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Kval ON-3 Operation Manual

Door lift system
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Operation Manual
Published: June 25, 2024
Innovation, Quality & Honesty
ON-3 Door Lift System
Stacker
Feeder

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Summary of Contents for Kval ON-3

  • Page 1 Operation Manual Published: June 25, 2024 Innovation, Quality & Honesty ON-3 Door Lift System Stacker Feeder...

  • Page 2: Proprietary Notice

    Mon-Thu:6:00 AM - 4:00 PM PST Fri: 6:00 AM - 3:30 PM PST Parts Contact us for all parts related needs, from orders to inquiries. Call, email, contact us on our web- site at the “Contact Us” page. email: parts@kvalinc.com KVAL ON-3 Lift Operation Manual...

  • Page 3: Technical Support

    KVAL ON-3 Lift Operation Manual Technical Support For machinery support and troubleshooting. Call, email, contact us on our website at the “Contact Us” page. Mon-Fri:4:00 AM - 4:00 PM PST email: support@kvalinc.com Field Service Support For any other inquiries or to schedule on-site service. Call, email, contact us on our website at the “Contact Us”...
  • Page 4 Revisions March 13 2024: Reformat of manual. Made Maintenance into a separate manual. June 25 2024 Minor updates in format. KVAL ON-3 Lift Operation Manual...

  • Page 5: Table Of Contents

    Table of Contents Introduction to the ON-3...Chapter 1 Overview of the ON-3 ................1-1 ON-3 as a Door Feeder ................1-1 ON-3 as a Door Stacker ................1-1 Available Options ..................1-2 About this Manual ..................1-4 Operation Manual ..................1-4 Service Manual ...................1-4 Access Manuals and Videos Easily ..........1-5...
  • Page 6 Powering Operations for the ON-3 ...........2-1 Steps Before Powering the ON-3 ............2-1 Powering the ON-3 ..................2-2 How to Power Down the ON-3 ..............2-3 About Emergency Shutdown and Recovery .........2-5 To Resume Normal Operation after an E-Stop ........2-5 Other Safety Controls ................2-6...
  • Page 7 ..............2-29 Stacker Maintenance Feed Thru ............2-29 Stacker Machine Data ................2-30 Stacker Maintenance Carriage Screen ..........2-31 Tour of the ON-3...Chapter 3 ON-3 Feeder Tour ..................3-1 Overview of Feeder ..................3-1 About the Feeder Gantry Assembly ............3-2 About the Feeder Lift Carriage Assembly ..........3-3...
  • Page 8 Table of Contents About the Valve Banks ................3-25 About Feeder Air Systems ..............3-26 About Stacker Air Systems ..............3-27 About Sensors ...................3-28 About Sensor Locations ................3-28 About Photo Sensors ................3-28 About Through-Beam Transmitters ............3-29 About Proximity Sensors .................3-29 Gantry Sensor Locations ..............3-30 Roll Table Sensor Locations ..............3-31...

  • Page 9: Introduction To The On-3

    Chapter 1 at a Glance Section Name Summary Page This section provides an overview of the ON-3. It page 1-1 Overview of the ON-3 includes a general description and a table of avail- able options...

  • Page 10: Overview Of The

    Overview of the ON-3 Overview of the ON-3 ON-3 as a Door Feeder automatically lifts individual doors from a stack and places the door Kval ON-3 Door Feeder 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.

  • Page 11: Available Options

    This option is required only if the feed direction of the complete line is right to left. Option HV 3-Phase High Kval Equipment is only manufactured for 460v service Feeder Stacker Voltage 3 Phase. For customers who have 600 volt 3 phase, Option HV must be purchased.
  • Page 12 Stacker trol Cable Sizer is included in the pre-hanging line so the control panel for the ON-3 can be mounted next to the door pre-hanging machine control panel. NOTE: This option is required when the 558 Door Sizer is installed between the ON-3 and the door pre- hanging machine.

  • Page 13: About This Manual

    Descriptions of Machine Line and Safety Information. Operation Interface Descriptions of how to power machine line, and operator interface user screens. Tour of the Machine Locations and descriptions of key assemblies on the ON-3 Service Manual Service Manual includes the following: Chapter Title...

  • Page 14: Access Manuals And Videos Easily

    Access Manuals and Videos Easily Access Manuals and Videos Easily You can easily access a range of resources including downloadable PDF manuals, Quick Start guides, Maintenance Summaries, links to instructional videos, and Electro-Mechanical Maps. To access these valuable materials, simply follow these steps: Visit https://kvalinc.com/machine-support or scan the QR code provided in this sec-...

