Related Manuals for Kval ON-3V
Summary of Contents for Kval ON-3V
- Page 1 Service Manual Published: February 02 2021 Innovation, Quality & Honesty ON-3V Door Lift System...
- Page 2 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.
- Page 3 KVAL ON-3V 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.
- Page 4 KVAL ON-3V Service Manual...
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Page 5: Table Of Contents
Table of Contents Introduction to the ON-3V Chapter 1 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... - Page 6 Table of Contents About the Air Assist Chain System .............2-10 Process to Lower the Lift ..............2-11 Sample of Grease Locations for ON-3V ........2-12 Lift Grease Locations................2-12 Table Grease Locations ..............2-13 Description of Air Input System..........2-14 Air Input with Lubrication ..............2-14 Air Line Without Lubricator ..............2-15...
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Page 7: Chapter 1 At A Glance
Chapter 1 at a Glance Section Name Summary Page This section provides an overview of the ON-3V. It page 1-2 Overview of the ON-3V includes a general description and a table of available options IMPORTANT safety information is described in... -
Page 8: Overview Of The On-3V
'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. -
Page 9: About This Manual
Overview of the ON-3V About this Manual This manual is part of a package delivered with the machine line. includes the following: Operation Manual Chapter Title Description Introduction Descriptions of Machine Line and Safety Information. Operation Interface Descriptions of how to power machine line, and operator inter- face user screens. -
Page 10: Safety First
See “Safety Sign-Off Sheet” on page 1-16. Safety Terminology of Labels In addition to the nameplate, KVAL machines may have other warning labels or decals that pro- vide safety information to operators. Safety labels should be clearly visible to the operator and must be replaced if missing, damaged, or illegible. - Page 11 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. KVAL Manual...
- Page 12 This should be done in accordance with applicable state and/or federal code requirements. Laser Warnings On some machines, laser indicators are used to set boundaries. Follow the manufacturers safety precautions. KVAL Manual...
- Page 13 Safety First! Compliance with Codes and Regulations 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.
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Page 14: Lockout-Tagout Guidelines
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 KVAL Manual... -
Page 15: Lockout Tagout Procedure
Turn Switch to the Lock and Tag out Insert Lock into hole. OFF position Note: When multiple people are working on the machine, each person needs to have a lock on the handle in the extra holes provided. KVAL Manual... -
Page 16: Lockout Tagout Air Supply
The lock and tag can now be removed (only by the person(s) who placed them), and the machine can be re-energized. The tags must be destroyed and the locks and keys returned to the lockout center. KVAL Manual 1-10... -
Page 17: Zero-Energy To Start-Up
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”... - Page 18 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. KVAL Manual 1-12...
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Page 19: Getting Help From Kval
Getting Help from KVAL Getting Help from KVAL Before you seek help, first try the troubleshooting procedures. Follow the procedures below. If you are unable to resolve the problem: Locate the machine’s Specification Plate and record the serial number, 3 phase volts, electrical print number, and air print number. - Page 20 • With what equipment is the unit interfaced? • What was the application? • What was the system environment (temperature, spacing, contaminants, etc.)? Call KVAL customer support for a Return Material Authorization (RMA). When you call: • Have the packing slip or invoice numbers available.
- Page 21 Getting Help from KVAL Page Intentionally Left Blank KVAL Manual 1-15...
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Page 22: Safety Sign-Off Sheet
Note: It is recommended you make a copy of this sheet for new operators. If a copy is needed, you may download a PDF at the KVAL website (http://www.kvalinc.com). You may also contact our Service Department at (800) 553-5825 or email at service@kvalinc.com. -
Page 23: Chapter 2 Maintenance Of On-3V
This chapter describes preventative maintenance steps for . The content is KVAL ON-3V System geared to guide technicians to keep a regular maintenance schedule for your KVAL machine. Keeping your KVAL machine maintained is an important piece for successful operation of your door production process. -
Page 24: Maintenance Schedule
Maintenance Schedule Maintenance Schedule KVAL recommends the following maintenance schedule to ensure that the machine operates properly. Cycles refers to the quantity of processed doors. Cleaning curtails build up of sawdust and grime which causes issues with the operation of the machine. Inspecting, finds issues before they become problems. - Page 25 Clean linear bearings and the chrome shaft with a clean dry cloth, then lubricate. Clean Check all air lines & electrical wiring for kinks or rubbing. Check Refill lubricator with an ISO 32 standard hydraulic oil (KVAL part# SYSLUBG) LUBE Six Month Preventive Maintenance Operation Description Wash filter and lubricator bowls with soapy water.
