearings...................................... 2-25

Recommended Tools ..........................................................................2-25

Lock Carriage Bearing Greasing Procedure.......................................2-25

Locations of the Lock Carriage Head Bearings ..................................2-25

Greasing the Frame Bearings.................................................. 2-27

Recommended Tools ..........................................................................2-27

Frame Bearing Greasing Procedure...................................................2-27

Locations of the Frame Bearings........................................................2-27

Greasing Lock Carriage Servo Bearings ................................. 2-29

Recommended Tools ..........................................................................2-29

Lock Servo Assembly Greasing Procedure ........................................2-29

Z–Axis Servo Assembly Part Identification .........................................2-30

Y–Axis Servo Assembly Part Identification.........................................2-31

About the Tool Kit and Tool Identification................................. 2-32

About the Tool Kit................................................................................2-32

About the Tools in the Carriage .............................................. 2-33

How to Access the Tool Config Screen.................................... 2-34

Check the Tool Config.........................................................................2-34

How to Access to Bit Assemblies........................................................2-35

Changing a Tool Bit.............................................................................2-35

Remove and Replace the Router or Pre-Drill Bits ................... 2-36

Remove Old Bit...................................................................................2-36

Inspect Collet......................................................................................2-36

Insert New Bit .....................................................................................2-37

Remove and Replace the Router or Pre-Drill Bits ..............................2-37

About the Self Lubricator Module ............................................ 2-39

How the Self Lubricator Works ...........................................................2-39

Replace the Lubricator Well................................................................2-39

Description of Air Input System................................................ 2-45

Air Input with Lubrication ...................................................................2-45

Adjusting the Air Line Lubricator ........................................................2-45

Priming the Air Line Lubricator............................................................2-46

Air Line Without Lubricator .................................................................2-46

MLX Service Manual

Table of Contents

Collet Torque Values................................................................ 2-47

Addition Collet Torque Values.............................................................2-48

Chapter 3 Troubleshooting the MLX

Get Live Technical Help ........................................................... 3-1

Troubleshooting Basics ........................................................... 3-2

Before you Adjust..................................................................................3-2

Analyze the Sub Systems.....................................................................3-4

About Motion Control ............................................................... 3-5

Sequencing...........................................................................................3-5

Point to Point ........................................................................................3-5

Incremental...........................................................................................3-5

Basic Control Circuit ................................................................ 3-6

About Typical VFD Motor Drive Control................................... 3-7

About the VFD ......................................................................................3-8

About VFD Troubleshooting..................................................................3-9

About a Typical Pneumatic Circuit ........................................... 3-10

Typical Pneumatic Assembly ..............................................................3-11

About the Coil (Solenoid)....................................................................3-11

About Cylinder Operation ...................................................................3-12

How the Pneumatic System Works ......................................... 3-13

Important Notice about Adjusting Cylinder Speed ..............................3-15

Adjusting Cylinder Extend Speed .......................................................3-15

Adjusting Cylinder Retraction Speed..................................................3-15

Air Assembly Locations............................................................ 3-17

Network System Overview....................................................... 3-18

Connections to Servo Drives ..............................................................3-18

Servo Motor Locations............................................................. 3-20

About Switches and Sensors................................................... 3-22

Using Sensors to Trouble Shoot .........................................................3-23

Download the Machine Electro-Mechanical Map................................3-23

QR CODE...........................................................................................3-24

Description of the Light Tower ................................................ 3-25

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 1-3

Safety First! IMPORTANT safety information is described

in this section

page 1-5

Lockout-Tagout Guidelines Procedures describing Lockout Tagout. page 1-7

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 1-17

Overview of the MLX Multi-Point Lock Router

1-3

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".

About this Manual

1-4

About this Manual

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

Integration Package includes the following:

Operation Manual includes the following:

Service 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 MLX Identification and descriptions of

the MLX assemblies.

Chapter Title Description

1Introduction Safety Information.

3Maintenance Maintenance steps for the

machine line

4Trouble Shooting Troubleshooting tips and theory of

operation.

