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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.

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Summary of Contents for ON-3V

Page 1: ...Innovation Quality Honesty Operation Manual Published February 2 2021 ON 3V Door Lift System ON 3V Operation Manual ...

Page 2: ...stered 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 Depa...

Page 3: ...KVAL ON 3V Operation Manual KVAL ON 3V Operation Manual Your Feedback is Welcome NOTE ...

Page 4: ...KVAL ON 3V Operation Manual ...

Page 5: ... 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...

Page 6: ...rols 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 Ligh...

Page 7: ...hain 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 ...

Page 8: ...KVAL ON 3V Operation Manual Table of Contents ...

Page 9: ... 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 c...

Page 10: ...um 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 manuall...

Page 11: ...ine Descriptions of how to power machine line and operator inter face user screens 3 Tour of ON 3V Identification and descriptions of the ON 3V machine assemblies Chapter Title Description 1 Introduction Safety Information 2 System IT Admin istration Descriptions of the PLC system and computer system 3 Maintenance Maintenance steps for the machine line 4 Troubleshooting Troubleshooting tips and th...

Page 12: ...t 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 ...

Page 13: ...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 performi...

Page 14: ...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 ...

Page 15: ...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 ...

Page 16: ...n 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...

Page 17: ...nd 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 Pla...

Page 18: ...etely 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 lock...

Page 19: ...ergy 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...

Page 20: ...our 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 ...

Page 21: ...Getting Help from KVAL 1 13 Getting Help from KVAL 1 2 Air Driven Machines Pre 2019 Machines look for the brass plate ...

Page 22: ...application What was the system environment temperature spacing contaminants etc 3 Call KVAL customer support for a Return Material Authorization RMA When you call Have the packing slip or invoice numbers available Have the documented reason for return available 4 Send the merchandise back to KVAL Make sure the item s you are returning are securely packaged and well protected from shipping damage ...

Page 23: ...Getting Help from KVAL 1 15 KVAL Manual Page Intentionally Left Blank ...

Page 24: ...mpany s safety procedures I have read and understand these guidelines Machine Safety Concerns I have been given a tour of the machine and understand all the safety labels E Stops and the actions to take in case of an emergency I will make sure all guards are in place before operation I will turn off the compressed air before loading hardware staples screws etc I will turn off the electrical power ...

Page 25: ...tion Name Summary Page Summary of Machine Process Summary of the process of the door through the machine page 2 2 Powering Operations for the ON 3V Descriptions of power up power down homing and emergency stops page 2 6 Process to Feed a Door Summary of operating the Feeder page 2 9 Summary of the Interface Summary of the Interface Screens page 2 13 About the Interface Detailed information about t...

Page 26: ...er Kval Note ON V3 Note Note Chapter 3 Load the Doors into the Staging Area and Program Door Process Request Access Button Lift is Lowered to the Door Stack 5 Boom Vacuum Lift 6 Vacuum Lift 7 Load Doors Power Up Load Doors Program Door Process Start Sequence Door is Secured by Vacuum ...

Page 27: ...ch the correct swing LH or RH 9 The Boom moves the door over the Roll Table 10 The door is placed on the Roll Table The Door is Fed into the Next Machine 11 The door is elevated on four sets of bars with urethane rollers and then pulled side ways to a fixed fence for alignment to the next machine 12 The Lift releases the door and moves up 13 The Feed Belt drive rolls door to the next machine ...

Page 28: ...e 4 The Vacuum Lift lowers to the door 5 The door is secured by suction of the lifting pads Stops Door is Secured by Vacuum ON 3V Stacker Process Summary The Kval ON 3V Door Stacker is a touch screen driven machine designed to receive processed doors from a Kval machine and stack them in a staging area Note For power up of the machine see Powering Operations for the ON 3V on page 2 6 Note For a to...

Page 29: ...a 8 The next door is fed in and process repeats Move Stacked Doors out of Staging Area Temporarily disable the safety circuit is by selecting the Request Access Button See Staging Area Controls on page 2 11 Move the door stack in the staging area At the Main Menu program door process and start the process Door is Lifted Door may be Rotated if machine has this option Door is Lifted Remove Door Stac...

