Kval ON-3 Operation And Service Manual

Innovation, Quality & Honesty

Operation and Service Manual

Published: 2/15/2023

ON-3 Door Lift System

ON-3 Operation and Service Manual

KVAL ON-3 Operation and Service Manual

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]

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: ON-3 Operation and Service Manual

Manual Revision: 35-MV100.2 (A)

ON-3 is a 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 ON-3 Operation and 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]

Kval Website

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

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

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

http://www.kvalinc.com

KVAL ON-3 Operation and Service Manual

ON-3 Operation and Service Manual

Table of Contents

Chapter 1 Introduction to the ON-3

Overview of the ON-3 .............................................................. 1-2

ON-3 as a Door Feeder ........................................................................1-2

ON-3 as a Door Stacker .......................................................................1-2

Available Options..................................................................................1-2

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

ON-3 Operation and Service Manual

Table of Contents

Chapter 2 Operation of the ON-3

Process of a Feeder ................................................................ 2-3

Process of a Stacker................................................................ 2-4

Operator’s Tour ........................................................................ 2-5

ON-3 Top View......................................................................................2-5

Option (Vacuum Lifting System) ...........................................................2-7

Motor (Up and Down) Assembly Descriptions ......................................2-8

Operators Station..................................................................................2-9

Control at Door Staging Area..............................................................2-10

About the Safety Curtain and the Safety Laser Scanner ......... 2-11

About Bar Type Sensors.....................................................................2-11

If the Beam is Broken .........................................................................2-12

To Resume Normal Operation after an Beam is Broken.....................2-12

About the Electrical Panels...................................................... 2-13

VFD Resistors.....................................................................................2-14

About the PLC ......................................................................... 2-15

Description of the Six Light Panel ........................................... 2-16

About Switches and Sensors................................................... 2-17

Available Options..................................................................... 2-19

About Option M1.................................................................................2-19

Option Q1: Above Ground Auto Door Stack Loading and Pallet Eject2-20

Process...............................................................................................2-20

About Option A, G, and L....................................................................2-21

Quick Start Feeder or Stacker ................................................. 2-22

Powering the ON-3 .................................................................. 2-23

How to Power Up the ON-3 ................................................................2-23

How to Power Down the ON-3............................................................2-24

Emergency Shutdown and Recovery .................................................2-24

To Resume Normal Operation after an E-Stop...................................2-24

Pause (Disable and Hold Button) .......................................................2-24

Description of User Interface Screens ..................................... 2-25

Screen Selection Menu Map as a Feeder or Stacker.........................2-25

Main Menu..........................................................................................2-26

Run Screen.........................................................................................2-26

Auto Run Screen (Options: M1 and G)...............................................2-27

Maintenance Feed Thru......................................................................2-27

Machine Data......................................................................................2-28

Manual Run Screen............................................................................2-28

ON-3 Operation and Service Manual

Table of Contents

Maintenance Carriage Screen............................................................2-29

Chapter 3 Maintenance of ON-3

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

Daily, Monthly, Six Month Maintenance ................................................3-2

Lubrication Requirements........................................................ 3-4

Typical Lucubration Kit..........................................................................3-4

Bearing Descriptions................................................................ 3-5

Pillow Block Bearing Housings ............................................................3-5

Flange Bearing Housings .....................................................................3-6

Ball Rail Bearing ...................................................................................3-6

About Taper Bearings ...........................................................................3-7

Tapered Bearing Housings ...................................................................3-7

Ball Screw Nut ......................................................................................3-8

Ball Screw Drive Assembly ...................................................................3-8

Pulley and Idler Shafts..........................................................................3-9

Sample of Grease Locations for ON-3..................................... 3-10

Lift Grease Locations..........................................................................3-10

Table Grease Locations......................................................................3-11

Option Q1:Grease Locations ..............................................................3-12

Description of Air Input System................................................ 3-13

Air Input with Lubrication ...................................................................3-13

Air Line Without Lubricator .................................................................3-14

Chapter 4 Troubleshooting the ON-3

About Motion Control ............................................................... 4-2

Basic Control Circuit .............................................................................4-2

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

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

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

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

About a Typical Contactor Control ........................................... 4-6

About Contactor Troubleshooting .........................................................4-7

About Typical VFD Motor Drive Control................................... 4-8

About the VFD ......................................................................................4-9

About VFD Troubleshooting................................................................4-10

About a Typical Pneumatic Circuit ........................................... 4-11

Typical Pneumatic Assembly ..............................................................4-12

ON-3 Operation and Service Manual

Table of Contents

About the Coil (Solenoid)....................................................................4-12

About Cylinder Operation ...................................................................4-13

How the Pneumatic System Works ....................................................4-13

Important Notice about Adjusting Cylinder Speed ..............................4-15

Adjusting Cylinder Extend Speed .......................................................4-16

Adjusting Cylinder Retraction Speed .................................................4-16

Using Sensors to Trouble Shoot .............................................. 4-17

Troubleshooting Electrical Problems ....................................... 4-18

If the Power Stops During Normal Operation .....................................4-18

Troubleshooting with the Status Light Panel .......................... 4-20

Symptoms and Possible Causes ............................................. 4-25

1-1

CHAPTER 1 Introduction to the ON-3

This chapter provides an overview of the Kval ON-3 system and important safety information to

follow when operating the machine.