KvalCAM Reference Manual

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

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 1-17.

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

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.

• 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.

Lockout/Tagout Guidelines

1-7

Lockout/Tagout Guidelines

Follow these 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

1-8

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.

https://www.osha.gov/

Pre-Steps Before Lockout/Tagout

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.

Lockout/Tagout Power

Note: When multiple people are working on the machine, each person needs to have a

lock on the handle in the extra holes provided.

4. Turn the Main Power on ALL electrical panels to the OFF position.

a.Lever style Electrical Panels: ensure the lever is in the down position, insert

lock and tag into the lever hole making sure the lever cannot move, lock as per

the tagout guidelines. (see illustration below).

Lockout/Tagout Procedure

1-9

b.Disconnect style Electrical Panels: push the red tab to pop it out. Place a pad-

lock through the hole. Place your tag on the padlock, as per the tagout guide-

lines below. (see illustration below).

Lockout/Tagout Air Supply

5. Turn all air valves to the OFF position and place a padlock through the hole (see

illustration below).

NOTE: Place your tag on the padlock, as per the tagout guidelines.

Start Maintenance

6. Once the locks and tags are in place and all personnel are clear, attempt to operate

the machine to ensure equipment will not operate.

7. Maintenance or repairs may started.

Post Maintenance Steps

8. 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.

Insert Lock into hole.

Turn Switch to the

OFF position

Lock and Tag out

Lockout/Tagout Procedure

1-10

9. 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.

10. The lock and tag can now be removed (only by the person(s) who placed them),

and the machine can be re-energized.

11. The tags must be destroyed and the locks and keys returned to the lockout center.

Zero-Energy to Start-Up

1-11

Zero-Energy to Start-Up

Starting the equipment properly is just as important as the Lockout/Tagout guidelines in terms of

safety.The following guidelines below should be followed to start the equipment.

Inspect

The equipment must be inspected for proper adjustment before starting equipment.

Clean Up

All materials and debris must be cleaned up. Any combustible materials or old parts used during

repairs must be cleaned up and/or properly disposed of.

Replace Guards

Replace all equipment guards. If part of equipment cannot be properly adjusted after start-up with

guard on, contact the Kval Technical Support. See “Getting Help from Kval” on page 1-13.

Check Controls

Confirm that all switches are in the “OFF” position. Please be advised that some components of

the machine may start automatically when energy is restored.

Remove Locks

Each operator must remove his or her own lock and tag. This will ensure that all operators are in a

safe place when the equipment is started.

Perform Visual Checks

If the equipment is too large to see all around it, station personnel around the area and sound the

personnel alarm before starting the equipment. If your operation is more complex, your com-

pany’s comprehensive safety procedure may involve additional steps. You will need to ask your

supervisor about these procedures. The company’s lockout procedure should be posted at each

machine. On larger or long-term maintenance or installation projects, the company’s procedures

must be explained to all new operators and a copy of the company’s procedures should be posted

on-site for the duration of the work.

The Company’s procedures should also include provisions for safely handling shift changes and

changes in operators or new operators.Comprehensive Lockout/Tagout may use a gang box or

other system to ensure that locks are secure and not removed without authorization.

Remember, Lockout/Tagout procedures work because you are the only one with the key to your

lock. Proper Lockout/Tagout can save lives, limbs, and money. Help make your work environment

safe for you and your fellow workers. Be sure to follow the P-R-O-P-E-R Lockout/Tagout proce-

dures, and that those around you do also.

Zero-Energy to Start-Up

1-12

Close the Cage Gate

Verify all cage gates are securely closed. Ensure all safety protocols are in effect.

Getting Help from Kval

1-13

Getting Help from Kval

Before you seek help, first try the troubleshooting procedures. Follow the procedures below.

If you are unable to resolve the problem:

1. Locate the machine’s Specification Plate and record the serial number, 3 phase

volts, electrical print number, and air print number.

2. Contact our customer support team:

• 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

• Email address is [email protected]

• 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

Air Driven Machines

Look for the brass plate

on pre-2019 machines.

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