Page 30: ...he ON 3V ON 3V How to Power Up the ON 3V 1 2 Note 3 ON 4 Control Circuit ON Note Note 990 machine manual 5 Start Machine Buttons 6 Ready to Home Control Circuit Start Machine Note Stacker Controls may contain Machine Power button in place of a Start Machine Button ...

Page 31: ... Operations for the ON 3V 2 7 Home the ON 3V must Home Machine Main Control Screen 1 2 3 The Machine is ready to Work How to Power Shut Down the ON 3V 1 Stop Buttons Note Stop Button Control Circuit Note 7 Note ...

Page 32: ...Powering Operations for the ON 3V 2 8 2 Exit Application Button 3 Control Circuit 4 Shut Down and Recovery Note ...

Page 33: ...equest Access Out Reset Button Home Machine Select Rotation Enter Qty of Doors Enter Door Process Information Press Start Sequence Button Door is picked up from the stack 1 ON 3V 2 Request Access Button 3 4 Request Access Button 5 Reset Button 6 Home 7 Main Screen Load Quantity 8 Start Sequence ...

Page 34: ...ng Process begins 1 Power up the ON 3V See Powering Operations for the ON 3V on page 2 6 2 Push the Request Access Button See Staging Area Controls on page 2 11 3 Load the pallet into the staging area 4 Pull out the Request Access Button 5 Push the Reset Button See Staging Area Con trols on page 2 11 6 Home the Machine 7 If a change in normal process is needed select the Feed Through button or cha...

Page 35: ...y Stop on page 2 11 To Enter Staging Area Request Access To Exit the Staging Area Blinking Push Solid OK to Enter 1 Push the Request Access Button the blue light will blink and the lift will move a door over the roll ers 2 After door is over rollers and the light becomes solid it is safe to enter the Door Staging Area Press Pull Out 3 After task is completed exit the Door Staging Area and PULL OUT...

Page 36: ...n or Laser Safety Scanner Note Light Curtain Safety Laser Scanners Emitter Receiver Breaking of any beam stops the machine Press the Reset Button to Con tinue Processing the Doors Breaking of the beam stops the machine Press the Reset Button to Continue Processing the Doors ...

Page 37: ...ens that control the machine Main Control Includes Home Button control of the rotate process control of aces to the machine and quantity of doors to be processed See About the Feeder Main Screen on page 2 17 Manual Servo Control At this screen move the Gantry and Table Assemblies manually See About the Feeder Manual Control Screen on page 2 21 Diagnostic Screen At this screen the feedback codes fr...

Page 38: ... control of the Door Stops on the table See About the Stacker Main Screen on page 2 19 Manual Servo Control At this screen move the Gantry and Table Assemblies manually and control the Door Stops on the table See About the Stacker Manual Control Screen on page 2 22 Diagnostic Screen At this screen the feedback codes from the machine are displayed See About the Diagnostic Screen on page 2 23 ...

Page 39: ...sical reference point on the frame When this point is found the position is stored and then used to calculate the location of all moves during the machine process The home sequence must be performed every time the machine is powered up or reset Reset Button If a fault occurs that cannot be cleared select the Reset Machine button This button will reset the machine to the start position before homin...

Page 40: ...er the table and lower to the table position The Request Access light will blink Pause Resume Select the Pause button to hold process of the door Select again to Resume from the point where the pause was initiated Vacuum Sleep Select to stop the vacuum pump when not in use Cancel Operation Select to stop the process If in process the door will be placed backed on the stack ...

Page 41: ...feed to finish Ensure all machines in the production line are powered up homed and is clear to process Door Quantity Select and enter the number of doors to be processed Note Entering 0 into the Quantity box puts the machine in Full Stack Mode The machine will process the full stack and stop when the last door is finished Queue See Summary of the Rotate Functions on page 2 18 ...

Page 42: ...About the Feeder Main Screen 2 18 Summary of the Rotate Functions Rotate Off Rotate All Rotate Alternate Rotate Queue More Pages ...

Page 43: ... Feed Through Button Select to bypass stacking and pass to the next pro cess Door Length Buttons Select to a Length button bypass the auto length Select Confirm Manual Data button to confirm override and extend the selected stop Door Length Box Displays the Length determined from the pre vious machine or the length from the manual selection Stop 1 Stop 2 Stop 3 ...