  • Page 15: Safety First

    Safety Terminology of Labels In addition to the nameplate, machines may have other warning labels or decals that provide Kval safety information to operators. Safety labels should be clearly visible to the operator and must be replaced if missing, damaged, or illegible.

  • Page 16: Safety Guidelines

    Safety Guidelines Safety Guidelines In addition to the caution and warning labels affixed to this machine, follow the guidelines next to help ensure the safety of equipment and personnel. Different versions of the stickers may have been applied to the machine. The Note: intent of safety is the same.

  • Page 17: Lockout/Tagout Guidelines

    Lockout/Tagout Guidelines Lockout/Tagout Guidelines Follow these 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) •...

  • Page 18: Lockout/Tagout Procedure

    Lockout/Tagout Procedure 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.

  • Page 19: Lockout/Tagout Air Supply

    Lockout/Tagout Procedure push the red tab to pop it out. Place a pad- Disconnect style Electrical Panels: lock through the hole. Place your tag on the padlock, as per the tagout guide- lines next. (see illustration next). Turn Switch to the Insert Lock into hole.

  • Page 20: Post Maintenance Steps

    Lockout/Tagout Procedure Post Maintenance Steps 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. 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.

  • Page 21: 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 See “Getting Help from Kval” on page 1-14. Kval Technical Support. Check Controls Confirm that all switches are in the “OFF” position. Please be advised that some components of the machine may start automatically when energy is restored.

  • Page 22: Close The Cage Gate

    Zero-Energy to Start-Up Close the Cage Gate Verify all cage gates are securely closed. Ensure all safety protocols are in effect. Zero-Energy to Start-Up 1-13...

  • Page 23: Getting Help From Kval

    Getting Help from Kval Getting Help from Kval Before you seek help, first try the troubleshooting procedures. Follow the procedures next. 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 24: Kval Return And Warranty Policy

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

  • Page 25: Customer Errors

    Kval Return and Warranty Policy Customer Errors If the item is to be returned due to customer ordering error, the customer must return the item to or the shipper of origin at its expense. A 15% restocking fee may apply to manufactured...

  • Page 26: Safety Sign-Off Sheet

    Name (print):___________________ Signature: __________________ Date:____/____/____ Supervisor/Safety Officer/Trainer Name (print):__________________Signature: __________________ Date:____/____/___ recommends you make a copy of this sheet for new operators. If a copy is Note: Kval needed, contact our at (800) 553-5825 or email at sup- Technical Support port@kvalinc.com.

  • Page 27: Operation Of The On-3

    Chapter 2 at a Glance Section Name Summary Page Powering Operations for the ON-3 page 2-1 Instructions to power up and power down the machine. Descriptions of the types of emergency page 2-5 About Emergency Stops assemblies on the machine.

  • Page 28: Powering Operations For The On-3

    Powering Operations for the ON-3 Powering Operations for the ON-3 This section describes how to power up and power down the ON-3. Learn all safety precautionary controls on the machine. Important: Powering up the system includes: • Applying power to the entire system.

  • Page 29: Powering The On-3

    Powering Operations for the ON-3 Powering the ON-3 Access the and the at the lift entrance To power on the , fol- Operator Station Local Controls ON-3 low these steps: At the , turn the green and Stacker switches. Operator Station Feeder switch may have a switch or push button.

  • Page 30: How To Power Down The On-3

    To finish the power up operations, press the Reset Light Curtain button on the hat are located at the lift entrance. Local Controls t How to Power Down the ON-3 To power down the , follow these steps ON-3 Push the button.
  • Page 31 Powering Operations for the ON-3 also recommends that you turn the switch to 3. Kval Main Power position All status lights on the will be Six Light Panel All six lights are off Powering Operations for the ON-3...

  • Page 32: About Emergency Shutdown And Recovery

    About Emergency Shutdown and Recovery About Emergency Shutdown and Recovery Important: Before operating this machine, learn all safety precautionary controls on the machine. Depending on the model of machine, there are emergency shutdown ( Note: E-Stop switches located at key points around the machine. switches are to be used when the machine is out of control or is about to damage per- E-Stop sonnel or equipment.

  • Page 33: Other Safety Controls

    About Emergency Shutdown and Recovery Other Safety Controls Other safety controls can include: • Gate Latches: Sensors are located on the gates surrounding the machine. If a gate is opened the machine will shut down. • Safety Curtain: This is similar to the Laser Safety Scanners. This creates an invisi- ble curtain on all entrances to the machine.

