Kval Handler Operation And Service Manual
Innovation, Quality & Honesty
Handler Feeder or Stacker
Operation and Service Manual
Published: 6/15/16
Handler Feeder or Stacker
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. For authorization to copy this information, please
call Kval Customer Support at (800) 553-5825 or fax (707) 762-0485. Outside the
U.S. and Canada, call (707) 762-7367.
Manual Part Number: 020_OPSRV_Hand_V2 (Starting at SN 16-20-448)
The Handler is a trademark of Kval Incorporated.
Copyright 2005 Kval Incorporated. All rights reserved.
All other products are trademarks or registered trademarks of their respective holders,
all rights reserved. Reference to these products is not intended to imply affiliation with
or sponsorship of Kval Incorporated.
Contacting KVAL
Customer Service: For further information about this manual or other Kval Incorporated products, contact the Customer Support Department
• Mailing address:
Customer Support Department
Kval Incorporated
825 Petaluma Boulevard South
Petaluma, CA 94952
• Phone and Fax:
In
the U.S and Canada, call (800) 553-5825 or fax (707) 762-0485
Outside the U.S. and Canada, call (707)
• Business hours:
T
echnical Support:
6:00 AM to 4:00 PM Pacific Standard Time, Monday through Thursday
6:30 AM to 1:30 PM Pacific St
Parts & Service Sales:
6:30 AM to 4:00 PM Pacific Standard Time, Monday through Thursday
6:30 AM to 1:30 PM Pacific St
(Other sales related inquiries: http://www.kvalinc.com)
• Email: service@kvalinc.com
762-7367 or fax (707) 762-0485
andard Time, Friday
andard Time, Friday
KVAL Handler Operation/Service Manual
KVAL Handler Operation/Service Manual
http://www.kvalinc.com
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.
What was easy or difficult to use or to learn? If you could change something about the
design, what would it be? Please email your comments and suggestions for improvement to userexperience@kvalinc.com. (NOTE: This is not a customer support email
link. For that, please refer to the Customer Service contact information above.) Thank
you!
KVAL Handler Operation/Service Manual
KVAL Handler Operation/Service Manual
Table of Contents
Chapter 1 Introduction to the Handler
Chapter 1 at a Glance........................................................................................... 1-1
Overview of the Handler...................................................................................... 1-2
Handler as a Feeder........................................................................................ 1-2
Available Options...........................................................................................1-2
Safety First!.......................................................................................................... 1-4
Safety Sheet Sign-Off Sheet ..........................................................................1-4
Safety Terminology of Labels........................................................................ 1-4
Safety Guidelines........................................................................................... 1-4
Lockout-Tagout Guidelines ................................................................................. 1-8
Follow the P-R-O-P-E-R lockout rule of thumb............................................ 1-8
Lockout Tagout Procedure................................................................................... 1-9
Pre-Steps Before Lockout Tagout.................................................................. 1-9
Lockout Tagout Power................................................................................... 1-9
Lockout Tagout Air Supply ......................................................................... 1-10
Start Maintenance ........................................................................................ 1-10
Post Maintenance Steps............................................................................... 1-10
Zero-Energy to Start-Up.................................................................................... 1-11
Getting Help from KVAL ..................................................................................1-13
On-Line Help............................................................................................... 1-13
Product Return Procedure............................................................................ 1-13
How to Download the Service Application....................................................... 1-15
Download Application................................................................................. 1-15
Safety Sign-Off Sheet........................................................................................ 1-18
A Note to the Operator................................................................................. 1-18
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 ............................................................................... 2-6
About Switches and Sensors.......................................................................... 2-8
About the Electrical Panels............................................................................2-9
Description of the Six Light Panel .............................................................. 2-10
Process to Pick up and Feed a Door .................................................................. 2-11
About Option H ........................................................................................... 2-11
Quick Start Feeder ............................................................................................. 2-12
KVAL Handler Operation/Service Manual
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 ............................................................... 2-15
Screen Selection Menu Map as a Feeder or Stacker.................................... 2-15
