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Kval ON-3 Operation And Service Manual

Door stacker lift system
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Innovation, Quality & Honesty
ON-3 Door Stacker Lift System
With RT-2 Inspection Table
Operation and Service Manual
Published: 2/27/2019

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Summary of Contents for Kval ON-3

  • Page 1 Operation and Service Manual Published: 2/27/2019 Innovation, Quality & Honesty ON-3 Door Stacker Lift System With RT-2 Inspection Table...

  • Page 2: Proprietary Notice

    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-3 Operation and 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-3 Operation and Service Manual...

  • Page 5: Table Of Contents

    Safety Sign-Off Sheet .............. 1-18 A Note to the Operator................1-18 Operation of the ON-3 Chapter 2 About the ON-3 Feeder and the Stacker ......... 2-2 Process of a Feeder ................2-2 About the ON-3 Process with RT-2............2-3 Process of a RT-2 .................2-4 Process of a Stacker................2-4...
  • Page 6 Table of Contents Operator’s Tour of the ON-3 ............ 2-5 Identification of Assemblies on a ON-3 Stacker........2-5 Identification of Assemblies on the Stacker Feed Table .......2-6 Identification of Assemblies (Front View)..........2-6 Lift Assembly Descriptions..............2-7 Operators Station..............2-8 RT-2 Controls (Option)................2-8 Control at Door Staging Area...........
  • Page 7 Tapered Bearing Housings ..............4-7 Ball Screw Nut ..................4-8 Ball Screw Drive Assembly ..............4-8 Pulley and Idler Shafts................4-9 Sample of Grease Locations for ON-3........4-10 Lift Grease Locations................4-10 Table Grease Locations ..............4-11 Description of Air Input System..........4-12 Air Input with Lubrication ..............4-12 Air Line Without Lubricator ..............4-13...
  • Page 8 Adjusting Cylinder Retraction Speed ..........5-17 Using Sensors to Trouble Shoot ..........5-18 Troubleshooting Electrical Problems ........5-19 If the Power Stops During Normal Operation ........5-19 Troubleshooting with the Status Light Panel ......5-21 Symptoms and Possible Causes ..........5-25 KVAL ON-3 Manual...

  • Page 9: Introduction To The

    Introduction to the ON-3 CHAPTER 1 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 This section provides an overview of the ON-3. It...

  • Page 10: Overview Of The On-3

    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.
  • Page 11 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"...

  • Page 12: About This Manual

    Overview of the ON-3 About this Manual This manual is part of a package delivered with the machine line. includes the following: Operation/Service Manual Chapter Title Description Chapter 1 Introduction Descriptions of Machine Line and Safety Information. Chapter 2 Operation Interface Descriptions of how to power machine line, and operator interface user screens.

  • Page 13: Safety First

    See “Safety Sign-Off Sheet” on page 1-18. 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 14: Protective Gear

    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 1-10. KVAL ON-3 Operation/Service Manual...

  • Page 15: Laser Warnings

    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 ON-3 Operation/Service Manual...
  • Page 16 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.

  • Page 17: 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 ON-3 Operation/Service Manual...

  • Page 18: 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 ON-3 Operation/Service Manual 1-10...

  • Page 19: 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 ON-3 Operation/Service Manual 1-11...

  • Page 20: 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 1-14. Check Controls Confirm that all switches are in the “OFF”...
  • Page 21 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 ON-3 Operation/Service Manual 1-13...

  • Page 22: Getting Help From Kval

    • Outside the U.S. and Canada, call (707) 762-7367 or fax (707) 762-0485 • Email address is service@kvalinc.com • Hours: 6:00 AM to 4:00 PM Pacific Standard Time, Monday through Thursday 6:30 AM to 1:30 PM Pacific Standard Time, Friday KVAL ON-3 Operation/Service Manual 1-14...

  • Page 23: Kval Return And Warranty Policy

    KVAL Return and Warranty Policy KVAL Return and Warranty Policy KVAL's goal is to provide customers with high quality products. If, for any reason, you are not completely satisfied with your purchase, please contact us at: Email: parts@kvalinc.com +1 (800) 553-5825 Phone: •...

  • Page 24: Customer Errors

    Kval provides a warranty to products that are deemed defective. Within 30 days of discovery of said defect, please notify Kval, but no more than one (1) year after delivery will the product be covered under Warranty. The repair, replacement, or payment in the manner described above shall be the exclusive remedy of Buyer for breach of Kval’s warranty or for claims based upon failure...
  • Page 25 KVAL Return and Warranty Policy Page Intentionally Left Blank KVAL ON-3 Operation/Service Manual 1-17...