  • Page 34: About Processing A Door

    Clear the of clutter. Ensure all personnel are clear of the area. Door Bays Power up each For powering steps, see “Powering Operations for the ON-3” ON-3. on page 2-1. Step 2: Initialize the Lifts At the Feeder Screen Press the button at the screen.

  • Page 35: At The Stacker

    About Processing a Door At the Stacker Press the button the screen. Auto Run Screen Stacker Main Press Auto Run Screen Press the Auto Run Screen Buttons FIGURE 2-7. To “wake up” the system, press the buttons at the interface. Reset Lift Stacker Stacker...
  • Page 36 About Processing a Door To Enter the Bay Push the blue button to enter the bay; the Request Access blue light will blink, and the lift will finish the current task. Once the lift is positioned over the rollers, proceed to enter to place the doors.

  • Page 37: At The Feeder

    About Processing a Door Step 3: Setup the Run Screens at the Feeder and the Stacker At the Feeder At the screen. Set the button to Gantry Set the button to at the screen. Auto Feed Feeder Run Enter the quantity of doors to be processed in the box.
  • Page 38 About Processing a Door Step 4:Start the Process at the Feeder At the Run screen, Press the button at the screen to start the process. Call Door Feeder is not set to , press feed each door. Note: Auto Feed Call Door Feeder Press Call Door to Start...

  • Page 39: On-3 Feeder Door Path

    ON-3 Feeder Door Path ON-3 Feeder Door Path performs the following steps: ON-3 1. Door Pickup: • The gantry picks up a door from the door stack. 2. Placement on Feed Table: • The gantry places the door on the feed table.
  • Page 40 ON-3 Feeder Door Path on the edge of the door and picks it up. Grabber closes In an case, the vacuum lift will pick the door up. Note: Option V The Grabber clamps the edges of the top door on the door stack.
  • Page 41 ON-3 Feeder Door Path transports the door to the next machine for processing while the 8. The Roller Table moves to the next door. Gantry The door is transported to the next machine The process is repeated until the stack is depleted or the programmed quantity of doors is met.

  • Page 42: On-3 Stacker Door Path

    ON-3 Stacker Door Path ON-3 Stacker Door Path performs the following steps: ON-3 Stacker 1. Door is Fed In • The door is popped up and is aligned to the fence. • The door is fed to the selected Door Stop 2.
  • Page 43 ON-3 Stacker Door Path the Lift moves down and picks up the door. The lift moves the door over to the door stack. Door is Picked up by the Lift Door is moved to the Door Stack moves the door to the side fence to align it to the next machine.

  • Page 44: Feed Through Option

    Feed Through Option Feed Through Option Operator can select a door for feed through. The door will feed up to a photo eye before the fence gate with a door slot. A foot pedal will release the door through the slot to the next operation. The option also provides controls to allow a door to be feed back into the stacker.

  • Page 45: Description Of The Feeder User Interface Screens

    This section describes the user interface screen. The user interface allows the operator to use a touch screen to control the door machining process. Below are the menu selections for the ON-3 Feeder Menu Map ON-3Menu Map for Feeder and Stacker FIGURE 2-14.

  • Page 46: Feeder Main Menu

    Monitors feed sensors and motors Machine Data: Overall and Daily Totals Program Revision Manual Run Screen: Manual control of ON-3 functions Base Menu Screen FIGURE 2-15. Feeder Run Screen boots up into the screen. The operation of the is controlled from this screen.
  • Page 47 Description of the Feeder User Interface Screens Un-Clamp: Reset Lift: Release the clamp Puts the lift into a safe position mechanism. In Man- or starts the first pick up ual Mode, starts sequence. Load Qty: Qty Remaining: every door out. Using the keypad, enter Keeps track of the number of doors to...

  • Page 48: Feeder Manual Run Screen

    Description of the Feeder User Interface Screens Feeder Manual Run Screen At this screen control the operation of the and the Gantry Feed Table. Gantry: Feed: Press the desired button to: Press the desired button to control the feed through of the door. •...

  • Page 49: Feeder Maintenance Screen

    Description of the Feeder User Interface Screens Feeder Maintenance Screen This screen provides feedback on the operation of the feed thru motors, switches, and optical sen- sors. OK to Feed Out: OK to Feed In: Feed Switch ON/OFF: Next machine calling for Indicates clear to feed in Red = Off, Green = ON door...