Main Menu................................................................................................... 2-16
Machine Data Setup.....................................................................................2-16
Run Menu .................................................................................................... 2-17
About the Maintenance Screens .................................................................. 2-18
About the Status Screens ............................................................................. 2-18
About the Manual Screen (Jog)................................................................... 2-20
Chapter 3 System IT Administration
About the PLC ..................................................................................................... 3-2
Chapter 4 Maintenance of Handler
Maintenance Schedule......................................................................................... 4-2
Maintenance NO-GOES ...................................................................................... 4-4
Lubrication Schedule........................................................................................... 4-5
Lubrication Requirements.................................................................................... 4-6
Linear Bearings, Flange Bearing, and Pillow Blocks.................................... 4-6
Gear Motor Lubrication Requirements.......................................................... 4-7
Ball Screws .................................................................................................... 4-7
Description of Air Input ................................................................................ 4-7
Adjusting the Air Line Lubricator ................................................................ 4-8
Priming the Air Line Lubricator.................................................................... 4-8
Chapter 5 Troubleshooting the Handler
About Motion Control ......................................................................................... 5-2
Basic Control Circuit ..................................................................................... 5-2
Troubleshooting Basics........................................................................................ 5-4
Before you Adjust.......................................................................................... 5-4
Before you Adjust.......................................................................................... 5-5
Analyze the Sub Systems............................................................................... 5-5
About a Typical Contactor Control......................................................................5-7
About Contactor Troubleshooting ................................................................. 5-8
About Typical VFD Motor Drive Control........................................................... 5-9
About the VFD............................................................................................. 5-10
About VFD Troubleshooting....................................................................... 5-11
About a Typical Pneumatic Circuit....................................................................5-12
Typical Pneumatic Assembly....................................................................... 5-13
About the Coil (Solenoid)............................................................................5-13
Handler Feeder System
About Cylinder Operation ........................................................................... 5-14
How the Pneumatic System Works.............................................................. 5-14
Important Notice about Adjusting Cylinder Speed...................................... 5-16
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
Handler Feeder System
CHAPTER 1 Introduction to the Handler
This chapter provides an overview of the KVAL Handler and important safety information to follow when operating the machine.
Chapter 1 at a Glance
Section Name Summary Page
Overview of the Handler
Safety First!
Zer
o-Energy to Start-Up
Getting Help from KVAL
How to Download the
Service Application
Safety Sign-Off Sheet
This section provides an overview o
includes a general description and a table of available
options
IMPORTANT safety information
section
Procedure to power up your machine for the first time. page 1-11
This section describes the method to contact the KVAL
service ce
information from the specification plate tor provide to
KVAL, service center hours, and return procedures
Pr
ocedure to download an interactive application to
allow Service T
help troubleshoot. (Windows Op Systems Only)
A record to track operators that are trained on the
mac
nter for help. The sec
echnicians to control your machine and
hine.
f the Handler. It
is described in this
tion includes how to get
page 1-2
page 1-4
page 1-13
page 1-15
pa
ge 1-18
1-1
Overview of the Handler
Overview of the Handler
Handler as a Feeder
The KVAL Handler Door Feeder transfers doors from stacks as high as 7 feet onto a powered roll
table. 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. Door is then lowered onto a powered roll table, which will move it to the adjacent machine on demand. Cycle time
is 40 seconds.
A variable speed drive is installed, with controls, to match the feed speed of the next machine.
SPECIFICATIONS
Footprint Size: 8'x 10'
Crated Dimensions: 134"L x 93"W x 90"H
Shipping Weight: 2,000 lbs.
Overall Machine Height: 120" from floor to top of horizontal tube
Available Options
The table below lists the available Options for this machine. Check the machine contract to verify
what options are applied to your machine.
TABLE 1-1. Options Available
Option Title Description
Option A Reverse Stack In a pre-hanging operation, this places the stack
operator side of a Commander or F-Series machine.
