Kval ON-3V Manuale utente
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 (800) 553-5825 or fax (707) 762-0485. Outside the
U.S. and Canada, call (707) 762-7367.
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
Windows 7® is a registered trademark of Microsoft Corporation.
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 (800) 553-5825 or fax (707) 762-0485
Outside the U.S. and Canada, call (707) 762-7367 or fax (707) 762-0485
• Business hours:
Technical Support:
6:00 AM to 4:00 PM Pacific Standard Time, Monday through Thursday
6:30 AM to 1:30 PM Pacific Standard Time, Friday
Parts & Service Sales:
6:30 AM to 4:00 PM Pacific Standard Time, Monday through Thursday
6:30 AM to 1:30 PM Pacific Standard Time, Friday
(Other sales related inquiries: http://www.kvalinc.com)
• Email: [email protected]
KVAL ON-3V Operation Manual
KVAL ON-3V Operation Manual
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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.
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