  • Page 50: Feeder Maintenance Carriage Screen

    Description of the Feeder User Interface Screens Feeder Maintenance Carriage Screen This screen provides feedback on the operation of the feed thru motors, switches, and optical sen- sors in relation to the carriage. Carriage is Over Stack Carriage Going Down Stack in Chain Limit Stack at Mid Level Move to Stack Value...

  • Page 51: Description Of A Stacker User Interface Screens

    This section describes the user interface screen. The user interface allows the operator to use a touch screen to control the door machining process. Below are the menu selections for the ON-3 Stacker Menu Map ON-3 Menu Map for Feeder and Stacker FIGURE 2-21. Description of a Stacker User Interface Screens 2-26...

  • Page 52: Stacker Main Menu

    Operation Controls Maint. 1 Feed and Drills: Monitors feed sensors and motors Machine Data: Overall and Daily Totals Program Revision Manual Run Screen: Manual control of ON-3 functions Base Menu Screen FIGURE 2-22. Description of a Stacker User Interface Screens 2-27...

  • Page 53: Stacker Run Screen

    Description of a Stacker User Interface Screens Stacker Run Screen boots up into the screen. The operation of the is controlled from this screen. ON-3 ON-3 Stops #1 to #3 Reset Lift: Press to toggle the Puts the lift into a safe position...

  • Page 54: Stacker Manual Run Screen

    Description of a Stacker User Interface Screens Stacker Manual Run Screen At this screen control the operation of the and the Gantry Feed Table. Gantry: Feed: Press the desired button to: Press the desired button to control the feed through of the door: •...

  • Page 55: Stacker Machine Data

    Description of a Stacker User Interface Screens OK to Feed Out: OK to Feed In: Feed Switch ON/OFF: Next machine calling for Indicates clear to feed in Red = Off, Green = ON door Feed Motor ON/OFF: Red = Off Green =ON Machine Sensors: Indicates operating sen- sors...

  • Page 56: Stacker Maintenance Carriage Screen

    Description of a Stacker User Interface Screens Stacker Maintenance Carriage Screen This screen provides feedback on the operation of the feed motors, switches, and optical sensors in relation to the carriage. Carriage is Over Stack Carriage Going Down Stack in Chain Limit Stack at Mid Level Move to Stack Value Stack All the Way Up...

  • Page 57: Tour Of The On-3

    Tour of the ON-3 CHAPTER 3 This chapter describes components, assemblies, and the user interface of the The con- Kval ON-3. tent is geared to help operators understand the basic operation of the machine. Section Name Summary Page Location and Descriptions of the Feeder Parts...

  • Page 58: On-3 Feeder Tour

    ON-3 Feeder Tour ON-3 Feeder Tour This section provides a general introduction to the when it functions as a . It outlines ON-3 Feeder its role in taking doors from a stack and inputting them into the door machining line for process- ing.

  • Page 59: About The Feeder Gantry Assembly

    ON-3 Feeder Tour About the Feeder Gantry Assembly is a crucial component of the system. Key components are Feeder Gantry Assembly Feeder illustrated in Figure 3-2. Lift Carriage: The Lift Carriage moves down to the desired door stack and moves it the table...

  • Page 60: About The Feeder Lift Carriage Assembly

    ON-3 Feeder Tour About the Feeder Lift Carriage Assembly Figure 3-3 shows the key components located on the Feeder Lift Carriage Assembly. The standard utilizes a mechanical grabber to transport the doors during Note: Feeder the process. Alternatively, the uses a vacuum lift for door Option V Feeder movement.

  • Page 61: About The On-3 Feeder Tables

    ON-3 Feeder Tour About the ON-3 Feeder Tables is synchronized with the lift. The combination of sensors and programming Feeder Table combine to create timing to load, unload, and rotate the door. Figure 3-4 illustrates the door alignment process. About Door Alignment: moves a door into the table.

  • Page 62: On-3 Stacker Tour

    ON-3 Stacker Tour ON-3 Stacker Tour This section provides a general introduction to the when it functions as a . It outlines ON-3 Stacker its role in taking completed doors from the stacker table and placing them on a door stack.

  • Page 63: About Stacker Gantry Assembly

    ON-3 Stacker Tour About Stacker Gantry Assembly is a crucial component of the system. Key components are Stacker Gantry Assembly Stacker illustrated in Figure 3-6. Lift Carriage: The Lift Carriage moves down to the desired door stack and moves it the table...

