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,

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

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

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

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

• 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

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

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

Operator’s Tour

Electrical

Panel

Roll Table

Boom

Motor

Up and

Down Motor

Safety Curtain

Sender

Door Lift

Boom and Grabber

Door Out

Fence

Safety Curtain

Receiver

Door

Stack

Area

Option H: Manual

Door Feed

Clamps

Door

Stack

Area

Fence

Staging Area

Control

Feed

Motor

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. This manual describes the Handler as a feeder.

Handler Top View

FIGURE 2-1. To p View of the Handler

KVAL Handler Operation/Service Manual

2-2

Identification of Assemblies on Handler

Bottom View

Wooden Door Guides

Door Stack Area

Push Over Belts

In Feed Motor:

Drives belt driven rollers to move door into the next machine.

Grabber

Up and Down Motor

In Feed Motor

Safety Curtain

Stops the process if Stack area is entered.

Controls

Main Operating Station

Enter Stack Area Control

Pop-up Cylinders:

Pops up to move door to fence

Boom Motor

ClampsX2

Cylinders move clamps Inwards to clamp the door.

Outwards to unclamp

Clamp

Boom Chain

Operator’s Tour

FIGURE 2-2. Door Input Area

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2-3

Operator’s Tour

The Brake:

Automatically applies braking force when the gripper comes to a stop while grabbing doors from the stack, and when it raises the gripper (and door) to the top of the carriage.

Prevents the gripper from lowering too far, and/or unexpectedly lowering once raised or when air pressure to the clutch fails.

Boom Chain: Moves boom over to door stack for pick up and back to the rollers for placing the door.

Driven by the Boom Motor located under the feed table.

The Motor:

Works with Speed Reducer and Brake to move the grabber up and down to pick up and place doors.

Speed Reducer Reduces speed of the Up and Down

Motor when picking up or loading doors.

The Boom: Moves to lower to

pick up doors and move to place on feed table

Clutch:

.Controls Torque for the weight of the door

About the Up and Down Motor

FIGURE 2-3. About the Up and Down Motor

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2-4

Operator’s Tour

Handler

Feeder

Controls

CONTROL TRANSFORMER button START MACHINE button. STOP Machine button DISABLE (Pause) Machine button

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.

FIGURE 2-4. Operator Station Example

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2-5

Operator’s Tour

To Enter Staging Area (Request Access):

1. Push the blue Request Access button out

2. A blue light will blink and the lift will move a door over

the rollers.

3. After the blue light goes solid, it is OK to enter.

4. After completed task, EXIT staging area

5. Pull the blue Request Access button out

6. Press the Blue Reset Light Curtain button to continue

with door processing, after the safety light curtain is broken.

Disable Lift: Press to disable or pause the lift. the lift will hold at

the point of being disabled.

Emergency Stop: Press in Emergency will stop machine. Will

maintain clamp and lift.

Control at Door Staging Area

These controls are normally located at the door placement area. The controls are designed for safety during the operation of the machine. The controls can pause the machine to allow safe entry, disable the lift, reset the lift, and apply emergency stop.

About the Safety Curtain

The Safety Curtain provides safety for personnel who enter the defined area when the machine is active. If any part of an operator’s body is detected in the defined area, the machine stops the operation.The machine must be reset from the operators station to continue machining.

The Safety Curtain is composed of an EZ-Screen emitter and receiver. The emitter has a row of synchronized light-emitting diodes (LEDs) that send signals to the receiver. The receivers have a a matching row of synchronized photo detectors that read the signal from the emitter. When the signal is blocked of any beam, the machine stops. To continue machining push the Start button

If the beam is broken, ensure stacking area is clear and press the Reset Light Curtain button

Important: The EZ-Screen system is aligned at the factory. Do not move the emitter or

receiver modules. This may cause misalignment, if the system is misaligned the machine will not start

located on the control at the staging area. See “Control at Door Staging Area” on page 2-6.

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2-6

Emitter

Receiver

Emitter

Receiver

Machine in operation

Breaking of any beam

stops the machine

Operator’s Tour

FIGURE 2-5. Operation of Safety Curtain

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2-7

Operator’s Tour

The Photo Electronic Detector uses light as a trigger.

• Photo Eye Detectors contain both emitter and receiver.If an

object is within the Photo Eye’ s sensing field light from the emitter is reflected from the object back to the receiver. With no object is in front of the Photo Eye a constant 24VDC is sent to the PLC. If an object is sensed by the Photo Eye, 0VDC is sent to the PLC.

• As a result, any of the photo detectors output equals 0VDC when a door is sensed.

• Some detectors have an emitter and receiver built in one unit, such as an in-feed sensor where a door blocks the light and reflects back to the unit.

• Some detectors have an emitter and receiver built in separate units, such as the through beam sensor set at a distance from each other. If an assembly is in between the two sensors the machine will not operate.

One Package

The Proximity Sensor detects metallic objects without touching them.

• An inductive proximity sensor consists of a coil and ferrite core arrangement, an oscillator and detector circuit, and a solid-state output. The ferrite core and oscillator create a field generating out the front of the sensor. When a metal object enters the field, a loss in amplitude occurs. The detector circuit recognizes the loss of amplitude and generates 0VDC to send to the PLC. When the metal object leaves the sensing area, the sensor to returns to 24VDC and sends it to the PLC.

• As a result, if a metal object is sensed, the output of the sensor equals 0VDC

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

About Switches and Sensors

On the this machine sensors and limit switches provide input to the PLC as part of the automation of the door moving process. Inputs can include feed through, door clamping, door location, and limits of movement of machine assemblies.

Sensors are electronically tripped while limit switches are mechanically tripped. It is important to keep the sensors cleaned and aligned to keep the door process running smoothly. There are two classifications of sensors: Photo Electronic and Inductive Proximity Sensor.

.

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2-8

Operator’s Tour

The Main Electrical Panel:

• Supplies voltages to the machine

• Contains the PLC (Programmable Logic Controller)

• Contains VFD’s (Variable Frequency Drives).

Warning: High Voltage is present in this pan el at the top of the Three Phase

input even with the disconnect off. If working on the panel, follow disconnect protocol. See “Lockout Tagout Procedure” on page 1-9.