Option B Reverse Feed Direction Reverses the feed direction of the powered roll table and changes
the positions of the door sensing photo eyes. It is required when
choosing Handler Option A for use with a standard feed (left to
right) in a Commander or F-Series line.
rom
Option H Remote Switch for Manual Feed-
Through
Option H1 Remote Foot Switch for Manual Call Foot switch enables operator to feed door
Allows door to be fed manually f
the next machine.
the end of the machine
of doors on the
out of the Handler to
KVAL Handler Operation/Service Manual
1-2
Overview of the Handler
TABLE 1-1. Options Available
Option Title Description
Option L Raised Molding Capability Handler will accommodate doors with raised moldings up to 3/4"
high on one side or both sides.
The Handler feed table will be revised to include rub
rolls on close centers to support the door on the molding. The
clamp support pads will be increased in size and the standard rubber pads replaced with 1" thick f
NOTE: If Handler is used to feed a 555
Sizer option R powered in-feed extension is required.
Option S Short Boom Version This option makes a short boom version of the standar
Door Feeder. It will accommodate door stacks up to 65" high.
Overall height of machine will be 95" from floor to top of the horizontal tube. Selection of this option dedu
Option T Extended Control Cable Extended cable length required when the 555 Door Sizer or 558
Door Sizer is included in the
for the Handler can be mounted next to the door pre-hanging
machine control panel.
NOTE: This option is required when the
Door Sizer is installed between the Handler and the door prehanging machine.
Option U Chain Conveyor Includes dual chain conveyor system allowing a
be
positioned outside the main feeder framework for immediate
in-feed when required. The chains also extend under the feeder's
power conveyor table to move caul boards towards the table's
backside. Caul boards exit onto customer supplied skids or rollers
for manual re stacking. The conveyor chain is jogged by the operator holding down an electric foo
eyes are mounted at the conveyor table to stop the chain, until the
pedal is released and pressed again. Maximum Caul board size is
36" x 84" to clear the table's underside.
The design includes 4" tall bumpers
end. A lift driver lowers a new stack to just above the chain, then
backs up to align the stack against the bumpers before lowering to
the chain. This aligns the stack for in-feed up to the conveyor
table.
Two vertical light curtains
feeder to remain operating while a new stack is loaded on the conveyor chains. The inner light curtain is a full emer
while the outer curtain, spaced 14" further, pauses the vacuum
platen travel. The inner curtain will be positioned approximately
2" past a 36" door stack.
PLEASE NOTE: this option does red
capacity from 7'0" above the floor to 6'2" above the chains inclusive of caul boards or pallets.
Option Tooling and Lubrication Package Please review with your KVAL Consultant
needs.
Option Spare Parts Package Please review with your KVAL Consultan
needs.
oam rubb
pre-hanging line so the control panel
t
will also be provided
er.
Door Sizer or 558 Door
cts
55
5 Door Sizer or 558
-pedal. A set of stack position
ab
ove the chain on the outer
uce overall
to determine your
t
to determine your
ber covered
d Handler
new door stack to
to allow the
gency stop,
stack height
KVAL Handler Operation/Service Manual
1-3
Safety First!
This machine is a powerful electro-mechanical motion control
system. You should test your motion system for safety under
all potential conditions. Failure to do so can result in dam-
age to equipment and/or serious injury to personnel.
Ensure that all employees who operate this machine
are aware of and adhere to all safety precautions
posted on the machine and are trained to operate this
machine in a safe manner.
Training
Safety First!
Safety Sheet Sign-Off Sheet
At the end of this chapter, there is a safety sign-of f sheet. It lists personnel and machine safety criteria to understand before operating the machine. It is highly recommended that personnel operating, working on a machine meet the criteria listed in this sheet. It is recommended the sheet be
signed and kept for records. 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 provide safety information to operators. Safety labels should be clearly visible to the operator and
must be replaced if missing, damaged, or illegible.
There are three types of warning labels or decals:
• DANGER means if the danger is not avoided, it will cause death or serious injury.
• WARNING means if the warning is not heeded, it can cause death or serious
injury.
• CAUTION means if the precaution is not taken, it may cause minor or moderate
injury.
Safety Guidelines
In addition to the caution and warning labels affixed to this machine, follow the guidelines below
to help ensure the safety of equipment and personnel.
KVAL Handler Operation/Service Manual
1-4
Never operate the machine without proper eye and
ear protection.