  • Page 64: About The Vacuum System

    ON-3 Stacker Tour About the Vacuum System Unlike the standard configuration, which uses a mechanical gripping system to lift a door, Feeder uses a vacuum system to lift the door. Stacker Figure 3-7 shows the key components located on the Vacuum Lift System.

  • Page 65: About The Stacker Lift Carriage Assembly

    ON-3 Stacker Tour About the Stacker Lift Carriage Assembly Figure 3-8 shows the key components located on the Stacker Lift Carriage Assembly. Alternatively, the also uses a vacuum lift for door movement. Note: Option V Feeder The Motor: Vertical Pulley: Works with Speed Reducer and Brake to Moves the lift up and down.

  • Page 66: About The On-3 Stacker Table

    ON-3 Stacker Tour About the ON-3 Stacker Table is synchronized with the lift. The combination of sensors and programming Stacker Table combine to create timing to load, unload, and rotate the door. For describes of sensors located on the machine, see “About Sensors”...

  • Page 67: About Controls On On-3

    Controls located here include machine line The main controls are located on the Operator Station. interfaces and the mechanical controls. For detailed information about the start-up process, see See “Powering Operations for the ON-3” on page 2-1. Feeder Controls Stacker Controls Operation Station FIGURE 3-10.

  • Page 68: About The Main Control Selections

    About Controls on ON-3 About the Main Control Selections The mechanical controls include powering operations for the and the Feeder Stacker Figure 3-11 shows the Feeder controls. The has the same controls except Note: Stacker button. Start Sequence Control Circuit:...

  • Page 69: On-3 Local Controls

    About Controls on ON-3 ON-3 Local Controls At the lift bays, local controls include controls to enter the door bay without tripping the safety curtain. Request Access: Push to enter the lift bay. The button light will blink when activated. Note: After pushing, the lift will finish the task in process.

  • Page 70: About The Safety Light Curtain

    About the Safety Light Curtain About the Safety Light Curtain provides safety for personnel who enter the defined area when the Safety Light Curtain machine is active. If obstruction is detected in the defined area, the machine stops the opera- tion.The machine must be reset from the operators station to continue machining.

  • Page 71: Light Curtain Location

    About the Safety Light Curtain Light Curtain Location control are located at entrances. Reset Light Curtains ON-3 Light Curtain Bar Stacker Feeder Doors In Doors Out Light Curtain Locations FIGURE 3-15. About the Safety Light Curtain 3-14...

  • Page 72: About The Electrical Panel

    About the Electrical Panel About the Electrical Panel This section provides descriptions of the components located in the or the Electrical Panels f Feeder Stacker Each area identified in Figure is described in the following sections. The layout in the panel may change due to options and customer specials, how- Note: ever, the definitions in this section are still valid.

  • Page 73: The Stacker Electrical Panel

    About the Electrical Panel The Stacker Electrical Panel contains the same types of components except the section Stacker Electrical Panel includes a to drive the Vacuum. contains the same components as the panel. Note: Option V Feeder Stacker PLC Section PLC Terminals Analog Voltage Section Analog Terminals (24 VDC and 110 vac)

  • Page 74: Plc Section

    About the Electrical Panel PLC Section section of the predominately contains components for the on-board Electrical Panel industrial computer. Table 3-1 and Figure 3-18 identifies and defines the components in the section. Refer to the labels in the cabinet and the electrical schematic for more informa- Note: tion.

  • Page 75: Analog Voltage Section

    About the Electrical Panel Analog Voltage Section This section predominately contains components that control, supply, or route the analog volt- ages. Table 3-4 and Figure 3-19 identifies and defines the components in the section. Analog Refer to the labels in the cabinet and the electrical schematic for more informa- Note: tion.

  • Page 76: Voltage Input Section

    About the Electrical Panel Voltage Input Section This section predominately contains at the input disconnect that accepts factory power. Table 3-6 and Figure 3-20 identifies and defines the components of the section. Circuit Breaker Refer to the labels in the cabinet and the electrical schematic for more informa- Note: tion.

  • Page 77: Transformer Section

    About the Electrical Panel Transformer Section This section contains the control transformer and the feed motor circuitry. Table 3-7 and Figure 3-21 identifies and defines the components in the section. Transformer Refer to the labels in the cabinet and the electrical schematic for more informa- Note: tion.
  • Page 78 About the Electrical Panel Feeder VFD Section Feed Table VFD Thermal Resistors(X2) UP/ Down VFD Carriage VFD Conveyor VFD (Option) Feeder VFD Section FIGURE 3-22. Stacker VFD Section - Also “Option V” Feeder Feed Table VFD Thermal Resistors UP/ Down VFD Carriage VFD Vacuum VFD Vacuum Lift VFD Section...