PLC (Handler)

Relays

24V DC Supply

110 VAC

Terminals

24VDC-

Terminals

VFD/ Feeder Motor

Transformer

High Voltage Input

PDR / Disconnect

Contactors and Thermal Over-

load (Up and Down Motor)

Fuses

Hub

About the Electrical Panels

This section is an overview of the electrical components in the Main Electrical Panel. Refer the machine's electrical prints for in-depth information.

FIGURE 2-6. Feeder Electrical Panel

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2-9

Operator’s Tour

Control Power –This

light illuminates when the Control Transformer turned on and the power is working on secondary side-of transformer

Overload Relay –

This circuit is jumped. It should always light.

E-Stop – The back gate is closed and Frame E-stop is not activated when this light is on.

24VDC – This light

comes on once the ACR is latch and the 24VDC power Supply is working

Stop – This light will

be on if Machine

Stop button is deac-

tivated.

Start – This light will

be on once the

Machine Start button

is pressed and the

ACR Relay is latched.

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.

The Sequence that the lights activate is as follows:

1. Control Power

2. Overload Relay

3. E-Stop

4. Stop

5. Start

6. 24VDC

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2-10

Process to Pick up and Feed a Door

Door

Stack

Area

Door

Stack

Area

T o the Next Machine

Input Door

Process to Pick up and Feed a Door

1. The Boom moves the Grabber over and down to clamp door

2. The Grabber Picks up a door

3. The Boom moves the door over the Roller Table.

4. The door is placed on the Roller Table

5. The Grabber releases the door and moves up.

6. The Pop up cylinders and the push over belts move the door to the fence

7. The Feed Belt drive rolls door to the next machine

About Option H

The Option H machine allows door to be fed manually from the end of the machine. Press the Reset Lift Button. Press the End-Feed Mode button on the Run screen to enter this mode. When active, the boom will

move over the stack area and the input will switch to the end of the machine. 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.

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2-11

Quick Start Feeder

Ensure factory air is present at machine and the Handler main air supply valve is turned on.

Power up the Handler. See “How to Power Up the Handler” on page 2-13.

Clear the stacking area of clutter. Ensure all personnel are clear of the area. Place a pallet to stack doors upon

P lace the stack of doors against the wooden stops.

After performing the steps in “How to Power Up the Handler” on page 2-13, select the Run Button from the Main screen.

Select the Set Counter button.

Enter the number of doors to

be processed by way of the keypad that is displayed. Press the ENT button and Pre-

vious Menu

to return to the

Run Screen

d

Select the Auto Feed Button Select the Reset Lift Button (To Home machine) Select the Reset Lift Button (To enable Sequence) Select the Call Door Button to start the Door Feeding

Process. The Handler will load the quantity of doors in the Stack

Count

box.

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".

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2-12

Powering the Handler

4. Push the CONTROL TRANSFORMER button in

to the ON position. It should light up.

5. Push the Blue Rest Light Curtain Button,

located at the Handler staging area.

6. Push the green START MACHINE button.

7. All lights on the status light panel on the electrical

box should be illuminated.

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:

• Turning off the computer.

• Shutting down the control power.

• Removing power from the entire system.

How to Power Up the Handler

1. Ensure factory air is applied to machine and main air supply is turned on.

2. Check that all E-Stop buttons are out.

3. Make sure the electrical disconnect the electrical cabinet is turned to the ON posi-

tion.

Powering the Handler

.

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2-13

Powering the Handler

1

2

3

How to Power Down the Handler

1.

Push the STOP Button.

2. Push the CONTROL TRANSFORMER but-

ton in to the OFF position.

3. KV AL also recommends that you turn the

disconnect switch on the electrical cabinet to OFF; this helps reduce possible damage resulting from power surges from electrical storms.

Emergency Shutdown and Recovery

Depending on the model of machine, there are emergency shutdown (EStop) switches located at key points around the machine.

The E-Stop switches are to be used when the machine is out of control or is about to damage personnel or equipment.

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 Station Screen will remain on.

The Handler will maintain the position of the machine at the time of the Emergency Stop. There fore if the door is clamped in mid lift, the door will stay at that position.

Note: The machine responds in the same way if you press the STOP button on the

operator's station.

To Resume Normal Operation after an E-Stop

If an E-Stop is activated, use the following procedure to recover , after the cause of the emer gency stop is resolved:

1. De-activate the E-Stop switch by pulling it out.

2. Push the START MACHINE button on the operator's station

3. Home the Machine.

Pause (Disable and Hold Button)

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2-14

Description of User Interface Screens

This section describes the user interface screen. The user interface allows the operator to use a touch screen to control the door machining process. Below are the menu selections for the Handler

Screen Selection Menu Map as a Feeder or Stacker

FIGURE 2-7. Handler Menu Map for Feeder and Stacker

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2-15

Description of User Interface Screens

Software part Number & Rev

Input and Output Status: Press to display

an active list of input and output indicators. Use to troubleshoot machine

Run Menu: Press to display the Run Machine Menu

Maintenance: Press to display inputs and

outputs at the carriage and feed locations.

Machine Data Setup: Press to display number of doors processed and display controls.

Manual Run: Manually Jog the Feed and the Carriage

Total Doors:

Total number of doors processed

(not resettable)

Reset Daily:

Reset the daily count

Daily Total Doors: Total

number of doors processed for the day

Adjust Levels:

Select the arrow to increase or decrease Contrast or Color Brightness

Previous Menu:

Jump back to Start Screen

Main Menu

The Main Menu supplies buttons to link to all the Handler user screens. Press the buttons to go the selected user screens.

Machine Data Setup

Press the Machine and Data Setup button to check daily and total doors processed.

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2-16

Run Menu

Un-Clamp; Release the

clamp mechanism. Boom will move over to stack and unclamp

Call Door: In Auto mode starts the first door out. In Manual mode calls each door.

Cycle Enabled/Disabled:

This is an indicator that displays if the Handler is in Auto Feed or Manual Feed

Reset Lift: Starts the first pick up sequence. Puts the lift into a safe position.

Feed Auto/Man: Press to toggle between manual feed and

auto feed

Previous Menu: Press to go

to the Main Menu

Tip: Press and hold the

Reset Button to move an in-

process door to the stack.

Set Counter: Press to enter the number of doors to process.displays a keypad to enter door quantity

Stack Count: Displays the Quantity of doors to process. input byway of the Set Counter button.

Reset Counter: Press clear the quantity in the Stack Count box.

