Kval ON-3V User manual

Innovation, Quality & Honesty
Operation Manual
Published: February 2, 2021
ON-3V Door Lift System
ON-3V Operation Manual

KVAL ON-3V Operation 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 [phone] or fax [phone]. Outside the
U.S. and Canada, call [phone].
Manual Part Number: DOC-231-1-OP
ON-3V is a trademark of Kval Incorporated.
Copyright 2021 Kval Incorporated. All rights reserved.
Beckhoff® , TwinCAT 3, and EtherCat® are registered trademarks and are licensed by
Beckhoff Automation GmbH
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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
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
825 Petaluma Boulevard South
Petaluma, CA 94952
• Phone and Fax:
In the U.S and Canada, call [phone] or fax [phone]
Outside the U.S. and Canada, call [phone] or fax [phone]
• Business hours:
Technical Support:
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6:30 AM to 1:30 PM Pacific Standard Time, Friday
Parts & Service Sales:
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(Other sales related inquiries: http://www.kvalinc.com)
• Email: [email protected]

KVAL ON-3V Operation Manual
KVAL ON-3V Operation Manual
Your Feedback is Welcome:          
             
             
                
            -
   NOTE:       
            



KVAL ON-3V Operation Manual

Table of Contents
KVAL ON-3V Operation Manual
Chapter 1 Introduction to the ON-3V
Chapter 1 at a Glance.............................................................. 1-1
Overview of the ON-3V............................................................ 1-2
Available Options..................................................................................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
Safety Sign-Off Sheet .............................................................. 1-16
A Note to the Operator........................................................................1-16
Chapter 2 Operation of the ON-3V
ON-3V: Feeder Process Summary .......................................... 2-2
Load the Doors into the Staging Area and Program Door Process ......2-2
The Door is moved to the Roll Table.....................................................2-3
The Door is Fed into the Next Machine ................................................2-3
ON-3V: Stacker Process Summary ........................................ 2-4
The Door is Fed into the Stacker..........................................................2-4
ON-3V: Stacker Process Summary ........................................ 2-4
The Door is Fed into the Stacker..........................................................2-4
The Door is moved to the Stacking Area ..............................................2-5
Move Stacked Doors out of Staging Area.............................................2-5
Powering Operations for the ON-3V ........................................ 2-6
How to Power Up the ON-3V................................................................2-6
Home the ON-3V ..................................................................................2-7
How to Power Shut Down the ON-3V...................................................2-7

KVAL ON-3V Operation Manual
Table of Contents
Shut Down and Recovery.....................................................................2-8
Process to Feed a Door........................................................... 2-9
Process to Stack a Door .......................................................... 2-10
Staging Area Controls.............................................................. 2-11
To Enter Staging Area (Request Access)............................................2-11
To Exit the Staging Area .....................................................................2-11
To Pause and Resume the Process ...................................................2-11
Emergency Stop .................................................................................2-11
Breaking the Safety Curtain..................................................... 2-12
Light Curtain .......................................................................................2-12
Safety Laser Scanners .......................................................................2-12
Summary of the Interface ........................................................ 2-13
Feeder Machine Control .....................................................................2-13
Stacker Machine Control ....................................................................2-14
Universal Controls ................................................................... 2-15
About the Controls..............................................................................2-16
About the Feeder Main Screen................................................ 2-17
About the Main Control Menu.............................................................2-17
Summary of the Rotate Functions: .....................................................2-18
About the Stacker Main Screen ............................................... 2-19
Stop Location......................................................................................2-20
About the Manual Operation Screens...................................... 2-21
About the Feeder Manual Control Screen ..........................................2-21
About the Stacker Manual Control Screen .........................................2-22
About the Diagnostic Screen ................................................... 2-23
Diagnostic Screen...............................................................................2-23
Description of the Light Tower ................................................ 2-24
Chapter 3 Tour of the ON-3V
Operator’s Tour of the ON-3V .................................................. 3-2
Identification of Assemblies on the ON-3V ...........................................3-2
Feeder ..................................................................................................3-2
Stacker..................................................................................................3-3
Identification of Assemblies (Front View)..............................................3-4
About the Feed Table............................................................... 3-5
About the Feeder Table ........................................................................3-5
About the Stacker Table........................................................................3-6

Table of Contents
KVAL ON-3V Operation Manual
Boom and Lift Assembly Descriptions ..................................... 3-7
Operators Station..................................................................... 3-8
Staging Area Controls.............................................................. 3-9
Vacuum System....................................................................... 3-10
Assist Chain System................................................................ 3-11
About the Air Assist Chain System .....................................................3-11
About the Safety Curtain and the Safety Laser Scanner ......... 3-12
About Bar Type Sensors.....................................................................3-12
About Safety Laser Scanners.............................................................3-13
About the Main Electrical Panel............................................... 3-14
The Light Tower ..................................................................................3-15
About the Nodes.................................................................................3-15
Graphical Sample of Node Connections and Power Distribution .......3-16
IT Administration ..................................................................... 3-17
About the ON-3V Computer................................................................3-17
Connections on the PLC.....................................................................3-17
Appendix: About Switches and Sensors .................................. 3-18

