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Innovation, Quality & Honesty
Vision Lift System
®
With KvalCAM
Operation Manual
Published: February 20, 2024

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Summary of Contents for Kval Vision Lift

  • Page 1 Operation Manual Published: February 20, 2024 Innovation, Quality & Honesty Vision Lift System ® With KvalCAM...
  • Page 2 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 Vision Lift Operation Manual...
  • Page 3 KVAL Vision 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 LICENSE. IF YOU DO NOT AGREE TO ALL OF THE TERMS OF THIS LICENSE, THEN DO NOT USE THE KvalCAM SOFTWARE. Kval, Inc., is the owner of all rights in respect of the software and documentation (referred to as “Licensor”). You are the purchaser of Machinery operated by the KvalCAM Software are the “Licensee”.
  • Page 6: Table Of Contents

    About Emergency Shutdown and Recovery ......2-4 About Processing a Door............2-6 About the Vision Lift Interface Screens........2-11 About the Vision Lift Main Control Screen ....... 2-12 About the Vision Lift Manual Control Tab......... 2-18 About the Status Screen............2-20 About the Log Screen ..............
  • Page 7 Table of Contents Chapter 4 Tour of the Vision Lift Vision Lift Top Views ..............4-1 About Controls on Vision Lift ........... 4-3 About the Safety Light Curtain..........4-6 About the Lift Assembly ............4-8 About the Vision Lift Tables ............. 4-11 About the Main Electrical Panel..........
  • Page 9 This section describes the method to contact page 1-13 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...
  • Page 10: Overview Of The Vision Lift

    Overview of the Vision Lift Overview of the Vision Lift Feeder Stacker serves as a versatile Feeder and/or Stacker system designed specifically for Vision Lift Kval architectural doors and heavy residential doors. The configuration can function as a Vision Lift...
  • Page 11 Overview of the Vision Lift across the open end of the machine for door stacks. For scenarios requiring side access, additional light curtains can be added as optional features. The vacuum lifting system integrates servo motors for vertical and horizontal movement, ensur- ing precise and smooth positioning.
  • Page 12: About This Manual

    About this Manual About this Manual This manual is part of a package delivered with the machine line. Manuals and Quick Starts are available on line to download. Videos are avail- Note: able to view. See “Access Manuals and Videos Easily” on page 1-4. Operation Manual includes the following: Operation Manual...
  • Page 13: 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 14: 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 15: 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 16: 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 17: 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 18 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 19 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 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 See “Getting Help from Kval” on page 1-13. 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 21 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 1-12...
  • Page 22: 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 23: 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 24 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 25: 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 Vision Lift CHAPTER 2 This chapter describes the user interface of the The content is geared to help oper- Kval Vision Lift. ators understand the basic operation of the machine. Chapter 2 at a Glance Section Name...
  • Page 28: Powering For The Vision Lift

    • Powering the machine Powering down the system includes: • Powering down the machine • Removing power from the entire system Steps Before Powering the Vision Lift Don’t Forget Air ON Closed Gates and E-Stops Power the Main Electrical Cabinet...
  • Page 29 Powering for the Vision Lift Powering the Vision Lift At the , switch the green Operator Station Feeder Stacker Control Circuit switches to the position. Push the green button to “boot up” the machine. Start Machine Boot-up may take 2 to 3 minutes.
  • Page 30 Powering for the Vision Lift Select the button on the of the touch screens. Home Main Screens Feeder Stacker The following actions occur: a.Each machine gantry will move the lift to the home reference. b.Each machine gantry will then move the lift to its neutral position...
  • Page 31: 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 ( ) switches located at E-Stop 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 32 About Emergency Shutdown and Recovery • Gate Latches: Sensors are located on the gates surrounding the machine. If a gate is opened the machine will shut down. • Laser Safety Scanners: These are located on the front of the Edge-SS and Face- SS.
  • Page 33: About Processing A Door