End-Feed Mode (Not Ready/ Ready): Turns Green when

machine is ready to use the End-Feed Function

End-Feed Mode ON/OFF:

Press to put machine in End Feed Mode. This will move the Boom over the stack and allow feeding a door from the end of the machine See “About Option

H” on page 2-11.

Option H:

Control of the Handler is done at the Run Screen.

Description of User Interface Screens

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2-17

Description of User Interface Screens

The indicators on the screens show the area and location of the sensors. As troubleshooting tool, determine if the sensor is acting correctly at it’s point in the process

About the Maintenance Screens

Use this menu to check the operation of the sensors in the machine.With this tool, outputs and inputs can be viewed in there on and off states. The indicators on the screen show the area and location of the sensors. As troubleshooting tool, determine if the sensor is acting correctly at it’s point in the process

Note: Refer to the Electrical Drawings for definite information about the electrical

wiring and designation of the sensors.

INPUT INDICATORS Circular displays like these show the status of the controller inputs.

OUTPUT INDICATORS Square displays like this show the status of the controller outputs.

About the Status Screens

The Status Screens show the status of the inputs and outputs of the PLC. A red color shows a status 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

Description of User Interface Screens

KVAL Handler Operation/Service Manual

2-19

Description of User Interface Screens

Jog Carriage:

Press and Hold the button to move the carriage in the desired direction.

(Up, Down, T o S tack and To Rolls)

Table:

Press and Hold the

Feed Forward but-

ton to move the door through he machine.

Unclamp

Press and Hold the

Unclamp button to

release the door.

Do not unclamp if a door is elevated by the carriage. The door will fall

to the ground.

Cycle Enabled/Disabled:

This is an indicator that displays if the Handler is in Auto Feed or Manual Feed

About the Manual Screen (Jog)

The Manual Screen allows the operator to manually move the Feed and Carriage of the machine.

Important: This screen has access to manual control of the machine. The Unclamp button will unclamp when the carriage is at any position. DO NOT press the Unclamp button if a door is elevated by the carriage, the door will fall to the ground.

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Description of User Interface Screens

KVAL Handler Operation/Service Manual

2-21

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.

Chapter 3 at a Glance

Section Name Summary Page

About the PLC

This chapter describes the basic parts of the operation of the PLC in the machine. Such as

page 3-2

3-1

About the PLC

PLC

Inputs and

Outputs

Relays

Hub

24 VDC

Supply

About the PLC

This machine uses an IDEC® CPU module as a PLC (Programmable Logic Controller). In addition to the CPU and the chipset, the module also contains internal main memory. The controller

uses WinLDR® automation software to create the PLC and Motion Control method. Different model type IDEC PLC’s may be used for each machine. The basic two types are the “all

in one” model and the “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

KVAL Handler Operation/Service Manual

3-2

About the PLC

KVAL Handler Operation/Service Manual

3-3

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.

Chapter 4 at a Glance

Maintenance Schedule

Lubrication Requirements

This section describes the assemblies to schedule for maintenance.

• 300 Cycles

• 600 Cycles

• 3,000 Cy

• 12,000 Cycles

• 72,000 Cycles

is section describes the lubrication requirements for

Th the machine,

cles

including types of lube to use. This section

includes:

• Linear Bearings, Flange Bearing, and Pillow Blocks

• Gear Motor Lubrication Requirements

• Ball Screws

• Description of Air Input System

• Adjusting the Air Line Lubricator

• Priming the Air Line Lubricator

page 4-2

page 4-6

4-1

Maintenance Schedule

Prior to performing any maintenance, repairs, cleaning or when clearing jammed debris, you must disconnect, tagout, or lockout the electrical and air pressure systems. This should be done in accordance 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/

Maintenance Schedule

KVAL recommends the following maintenance schedule to ensure that the machine operates properly. Cycles refers to the quantity of processed doors. Cleaning curtails build up of sawdust and grime which causes issues with the operation of the machine. Inspecting, finds issues before they become problems. Lubricating decreases wear and keeps this machine running smoothly. Refer to sections following these tables for further description of the maintenance steps.

Note: The steps in the tables below are designed to perform maintenance on a produc-

tion line. Some of the steps may not pertain to all machines.

300 Cycles

Clean Use pressured air to blow off dust and debris on entire machine Clean Blowoutdustcollectioncans

600 Cycles

Inspect Air Pressure Gages. Adjust, if necessary, to the proper PSI located on the

label. (Adjust only if Trained in Maintenance)

Inspect Inspect Air Filter Water Traps. Empty if necessary Inspect Inspect the Tooling for wear, (Drill Bits, Cutting Tools, Screw Driver Bits)

Lubricate Lubricate the inside of the Hoppers with a light coat of dry silicone

Clean Empty All Dust Collection Units

spray.(990 Series Specific)

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4-2

Maintenance Schedule

3,000 Cycles

Inspect Inspect feed belts for proper tension or damage. Inspect Inspect screw drop tubes for kinks, cracks or wear from rubbing. Ensure tube

clamps are tight.(990 Series Specific)

Inspect Inspect all photo eyes secure and tight. Inspect Inspectalllimitswitcharmsfortightnessorbreaks Inspect Inspect split shells and screw receivers on six shooters for cracks or breaks.

Replace if broken.(990 Series Specific)

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.

12,000 Cycles

Inspect Inspect chains for proper tension or damage Inspect Inspect all air cylinders for air leaks. Replace if seal is leaking Inspect Inspecthydrauliclinesforloosefittings,leaksandcracks. Inspect Inspectballrailshaftsforpittingorabrasions.

Lubricate Cleanandlubricateallslidesandcylinderrodswithdrysiliconespray Lubricate Lubricateallbearingshaftswithsiliconeandcleanrag.

Clean

Clean inside hopper with WD-40 and a 3M Scotchbrite® pad. Wipe dry with a clean dry rag.(990 Series Specific)

72,000 Cycles

Inspect Inspect all nuts and bolts for tightnesses Tighten is necessary. Inspect Checkthatthereisasmoothtransitionwithadoorfeedingintoandoutof

machine.

Back-up Backupcomputersoftware.

Clean Washfilterandlubricatorbowlswithsoapywater.

KVAL Handler Operation/Service Manual

4-3

Maintenance NO-GOES

Do not perform the following. This machine is tuned an calibrated at the factory. If any of these conditions are changed, timing, accuracy, or damage may occur during the machine process.

• 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

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4-4

Lubrication Schedule

KVAL recommends the following lubrication schedule to ensure that the machine operates properly.

