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Summary of Contents for Kval ON-HD
- Page 1 Operation Manual Published: February 17, 2022 Innovation, Quality & Honesty ON-HD Lift...
- 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-HD Operation 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-HD Operation Manual...
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Page 5: Table Of Contents
How to Download the Service Application ....... 1-18 Download Application .................1-18 Safety Sign-Off Sheet .............. 1-21 A Note to the Operator................1-21 Operation of the ON-HD Lift Chapter 2 About the ON-HD Lift............... 2-2 Initial Powering Operations for the ON-HD Lift ......2-3 KVAL ON-HD Lift Manual... - Page 6 To Resume Normal Operation after an Field is Broken ......2-22 Location of Safety Curtain on the ON-HD Lift........2-23 Tour of the ON-HD Lift Chapter 3 Identification of Key Parts of the ON-HD Lift ......3-2 ON-HD Lift Top View................3-2 About the Lift Assembly ............3-3 Boom Assembly ..................3-3 Carriage Assembly................3-4...
- Page 7 About the Safety Curtain............3-10 If the Field is Broken ................3-10 To Resume Normal Operation after an Field is Broken ......3-10 Location of Safety Curtain on the ON-HD Lift........3-11 About the Electrical Panels............3-12 The Light Tower ..................3-13 About the Nodes .................3-13 Graphical Sample of Node Connections and Power Distribution ..3-14...
- Page 8 Table of Contents KVAL ON-HD Lift Manual...
- Page 9 This section describes the method to contact page 1-15 Getting Help from KVAL the KVAL service center for help. The section includes how to get information from the specification plate tor provide to KVAL, ser- vice center hours, and return procedures...
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Page 10: Overview Of The On-Hd Lift
Overview of the ON-HD Lift Overview of the ON-HD Lift is a vacuum lifting system ON-HD Lift that is combined with AC servo motors for vertical and horizontal movement which ensures accurate and smooth positioning. The power conveyor tables feature pop-up... -
Page 11: About This Manual
Overview of the ON-HD Lift About this Manual This manual is part of a package delivered with the machine line. Integration Package includes the following: Operation Manual Chapter Title Description Introduction Descriptions of Machine Line and Safety Information. Operation Descriptions of how to power... -
Page 12: Safety First
See “Safety Sign-Off Sheet” on page 1-21. 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 Safety First! KVAL ON-HD Operation Manual...
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Page 14: Safety First
See “Safety Sign-Off Sheet” on page 1-21. 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 15 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 1-11. KVAL ON-HD Operation Manual...
- Page 16 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-HD Operation Manual...
- Page 17 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 18: 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-HD Operation Manual 1-10... -
Page 19: 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-HD Operation Manual 1-11... -
Page 20: 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-HD Operation Manual 1-12... -
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 KVAL Service team. See “Getting Help from Kval” on page 1-15. Check Controls Confirm that all switches are in the “OFF”... - Page 22 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-HD Operation Manual 1-14...
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Page 23: 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-HD Operation Manual 1-15... -
Page 24: Kval Return And Warranty Policy
We can only accept items for a return if they are still in their original packaging and in undam- aged, resalable condition. Returns are accepted within 45 days of purchase and with an RMA number issued by Kval Inc. Returns after 45 days of purchase or without a Kval Inc. issued RMA number will not be accepted. -
Page 25: 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 26: 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 27 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 28 How to Download the Service Application Page Intentionally Left Blank KVAL ON-HD Operation Manual 1-20...
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Page 29: 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 30 Safety Sign-Off Sheet KVAL ON-HD Operation Manual 1-22...
- Page 31 Operation of the ON-HD Lift CHAPTER 2 This chapter describes components, assemblies, and the user interface of the . The content ON-HD is geared to help operators understand the basic operation of the machine. Included are instruc- tions to calibrate the machine and process a door.