    Ensure factory air is present at the machine and each main air supply Vision Lift valve is turned on. Power up each . See “Powering for the Vision Lift” on page 2-1. Vision Lift At the screen select the button on each lift.
  • Page 34 About Processing a Door Load a Door Steps FIGURE 2-7. Step 3: Feeder Set-Up There are different methods to setup the feeder before processing a door. About Auto Run ON operates without direct interaction of the operator. The initiation of the door process is Auto Run controlled by configurations specified in the settings.
  • Page 35 About Processing a Door About Auto Run OFF Set the to the position to bypass Enter the quantity of doors in the text Auto Run Auto Run. box. Select the button to start the process. Start Feeder Enter “0” into the text box to continue loading the doors until the door stack is Note: empty.
  • Page 36 To load the doors into the bay, the light curtain must be deactivated. At the door entrances, operate the local controls to load the doors. Vision Lift To Enter the Bay Push the blue button to enter the bay; the blue Request Access light will blink, and the lift will finish the current task.
  • Page 37 Step 6: About the Feeder and Stacker Process Although the door bay designs within the series may vary, the opera- Note: Vision Lift tional process remains consistent across all variations. Make sure the desired doors are loaded into the Feeder Bay a.If...
  • Page 38: About The Vision Lift Interface Screens

    Main Control This screen includes access to the most commonly used controls for the Vision Lift. See “About the Vision Lift Main Control Screen” on page 2-12 Manual Servo Control Operate the machine manually by moving the servo motors.See “About the Vision Lift Manual Control Tab”...
  • Page 39: About The Vision Lift Main Control Screen

    About the Vision Lift Main Control Screen About the Vision Lift Main Control Screen This section outlines the l screens for the highlighting Main Contro Vision Lift Feeder Stacker, instances where controls overlap or are duplicated between the feeder and stacker interfaces.
  • Page 40 About the Vision Lift Main Control Screen About the Main Control Section The main controls on both the feeder and the stacker serve the same function for each machine. Home Machine This button starts the home sequence on the machine, which scans to find a physical reference point on the frame.
  • Page 41 About the Vision Lift Main Control Screen Feeder Operation Cull Board Mode Auto Feed Auto Run Feeder: Once the feeder stack is Select to enable the auto-feed or Select to automatically start empty, the lift will grab the cull disable the auto and put it in manual...
  • Page 42 About the Vision Lift Main Control Screen Stacker Operation Auto Feed Select to enable the auto-feed or disable the auto and put it in manual mode. Rotate Next Door Select to rotate the next door that is fed into the machine. Also acts as an indicator, it will have an orange background rotate is activated.
  • Page 43 About the Vision Lift Main Control Screen Start Move Select to start the process of rearranging the doors. Rotate Next Door Select to rotate the next door to be fed into the machine. Rotates one time only Door Quantity Select and enter the number of doors to be moved.
  • Page 44 About the Vision Lift Main Control Screen About the Inspection Control Sections The door inspection feature is an optional control. Once doors are processed, specific ones are redirected to an inspection table situated next to the stacker. Following the inspection, a control allows you to reintroduce the door into the stacker process.
  • Page 45: About The Vision Lift Manual Control Tab

    About the Vision Lift Manual Control Tab About the Vision Lift Manual Control Tab This section outlines the screens for the . It will Manual Control Vision Lift Feeder Stacker highlight instances where controls overlap or are duplicated between the feeder and stacker inter- faces.
  • Page 46 About the Vision Lift Manual Control Tab About the Table Control Sections To manually control the table, disable the The stacker table in this example has an Auto Feed. optional cross feed table. In this case control the cross feed vertical and horizontal table move- ments.
  • Page 47: About The Status Screen

    About the Status Screen About the Status Screen At this screen, real time feedback during the operation of the machine can be viewed. The feed- back includes times, dates, and machine status. Status includes a if the assembly is in operation or a if not in operation.
  • Page 48: About The Log Screen

    Report is a non-issue Yellow Warning If the machine issue can not be resolved, contact (1-800-553-5825). Have Kval Technical Support any error code that is displayed, ready to give the representative to aid in troubleshooting and Kval shorten downtime. Log Screen FIGURE 2-24.
  • Page 49: About The Light Tower

    About the Light Tower About the Light Tower indicates the working status of the system. Highly visible indicator lights are Light Tower mounted on top of the Electrical Boxes. A series of colors and flashing codes helps determine the machine error. In this section, troubleshooting steps are defined.
  • Page 51 Calibration of the Vision Lift CHAPTER 3 This chapter describes steps to calibrate the Vision Lift Chapter 3 at a Glance Section Name Summary Page How to Enter Calibra- Process to enter calibration data. page 3-1 tion Data About the Calibration Overview of the calibration interface.
  • Page 52: How To Enter Calibration Data