TABLE 4-2. Recommended Lubrication Schedule

Type of Assembly Recommended Schedule Recommended Lubrication Type

Linear Bearing

Every 250 Hours of Machine Operation Dura-Lith Grease (KV Flange Block Bearing Ball Screw Every 80 Hours of Machine Operation Air Line Lubricator One drop of oil every 2 or 3 cycles

Check the lines every week to two weeks

Gear Box 2000 Hours of Machine Operation or six months

ation

of oper

AL P/N L

Either lubricant listed below to use.

• KVAL P/N SYSLUBG

• Chevron AW Hydraulic Oil 32

• G-C lubricants light AW R&O

• Mobile DTE 24

• Shell Tellus32

• Gulf Harmony 32

• AGMA #8 gear lube

• MOBILUBE HD 80 W-90

• or equivalent

ube EP-2)Pillow Block Bearing

is approved

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4-5

Lubrication Requirements

Zerk Fittings

Zerk Fitting Location

Depends on Position of

Slide

Lubrication Requirements

This section describes the parts of the machine that require periodic lubrication, and specifies the lubricants. In addition, it explains how to maintain the lubrication s on the machine.

Linear Bearings, Flange Bearing, and Pillow Blocks

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.

Note: Bearings without grease fittings have been pre-lubricated at the factory and do

not require further lubrication.

FIGURE 4-8. Zerk Fittings

KVAL Handler Operation/Service Manual

4-6

Lubrication Requirements

Ball screw lubrication points.

Ball Nut

Ball Screw

End Bearing

Shop

Air

Input

Air On-

Off Knob

Muffler

Filter

(purge)

Pressure Gauge with adjust Clean Dry Air (CDA) to

Air Blow Off

Lubricator

Lubricated

Air Output

Gear Motor Lubrication Requirements

Oil change is recommended after 2000 operation hours of operation. Use AGMA #8 gear lube or 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.

FIGURE 4-9. Example of a Typical Ball Screw

Important: Make sure to clean excess grease to avoid contact with feed belts, clamping areas, or the door.

Description of Air Input

The air input 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.

FIGURE 4-10. Typical Air Line Filter and Lubrication

KVAL Handler Operation/Service Manual

4-7

Lubrication Requirements

(Sight Glass). When the oiler has run dry, open the knob all the way until flow begins. Once you have a steady flow, tighten knob back down until you have one drop per every other cycle.

Drop will form at end of cane shaped tube visible inside glass.

Top of Lubricator

Adjusting the Air Line Lubricator

Using the knob on the top of the lubricator, adjust until one drop per every other cycle is used (as observed through sight glass.)

Priming the Air Line Lubricator

New and used machinery run out of oil from time to time. It is a good practice to check your machine lubricator to insure that it is putting the proper dose of oil in the air lines. Usually 1 drop of oil every other cycle is a good rule of thumb. The approved list of oil for lubricators is as follows:

• KVAL P/N SYSLUBG

• Chevron AW Hydraulic Oil 32

• G-C lubricants light AW R&O

• Mobile DTE 24

• Shell Tellus32

• Gulf Harmony 32

To prime the lubricator, find an air line on the carriage section of the machine that is energized, and disconnect it, allowing the air stream to bleed air pressure away from any persons. Direct the air stream at the machine so you can see when there is an oily film blowing out of the air hose. Repeat this same procedure for the back section and other trouble areas.

It is recommended to check the lines every week to two weeks.

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4-8

Lubrication Requirements

KVAL Handler Operation/Service Manual

4-9

CHAPTER 5 T roubleshooting the Handler

Refer to the Air and Electrical drawings provided with delivery of the machine. The drawings are normally located in the Electrical Panel. If copies are unavailable, contact the KVAL Service Department. Have drawings numbers, model number, and serial number of machine readily available.

Note:

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.

Chapter 5 at a Glance

Section Name Summary Page

About Motion Control

Troubleshooting Basics

About Contactor Control

About VFD Control

About Pneumatic Control

Using Sensors to Trouble Shoot

Troubleshooting Electrical Problems

This section contains basic information on the operation grams of the control circuits.

This section includes basic troublesho mation. Includes analyzing sub s to designate a starting point for troubles

Describes a typical contactor control circuit. page 5-7

Describes a typical VFD circuit. page 5-9

Describes the typical pneumatic circuit. page 5-12

Includes procedure to trouble shoot air cylinders, such

Includes voltages in the e Status Light panel to troubleshoot, and VFD troubleshooting.

of motion control circuits. Includes dia-

oting infor-

hooting.

adjusting extension and retraction speed.

as

lectrical pane

ls, using the

page 5-2

page 5-4

page 5-18

page 5-19

KVAL Handler Operation/Service Manual

5-1

About Motion Control

This section describes the positioning systems found in KVAL machinery. There are three basic types of motion control methods used in 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:

1. Move the door into position.

2. Clamp the door.

3. Make the cuts.

4. Unclamp the door.

5. Move the door out.

6. Wait for the next door.

Point to Point:

Point to point motion control involves moving a load from one fixed position to another fixed position at a constant speed and along one line (axis X,Y, or Z). A typical point to point would be a drill with a fixed-depth. The drill is either retracted or extended using a pneumatic cylinder. Typically the drill’s’ travel is limited by physical stops.

Incremental:

Incremental motion control is used when the load is required to be moved with high accuracy to multiple locations, sometimes in multiple directions (axes). A typical KVAL usage for this system is a computer controlled router in a door light machine where there is great variety in the cut size, shape and location.

Basic Control Circuit

This section describes a basic control circuit. The Figure below shows a block diagram of a common control circuit. There are four parts to a motion control system:

KVAL Handler Operation/Service Manual

5-2

Load

User Interface

Force

Positioning

System

Translated Positioning

Controller

Instructions

Positioning Instructions

(Optional)

Position Feedback

(Optional)

Machine’s Other

Subsystems

OK to move

Complete

Process

FIGURE 5- 11. Block Diagram of Basic Motion Control

The User Interface:

• Allows communication between the humans and the machine.

Examples: A touch screen, a PC or a button panel.

The Controller:

• Translates entered information into a form the positioning system can understand.

• Listens to the machine’s other subsystems waiting for the OK to move command.

• Sends the positioning instructions to the positioning system.

• Listens to the positioning system for position status (if there is a feedback loop).