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Page 26: Lubrication Requirements
Recommended Assembly Lubrication Type Linear Bearing Pillow Block Bearing Every 250 Hours of Machine Operation Flange Block Bearing Dura-Lith Grease (KVAL P/N Lube EP-2) Ball Screw Every 80 Hours of Machine Operation Idler Shafts (Pulley) Monthly Tapered Bearing One Pump 4 X a Year... -
Page 27: Bearing Descriptions
Closed Pillow Block Hub Style Opened Pillow Block parallel perpendicular mount Greasing Approximatively 1 Gram (one pump from grease gun) of Dura-Lith Grease (KVAL P/N: Lube EP-2). Every 250 hours of operation. Pillow Block Bearings FIGURE 2-1. KVAL Manual... -
Page 28: Flange Bearing Housings
Bearing Flange Bear- Greasing Housings Approximatively 1 Gram (one pump from grease gun) of Dura-Lith Grease (KVAL P/ Every 250 hours N: Lube EP-2). of operation. Flange Bearings FIGURE 2-2. Ball Rail Bearing are linear bearings that are attached to positioning rails. In most cases, the bear- Ball Rail Bearings ings are attached to assemblies to move them in the X,Y, or Z direction. -
Page 29: Pulley And Idler Shafts
Grease IN Note: It is important not to overfill the Idler Shaft. Avoid getting excess grease on the belts Grease Out Approximatively 1 Gram (one pump from grease gun) of Dura-Lith Grease Idler Shaft (KVAL P/N: Lube Monthly EP-2). KVAL Manual... -
Page 30: Assist Chain System: Important Safety Information
Failure to do so can result in damage to equipment and/ or serious injury to personnel. About the Air Assist Chain System The ON-3V is designed to reduce the bearing load on the door as the lift- Air Assist Chain System ing assembly settles on a door. -
Page 31: Process To Lower The Lift
After maintenance is performed, inspect the assist chain for any binding potential before returning air to the machine and to the Air Assist Chain System Note: In rare cases, excess chain slack may need to be safely guided as the assist cylinders retract and return to a load-bearing state. KVAL Manual... -
Page 32: Sample Of Grease Locations For On-3V
Sample of Grease Locations for ON-3V Sample of Grease Locations for ON-3V This machine is a powerful electro-mechanical Caution motion control system. If servicing this machine, fol- low the safety guidelines. Failure to do so can result in damage to equipment and/or serious injury to person- nel. - Page 33 Sample of Grease Locations for ON-3V Table Grease Locations Use an extender to reach tight areas. Make sure to Lockout/Tagout before maintenance. For rec- ommended greasing schedule, see “Maintenance Schedule” on page 2-2. Hub Bearings Pulley Idler Shaft Bearings 2 Total...
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Page 34: Description Of Air Input System
Description of Air Input System Description of Air Input System There are two types of air inputs on KVAL machinery. Not all machines have lubricator option installed. Check your machine or Air prints to verify installation. Air Input with Lubrication The air input system takes in shop air and supplies clean dry air (CDA) and lubricated air to the machine. -
Page 35: Air Line Without Lubricator
Usually 1 drop of oil every other cycle is a good rule of thumb. The approved list of oil for lubricators is as follows: • KVAL P/N SYSLUBG • Chevron AW Hydraulic Oil 32 • G-C lubricants light AW R&O •... - Page 36 Description of Air Input System KVAL Manual 2-14...
- Page 37 CHAPTER 3 This chapter describes troubleshooting steps to help technicians solve issues that may occur with your KVAL machine. If help is needed, call or contact our KVAL Service team at (800) 553-5825 or http://www.kvalinc.com. Refer to the Air and Electrical drawings provided with delivery of the machine.
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Page 38: About Motion Control
KVAL Machinery. Sequencing: Sequencing is a series of events executed in a predetermined order. Most KVAL machines use a form of sequential motion control. A typical series of events for a KVAL machine are: Move the door into position. - Page 39 Positioning System: • Moves the load. Examples: A motor or a pneumatic cylinder. The Position Feedback. • Provides location information to the controller. Examples: A limit switch, a photo eye, or ferrous eye, a resolver or an encoder KVAL Manual...