  • Page 26: 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 27 Safety Sign-Off Sheet KVAL ON-3 Operation/Service Manual 1-19...

  • Page 28: Operation Of The

    Operation of the ON-3 CHAPTER 2 This chapter describes components, assemblies, and the user interface of the KVAL ON-3 Feeder or Stacker The content is geared to help operators understand the basic operation of the on-2012. Chapter 2 at a Glance...

  • Page 29: About The On-3 Feeder And The Stacker

    About the ON-3 Feeder and the Stacker The ON-3 can be used as a feeder or a stacker. A feeder takes a door from a stack and inputs it into a door machine for processing. A stacker is located at the end process and takes the door from the door machine and stacks them to get ready for the next step in manufacturing.

  • Page 30: About The On-3 Process With Rt-2

    Door length is determined by sensors the and relayed to the RT-2 ON-3. The ON-3 will extend the correct door stop for the door in Door process. Path : 4 ft Wide x 10 Foot Long Door Capacity...

  • Page 31: Process Of A Rt-2

    About the ON-3 Feeder and the Stacker Process of a RT-2 Local Door OUT • Door is fed in from previous machine Controls Architect • The door has infeed sensors to trigger a “Door in machine state”. • The sensors on the table send door...

  • Page 32: Operator's Tour Of The On-3

    Operator’s Tour of the ON-3 The ON-3 can be used as a feeder or a stacker. A feeder takes a door from a stack and inputs it into a door machine for processing. A stacker is located at the end process and takes the door from the door machine and stacks them to get ready for the next step in manufacturing.

  • Page 33: Identification Of Assemblies On The Stacker Feed Table

    Operator’s Tour of the ON-3 Identification of Assemblies on the Stacker Feed Table Note: The Table for the ON- Feeder does not include the Door Stops or the Centering Assembly. The table positions the door with a cross feed belt.

  • Page 34: Lift Assembly Descriptions

    Operator’s Tour of the ON-3 Lift Assembly Descriptions Speed Reducer Reduces speed of the Up and Down Motor when picking up or loading doors. Valves: .Controls Clamping The Brake: Automatically applies braking force when the gripper comes to a stop while grabbing...

  • Page 35: Operators Station

    Operators Station Operators Station The operator’s station contains a touch screen to input data and operate the ON-3 machine. The location of station may vary due to customer specifications. Along with the ON-3, other interfaces may also be located in this area.

  • Page 36: Control At Door Staging Area

    Insert mode board inserts. While in this mode the lift will pause between doors and the Light Curtain will be disabled. Entrance into the loading bay is then possible to lay a protective piece under the door KVAL ON-3 Operation/Service Manual...

  • Page 37: Inspection Control (Option)

    Status Light Enter the work area and inspect the door After inspection, leave the work area. Press the Continue Cycle to re-enable the Button Light Curtain and continue process. Status Light Continue Cycle KVAL ON-3 Operation/Service Manual 2-10...

  • Page 38: About The Light Curtain

    This may cause misalignment, if the system is mis- aligned the machine will not start Receiver Emitter Emitter Receiver Breaking of any beam Machine in operation stops the machine Operation of Safety Curtain FIGURE 2-5. KVAL ON-3 Operation/Service Manual 2-11...

  • Page 39: If The Beam Is Broken

    If an E-Stop is activated, use the following procedure to recover, after the cause of the emergency stop is resolved: Press the Reset Light Curtain Button Push the button on START MACHINE the operator's station KVAL ON-3 Operation/Service Manual 2-12...

  • Page 40: Available Options

    Adds 5 seconds 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.
  • Page 41 Option A: Door Staging on Operator Side of Machine Option L: Supports raised door molding Option G: Supports 10 Foot Doors. May have extra stops for door lengths. On-3 Options A, G, and L FIGURE 2- 7. KVAL ON-3 Operation/Service Manual 2-14...

  • Page 42: About Switches And Sensors

    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 KVAL ON-3 Operation/Service Manual 2-15...

  • Page 43: About The Electrical Panels

    Ball Catch Feature) 24VDC- Terminals Fuses Transformer VFD Feeder Motor Contactors and Thermal Overload x2 (Option M1 Ball Catch Feature) Contactors and Thermal Over- load (Up and Down Motor) Feeder Electrical Panel FIGURE 2- 8. KVAL ON-3 Operation/Service Manual 2-16...
  • Page 44 Fuses Rotate Table Transformer Option: VFD Roller Table or Auto VFD Stacker Motor Rotate Table Option: VFD for Vacuum Control Contactors and Ther- mal Overload (Up and Down Motor) Stacker Electrical Panel FIGURE 2- 9. KVAL ON-3 Operation/Service Manual 2-17...