• Tells the machine’s other subsystems when the move process is completed.

Examples: A PLC or a dedicated motion control board.

Positioning System:

• 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

About Motion Control

KVAL Handler Operation/Service Manual

5-3

Troubleshooting Basics

Good trouble shooting starts with looking at the whole machine, where every part is suspect. Then narrowing down the view to the bad part.

Ask: Ask basic questions. For example:

• What was the Machine Trying to Do?

• What Was the Machine Trying to Do Next?

• Was the machine working before?

• Did it happen on first power up or during process?

Narrow: Narrow or determine the sequence and subsystem where the issue occurs. For example:

• Did the issue happen when door was being fed in?

• Is the router not cutting?

• Is the cut out of specification?

Note: See Table 5-1 on page 5 for sequence and subsystem information.

Verify: Verify or analyze the subsystem assembly that is responsible for the issue. For example:

• How is the subsystem supposed to work?

• What is keeping the subsystem from working?

Note: See“Analyze the Sub Systems” on page 5-5 for information on verifying and

analyzing subsystems.

Before you Adjust

Sometimes simple problems can seem to be complex issues. Before making adjustments, check for the following common issues.

1. Is the loaded setup correct for the current cut?

2. Are the stops set up correctly?

3. When did the problem first start?

• At first Start-Up?

• During the Run?

4. When was the last calibration?

5. Is the door true?

6. Use Router Bit Depth Gauge (PN: 432C) to check depth of Bits

7. Check tools for wear.

KVAL Handler Operation/Service Manual

5-4

Before you Adjust

Determine What:

What Subsystem is Responsible for the Failed Sequence Step.

Analyze the subsystem:

Check the Load. Check the Position Feed Back. Check the Positioning System

See “Analyze the Sub Systems” on

page 5-5

TABLE 5-1. Typical KVAL Machine Sequence

Typical Machine Sequence Responsible Subsystem

1. Move Door into Position Feed System

2. Clamp the Door Door Clamp

3. Make the Cuts Cutter Positioning Cutter Power

4. Unclamp the Door Door Clamp

5. Move Door Out Feed System

6. W ait for Next Door Feed System

Basic Troubleshooting Steps

Determine Where:

The Sequence Step Where the Failure Occurs

What was the Machine Trying to Do? What Was the Machine Trying to Do Next?

Check the Sequences in the Table Below.

How is the Broken Section Suppose to Work?

What is Keeping the Broken Section From Working?

What Part of the Machine is not Working?

Check the Subsystems in the Table Below.

Ask

Narrow

Verify

Troubleshooting Basics

Analyze the Sub Systems

1. Check the Load for mechanical issues

• Is the Load “bound up?

• Is there sufficient lubrication?

• Is it an alignment issue?

• Is anything damaged?

2. Check the Position Feed Back.

KVAL Handler Operation/Service Manual

5-5

Troubleshooting Basics

• Does the Position Feed Back agree with the Load position?

In other words are the correct photo eyes, limit switches or ferrous sensors acti-

vated?

Check the controller inputs to insure the proper sensors are activated. If the control-

ler is a PLC, an activated input is lit. Some touch screens have inputs status also.

3. Common Position Feedback failures:

• Photo Eye:

• Limit Switch: Stuck, or failure

• Wiring: Broken, worn insulation

• PLC: Bad input port

• Bad Output: Relay may be stuck

• Air Solenoid Valve: May be stuck or not working.

4. Check the Positioning System

a) Bad element or bad cable b) Eyes not set to correct height c) Lighting from ceiling may be interfering with sensor

Follow the circuit from the Controller output to the Load and check for component failures.

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5-6

About a Typical Contactor Control

High Voltage may cause personnel injury or death. Troubleshooting checks must be performed by a Qualified Electrical Technician.

PLC

Output

Fuse(s)

Line

Vol ta g e

(Power)

Contactor

Control

(Coil) Input

Power

Input

Power Output

Control Circuit

Common

ON

Should measure

Control Voltage

120 VAC here

Should measure

Line Voltage here

Should measure Line Voltage here

Line Voltage here

Should measure

Relay

120 VAC

DC -

Should measure

24 VDC here

Control Voltage

Motor

ON

Thermal

OverLoad

RESET

#2

Pre 2006 Machines do not have this Relay. Measure 120 VAC at the Control Coil

Schematic Drawing of Contactor and Thermal Overload

Note: Pre-2006

machines may not contain the 24 Volt relay. 120 Vac is directly fed into the Control Coil. Check the input circuitry to the Control Coil for 120 Vac.

About a Typical Contactor Control

Unlike general-purpose relays, contactors are designed to be directly connected to high-current load devices. Contactors are designed to control and suppress the arc produced when interrupting heavy motor currents.The figure below shows a block diagram of a typical contactor circuit with typical voltages.Thermal overload relays are commonly attached to the contactor. They offer protection for motors in the event of overload or phase failure. A Reset button is included to clear an error in the relay.

KVAL Handler Operation/Service Manual

FIGURE 5- 12. Block Diagram of a Common Contactor Circuit

5-7

Contactor

Thermal Overload

About a Typical Contactor Control

FIGURE 5- 13. Contactor Bank

About Contactor Troubleshooting

The Thermal Overload Circuit opens the motor circuit when current draw causes the motor to run too hot. The overload limits are set at the factory, do not adjust the limits.

The overloads are normally in series, therefore if one trips, all on that circuit stop working. Use the Six Light panel as a trigger to check the circuit. See “Troubleshooting with the Status

Light Panel” on page 5-21 .

1. Open the Main Electrical Cabinet to find the Contactor /Thermal Overload Assem-

bly

2. Press each ‘Green” Reset button on the Thermal Overload. An audible click will be

heard on the tripped circuit. (Take note of tripped circuit.)

3. Once the overloads are reset, verify LED’s are on.

4. Rerun the machine and verify that motor runs without tripping the circuit.

5. If the same overload keeps tripping, verify condition.

6. 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

5-8

About Typical VFD Motor Drive Control

High Voltage may cause personnel injury or death. Troubleshooting checks must be performed by a Qualified Electrical Technician.

Common Motor Drive Control:

PLC

Output

Fuse(s)

Line

Voltage

Motor

(Power)

Motor

Power

Input

Output

Power

Control Circuit

Common

ON

Measure

Control Voltage

-24 VDC here

Measure

Line Voltage here

Measure

Line Voltage here

ON

Drive

STF (Forward)

RL

STR (Revers 2)

SD (COMMON)

OFF

Run

300

Run Light

should be ON

Displays the

Motor Frequency

15 to 300 Mhz

Schematic Drawing of VFD

Note: The output to

motor “C” contains pulse signals at varying frequencies.