    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 (1-800-553-5825). Kval Technical Support Enter a Positive or Negative Number? has a zero point reference. Vision-Lift Reference FIGURE 3-2.
  • Page 53 How to Enter Calibration Data Base: Total: Combine: Offset: Is the result of the Com- Is the running total of Merges the offset Enter the desired off- bine selection. (The the Base and the Off- number to the base. set to bring into cali- merge of the Offset and bration.
  • Page 54 How to Enter Calibration Data About Restore Points Restore Points can be created to store a calibration point for recalibration. To create a Restore Point: Select the button Restore Points Select the button from the pop-up win- Save Current dow save current calibration Name and enter to save To Load or Delete a Restore Point: Select the restore point from the menu...
  • Page 55: About The Vision Lift Calibration Screen

    Barcode Scan Distance 1. The number of door stacks may vary due to the option that is ordered. 2. Cull Board is an option and may not be part of Vision Lift calibration. 3. Barcode capabilities are an option About the Vision Lift Calibration Screen...
  • Page 56: About Door Stack And Cull Board Calibrations

    About Door Stack and Cull Board Calibrations About Door Stack and Cull Board Calibrations The door stack, and cull board calibrations include adjusting the to meet the specifica- Lift Head tion of picking up the top door and bottom door in a stack. The calibration choices include: •...
  • Page 57 About Door Stack and Cull Board Calibrations Visually check the locations for stacking the doors/cull boards. Identify the middle of the stack. • Adjust until satisfied with the centering of the Horizontal Calibration Lift Identify the maximum top door of the stack and the bottom of the stack. •...
  • Page 58: About Table Calibration

    About Table Calibration About Table Calibration The table include adjusting the to the following: Lift Head • Horizontal Position (Centered on the table.) • Table Height. The example in this section describes the calibration of a feeder configuration. Note: The process also applies to the stacker configuration. Table Horizontal: Adjust until the gantry is centered on Feeder or...
  • Page 59 About Table Calibration Visually check the desired locations for stacking the doors. Identify the middle of the table. • Adjust until satisfied with centering of the Horizontal Calibration Lift Identify the top of the top of the table. • Adjust until satisfied with the location.
  • Page 60: About Gantry Calibration

    About Gantry Calibration About Gantry Calibration The gantry calibration includes adjusting the timing of door clamping, door unclamping, and door separation time. Also included in this example is the calibration of a . This is an option and may Bar Code Scanner not appear in your calibration menu.
  • Page 61 About Gantry Calibration Clamp Calibrations Load test doors into the Vision Bays Disable Auto Run Auto Feed. Enter at least a couple doors to be processed. Observe the amount the time the door is clamped. 4. Clamp Time: Observe the time the gantry waits before the door is un-clamped. 5.
  • Page 63 Tour of the Vision Lift CHAPTER 4 This chapter describes components, assemblies, and the user interface of the Kval Vision Lift Sys- The content is geared to help operators understand the basic operation of the machine. tem. Section Name Summary...
  • Page 64: Vision Lift Top Views

    Vision Lift Top Views Vision Lift Top Views offers customization options by incorporating table variations to function as a Vision Lift feeder, stacker, or a combined feeder and stacker within the same unit. The base machine typically includes one bay for door stacks, with the possibility of adding extra bays, allowing for a maxi-...
  • Page 65 Vision Lift Top Views Vision Lift Stacker Figure 4-15 shows a stacker configuration with five bays and an inspection table option. Inspect Controls Local Control Option Door Out Light Curtain: Front Loading of Doors Bay 4 Bay 5 Bay 3...
  • Page 66: About Controls On Vision Lift

    About Controls on Vision Lift About Controls on Vision Lift This section describes the types of controls located on the series. Vision Lift • Located at the operation station Main Controls: • Controls located at the bays. Local Controls: •...
  • Page 67 About Controls on Vision Lift Start Sequence: Control Circuit: After the Door job is loaded, the Energize and de-energize the doors are in place to process, and machines. the machines is homed, press the Start Sequence button to run the machine.
  • Page 68 About Controls on Vision Lift KvalCAM Interface The door bay entrance features a interface, mirroring the main interface found at the KvalCAM . All actions and steps performed on the main interface can be replicated on this Operator Station interface.
  • Page 69: About The Safety Light Curtain