Chapter 1 at a Glance

Section Name Summary Page

Overview of the ON-3 This section provides an overview of the ON-3. It

includes a general description and a table of avail-

able options

page 1-2

Safety First! IMPORTANT safety information is described in this

section

page 1-5

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 ON-3

1-2

ON-3 Operation and Service Manual

Overview of the ON-3

ON-3 as a Door Feeder

The Kval ON-3 Door Feeder automatically lifts individual doors from a stack and places the door

onto a powered roll table where the door can be fed to the next machine manually with a 'Call

Door' switch or automatically fed when the next machine in the line is ready to receive a door.

he Kval ON-3 Door Feeder is designed to lift flush or panel doors. The door is clamped on the top

and bottom rails with air cylinders or is lifted and held by air pressure by vacuum cups. The door

is fed into the machinery line.

ON-3 as a Door Stacker

The Kval ON-3 Door Stacker is designed to lift flush or panel doors off of a roll table and place

them on a door stack.

The door is received from the machinery line and is then lifted and held by air pressure by vac-

uum cups or is clamped on the top and bottom rails with air cylinders. The door is then moved

automatically on an overhead track system to be lowered onto a stack of doors.

The ON-3 Stacker automatically finds level of stack during the off-feed operation.

Available Options

The table below lists the available Options for this machine. Check the machine contract to verify

what options are applied to your machine.

TABLE 1-1. Options Available

Option Title Description Feeder

Stacker

Option A Reverse Stack In a pre-hanging operation, this places the stack of doors

on the operator side of a Commander or F-Series

machine.

Feeder

Stacker

Option B Reverse Feed

Direction

Re-orientates power buffer table rollers, drive and sen-

sors to opposite hand. This option is required only if the

feed direction of the complete line is right to left.

Feeder

Stacker

Option C Dual Stack

Feeder

The bridge in the ON-3 is increased in length to enable

the door clamp system to pick up doors on both sides of

the powered feed table, and to properly place the door

onto the powered feed table. The operator can select to

feed all doors from one side and then switch to the other

side. The ON-3 can also be set to automatically alternate

picking doors one from each side.

Feeder

Overview of the ON-3

1-3

ON-3 Operation and Service Manual

Option G 10 ft Door

Capacity

Machine has the capability to end clamp doors from 6'8"

to 10' in length.

Feeder

Stacker

Option H Remote Switch

for Manual Feed

Through

Allows doors to be fed manually from the end of the

machine. Includes a non marking plastic roll mounted in

the guard

Feeder

Stacker

Option L Ability to Feed

Doors with

Raised Molding

This option adds the capacity to feed doors with raised

molding on either or both sides. Maximum molding

height above door face will be 3/4 inch. Spacers used to

stack doors must be positioned so they do not interfere

with the clamp system. The clamp system supports must

be manually positioned to clear the molding prior to feed-

ing the doors. The feed table will be equipped with addi-

tional rubber covered rolls closely spaced to support the

door on the molding.

Feeder

Stacker

Option

L4

4-Foot Wide

Door With

Raised Molding

Capacity

The ON-3 Feed Table will be built with 2-1/2" diameter X

52" long rubber covered rolls placed on 4" centers to

support doors with raised molding. NOTE: Option L: Abil-

ity to Feed Doors with Raised Molding is required if this

option is selected.

Feeder

Stacker

Option

M1

Ball-Catch Drills

for 6'8" & 8'0"

High Doors

Heavy-Duty drills mounted on each end of the feed table

driven by 3HP three phase motors. A switch selects the

proper drill to drill a precision hole into the top of the

door, or to automatically positioned against a fence for

alignment for feeding into the next machine. Adds 5 sec-

onds to cycle time for a total elapsed time of 35 seconds

door to door. For ON-3 equipped with Option M1 add

Option A if door stacks are to be loaded into the machine

from the operator side of the door pre-hanging machine.

ON-3 equipped with Option M1 may also be set up to

load stacks of doors from the side opposite the door pre-

hanging machine operator. No additional options are

required.

Feeder

Option

Q1

Above Ground

Auto Door Stack

Loading and Pal-

let Eject

Heavy-duty chain drive conveyor positioned approxi-

mately 7" above the floor. Feed dogs automatically con-

vey and position a new stack of doors under the ON-3

while simultaneously powering the empty pallet under

and outside of the roll table. Saves time on an entire

assembly line by reducing downtime due to stack

changeover.

Feeder

TABLE 1-1. Options Available

Option Title Description Feeder

Stacker

Overview of the ON-3

1-4

ON-3 Operation and Service Manual

Option S In-Feed End

Loading

This option increases the length of the bridge in the ON-3

to allow pallets of doors to be loaded from the end of the

ON-3 parallel to the feed table. The in-feed end guard is

modified to include a safety gate that opens to allow

clearance for a pallet up to 45" wide.

Feeder

Option T Extended Con-

trol Cable

Extended cable length required when the 558 Door Sizer

is included in the pre-hanging line so the control panel for

the ON-3 can be mounted next to the door pre-hanging

machine control panel.

NOTE: This option is required when the 558 Door Sizer

is installed between the ON-3 and the door pre-hanging

machine.

Feeder

TABLE 1-1. Options Available

Option Title Description Feeder

Stacker

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.

ON-3 Operation and Service Manual

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 1-2shows 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.

ON-3 Operation and Service Manual

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

ON-3 Operation and Service Manual

Lockout Tagout Procedure

1-8

ON-3 Operation and 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.

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

ON-3 Operation and Service Manual

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

ON-3 Operation and Service Manual

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

ON-3 Operation and Service Manual

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

ON-3 Operation and Service Manual

Close the Cage Gate

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

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Kval ON-3 Operation And Service Manual

Kval ON-3 Operation And Service Manual

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