A DMM may not be able to measure the frequency and the pulse rate.

Use the VFD interface to check, current, voltage and frequency.

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 accurately drive motors for machining or moving product through the machine. The figure below shows a block diagram of a typical motor drive circuit.

FIGURE 5- 14. Block Diagram of a Common Drive Control

KVAL Handler Operation/Service Manual

5-9

About Typical VFD Motor Drive Control

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.

Line Voltage IN

Converted Signal OUT to Motor

Operation Panel: Access to manual operation VFD. This panel can be used for troubleshooting purposes. Fault Errors will be displayed if any occur.

During normal operation the

Run LED is lit or flickers and

the frequency of the motor is displayed.

Control Circuit Board: Contains connections to PLC and other control circuits.

Includes:

• Control input signals

• Speed Functions

• Relay Outputs

• Jumpers

• Output to reset switch

About the VFD

A VFD (Variable Frequency Drive) takes the raw input from the 3 phase line voltage and converts it by varying the frequency and voltage of the input voltage. Changes in the output voltage varies speed and force of the motor. For example: A lower frequency will result in a slower speed.

The VFD converts the voltage but is “told what to do” by the PLC (Programical Logic Controller). The output voltage is then sent to the motor . For a block diagram, see Figure 5- 14 on page 5-

9

.

FIGURE 5- 15. Sample of VFD

KVAL Handler Operation/Service Manual

5-10

About VFD Troubleshooting

VFD Reset

Buttons

This section describes some troubleshooting tools for the VFDs.

Error Checking on the Variable Frequency Drives

VFDs (Variable Frequency Drives) interact with hinge and faceplate routers, width adjust motors, and feed motors. If issues occur, error codes are displayed on the VFDs. To help troubleshoot, refer to the VFD manuals located in the High Frequency Panel for lists of the error codes.

Using the Reset Buttons

In some rare occasions an electrical spike may cause a VFD to shut down. The reset buttons are located on the door of the VFD panels. The button contains the VFD function printed on the button. If a VFD is tripped to “OFF” the button will be lit. To reset a VFD:

1. Push lighted button to reset the indicated motor

b.If the button light turns off, continue with production. c.If the button stays lit:

• identify the motor by way of the label on the button.

About Typical VFD Motor Drive Control

• turn off that function at the switch panel. Check the corresponding output on the PLC output. If the output is on it will not let the motor reset. Disconnect the output wire and verify that the motor circuit is not causing the issue.

d.If issue continues, read error code on the VFD* display and look up the error

code in the VFD manual. Follow the instructions in the VFD manual. If issues continue, contact our Service Center.

FIGURE 5- 16. VFD Reset Buttons

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

About a Typical Pneumatic Circuit

PLC

Output

High

Pressure

Air

Cylinder

Common

Control Circuit

ON

Measure

24 VDC here

Control Voltage

Should have High

Pressure air here

Cylinder

Control

(Coil)

Input

Air

Input

Air

Output

Val ve

Should have High

Pressure air on Activated Output

Schematic Drawing of Pneumatic Circuit

Note: Pre-2006

machines may not contain the 24 Volt relay. 120 Vac is directly fed into the Control Coil. Check the input circuitry to the Control Coil for 120 Vac.

Note: In this sample set-up, Port A is normally open and Port B is normally closed. If power is OFF, air should be on Port B.

About a Typical Pneumatic Circuit

A control valve (solenoid) is used to drive cylinders to move different loads in the machine. The solenoid if controlled by the PLC by applying a high voltage or a low voltage to a control coil. Controls for example are: extending and retracting router, drill, clamping a door.

KVAL Handler Operation/Service Manual

FIGURE 5- 17. Block Diagram of a Pneumatic Circuit

5-12

About a Typical Pneumatic Circuit

Air Input

Cylinder Retract

Cylinder Extend

Electrical Wiring Box:

Contains inputs from PLC to Coils (Solenoids)

Manifold: Base to accept air input and output air.

Coil (Solenoid): Receives input(24V) from PLC to open a port

Solenoid type will vary with machine application. Common controls include an operational LED and Manual operation button

Manual Activate Button: Push to toggle solenoid to the ‘ON’ state. activates if power is off.

Indicator: a Lit LED indicates the solenoid is in use.Red LED= the ‘A’ Port on a single valve. If double valve, Red LED= the ‘A’ Port and Green LED = the ‘B’ port.

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.

FIGURE 5- 18. Typical Pneumatic Assembly

About the Coil (Solenoid)

The Solenoids are connected to the top of the manifold. Labels indicating their function and PLC connections are attached to the solenoid body. Use this information to troubleshoot system if necessary.

FIGURE 5- 19. Solenoids in Manifold

KVAL Handler Operation/Service Manual

5-13

About a Typical Pneumatic Circuit

Retract Motion

Extend Motion

Air

1. PLC drives Control Valve.

2. Valve delivers compressed

air to the cylinder.

3. Cylinder piston rod is

extended when air is delivered to port “A”

4.

Cylinder piston rod is

retracted when air is delivered to port “B”

About Cylinder Operation

To see a block diagram of general pneumatic connections, see Figure 5- 17 on page 5-12. The figure below, shows a cross-section of a cylinder in action.

FIGURE 5- 20. Cross-section of Air Cylinder

How the Pneumatic System Works

The Pneumatic system consists of a brain (PLC), an action (Positioning System), and a result (Moving the Load). For a generalized representative, this section describes the process to move a router to the extend and the retract position with a double valve.

Extend Process

If PLC determines the conditions are right to extend the Router:

1. The PLC applies the control voltage to the Control Valve which directs com-

pressed air to extend port of the Cylinder.

2. The Cylinder and Router are extended deactivating the Retract Sensor

The Router fully extends activating the Extend Sensor.

3.

KVAL Handler Operation/Service Manual

5-14

About a Typical Pneumatic Circuit

Positioning

System

Load

Force

Translated Positioning

PLC

Instructions

Position Feedback

Extend Sensor:

Retracted Sensor:

Deactivated

Activated

24 Volts

Extended

Cylinder

24 V Applied

Router Assembly (Load)

Position Feed Back

Air In

Control Valve

Extend Sensor Activated

Air Pressure Extends Cylinder and Router Assembly

EXTENDED

4. The PLC senses the voltage from the Extend Sensor and removes the control voltage

to the Control Valve.