  • Page 79: Vfd Reset Buttons

    About the Electrical Panel VFD Section TABLE 3-8. Component Description Thermal Resistors VFD thermal overload protection is provided by thermal resis- tors. The thermal resistors will sense over current and shut down process. The Variable Frequency Drivers supply speed control to VFDs motors on the machine.

  • Page 80: Description Of The Six Light Panel

    Description of the Six Light Panel Description of the Six Light Panel The six lights on this panel indicate the status of the system. The Sequence that the lights activate is as follows: Control Power Overload Relay E-Stop Stop Start 24VDC Description of the Six Light Panel 3-23...

  • Page 81: About The Pneumatic System

    About the Pneumatic System About the Pneumatic System The air input system takes in shop air and supplies clean dry air (CDA) and lubricated air to the machine. The clean dry air is diverted to blow off nozzles. The lubricator, located after the CDA filters, delivers the lubricated air to valve banks and air cylinders.

  • Page 82: About The Valve Banks

    About the Pneumatic System Air System Descriptions TABLE 3-9. Component Description Air Distribution Block Distributes air to various parts of the machine. If after the Lubricator, nor- mally diverted to Valve Banks that need oiled air. Pressure Switch Low Pressure Switch used to protect the Carriage Heads from crashing during operation.

  • Page 83: About Feeder Air Systems

    About the Pneumatic System About Feeder Air Systems Air system controls for the are shown in Figure 3-27. Feeder For detailed air maps, see the machine air print that is included with the docu- Note: mentation. Grabber Manifold Mini Regulator Grabber Cylinders Pop up Cylinders Table Manifold...

  • Page 84: About Stacker Air Systems

    About the Pneumatic System About Stacker Air Systems Air system controls for the are shown in Figure 3-28. Stacker includes a table with air activated and a vacuum door lift system. Stacker Door Stops also uses a vacuum lift to move the doors instead of a Note: Option V Feeder mechanical grabber.

  • Page 85: About Sensors

    Kval Support number or machine model to access documentation for this machine. https://kvalinc.com/machine-support QR Code to goto Kval Support Page FIGURE 3-29. About Photo Sensors A photo sensor, also known as a photo detector or a light sensor, is a device that detects light or the absence of light and converts it into an electrical signal.

  • Page 86: About Through-Beam Transmitters

    About Sensors About Through-Beam Transmitters A through beam-transmitter is a type of photoelectric sensor used to detect the presence or absence of objects. It operates by using a separate transmitter and receiver, which are positioned opposite each other. When the beam is broken, signals are sent back to the , therefore tracking the object (door.) •...

  • Page 87: Gantry Sensor Locations

    Gantry Sensor Locations Gantry Sensor Locations The gantry sensors are predominately metal senors with a photo sensor and are designed to set boundaries for the gantry movement. The next figures are designed to be general sensor location maps. For a detailed Note: map, see the Electro-Mechanical Map...

  • Page 88: Roll Table Sensor Locations

    Roll Table Sensor Locations Roll Table Sensor Locations The roll table sensors are predominately photo sensors that track the door through the table and track the door to fence location. The next figures are meant to be a general sensor location map. For a detailed Note: map, see the Electro-Mechanical Map.

  • Page 89: Available Options

    • Press the Feed Forward Button to load the pal- let into the Door Stack area. • To eject the doors out of the stack area, press the Feed Reverse Button ON-3 Option Q1 - Above Ground Loading FIGURE 3-34. Available Options 3-32...

  • Page 90: Option A

    990- Series Option A: Door Staging on Opera- tor Side of Machine On-3 Option A - Side Stack Relocation FIGURE 3-35. Option L This option adds the capacity to feed doors with raised molding on either or both sides. Maximum molding height above door face will be 3/4 inch.

  • Page 91: Option S

    A dual vacuum pad system replaces the door clamp system on the . The option must be ON-3 included with Option S: Door Stacker Option. Option V: Add vacuum lift to Feeder Option V ON-3 Vacuum Feeder FIGURE 3-38. Available Options 3-34...

  • Page 92: Option T

    558 Door Sizer control panel for the can be mounted next to the door pre-hanging machine control panel. ON-3 This option is required when the 558 Door Sizer is installed between the Note: ON-3 and the door pre-hanging machine.
  • Page 96 http://www.kvalinc.com...

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