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Page 32: About The On-Hd Lift
About the ON-HD Lift About the ON-HD Lift For detailed descriptions of , see Chapter 3 of this manual. ON-HD Lift feeds doors from a stack into the machine line. The vacuum lifting head also ON-HD Lift rotates 180° for proper handing. This capability eliminates the requirement to manually orient doors correctly in the stack before processing. -
Page 33: Initial Powering Operations For The On-Hd Lift
Initial Powering Operations for the ON-HD Lift Initial Powering Operations for the ON-HD Lift This section describes how to power up and to power down the ON-HD Lift Powering up the system includes: • Applying power to the entire system •... -
Page 34: Home The Machine Line
Initial Powering Operations for the ON-HD Lift Home the Machine Line The Machine Line must go through a homing routine before any operations are performed. The homing routine sets a zero reference from which each machine measures its movement and cutting process. -
Page 35: About Emergency Shutdown And Recovery
SS. These assemblies create an invisible safety field protecting the Operator from entering the cutting area of the machine. • Safety Curtain: This is similar to the Laser Safety Scanners. This creates an invisi- ble curtain on all entrances to the ON-HD. KVAL ON-HD Operation Manual... -
Page 36: About Controls On On-Hd Lift
About Controls on ON-HD Lift About Controls on ON-HD Lift These controls are normally located at the door staging area. The controls are designed for safety during the operation of the machine. The controls can pause the machine to allow safe entry, dis- able the lift, reset the lift, and apply emergency stop. -
Page 37: Staging Area Controls
Note: If entering the staging area use the Request Access buttons located on the Staging area frames. Press the Emergency button to stop machine. Emergency Stop: Will maintain clamp and lift. To restart machine, see “To Resume Normal Operation after an E-Stop” on page 2-5. KVAL ON-HD Operation Manual... -
Page 38: About The On-Hd Lift Process
About the ON-HD Lift Process About the ON-HD Lift Process Ensure the Start-up process has been completed (See page 2-3), that the machine has been Homed doors are loaded to be processed, and the area is clear and safe to start production. -
Page 39: Summary Of The Interface
Manual Servo Control From this screen, move the Gantry and Table manually.See “About the ON-HD Lift Manual Operation Screen” on page 2-14. Calibration From this screen, calibrate the Gantry, Lift, and Table servos on machine.See “About the ON-HD Lift Calibration Screen” on page 2-16. -
Page 40: Universal Controls
If pushed before the door is picked up, the gantry will go into the park position Note: This operation must be utilized before the door is placed on the table. KVAL ON-HD Operation Manual 2-10... -
Page 41: About The Jump, Reset, And Home Buttons
Reset Button: If a fault occurs that cannot be cleared, press the Reset Machine button. This button will reset the machine to the start position before homing. Press after Reset Machine Home Machine KVAL ON-HD Operation Manual 2-11... -
Page 42: About The On-Hd Lift Main Screen
. From this Main Screen screen, all the basic user interface controls are available to run a door. About the ON-HD Lift Main Control Screen ON-HD Lift Main Screen FIGURE 2-1. Non Rotation Model: For the non-rotation model, just enter the number of doors to be processed. The processing will pause after all the quantity of doors is used up. - Page 43 About the ON-HD Lift Main Screen About the Main Control Menu Queue Door Quantity: Select and enter the number of doors to be processed. Note: Entering “0” into the Quantity box puts the machine in Full Stack Mode. The machine will...
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Page 44: About The On-Hd Lift Manual Operation Screen
About the ON-HD Lift Manual Operation Screen About the ON-HD Lift Manual Operation Screen The Main Screen is th boot-up screen, when at another screen, press the but- ton to jump back to the . From this screen, all the basic user Main Screen interface controls are available to run a door. - Page 45 About the ON-HD Lift Manual Operation Screen About the Manual Control Menu Select the button to put the machine into manual control mode. The but- Manual Mode ton will display a green background Feeder Table Buttons: Press the Gantry: Press the desired button desired button to control the feed to control the Gantry.
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Page 46: About The On-Hd Lift Calibration Screen
About the ON-HD Lift Calibration Screen About the ON-HD Lift Calibration Screen Select the Button open access to the: Calibration • screen Gantry Calibration) • screens Door Stack Calibration • screen Feeder In this screen, you can perform machine calibration of the lock... -
Page 47: Entering Calibration Offsets
Maximum offset is 0.50 inches. If more than 0.50 inches of adjustment is Note: needed, there is a high probability that another issue may be causing a problem. If issues can not be resolved, contact the KVAL Service Center KVAL Inc. (1- 800-553-5825). 2.Enter the offset positive or negative number in... - Page 48 About the ON-HD Lift Calibration Screen About the Door Stack Calibration Select the button to adjust stack parameters. Door Stack Calibration Jump Buttons: Select the to go to desired Calibration screens Door Stack #1 Horz: This adjusts the location of the gantry of the alignment to the stack.
- Page 49 About the ON-HD Lift Calibration Screen About The Feeder Calibration Select the button to adjust Feeder parameters. Feeder Calibration Jump Buttons: Select the to go to desired Calibration screens Feeder Table Horz: This adjusts the location of the gantry of the alignment...
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Page 50: About The On-Hd Lift Diagnostic Screen
If the machine issue can not be resolved, call KVAL Inc. (1-800-553-5825). Have any error code that is displayed, ready to give the KVAL representa- tive. This will aid in troubleshooting and shorten down time. -
Page 51: 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 ON-HD Operation Manual 2-21... -
Page 52: About The Safety Curtain
Emergency Shutdown (E- Stop). For information on the E-Stop function, see Chapter 2. To Resume Normal Operation after an Field is Broken If an E-Stop is activated, use the following procedure to recover, after the cause of the emergency stop is resolved: KVAL ON-HD Operation Manual 2-22... -
Page 53: Location Of Safety Curtain On The On-Hd Lift
About the Safety Curtain Location of Safety Curtain on the ON-HD Lift offers the versatility to load and unload doors from the front or sides.Safety Cur- ON-HD Lift tains are located on the sides and the front of the ON-HD Lift... - Page 54 About the Safety Curtain KVAL ON-HD Operation Manual 2-24...