  • Page 45: Description Of The Six Light Panel

    Available Options Description of the Six Light Panel The six lights on this panel indicate the status of the ON-3 system. Note: See “Troubleshooting with the Status Light Panel” on page 5-12., for informa- tion on using this panel for troubleshooting.

  • Page 46: Quick Start Feeder Or Stacker

    Quick Start Feeder or Stacker Quick Start Feeder or Stacker Warning: Never operate the ON-3 until you are sure that everyone is clear of the machine's movement area, and the doors “Drop Zone” Ensure factory air is present at machine and the ON-3 main air supply valve is turned on.

  • Page 47: Powering The On-3

    Powering the ON-3 Powering the ON-3 This section describe how to power up and to power down the ON-3 Powering up the system includes: • Applying power to the entire system. • Starting the Control Circuit. Powering down the system includes: •...

  • Page 48: How To Power Down The On-3

    Press the Reset Light Curtain Button. Pause (Disable and Hold Button) The ON-3 can be paused by pressing the yellow Disable Button located at the door staging area and at the operator station. See “Process of a Feeder” on page 2-2...

  • Page 49: Description Of User Interface Screens

    Below are a sample of menu selections for the ON-3. Screen Selection Menu Map as a Feeder or Stacker ON-3 Menu Map for Feeder and Stacker FIGURE 2- 10. KVAL ON-3 Operation/Service Manual 2-22...

  • Page 50: Controls On Interface (Stacker)

    Description of User Interface Screens RT-2 Controls on Interface (Stacker) The RT-2 is the feeder to the stacker. The RT-2 interacts with the ON-3 Stacker Software. Table Feed controls: Manually Control the Feed options on the RT-2 Door Length Sensors:...

  • Page 51: Auto Run Screen (Feeder)

    Description of User Interface Screens Auto Run Screen (Feeder) The ON-3 boots up into the screen. The operation of the ON-3 is controlled from this Auto Run screen Qty Remaining: Keeps track Load Qty: Using the keypad, of doors processed.

  • Page 52: Maintenance Feed Thru

    Total number of doors processed Reset Count: Reset the daily count Daily Total: Total number of doors Main Menu: processed for the Select to go back to menu Run Screen: Select to jump to the run screen KVAL ON-3 Operation/Service Manual 2-25...

  • Page 53: Manual Run Screen

    Carriage Going Down Carriage is Over Stack: Stack in Chain Limit Stack at Mid Level Stack All the Way Up Move to Stack Value Move to Rolls Value Horizontal (feed table) Sensors Clamp Activation: KVAL ON-3 Operation/Service Manual 2-26...
  • Page 54 Notes:...

  • Page 55: Chapter 3 System It Administration

    System IT Administration CHAPTER 3 This chapter describes the KVAL ON-3 controller. The controller is an on board computer that supplies the user interface and controls the operation of the machine. With the controller, KVAL can remotely help troubleshoot your machine.

  • Page 56: About The Plc

    “slim model”. Both types contain the following • ACPU module • Power supply (24V) • Input/Output modules (analog) • Connections to the user interface • Some models have Ethernet connections for Intranet interface 24 VDC Inputs and Relays Supply Outputs KVAL ON-3 Operation/Service Manual...

  • Page 57: Maintenance Of

    Maintenance of ON-3 CHAPTER 4 This chapter describes preventative maintenance steps for KVAL ON-3. The content is 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 58: 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 59: Weekly Preventive Maintenance

    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.

  • Page 60: 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 Monthly Idler Shafts (Pulley) Tapered Bearing One Pump a Year...

  • Page 61: 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 4-12. KVAL ON-3 Operation/Service Manual...

  • Page 62: Flange Bearing Housings

    X,Y, or Z direction. Greasing Ball Rail Bearing Approximatively 1 Gram (one pump from grease gun) of Dura-Lith Grease (KVAL P/ Every 250 hours N: Lube EP-2). of operation. Ball Rail Bearings FIGURE 4-14. KVAL ON-3 Operation/Service Manual...

  • Page 63: About Taper Bearings

    To identify a , look at the enclosure and verify there are seals Tapered Bearing Housing between the screw and the housing. Tapered Bear- ing Housing Tapered Bear- ing Seals Tapered Bearing Housing FIGURE 4-16. KVAL ON-3 Operation/Service Manual...

  • Page 64: Ball Screw Nut

    Ball Screw Drive Assembly. Ball Screw Nut Recommended every 80 Hrs Servo Motor Pillow Block (Hub Style Recommended every 250 Hrs Tapered Bearing Housing Recommend One Pump a Year Ball Screw Drive Assembly FIGURE 4-18. KVAL ON-3 Operation/Service Manual...