Page 44: ...About the Stacker Main Screen 2 20 KVAL Manual Stop Location The Door Stops are located at the end of the Stacker table FIGURE 2 2 Stop Location Door Stop 1 Door Stop 2 Door Stop 3 ...

Page 45: ...o use a different Windows application Gantry Select the desired button to control the Gantry Take the Gantry up or down Move doors to the roll table or to the stack Clamp or unclamp the door Feeder Table Buttons Select the desired button to control the feed through of the door Feed the door forward or reverse Forward to the next machine Reverse the door from the next machine into the Feeder Contro...

Page 46: ...Buttons Select the desired button to control the feed through of the door Select to manually engage Stop 1 Stop 2 or Stop 3 Feed the door forward or reverse Forward to the next machine Reverse the door from the next machine into the Feeder Control the cross feed in the forward or reverse direction Forward to the fence Reverse away from the fence Gantry Select the desired button to control the Gant...

Page 47: ...About the Diagnostic Screen 2 23 About the Diagnostic Screen Diagnostic Screen FIGURE 2 5 Diagnostics Screen ...

Page 48: ...ervo or Motor Error 3 Flashes 24 VDC Power Error Yellow External Error Solid General Error 1 Flash 3 Phase Voltage Error 2 Flashes Low Air Error Blue Operator Status Solid Waiting for Operator 1 Flash Reposition Door Green Machine is Operational Safety OFF Clear Safety Project not Running Red Safety PLC Error Blue Waiting for Safety Re Set Solid General Error Flashing Not Ready to Re Start E Sop S...

Page 49: ...op View and Front of on ON 3V page 3 2 Feeder Table page 3 5 Boom and Lift Assembly Descriptions page 3 7 Operators Station page 3 8 Control at Door Staging Area page 3 9 Vacuum System page 3 10 Assist Chain System page 3 11 About the Safety Curtain and Safety Scanner page 3 12 About the Electrical Panels page 3 14 About the Light Tower page 3 15 About Nodes page 3 15 IT Administration page 3 17 p...

Page 50: ...3 14 Feed Table See About the Feeder Table on page 3 5 Boom and Lift See Boom and Lift Assembly Descriptions on page 3 7 Light Curtain See About the Safety Curtain and the Safety Laser Scanner on page 3 12 Operators Controls See Staging Area Controls on page 3 9 Operators Controls See Operators Station on page 3 8 Assist Chain System See Assist Chain System on page 3 11 Light Tower See Description...

Page 51: ...s and stacks them for removal to the next process step The Stacker contains the same assemblies as a Feeder see Figure 3 1 on page 3 2 Note The Stacker may include pop stops to adjust to incoming doors FIGURE 3 2 Top View of ON 3V Stacker Stops See About the Stacker Table on page 3 6 ...

Page 52: ... Tour of the ON 3V 3 4 KVAL Manual Identification of Assemblies Front View FIGURE 3 3 Front View of ON 3V Controllers Request Access Boom And Lift Light Curtain Safety Staging Area Vacuum Blower Motor Feed Table ...

Page 53: ... doors About the Feeder Table The Feeder Table aligns the doors to be transferred to the next machine FIGURE 3 4 Machine Table Assembly Locations Pop Up Cylinders x4 Elevates rollers to move door to the fence Cross Feed and Feed Motor When cross feed belts pop up this motor moves the door to the fence When cross feed cylinders re retracted door is fed into table Feed Rollers Moves door out Cross F...

Page 54: ...age 3 5 Some changes between the Feeder and Stacker Table may include pop up stops triggered by table sensors The sensors are triggered by door length to act like a stop for the triggered door size FIGURE 3 5 Stacker Machine Table Assembly Locations Feed Rollers Moves door In Photo Sensor Door Stops Photo Sensor Mid Machine and at Fence Photo Sensor Infeed ...

Page 55: ...om lowering too far and or unexpectedly lowering once raised or when air pressure to the clutch fails The Motor UP and Down Works with Speed Reducer and Brake to move the Lift up and down to pick up and place doors Foam Lifters Suction powered foam lifters Lifts doors and moves doors Feeder Door staging area to feed table The Motor Across Moves the Lift Assembly to X axis position above the door S...

Page 56: ...nd main tained Note If entering the staging area use the Request Access buttons located on the Staging area frames Start Sequence Starts the process of LIFT ING the door E Stop Press to emergency stop the function of the entire machine line Start Machine Wakes up the machine similar to a boot up Interface See Chapter 2 Control Location Options Depending on customer desired options the con trols ma...

