Kval Handler Operation And Service Manual

Feeder or stacker
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Innovation, Quality & Honesty
Handler Feeder or Stacker
Operation and Service Manual
Published: 6/15/16

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Summary of Contents for Kval Handler

  • Page 1 Innovation, Quality & Honesty Handler Feeder or Stacker Operation and Service Manual Published: 6/15/16...
  • 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 Handler Operation/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 Handler Operation/Service Manual...
  • Page 5: Table Of Contents

    Chapter 2 Operation of the Handler Operator’s Tour ....................2-2 Handler Top View ..................2-2 Identification of Assemblies on Handler ............2-3 About the Up and Down Motor ..............2-4 Operators Station ................... 2-5 Control at Door Staging Area ................ 2-6 About the Safety Curtain ................
  • Page 6 Powering the Handler ..................2-13 How to Power Up the Handler..............2-13 How to Power Down the Handler..............2-14 Emergency Shutdown and Recovery ............2-14 To Resume Normal Operation after an E-Stop ..........2-14 Pause (Disable and Hold Button)..............2-14 Description of User Interface Screens ...............
  • Page 7 Adjusting Cylinder Extend Speed..............5-17 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 KVAL Handler Operation/Service Manual...
  • Page 8 Handler Feeder System...
  • Page 9: Chapter 1 At A Glance

    CHAPTER 1 Introduction to the Handler This chapter provides an overview of the KVAL Handler and important safety information to fol- low when operating the machine. Chapter 1 at a Glance Section Name Summary Page This section provides an overview of the Handler. It...
  • Page 10: Overview Of The Handler

    Accommodates up to 3'0" x 8'0" doors weighing up to 125 lbs. The Handler is designed to lift flush or panel doors off of a stack and to automatically feed them to the next machine. The door is lifted and held by air pressure clamps from both edges of the door, then moved automatically on an track system over the powered roll table.
  • Page 11 1" thick foam rubber. NOTE: If Handler is used to feed a 555 Door Sizer or 558 Door Sizer option R powered in-feed extension is required.
  • Page 12: 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 13 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 Handler Operation/Service Manual...
  • Page 14 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 Handler Operation/Service Manual...
  • Page 15 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 16: 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 Handler Operation/Service Manual...
  • Page 17: 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 Handler Operation/Service Manual...
  • Page 18: 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 Handler Operation/Service Manual 1-10...
  • Page 19: 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 20 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 Handler Operation/Service Manual 1-12...
  • Page 21: Getting Help From Kval

    Ask about this procedure when calling are service team Product Return Procedure If you’ve contacted Kval for help and it is determined that a return is necessary, use the procedure below to return the machine or part.
  • Page 22 • 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 23: How To Download The Service Application

    Download Application To download the application, go the KVAL website ( http:// www.kvalinc.com At the KVAL website, select the tab. Follow the instruc- Support tions on the Support web page. Click the Download button to download the application that...
  • Page 24 Session code: An internal number to track this machine. It is auto filled. Your Name Field: Enter your name. The KVAL tech- nician will use this field to identify this machine. Description: Enter machine Serial number and issue.
  • Page 25 How to Download the Service Application Page Intentionally Left Blank KVAL Handler 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 Handler Operation/Service Manual 1-19...
  • Page 28 CHAPTER 2 Operation of the Handler This chapter describes components, assemblies, and the user interface of the KVAL Handler Feeder or Stacker The content is geared to help operators understand the basic operation of the Handler. Chapter 2 at a Glance...
  • Page 29: Operator's Tour

    Operator’s Tour The Handler 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: Identification Of Assemblies On Handler

    Operator’s Tour Identification of Assemblies on Handler In Feed Motor Boom Chain Boom Motor Up and Down Motor Clamp ClampsX2 Cylinders move clamps Inwards to clamp the door. Outwards to unclamp Grabber Safety Curtain Stops the process if Door Stack Area Stack area is entered.
  • Page 31: About The Up And Down Motor

    Speed Reducer Reduces speed of the Up and Down Motor when picking up or loading doors. Clutch: .Controls Torque for the weight of the door About the Up and Down Motor FIGURE 2-3. KVAL Handler Operation/Service Manual...
  • Page 32: Operators Station