Protective Gear
• Never reach hands beyond safety cage. Servo
motors can unexpectedly move quickly.
• Never clear screws or hinges out of the machine
while it is running.
• Never reach into the router area to retrieve a
hinge. The router may still be running down
after shut down.
• Never perform any maintenance unless machine
is at zero state.
• Never clean the machine while it is running.
• Never walk away from the machine while it is
running.
When the Machine is ON
The compressed air system connected to this
machine should have a three-way air valve
for shut-off and pressure relief.
All cylinders on machine are under high
pressure and can be very dangerous when
activated. Before performing any maintenance or repairs on this machine turn off the
main air disconnect. Lockout and tagout
this connection.
See “Lockout Tagout Procedure” on
page 1-9.
Compressed Air
Safety First!
KVAL Handler Operation/Service Manual
1-5
Electrical circuitry on this
machine is protected by an
approved lockable disconnect
circuit. In addition to this equipment, you must install an
approved disconnect for the
electrical power supplying this
machine.
When opening the cabinet you must first turn off the
disconnect switch. When the cabinet door is open there
is still power on the top side of the disconnect switch.
Some machines are powered by more than one supply
located at different locations. Before performing any repairs or maintenance, lockout and tagout must be installed at all locations
All maintenance and repairs to electrical circuitry should only be performed by a qualified electrician.
Still has power
in OFF position
Electrical
Prior to performing any maintenance, repairs,
cleaning or when clearing jammed debris, you
must disconnect, tag out, or lock out the electrical
and air pressure systems. This should be done in
accordance with applicable state and/or federal
code requirements.
Before Conducting Maintenance
Laser Warnings
On some machines, laser indicators are used to set boundaries. Follow the
manufacturers safety precautions.
Safety First!
KVAL Handler Operation/Service Manual
1-6
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 regulations which apply in your geographic area.
Compliance with Codes and Regulations
Other Hazard Control Action
Report a Hazard
Before You Report an Accident
If you believe any part or operation of this machine is in
violation of any health or safety regulation, STOP production. It is your responsibility to immediately protect
your employees against any such hazard.
Additional detailed safety guidelines are included in the
operating instructions of this manual. KVAL will be
pleased to review with you any questions you may have
regarding the safe operation of this machine
Follow Your Company’s Safety Procedures
In addition to these safety guidelines. Your company
should have on-site and machine specific safety procedures to follow.
Safety First!
KVAL Handler Operation/Service Manual
1-7
Lockout-Tagout Guidelines
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)
• If more than one person is working on the
machine, each additional person places a lock
and tag on each disconnect.
• Only each operator may remove their own
lock and tag.
Important: When many people are all working
on the same machine you will need a multiple
lockout device, such as the one shown here.
Follow the P-R-O-P-E-R lockout rule of thumb.
P...... Process shutdown
R ...... Recognize energy type (electrical, pneumatic, mechanical, etc.)
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
1-8
Lockout Tagout Procedure
1. Evaluate the equipment to fully understand all energy sources (multiple electrical
supplies, air supply and pressure, spring tension, weight shifts, etc.).
2. Inform all affected personnel of the eminent shutdown, and the duration of the
shutdown.
3. Obtain locks, keys, and tags from your employer’s lockout center.
4. Turn off machine. See Chapter 2 for power down and power up procedures.
5. Turn the disconnect switches on ALL electrical and frequency panels to the OFF
position. Then push the red tab to pop it out. Place a padlock through the hole.
Place your tag on the padlock, as per the tagout guidelines below. (see illustration
below).
Power
Note: When multiple people are working on the machine, each person needs to
have a lock on the handle in the extra holes provided.
Insert Lock into hole.
T urn Switch to the
OFF position
Lock and Tag out
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. Be sure to use the tagout guidelines noted below.
Pre-Steps Before Lockout Tagout
Lockout Tagout Procedure
Lockout Tagout Power
KVAL Handler Operation/Service Manual
1-9
Lockout Tagout Procedure
6. Turn all air valves to the OFF position and place a pad-
lock through the hole (see illustration below).