Page 57: ... Note See Staging Area Controls on page 2 11 for further descriptions of the Stag ing Controls FIGURE 3 8 Staging Area Controls Request Access Button Press to enter the staging area safely Mainly to load doors to be processed Reset Light Button If the light curtain is broken press to reset the safety cir cuit Pause Resume Lift Press the Pause Resume Button to disable or pause the process cycle To ...

Page 58: ...y Kval operation software The main compo nents include a high efficient vacuum blower motor control solenoids connectors and grabbing suction foam pads Note For more information about the vacuum system refer to OEM documentation FIGURE 3 9 Vacuum System Vacuum Input Do not adjust gauge unless for merly trained Vacuum Pads Two Pads Vacuum Motor Blower Vacuum Connector Includes Solenoid ...

Page 59: ...sist Chain System About the Air Assist Chain System Air Assist Chain System FIGURE 3 10 Chain Assist System Caution Air Assist Chain System Vertical Lift Assembly Lockout Tagout Procedures Buffer Tank Assist Cylinders Lift Chain ...

Page 60: ...t Curtain or Safety Laser Scanner Note Important About Bar Type Sensors FIGURE 3 11 Bar Type Light Curtain System Emitter Receiver Breaking of the beam stops the machine Press the Reset Button to Continue Processing the Doors Emitter Receiver Emitter Receiver Machine in operation Breaking of any beam stops the machine ...

Page 61: ...Laser Scanners General Information of the Scanner TABLE 3 1 Number Function Color 1 Off State Red 2 On State Green 3 Warning Field Yellow 4 Restart Interlock Flashing Yellow Breaking of the beam stops the machine Press the Reset Button to Continue Processing the Doors Note ...

Page 62: ...ical components in the Main Electrical Panel Refer the machine s electrical prints for in depth information The Main Electrical Panel Supplies voltages to the machine Contains the PLC Programmable Logic Controller Contains VFD s Variable Frequency Drives FIGURE 3 12 Feeder Electrical Panel Relays 24 VDC Terminals Thermal Resistors VFD Feeder Motors Out Feed Up Down Carriage Vacuum Transformer Fuse...

Page 63: ... Electrical Panel 3 15 The Light Tower Note About the Nodes PLC Note FIGURE 3 13 Sample of a Frame Node PLC Interface Top Ethernet cable is PLC Bottom Ethernet goes to Cutter Node Inputs and Outputs Interconnect Bar ...

Page 64: ...al Panel 3 16 KVAL Manual Graphical Sample of Node Connections and Power Distribution The ON 3V frame node is located on the machine boom FIGURE 3 14 Node Location Power Frame Node Power Distrib uted to Points in the machine ...

Page 65: ...out the ON 3V Computer Connections on the PLC FIGURE3 15 Connections on the Controller Smart Power Supply and EtherCat DVI USB Module to User Interface CPU Module RJ45 to Intranet Compact Flash Card Interface to Servos Battery Interfaceto Frame ...

Page 66: ...Appendix About Switches and Sensors 3 18 Appendix About Switches and Sensors Photo Electronic Detector Photo Eye Detectors no object One Package Proximity Sensor ...

Page 67: ...The Limit Switch is activated by an assembly moving a switch arm Depending on the model of limit switch the amount of pre travel amount of movement from the arms resting position is either 5 or 20 degrees before the limit switch actuates Clicks Switch Arm ...

Page 68: ...Appendix About Switches and Sensors 3 20 KVAL Manual ...

Page 69: ...ote connection 17 RJ45 to intranet 17 intranet RJ45 connection 17 L LCD display smart power supply 17 lockout and tagout Guidelines 11 lockout procedure 9 M main electrical panel description 14 P PLC battery location 17 connections 17 location 17 power lock out procedure 9 powering up and down machine 6 programmable logic controller PLC 17 S safety guidelines 4 Safety Sign Off Sheet Safety Concern...

Page 70: ...Index Kval ON 3V ...

Page 71: ......

Page 72: ...partment Kval Incorporated 825 Petaluma Boulevard South Petaluma CA 94952 Contacting KVAL 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 Email service kvalinc com http www kvalinc com ...

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