    Operator’s Tour Operators Station The operator’s station contains a touch screen to input data and operate the Handler. The location of station may vary due to customer specifications. Along with the Handler, other interfaces may also be located in this area.
  • Page 33: Control At Door Staging Area

    If the beam is broken, ensure stacking area is clear and press the button Reset Light Curtain located on the control at the staging area. See “Control at Door Staging Area” on page 2-6. KVAL Handler Operation/Service Manual...
  • Page 34 Operator’s Tour Receiver Emitter Emitter Receiver Breaking of any beam Machine in operation stops the machine Operation of Safety Curtain FIGURE 2-5. KVAL Handler Operation/Service Manual...
  • Page 35: 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 Handler Operation/Service Manual...
  • Page 36: About The Electrical Panels

    PLC (Handler) Relays 24V DC Supply High Voltage Input 24VDC- PDR / Disconnect Terminals 110 VAC Terminals Fuses VFD/ Feeder Motor Contactors and Thermal Over- load (Up and Down Motor) Transformer Feeder Electrical Panel FIGURE 2-6. KVAL Handler Operation/Service Manual...
  • Page 37: Description Of The Six Light Panel

    Operator’s Tour Description of the Six Light Panel The six lights on this panel indicate the status of the Handler system. Note: See “Troubleshooting with the Status Light Panel” on page 5-12., for informa- tion on using this panel for troubleshooting.
  • Page 38: Process To Pick Up And Feed A Door

    Manual fed in doors will trigger the infeed sensor and move the door to the next machine. Option H1: Option H1 adds a foot switch to manual to feed door out of the Handler to the next machine.
  • Page 39: Quick Start Feeder

    Quick Start Feeder Quick Start Feeder Warning: Never operate the Handler 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 Handler main air supply valve is turned on.
  • Page 40: Powering The Handler

    Powering the Handler Powering the Handler This section describe how to power up and to power down the Handler Powering up the system includes: • Applying power to the entire system. • Starting the Control Circuit. Powering down the system includes: •...
  • Page 41: How To Power Down The Handler

    When an E-Stop switch is activated, high voltage power is cut to the machine. The motors will stop but power to the PLC and the Operator Sta- tion Screen will remain on. The Handler will maintain the position of the machine at the time of the There Emergency Stop.
  • Page 42: Description Of User Interface Screens

    Below are the menu selections for the Han- dler Screen Selection Menu Map as a Feeder or Stacker Handler Menu Map for Feeder and Stacker FIGURE 2-7. KVAL Handler Operation/Service Manual 2-15...
  • Page 43: Main Menu

    Description of User Interface Screens Main Menu supplies buttons to link to all the Handler user screens. Press the buttons to go the Main Menu selected user screens. Manual Run: Manually Jog the Feed and the Carriage Software part Number & Rev...
  • Page 44: Run Menu

    Description of User Interface Screens Run Menu Control of the Handler is done at the Run Screen. Tip: Press and hold the Reset Lift: Starts the first pick to move an in- Reset Button up sequence. Puts the lift into a safe position.
  • Page 45: About The Maintenance Screens

    PLC. A red color shows a sta- Status Screens tus of inactive a green color shows a status of active. Use the results of the screens and compare to the electrical drawing of the PLC to troubleshot. KVAL Handler Operation/Service Manual 2-18...
  • Page 46 Description of User Interface Screens KVAL Handler Operation/Service Manual 2-19...
  • Page 47: About The Manual Screen (Jog)

    Feed and Carriage of the machine. Manual Screen The Handler must be paused by pressing the yellow Disable Button to jog the carriage or feed. Important: This screen has access to manual control of the machine. The...
  • Page 48 Description of User Interface Screens KVAL Handler Operation/Service Manual 2-21...
  • Page 49: Chapter 3 System It Administration

    CHAPTER 3 System IT Administration This chapter describes the KVAL Handler 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 50: 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 Handler Operation/Service Manual...
  • Page 51 About the PLC KVAL Handler Operation/Service Manual...
  • Page 52: Chapter 4 Maintenance Of Handler

    CHAPTER 4 Maintenance of Handler This chapter describes preventative maintenance steps for KVAL Handler. 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 53: Maintenance Schedule