- Page 55 Tour of the ON-HD Lift CHAPTER 3 This chapter describes components, assemblies, and the user interfaces of the KVAL ON-HD Lift Chapter 3 at a Glance Section Name Summary Page Description of the Feeder and Stacker within the ON-HD page 3-2...
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Page 56: Identification Of Key Parts Of The On-Hd Lift
Identification of Key Parts of the ON-HD Lift Identification of Key Parts of the ON-HD Lift This section describes the key parts of the ON-HD Lift ON-HD Lift Top View Light Curtain: Front Loading Infeed Door Roll Table of Doors... -
Page 57: About The Lift Assembly
Option Rotate Door: Some ON-HD Lift have a gear drive to rotate doors. Vacuum Pads: Uses suction to move a door. Components on thew Boom Assembly FIGURE 3-7. KVAL ON-HD Operation Manual... -
Page 58: Carriage Assembly
Vacuum Motor: Motor Vacuum Pads: Two Pads Up and Down Up and Down Brake Gear Box Air Manifold: Con- trols Pneumatics in Carriage Option Rotation Gear: Rotates Door 180 Components on the Lift Assembly FIGURE 3-8. KVAL ON-HD Operation Manual... -
Page 59: About The Grabber
About the Lift Assembly About the Grabber Rotate Track Vacuum Input Gripper (X2) Gripper Gauge Gauge KVAL ON-HD Operation Manual... -
Page 60: About The Feed Table
Cross Feed Belts (X2): Pop-Up Cylinders: (x4) Moves door to the fence. Elevates rollers to move door to the fence Locations of the In-feed and Outfeed Tables FIGURE 3-9. KVAL ON-HD Operation Manual... -
Page 61: About Controls On On-Hd Lift
About Controls on ON-HD Lift About Controls on ON-HD Lift These controls are normally located at the door staging area. The controls are designed for safety during the operation of the machine. The controls can pause the machine to allow safe entry, dis- able the lift, reset the lift, and apply emergency stop. - Page 62 About Controls on ON-HD Lift Control Transformer: Energize and De-Energize the machines Start Machine Button: Wakes up the machine, similar to a boot-up Stop Machine Button: Puts the machine to sleep. Pause/Resume Lift: Press to pause lift. Pull-out the button to Resume Oper- ation.
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Page 63: Staging Area Controls
About Controls on ON-HD Lift Staging Area Controls To Enter Staging Area (Request Access): Push the blue button IN Request Access The blue light will blink and the lift will move a door over the rollers. After door is over rollers, enter the Staging Area... -
Page 64: About The Safety Curtain
Emergency Shutdown (E- Stop). For information on the E-Stop function, see Chapter 2. To Resume Normal Operation after an Field is Broken If an E-Stop is activated, use the following procedure to recover, after the cause of the emergency stop is resolved: KVAL ON-HD Operation Manual 3-10... -
Page 65: Location Of Safety Curtain On The On-Hd Lift
About the Safety Curtain Location of Safety Curtain on the ON-HD Lift offers the versatility to load and unload doors from the front or sides.Safety Cur- ON-HD Lift tains are located on the sides and the front of the ON-HD Lift... -
Page 66: About The Electrical Panels
• Supplies voltages to the machine • Contains the PLC (Programmable Logic Controller) • Contains VFD’s (Variable Frequency Drives) and Servo Drives ON-HD Lift PLC (ON-HD Lift), Electrical Outlet, 24 VDC,110 VAC Light Curtain Terminals 24 VDC Supply Relays High Voltage Input... -
Page 67: The Light Tower
The node layout in the figure below is generic. For information about the spe- Note: cific machine node, refer to the machine electronic schematic. PLC Interface Inputs and Outputs Top Ethernet cable is PLC Bottom Ethernet goes to Cutter Node Interconnect Bar KVAL ON-HD Operation Manual 3-13... -
Page 68: Graphical Sample Of Node Connections And Power Distribution
Power and PLC connections are located ON-HD in the node boxes.. Power and PLC Distributed to Points in the Machine Node Location Sample of a Frame Node FIGURE 3-12. KVAL ON-HD Operation Manual 3-14... - Page 69 1-18 reset machine button description user interface 2-10 safety guidelines 1-4, 1-6 Safety Sign Off Sheet Safety Concerns 1-21 six light panel description 2-21 start machine button power up 2-3, 2-6, 3-8 tagout procedure 1-11 Kval ON-HD...
- Page 70 Index Kval ON-HD...
- Page 72 Customer Service Contacting KVAL 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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