KVAL ON-3V Operation Manual
Table of Contents

1-1
CHAPTER 1 Introduction to the ON-3V
This chapter provides an overview of the KVAL ON-3V system and important safety information
to follow when operating the machine.
Chapter 1 at a Glance
Section Name Summary Page
Overview of the ON-3V This section provides an overview of the ON-3V. 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 1-4
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 1-16

Overview of the ON-3V
1-2
KVAL Manual
Overview of the ON-3V
The KVAL ON-3V Door Feeder/Stacker 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. Cycle time is approximately 20 seconds. The ON-3V can lift and feed flush doors and up to
4ft wide by 8ft high. The door is lifted via a vacuum system which utilizes two vacuum pads to
lift the unit. The lift system will lift doors that vary in height from 6’-6” to 8’-0” without any
adjustment. Door thickness can vary from 1-3/8” to 2-1/4”. Maximum door weight 175lb. A vari-
able speed drive is utilized, with controls, to match the feed speed of following Kval equipment,
i.e 558 Door Sizer or Kval Pre-hanging line. Wire guards are attached to the ON-3V frame on
three sides; slot openings allow the door to be manually fed into the feeder as well as fed out to
the next machine.
Note: Maximum door stack height is 60” from the ground including call board and or
conveyor system.
Note: Minimum ceiling height required for clearance for the clamp assembly is at
maximum height is 15’-0”.
Available Options
TABLE 1-1. Options Available
Option Title Description
Option L Raised
Moulded Doors
This option adds the capacity to feed doors with raised moulding on
either or both sides. Maximum moulding 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 moulding prior to feeding the doors.
The feed table will be equipped with additional rubber covered rolls
closely spaced to support the door on the moulding. Note: When spec-
ifying a line that includes a 558 Sizer, add Option R to the 558 Door
Sizer to also make it capable of feeding doors with raised mouldings.
Option R Door Rotate Adds rotate capability to the vacuum lifting fixture so doors can rotate
180 degrees as they transfer to the infeed table, or door stack. Touch
screen programming is included to rotate every door, every other door
or one door. PLC inputs are also available to automatically rotate as
part of a down-load process
Option S Stacker Option Makes the ON3V a Door Stacker Opposed to Door Feeder.
Option T Extended Con-
trol Cable
Extended cable length required when a supplemental machine is
placed between the door feeder and main machining center. I.e option
is required when the 558 Door Sizer is installed between the ON-3 and
the door pre-hanging machine.

Overview of the ON-3V
1-3
 
About this Manual
           
Operation Manual   
Service Manual includes the following
Chapter Title Description
1Introduction Descriptions of Machine Line and
Safety Information.
2
Operation of the
Machine
Descriptions of how to power
machine line, and operator inter-
face user screens.
3Tour of ON-3V Identification and descriptions of
the ON-3V- machine assemblies.
Chapter Title Description
1Introduction Safety Information.
2System IT Admin-
istration
Descriptions of the PLC system,
and computer system.
3Maintenance Maintenance steps for the
machine line
4Troubleshooting Troubleshooting tips and theory of
operation.

Safety First!
1-4
 
Safety First!
Safety Sheet Sign-Off Sheet
                  -
             -
                 
           
Safety Terminology of Labels
               -
              
       
        
 DANGER              
 WARNING             

 CAUTION             

Safety Guidelines
               
        
       
         
   Failure to do so can result in dam-
age to equipment and/or serious injury to personnel.
       
        
         
    
Training

Safety First!
1-5
KVAL 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!
1-6
 
   
    
  
     -
    
   
   

         
        
 still power on the top side of the disconnect switch
        
         -
    must be installed at all locations
          -
    
  
  
Electrical
     
      
        
        
     
 
Before Conducting Maintenance
Laser Warnings
           
  

Safety First!
1-7
 
       
      
       
     -
      
Compliance with Codes and Regulations
Other Hazard Control Action
Report a Hazard
Before You Report an Accident
           
       STOP -
       
     
       
       
         
      
Follow Your Company’s Safety Procedures
       
       -
  

Lockout-Tagout Guidelines
1-8
KVAL 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

Lockout Tagout Procedure
1-9
KVAL 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).
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.
Insert Lock into hole.
Turn Switch to the
OFF position
Lock and Tag out

Lockout Tagout Procedure
1-10
KVAL Manual
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.

Zero-Energy to Start-Up
1-11
KVAL Manual
Zero-Energy to Start-Up
Starting the equipment properly is just as important as the lockout/tagout guidelines in terms of
safety.
Start-up Guidelines
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 Service team. 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 com-
ponents 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 oper-
ators 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 company’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 mainte-
nance 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.

Zero-Energy to Start-Up
1-12
KVAL Manual
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 procedures, and that those around you do also.
Close the Cage Gate
Verify all cage gates are securely closed. Ensure all safety protocols are in effect.