Retract Process

If the PLC determines the conditions are right to retract the Router:

1. The Control Valve directs compressed air to the retract port of the Cylinder.

The Cylinder and Router retract deactivating the Extend Sensor

2.

When the Cylinder and Router are fully retracted, the Retract Sensor is activated.

3.

4. The PLC senses the voltage from the Retract Sensor completing the process

KVAL Handler Operation/Service Manual

5-15

Cylinder

0 V

Router Assembly (Load)

Position Feed Back

Air In

Control Valve

Retract Sensor Activated

Air Pressure Retracts Cylinder and Router Assembly

RETRACTED

Positioning

System

Load

Force

Translated

Positioning

PLC

Instructions

Position Feedback

Extended Sensor:

Retracted Sensor:

Activated

Deactivated

0 Volts

Retracted

About a Typical Pneumatic Circuit

Important Notice about Adjusting Cylinder Speed

Do not adjust the cylinders to speed up production. The air cylinder timing is part of a well tuned system of electronics, programming, and mechanics. Adjustment of the cylinders for speed can cause unsatisfactory results, in-feed and out-feed problems, far marks in the corners of hinge pockets, and flipping screws in Hoppers.

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

Adjusting Cylinder Extend Speed

:

Adjusting Cylinder Retraction Speed

About a Typical Pneumatic Circuit

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

Using Sensors to Trouble Shoot

• Photo Sensors often get dirty. Make sure they are clean. If they are not clean, d ebris may block the signal or provide a false signal.

• Check output voltages of the sensors in the active mode. The voltage should effectively equal 0 VDC

• 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. T y pically 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

Troubleshooting Electrical Problems

Refer to Air and Electrical Schematics provided with delivery of the machine. Schematics are located in the Electrical Panel. If copies are unavailable, contact the KVAL Service Department. Have model number and serial number of machine readily available.

NOTE:

The following checks require the electrical panel to be energized. These troubleshooting checks must be performed by a Qualified Electrical Technician.

Troubleshooting Electrical Problems

The electrical component systems are designed to expedite the troubleshooting process and minimize “down time”. In general, component systems have the input or feed functions at the top. Output or load functions are positioned at the bottom. Most two-voltage electrical panels are designed with the LOW VOLTAGES on the LEFT, and the HIGH VOLTAGES on the RIGHT. The majority of the system components are labeled with numbers that correspond with the electrical prints included in the electrical box door.

Computer controlled machines have signals on the computer that light up when the input or output functions are energized, respectively. Computer controlled as well as non-computer controlled machines have white 120V control power terminal strips. This will indicate power supply from the respective circuits.

PLC controllers also have lights on them for the input and output functions. You can easily find out which circuits are failing by watching the lights turn on or off. Compare the lights on the IDEC or Beckhoff controllers to the electrical print to determine what systems are being affected.

If the Power Stops During Normal Operation

1. Check that the input power disconnect switch is not turned off.

2. Check that all of the emergency stop buttons are in the normal position.

3. Check the Six Lights on the Electrical Panel. See “Troubleshooting with the Status

Light Panel” on page 5-21.

Lockout and Tagout the main power source.

1. Turn the panel disconnect switch in the off position, open the electrical panel door.

2. Observe the disconnect switches. Look for loose or broken wires at the disconnect

then at all of the components.

3. Check for continuity of all fuses with an OHM meter. (Fuses need to be removed

from the bottom side of the fuse holder before measuring the fuses)

KVAL Handler Operation/Service Manual

5-19

4. W ith the power of f, check for motor overloads by pressing each reset button (usu-

ally at the bottom of the panel) in SEQUENCE. If one is tripped there will be a slight resistance to touch and a “click” sound as it is reset.

Trip Indicator

Press Reset

Thermal Overload Relay

Test

Troubleshooting Electrical Problems

Check for Tripped Circuits

1. Remove lock and tag outs on the main power sources.

2. Manually close disconnect sensors and energize the control circuit or transformer

with its respective sensor. Check the Status Light Panel,. If all lights are observed, there are no overloads or emergency stops tripped.

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

Troubleshooting with the Status Light Panel

The sequence that the lights turn on are as follows:

1. Control Power (Amber)

2. Overload Relay (Amber)

3. E-Stop (Amber)

4. Stop (Amber)

5. Start (Amber)

6. 24VDC (Green)

Troubleshooting with the Status Light Panel

The Status Light Panel is located on the Electrical Panel. All six lights are illuminated when the system is in proper working order. The lights turn on in a sequence and will stop at the point where a fault is first detected.

If one or more lights are OFF, follow the process below to isolate the cause.



NOTE: Be sure to proceed down the table, starting with the CONTROL POWER light.

STEP 1:Control Power (Amber). If light is OFF go to item A on page 5-22. STEP 2:Overload Relay (Amber) If light is OFF go to item B on page 5-23. STEP 3:E-Stop (Amber) If light is OFF go to item C on page 5-23. STEP 4: Stop (Amber) If light is OFF go to item D on page 5-23. STEP 5: Start (Amber) If light is OFF go to item E on page 5-24. STEP 6: 24VDC (Green light is OFF go to item F on page 5-24.

KVAL Handler Operation/Service Manual

5-21

1. Check if the Control Transformer button is pulled

out.

4. Is there 120 VAC between #1 & #2 on the 120 VAC Terminal Strip? If not, check

the fuse on the output side of the Control Transformer . If fuse is good, check power coming out of Control Transformer.

5. If no power on the output side, and there is power going into the top of the Control

Transformer, replace the Control Transformer.

6. If there is power at the Control Transformer, check the wiring of the black and

white wire going from the Control Transformer to the 120 VAC Terminal Strip.

7. If there is no power between #1 and #2, check the secondary side of the trans-

former.

a.Check between 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.

2. Is the Disconnect Switch on the main electrical cabinet set to

ON?

Switch

3. Is there 208, 220, 440, or 575 VAC to the top side (input) of the Control Trans-

former? If not, check the fuses at the Fuse Block, and the contacts on the Control Transformer button on the switch panel.

