Kval EFX User manual

Innovation, Quality & Honesty
Service Manual
Published: March 2, 2020
EFX Door Machining System
Service Manual EFX System

KVAL EFX System Service Manual
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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 [phone] or fax [phone]. Outside the
U.S. and Canada, call [phone].
Manual Part Number: DOC-229-1-SRV
EFX is trademarks of Kval Incorporated.
Copyright 2020 Kval Incorporated. All rights reserved.
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rated products, contact the Customer Support Department
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Kval Incorporated
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• Business hours:
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(Other sales related inquiries: http://www.kvalinc.com)
• Email: [email protected]

KVAL EFX System Service Manual
KVAL EFX System Service Manual
Your Feedback is Welcome: To help us design products that make your job easier
and your business more successful, we'd like to gain your perspective about your user
experience with our product - that is, the manual, the machinery, the software, etc.
What was easy or difficult to use or to learn? If you could change something about the
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link. For that, please refer to the Customer Service contact information above.) Thank
you!
http://www.kvalinc.com

KVAL EFX System Service Manual

KVAL EFX System Service Manual
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
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 revisions 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.
e.This License will terminate automatically if Licensee fails to comply with the limitations
described above.

KVAL EFX System Service Manual

Table of Contents
KVAL EFX Manual
Chapter 1 Introduction to the Edge-SS System
Overview of the EFX System................................................... 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
On-Line Help.......................................................................................1-14
Product Return Procedure..................................................................1-14
How to Download the Service Application............................... 1-15
Download Application.........................................................................1-15
Safety Sign-Off Sheet.............................................................. 1-18
A Note to the Operator........................................................................1-18
Chapter 2 System IT Administration
System IT Administration......................................................... 2-2
About the EFX Line Computer..............................................................2-2
Connections on the PLC.......................................................................2-2
About Backing up the Data...................................................... 2-3
About Remote Connection to KVAL Service.........................................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

KVAL EFX Manual
Table of Contents
Check Air Gauges and Inspect Water Traps ........................................3-5
Inspect Tooling......................................................................................3-5
Clean Air Condition Filters....................................................................3-6
Empty Dust Collection Units.................................................................3-6
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
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
Sample of Grease Locations for EFX...................................... 3-20
Locations of Hub Bearings..................................................................3-20
Locations of Rail Bearings on the Carriage Head...............................3-21
Edge Cutting Section Lubrication .......................................................3-22
Face Cutting Section Lubrication........................................................3-23

Table of Contents
KVAL EFX Manual
Stops and Probe Assembly Lubrication..............................................3-24
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
Changing Chisels on a Machine.........................................................3-32
How to Access to Bit Assemblies ............................................ 3-33
About the Tool Kit................................................................................3-33
Changing a Tool Bit and Using Tool-Change Tightening Fixture ........3-33
Remove and Replace the Router or Pre-Drill Bits.............................3-34
Replacing the Self Lubricator................................................... 3-36
Collet Torque Values................................................................ 3-39
Chapter 4 Troubleshooting the EFX Line
Troubleshooting Basics ........................................................... 4-2
Before you Adjust .................................................................................4-2
Analyze the Sub Systems.....................................................................4-4
About Motion Control............................................................... 4-5
Sequencing...........................................................................................4-5
Point to Point ........................................................................................4-5
Incremental...........................................................................................4-5
Basic Control Circuit................................................................ 4-6
About a Typical Contactor Control........................................... 4-7
About Contactor Troubleshooting.........................................................4-8
About Typical VFD Motor Drive Control................................... 4-9
About the VFD....................................................................................4-10
About VFD Troubleshooting ...............................................................4-11
About a Typical Pneumatic Circuit........................................... 4-12
Typical Pneumatic Assembly..............................................................4-13
About the Coil (Solenoid)....................................................................4-13
About Cylinder Operation ...................................................................4-14
How the Pneumatic System Works ....................................................4-14
Important Notice about Adjusting Cylinder Speed..............................4-16
Adjusting Cylinder Extend Speed .......................................................4-17

KVAL EFX Manual
Table of Contents
Adjusting Cylinder Retraction Speed.................................................4-17
Valve Bank Locations .............................................................. 4-18
Location of Valve Banks on the EFX ..................................................4-18
Network System Overview....................................................... 4-19
Connections to Servo Drives..............................................................4-19
EFX Servo Motor Locations................................................................4-20
About Switches and Sensors................................................... 4-21
Using Sensors to Trouble Shoot.........................................................4-22
About Checking the Revision Status........................................ 4-23
Troubleshooting Electrical Problems ....................................... 4-24
If the Power Stops During Normal Operation......................................4-24
Description of the Light Tower ................................................ 4-26

Notes:

1-1
KVAL Service Manual
CHAPTER 1 Introduction to the Edge-SS 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 1-9
Zero-Energy to Start-Up Procedure to power up your machine for the
first time. page 1-12
Getting Help from KVAL This section describes the method to con-
tact the KVAL Service Center for help. The
section includes how to get informationfrom
the specification plate to provide to KVAL,
service center hours, and return procedures
page 1-14
Safety Sign-Off Sheet A record to track operators that are trained
on the machine. page 1-19

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 multipoints, 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.
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.
2About KvalCAM Descriptions of the KvalCAM user
interface.
3Operation Inter- face Descriptions of how to power machine line, and operator inter-
face user screens.
4Calibration Descriptions of Calibration Rou-
tines and how to use the interfaces
5Tour of the
Machine Descriptions the assemblies on the machine.
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
4Troubleshooting Troubleshooting tips and theory of
operation.

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 1-19.
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!
KVAL Service Manual
1-6
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 1-10.
Compressed Air

Safety First!
1-7
KVAL Service Manual
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!
KVAL Service Manual
1-8
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
1-9
KVAL Service Manual
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