    This should be done in accor- dance with applicable state and/or federal code requirements To view a video of the maintenance process, visit the KVAL website. Select the Video Tab to view videos. http://www.kvalinc.com/...
  • Page 54 Inspect Inspect all airlines for kinks or rubbing. Lubricate Refill all lubricators. Replace fluid if milky or discolored. Use ab ISO 32 stan- dard hydraulic oil (KVAL PN:SYS-LUBEG). Lubricate Grease ball screw bearings (if applicable). Clean Clean all bearing shafts with clean, dry cloth.
  • Page 55: Maintenance No-Goes

    • Do not adjust air PSI above or below factory settings • Do not adjust any and all flow controls from factory settings • Do not remove shim stock KVAL Handler Operation/Service Manual...
  • Page 56: Lubrication Schedule

    Lubrication Schedule Lubrication Schedule KVAL recommends the following lubrication schedule to ensure that the machine operates prop- erly. Recommended Lubrication Schedule TABLE 4-2. Type of Assembly Recommended Schedule Recommended Lubrication Type Linear Bearing Pillow Block Bearing Every 250 Hours of Machine Operation...
  • Page 57: Lubrication Requirements

    If the bearing is equipped with a grease fitting (Zerk Fitting), it should receive 1 Gram (one pump from grease gun) of Dura-Lith Grease (KVAL P/N Lube EP-2) every 250 hours of operation. Bearings without grease fittings have been pre-lubricated at the factory and do Note: not require further lubrication.
  • Page 58: Gear Motor Lubrication Requirements

    MOBILUBE HD 80 W-90 or equivalent. Ball Screws All ball screws should be lubricated Dura-Lith Grease (KVAL P/N Lube EP-2) for every 80 hours of operation. At each lubrication grease should be pumped into the fitting until clean grease comes out around the ball screw.
  • Page 59: Adjusting The Air Line Lubricator

    Repeat this same procedure for the back section and other trouble areas. It is recommended to check the lines every week to two weeks. KVAL Handler Operation/Service Manual...
  • Page 60 Lubrication Requirements KVAL Handler Operation/Service Manual...
  • Page 61 Troubleshooting the Handler 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 62: 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 63 • 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 Handler Operation/Service Manual...
  • Page 64: 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 Handler Operation/Service Manual...
  • Page 65: Analyze The Sub Systems

    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 Handler Operation/Service Manual...
  • Page 66 • 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 Handler Operation/Service Manual...
  • Page 67: About A Typical Contactor Control

    Common DC - Thermal Control Coil for 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- 12. KVAL Handler Operation/Service Manual...
  • Page 68: 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 Handler Operation/Service Manual...
  • Page 69: 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 70: About The Vfd

    Figure 5- 14 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 71: 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 Handler Operation/Service Manual 5-11...
  • Page 72: 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- 17. KVAL Handler Operation/Service Manual 5-12...
  • Page 73: 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 74: 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 Handler Operation/Service Manual 5-14...
  • Page 75 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 Handler Operation/Service Manual 5-15...
  • Page 76: 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 Handler Operation/Service Manual 5-16...
  • Page 77: 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 Handler Operation/Service Manual 5-17...
  • Page 78: 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 Handler Operation/Service Manual 5-18...
  • Page 79: 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 80 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 Handler Operation/Service Manual 5-20...
  • Page 81: 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 Handler Operation/Service Manual 5-21...
  • Page 82 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 Handler Operation/Service Manual 5-22...
  • Page 83 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 Handler Operation/Service Manual 5-23...
  • Page 84 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 Handler Operation/Service Manual 5-24...
  • Page 85 Notes:...
  • Page 86 KVAL, getting help1-13 start light description2-10 start machine button power up2-5, 2-13 linear bearing, maintenance schedule4-5 status light panel lockout and tagout Guidelines1-11 description5-21 lockout procedure1-9 use as troubleshooting key5-21 stop light description2-10 KVAL Handler Operation / Service Manual...
  • Page 87 USB module3-2 user interface screens menu map2-15 zerk fittings4-6 locations4-6 zero-energy start-up clean up1-11 inspect1-11 KVAL Handler Operation / Service Manual...
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  • Page 92 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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