    To recover if the light curtain is broken, press the Reset Light Curtain Button. Reset Light Cur- is located on the local control at the entrance. tain Vision Lift control may have more locations due to machine design. Note: Reset Light Curtain Reset Light Curtain FIGURE 4-21.
  • Page 70 About the Safety Light Curtain Light Curtain Location Sensors are located at the entrance of the Vision Lift. The standard utilizes light curtains across the open end of the machine Note: Vision Lift for door stacks. For scenarios requiring side access, additional light curtains can be added as optional features.
  • Page 71: About The Lift Assembly

    About the Lift Assembly About the Lift Assembly This section identifies the main parts on the gantry assembly. The lift assembly moves the doors into processing and out to stack after processing. The control of the door movement is a combination of sensors and programming to create a smooth transfer. About Gantry Assembly Figure 4-23 shows the key components of the Gantry Assembly.
  • Page 72 About the Lift Assembly About the Lift Carriage Assembly Figure 4-24 shows the key components located on the Lift Carriage Assembly. Lift Carriage Node: Vertical Track: Electrical and PLC Link Rails to move the Lift Carriage from the Main Electrical up and down.
  • Page 73 About the Lift Assembly About the Grabber Figure 4-25 shows the components of the grabber portion of the Lift Carriage Assembly Vacuum Pads Adjustment: Rotation Gear: DO NOT Adjust unless trained Rotates Door 180 Driven by an air cylin- der. Vacuum Pads: Lifts the doors by way of suction...
  • Page 74: About The Vision Lift Tables

    About the Vision Lift Tables About the Vision Lift Tables are synchronized with the lift. The combination of sensors and program- Vision Lift Tables ming combine to create timing to load, unload, and rotate the door. About Door Alignment Tables The feed table receives a door.
  • Page 75 About the Vision Lift Tables About Inspection Tables (Option) The stacker table receives a door from previous machine. The door inspection option sends the door to an inspection table. The stacker table will center the door in the width and justify the length to the top of the door before stacking.
  • Page 76: About The Main Electrical Panel

    About the Main Electrical Panel About the Main Electrical Panel This section provides descriptions of the components located in the or the Main Electrical Panel f feeder and stacker. Each area identified in Figure 4-28 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 77 About the Main Electrical Panel PLC Section section of the predominately contains components for the on-board Electrical Panel industrial computer. Table 4-1 and Figure 4-29 show the locations and descriptions of the components in the sec- tion. Refer to the labels in the cabinet and the electrical schematic for more informa- Note: tion.
  • Page 78 About the Main Electrical Panel Analog Voltage Section This section predominately contains components that control, supply, or route the analog volt- ages. Table 4-2 and Figure 4-29 below shows the locations and descriptions of the components in the section. Analog Refer to the labels in the cabinet and the electrical schematic for more informa- Note: tion.
  • Page 79 About the Main Electrical Panel Voltage Input Section This section predominately contains at the input disconnect that accepts factory power. Table 4-3 and Figure 4-31 show the locations and descriptions of the section. Circuit Breaker Refer to the labels in the cabinet and the electrical schematic for more informa- Note: tion.
  • Page 80 About the Main Electrical Panel Transformer Section This section contains the control transformer and the feed motor circuitry. Table 4-4 and Figure 4-32 show the locations and descriptions of the components in the Trans- section. former Refer to the labels in the cabinet and the electrical schematic for more informa- Note: tion.
  • Page 81 About the Main Electrical Panel VFDs Servo Drive Modules Servo Drive Section FIGURE 4-33. Servo Drive Section Descriptions TABLE 4-5. Component Description The Variable Frequency Drivers supply speed control to VFDs motors on the machine. • Vacuum Pump • Feed Motor •...
  • Page 82: 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 83 About the Pneumatic System Air System Descriptions TABLE 4-6. 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 84 About the Pneumatic System Valve Bank Descriptions TABLE 4-7. Component Description Manifold Manifold includes push-connect fittings, base to connect sole- noids, and an EtherCAT interface. EtherCAT Interface EtherCAT interface includes an EtherCAT input connector, power in connector, and Led display. The display includes: •...
  • 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 4-37. 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 Sensors About Proximity Sensors Metal sensors in machinery are frequently employed as part of quality control measures. They're utilized to detect the presence of metallic assemblies as the machine operates. These sensors help ensure product integrity, prevent damage to equipment, and maintain safety standards by identify- ing any unexpected metal pieces in the processed items.
  • Page 87 4-24...
  • Page 88 http://www.kvalinc.com...

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