Input

High Vac

Output

120 Vac

Typical Control Transformer

Control Power Light OFF

Troubleshooting with the Status Light Panel

KVAL Handler Operation/Service Manual

5-22

1. Check Motor Overload Circuits

2. W ith power on, check the trip indicator LED on the

overload. If indicator is orange, press the Reset Button to reset the overload circuit. Retest the Machine.

Overload Relay Light OFF

Contactors

Overload

Relays

Reset Button. Factory set on the ''H''

Setting.

Test or Stop

Trip Indicator

Factory Set Current

Rating Adjust

E-Stop Light OFF

Check if any E-Stop buttons are pulled out.



NOTE: Location and quantity of E-Stop buttons varies

depending on customer need. Typical locations for EStop buttons are near the Rear Access Gate and near the Tool Changer Access Gate

Stop Light OFF

Check for 120 VAC between #2 and #4 If there is voltage, press the 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.

Troubleshooting with the Status Light Panel

KVAL Handler Operation/Service Manual

5-23

Start Light OFF

If the Start light remains unlit, push in the Start button and hold it in while a second person checks for voltage between #2 and #5. If there is 120 VAC, replace the ACR relay. If there is no voltage while the button is held in, check the wiring or the contact on the Start button.

First isolate the power supply . Check between DC+ and DC- for 24VDC. If no DC voltage, disconnect the output (V+) wire from the 24VDC power supply and check for DC voltage where those wires were disconnected.

If no voltage: Check the input side for 120 VAC. If no 120 VAC, check the fuse. If there is 120

VAC and no 24VDC, replace the 24VDC Power Supply.

If there is 24VDC:

Reconnect the (V+) wire to the 24VDC power supply. Trace the output wire to the DC terminal block. Disconnect all (+ 24V positive) wires from the + DC from the DC terminal block

except the + output wire from the + 24VDC power supply. 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.

Input 120 VAC

Output 24 VDC

24VDC Light OFF

Troubleshooting with the Status Light Panel

KVAL Handler Operation/Service Manual

5-24

Notes:

Index

A

air input system

description4-7 lubricator4-7

air line lubricator

adjusting4-8 priming4-8

air line lubricator, maintenance schedule4-5

B

ball screw, maintenance schedule4-5 Beckhoff® CPU module3-2

C

control panel light

not on? troubleshoot5-22 control power indicator light description2-10 control transformer switch

power up2-5, 2-13, 2-14

D

dura-lith grease, bearing lube4-5

E

electrical panels

description2-9 emergency shutdown

description2-14 e-stop light

description2-10 Ethernet module

connection to servo amplifiers3-2

F

flange block bearing, maintenance schedule4-5

G

gear box, maintenance schedule4-5

K

KVAL, getting help1-13

L

linear bearing, maintenance schedule4-5 lockout and tagout Guidelines1-11 lockout procedure1-9

M

main electrical panel

description2-9

main screen

interface2-16

menu map2-15

O

overload relay light description2-10

P

pillow block bearing, maintenance schedule4-5 power

lock out procedure1-9

power up

troubleshooting5-19 product return procedure1-13 programmable logic controller,PLC3-2

Q

quick start 2-12

R

remote operation, setting up machine for1-15 return material authorization (RMA)1-13 returning the product to Kval1-13

S

safety guidelines1-4 Safety Sign Off Sheet

Safety Concerns1-18 sensors

troubleshooing5-18

types2-8

voltage levels2-8 service center, contacting information1-13 six light panel

description2-10

sequence list2-10 start light

description5-24 start light description2-10 start machine button

power up2-5, 2-13 status light panel

description5-21

use as troubleshooting key5-21 stop light description2-10

KVAL Handler Operation / Service Manual 1-1

T

tagout procedure1-9 troubleshooting

using status lights5-21

U

USB module3-2 user interface screens

menu map2-15

Z

zerk fittings4-6

locations4-6

zero-energy start-up

clean up1-11 inspect1-11

1-2 KVAL Handler Operation / Service Manual

Notes:

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http://www.kvalinc.com

Contacting KVAL

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) 762-7367

or fax (707) 762-0485 Email: service@kvalinc.com

http://www.kvalinc.com

Customer Service

Mailing address: Customer Support Department Kval Incorporated 825 Petaluma Boulevard South Petaluma, CA 94952

Kval Handler Operation And Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

CHAPTER 1 Introduction to the Handler

Chapter 1 at a Glance

Overview of the Handler

Handler as a Feeder

Available Options

Safety First!

Safety Sheet Sign-Off Sheet

Safety Terminology of Labels

Safety Guidelines

Laser Warnings

Other Hazard Control Action

Follow Your Company’s Safety Procedures

Lockout-Tagout Guidelines

Follow the P-R-O-P-E-R lockout rule of thumb.

Lockout Tagout Procedure

Pre-Steps Before Lockout Tagout

Lockout Tagout Power

Lockout Tagout Air Supply

Start Maintenance

Post Maintenance Steps

Zero-Energy to Start-Up

Start-up Guidelines

Inspect

Clean Up

Replace Guards

Check Controls

Remove Locks

Perform Visual Checks

Close the Cage Gate

Getting Help from KVAL

On-Line Help

Product Return Procedure

Note: Non-Warranty returns are subject to a 15% restocking charge.

How to Download the Service Application

Download Application

Safety Sign-Off Sheet

A Note to the Operator

Personnel Safety Concerns:

Machine Safety Concerns:

CHAPTER 2 Operation of the Handler

Chapter 2 at a Glance

Operator’s Tour

Handler Top View

Identification of Assemblies on Handler

About the Up and Down Motor

Operators Station

Control at Door Staging Area

About the Safety Curtain

About Switches and Sensors

About the Electrical Panels

Description of the Six Light Panel

Process to Pick up and Feed a Door

About Option H

Quick Start Feeder

Powering the Handler

How to Power Up the Handler

How to Power Down the Handler

Emergency Shutdown and Recovery

To Resume Normal Operation after an E-Stop

Pause (Disable and Hold Button)

Description of User Interface Screens

Screen Selection Menu Map as a Feeder or Stacker

Main Menu

Machine Data Setup

Run Menu

About the Maintenance Screens

About the Status Screens

About the Manual Screen (Jog)

CHAPTER 3 System IT Administration

Chapter 3 at a Glance

About the PLC

CHAPTER 4 Maintenance of Handler

Chapter 4 at a Glance

Maintenance Schedule

Maintenance NO-GOES

Lubrication Schedule