NOTE: Place your tag on the padlock, as per the
tagout guidelines.
Lockout Tagout Air Supply
Start Maintenance
7. Once the locks and tags are in place and all personnel are clear, attempt to operate
the machine to ensure equipment will not operate.
8. Maintenance or repairs may started.
Post Maintenance Steps
9. 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.
10. 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.
11. The lock and tag can now be removed (only by the person(s) who placed them),
and the machine can be re-energized.
12. The tags must be destroyed and the locks and keys returned to the lockout center.
KVAL Handler Operation/Service Manual
1-10
Zero-Energy to Start-Up
Zero-Energy to Start-Up
Starting the equipment properly is just as important as the lockout/tagout guidelines in terms of
safety.
Start-up Guidelines
The following guidelines below should be followed to start the equipment.
Inspect
The equipment must be inspected for proper adjustment before starting equipment.
Clean Up
All materials and debris must be cleaned up. Any combustible materials or old parts
used during repairs must be cleaned up and/or properly disposed of.
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” position. Please be advised that some components of the machine may start automatically when energy is restored.
Remove Locks
Each operator must remove his or her own lock and tag. This will ensure that all operators are in a safe place when the equipment is started.
Perform Visual Checks
If the equipment is too large to see all around it, station personnel around the area and
sound the personnel alarm before starting the equipment. If your operation is more
complex, your company’s comprehensive safety procedure may involve additional
steps. You will need to ask your supervisor about these procedures. The company’s
lockout procedure should be posted at each machine. On larger or long-term maintenance or installation projects, the company’s procedures must be explained to all new
operators and a copy of the company’s procedures should be posted on-site for the
duration of the work.
The Company’s procedures should also include provisions for safely handling shift
changes and changes in operators or new operators.Comprehensive lockout/tagout
may use a gang box or other system to ensure that locks are secure and not removed
without authorization.
KVAL Handler Operation/Service Manual
1-11
Zero-Energy to Start-Up
Remember, lockout/tagout procedures work because you are the only one with the key
to your lock. Proper lockout/tagout can save lives, limbs, and money. Help make your
work environment safe for you and your fellow workers. Be sure to follow the P-R-OP-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
Getting Help from KVAL
Serial Number
3 phase volts
Electrical Print
Air Print
Getting Help from KVAL
Before you seek help, first try the troubleshooting procedures. Follow the procedures below.
If you are unable to resolve the problem:
1. Locate the machine’s Specification Plate and record the serial number, 3 phase
volts, electrical print number, and air print number.
2. Contact our customer support team:
• In the U.S and Canada, call (800) 553-5825 or fax (707) 762-0485
• 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
On-Line Help
On machines with a Beckhoff® PLC and an internet connection, our service team are able to connect, run, and troubleshoot your machine. 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.
Note: Non-Warranty returns are subject to a 15% restocking charge.
Obtain the packing slip and/or invoice numbers of the defective unit, and secure a
1.
purchase order number to cover repair costs in the event the unit is determined to be
out of warranty.
2. Reason for return: Before you return the unit, have someone from your organization
with a technical understanding of the machine and its application include answers to
the following questions:
KVAL Handler Operation/Service Manual
1-13
Getting Help from KVAL
• What is the extent of the failure/reason for return? What are the relevant error messages or error codes?
• How long did it operate?
• Did any other items fail at the same time?
• What was happening when the unit failed (e.g., installing the unit, cycling power,
starting other equipment, etc.)?
• How was the product configured (in detail)?
• Which, if any, cables were modified and how?
• With what equipment is the unit interfaced?
• What was the application?
• What was the system environment (temperature, spacing, contaminants, etc.)?
3. Call Kval customer support for a Return Material Authorization (RMA). When you
call:
• Have the packing slip or invoice numbers available.
• Have the documented reason for return available.
4. Send the merchandise back to Kval.
• Make sure the item(s) you are returning are securely packaged and well protected
from shipping damage
• Include the packing slip or invoice numbers.
• Include the documented reason for return.
• Include the RMA number with the parts package.