  • Page 65: Pulley And Idler Shafts

    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 ON-3 Operation/Service Manual...

  • Page 66: Sample Of Grease Locations For On-3

    Sample of Grease Locations for ON-3 Sample of Grease Locations for ON-3 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 67 Sample of Grease Locations for ON-3 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 4-2. Hub Bearings 8 Total Pulley Idler Shaft Bearings...

  • Page 68: 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 69: Air Line Without Lubricator

    The air input system takes in shop air and supplies clean dry air (CDA). Shop Clean Dry Air (CDA) to Air Blow Off Input Air On- Off Knob Muffler Filter (purge) Pressure Gauge with adjust Air Distribution Block Air Filter without Lubricator FIGURE 4-20. 4-13 KVAL ON-3 Operation/Service Manual...
  • Page 70 Notes:...
  • Page 71 Notes:...

  • Page 72: Troubleshooting The

    CHAPTER 5 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.

  • Page 73: 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 74: The User Interface

    • 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 ON-3 Operation/Service Manual...

  • Page 75: Troubleshooting Basics

    When did the problem first start? • At first Start-Up? • During the Run? When was the last calibration? Is the door true? Use Router Bit Depth Gauge (PN: 432C) to check depth of Bits Check tools for wear. KVAL ON-3 Operation/Service Manual...

  • Page 76: Basic Troubleshooting Steps

    Analyze the Sub Systems Check the Load for mechanical issues • Is the Load “bound up? • Is there sufficient lubrication? • Is it an alignment issue? • Is anything damaged? Check the Position Feed Back. KVAL ON-3 Operation/Service Manual...
  • Page 77 • Bad Output: Relay may be stuck • Air Solenoid Valve: May be stuck or not working. Check the Positioning System Follow the circuit from the Controller output to the Load and check for component failures. KVAL ON-3 Operation/Service Manual...

  • Page 78: 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 5- 22. KVAL ON-3 Operation/Service Manual...

  • Page 79: 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 ON-3 Operation/Service Manual...

  • Page 80: 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 81: About The Vfd

    Figure 5- 24 on page 5- 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 82: 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 ON-3 Operation/Service Manual 5-11...

  • Page 83: 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 5- 27. KVAL ON-3 Operation/Service Manual 5-12...

  • Page 84: 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 85: 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 ON-3 Operation/Service Manual 5-14...
  • Page 86 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 ON-3 Operation/Service Manual 5-15...

  • Page 87: 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 ON-3 Operation/Service Manual 5-16...

  • Page 88: 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 ON-3 Operation/Service Manual 5-17...

  • Page 89: 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 ON-3 Operation/Service Manual 5-18...

  • Page 90: 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 91 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 ON-3 Operation/Service Manual 5-20...

  • Page 92: Troubleshooting With The Status Light Panel

    STEP 4: Stop (Amber) If light is OFF go to item page 5-23. STEP 5: Start (Amber) If light is OFF go to item page 5-24. STEP 6: 24VDC (Green light is OFF go to item page 5-24. KVAL ON-3 Operation/Service Manual 5-21...
  • Page 93 X1 and X2. If no power is measured it is a bad transformer. b.If there is power at X1 and X2, check the other side of the fuse. If now power, replace the fuse. KVAL ON-3 Operation/Service Manual 5-22...
  • Page 94 Start button. If no voltage, check the Stop button to make sure it is all the way out and not stuck in, then check the contact to make sure it is closed. If still no voltage, check the wiring. KVAL ON-3 Operation/Service Manual 5-23...
  • Page 95 Check for +24VDC at between any –DC and +DC terminal on the DC Terminal block. Reinstall the (+ 24V positive) wires one by one, checking for +24VDC after installing each. If at any point no voltage is found trace the last reinstalled wire and check for shorts. KVAL ON-3 Operation/Service Manual 5-24...

  • Page 96: Symptoms And Possible Causes

    Prime lubricator Faulty Lubricator Replace Lubricator Feed System Doesn’t Clean Photo Eyes Regularly Debris on Photo Ey Stop for Door to Clamp Replace Eye Defective Photo Eye Adjust Feed Belt Height Feed Belt Too Low KVAL ON-3 Operation/Service Manual 5-25...
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  • Page 101 15 description 21 use as troubleshooting key 21 stop light description 18 linear bearing, maintenance schedule 4 lockout and tagout Guidelines 12 lockout procedure 10 tagout procedure 10 troubleshooting using status lights 21 main electrical panel Kval ON-3...
  • Page 102 Index USB module 2 user interface screens menu map 22 zerk fittings 5 locations 5 zero-energy start-up clean up 12 inspect 12 Kval ON-3...
  • Page 104 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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