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Page 40: Troubleshooting Basics
• Is the cut out of specification? Verify: Verify or analyze the subsystem assembly that is responsible for the issue. For example: • How is the subsystem supposed to work? • What is keeping the subsystem from working? KVAL Manual... -
Page 41: About A Typical Contactor Control
Control Circuit Common DC - Control Coil for Thermal OverLoad 120 Vac. Should measure Line Voltage here Motor Schematic Drawing of Contactor and Thermal Overload Block Diagram of a Common Contactor Circuit FIGURE 3- 12. KVAL Manual... -
Page 42: About Contactor Troubleshooting
Rerun the machine and verify that motor runs without tripping the circuit. If the same overload keeps tripping, verify condition. Follow circuit path using the E-Drawing as a reference. a.Common issues: Check for bad wire, bad motor, or if load is too great for cur- rent draw. KVAL Manual... -
Page 43: About Typical Vfd Motor Drive Control
An adjustable-speed drive is used to control the motor speed and torque by varying motor input frequency and voltage. A variable-frequency drive (VFD) is used in KVAL machinery to accu- rately drive motors for machining or moving product through the machine. The figure below shows a block diagram of a typical motor drive circuit. -
Page 44: About The Vfd
Figure 3- 14 on page 3- VFD models vary in KVAL machines depending on where it is used, voltage requirements and type of PLC used. This is a general view on the VFD. See the machine’s Electrical Print for detailed information. -
Page 45: About Vfd Troubleshooting
Note: The number of reset buttons depends on the machine type and option. The fig- ure above shows a machine with 11 VFDs The VFD manuals are located in the Electrical Panels. On some machines, documentation can be found in the operation station in the documen- tation folder. KVAL Manual... -
Page 46: About A Typical Pneumatic Circuit
Note: In this sample set-up, Port A is nor- mally open and Port B is nor- mally closed. If power is OFF, air should be on Port B. Block Diagram of a Pneumatic Circuit FIGURE 3- 17. KVAL Manual 3-10... -
Page 47: Typical Pneumatic Assembly
About a Typical Pneumatic Circuit Typical Pneumatic Assembly Pneumatic assembly setups vary in KVAL machines depending on where it is used and air requirements.This is a general overview of a pneumatic assembly. See the machine’s Air Print for detailed information. -
Page 48: About Cylinder Operation
Router applies the control voltage to the which directs com- Control Valve pressed air to extend port of the Cylinder are extended deactivating the Cylinder Router Retract Sensor fully extends activating the Router Extend Sensor. KVAL Manual 3-12... - Page 49 Control Valve Cylinder. retract deactivating the Cylinder Router Extend Sensor When the are fully retracted, the is activated. Cylinder Router Retract Sensor senses the voltage from the completing the process Retract Sensor KVAL Manual 3-13...
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Page 50: Important Notice About Adjusting Cylinder Speed
However, sometimes machine settling, mechanics be “broken in” may be cause to slightly adjust extend and retraction speed. If more than 1/2 turn on adjustment knobs are needed, call in a specialist or check with KVAL customer service at 1-800-553-5825. KVAL Manual 3-14... -
Page 51: Adjusting Cylinder Extend Speed
Adjusting Cylinder Extend Speed Adjusting Cylinder Retraction Speed Tip: If Installing a new flow control assembly, shut down the flow control and back out 4 to 5 turns. this position is a good starting point for kine adjust. KVAL Manual 3-15... -
Page 52: Using Sensors To Trouble Shoot
• Check the output voltages of the sensors in inactive mode.The voltage should effec- tively equal 24 VDC • The distance from an eye to the door should be in range. Typically the range should be 3/4'' to 7/8'' from the top of all eyes to the door. KVAL Manual 3-16... -
Page 53: Troubleshooting Electrical Problems
Refer to Air and Electrical Schematics provided with delivery of the machine. Schematics are located in the Electrical Panel. If copies NOTE: are unavailable, contact the KVAL Service Department. Have model number and serial number of machine readily available. Warning The following checks require the electrical panel to be energized. - Page 54 Note: Most electrical problems are related to mechanical malfunction (e.g., stuck motors, jammed chain, blocked photo sensors etc.) Note: If a solenoid valve is suspected, and not cleared in the air checks section, it can be electrically jumped to check operation. KVAL Manual 3-18...
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Page 55: Description Of The Light Tower
Solid: General Error • Flashing: Not Ready to Re-Start (E-Sop Switch is Active) Green: Machine is Operational Off: No Control Power Control Power ON (Green): 24 VDC Control Power ON Ready to Work Light Tower Rev 2 KVAL Manual 3-19... -
Page 56: Symptoms And Possible Causes
Lubricator Not Primed Prime lubricator Faulty Lubricator Replace Lubricator Feed System Clean Photo Eyes Regularly Debris on Photo Ey Doesn’t Stop for Replace Eye Defective Photo Eye Door to Clamp Adjust Feed Belt Height Feed Belt Too Low KVAL Manual 3-20... - Page 57 2 weekly 2 pillow block bearing, maintenance schedule 4 power lock out procedure 9 power up troubleshooting 17 safety guidelines 4 Safety Sign Off Sheet Safety Concerns 16 sensors troubleshooing 16 six light panel description 19 Kval ON-3V...
- Page 58 Index Kval ON-3V...
- Page 60 Contacting KVAL Customer Service Phone and Fax: Mailing address: In the U.S and Canada, call (800) 553-5825 or fax Customer Support Department (707) 762-0485 Kval Incorporated Outside the U.S. and Canada, call (707) 762-7367 825 Petaluma Boulevard South or fax (707) 762-0485 Petaluma, CA 94952 Email: service@kvalinc.com...
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