KVAL Handler Operation/Service Manual
1-14
How to Download the Service Application
1. To download the application, go
the KVAL website (http://
www.kvalinc.com
)
2. At the KVAL website, select the
Support tab. Follow the instruc-
tions on the Support web page.
3. Click the Download button to
download the application that
allows the KVAL technician to
have access to the operator station.
4. After the download is com-
pleted, double-click the program
icon.
Note: Web browsers have different methods of downloading programs. Below are samples of i.e
Explorer and Google web browsers.
Sample of Google Browser: Located at the
bottom left of the screen.
Sample of i.e Explorer: Located at the bottom of the screen. select the arrow and
choose Save and Run
How to Download the Service Application
On machines with Windows (8.1 / 8 / 7 / Vista / XP) and an internet connection, our service team
are able to connect, run, and troubleshoot your machine by way of the operator station.
Download Application
.
KVAL Handler Operation/Service Manual
1-15
5. A pop-up window is displayed.
Accept the request to run the program.
Note: Security settings may differ from plant to
plant. If issues occur, contact your IT department.
6. The interface of the KVAL Support App will be dis-
played. Enter your name in the Your Name field.
The fields are described below:
Session code: An internal number to track this
machine. It is auto filled.
Allow Remote Control: Program is ready to allow
technicians to access machine computer
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.
Indicator: Green indicates there is a good connec-
tion to the service center. If red, there could be an
issue with a LAN connection. Check the connections
in the plant.
7. After the KVAL Support App is
loaded and completed, call the
KVAL service center(1-800-553-
5825) and have the technician connect to the machine computer.
8. Click the Allow button to give the
KVAL service technician permission to access the operator station.
We are now ready to troubleshoot.
How to Download the Service Application
KVAL Handler Operation/Service Manual
1-16
How to Download the Service Application
Page Intentionally Left Blank
KVAL Handler Operation/Service Manual
1-17
Safety Sign-Off Sheet
Safety Sign-Off Sheet
Machine Model Number:_____________________________
A Note to the Operator
This machine can help you be highly productive only if you understand how to use it properly and
follow the safe operating practices described in this document and the machine’s manual. If you
do not understand the machine’s proper operation or ignore the safe operating practices, this
machine can hurt or kill you. It’s in your best interest to safely and properly operate this machine.
Personnel Safety Concerns:
• I have been properly trained in the operation of this machine.
• I will always wear ear protection when operating this machine.
• I will always wear eye protection when operating this machine.
• I will never wear loose clothing or gloves when operating this machine.
• I will watch out for other people. Make sure everyone is clear of this machine
before operation.
• I will always follow my company’s safety procedures. I have read and understand
these guidelines.
Machine Safety Concerns:
• I have been given a tour of the machine and understand all the safety labels, E-
Stops and the actions to take in case of an emergency.
• I will make sure all guards are in place before operation
• I will turn off the compressed air, before loading hardware (staples, screws, etc)
• I will turn off the electrical power, for setup
• If the machine should operate in an unexpected manner stop production I will
immediately and notify a manager, a supervisor, or a qualified service technician.
I have read and understand this document and agree to operate this machine in a safe manner as described above.
Employee
Name (print):___________________ Signature: __________________ Date:____/____/____
Supervisor/Safety Officer/Trainer
Name (print):__________________Signature: __________________ Date:____/____/___
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.
KVAL Handler Operation/Service Manual
1-18
Safety Sign-Off Sheet
KVAL Handler Operation/Service Manual
1-19
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
Section Name Summary Page
Operator’s Tour
Quick Start
Powering Operations for
the Commander III
Description of User
Interface Sc
reens
Descriptions of the operation of the parts and assemblies
machine.
of the
A summary of the steps to machine a door. page 2-12
Descriptions of
emergency stops
An overall description of the user interface.
• Screen Selection Menu Map 2-19
• Main Menu 2-20
• Auto Run Screen 2-21
• Maintenance Feed Thru 2-22
• Machine Data 2-23
• Manual Run Screen 2-24
• Maintenance Carriage Screen 2-24
power up, power down, homing, and
page 2-2
ge 2-13
pa
page 2-15
2-1
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