Kval ON-HD User manual

Innovation, Quality & Honesty
Operation Manual
Published: February 17, 2022
ON-HD Lift
ON-HD Operation Manual

KVAL ON-HD Operation Manual
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 [phone] or fax [phone]. Outside the
U.S. and Canada, call [phone].
Manual Part Number: DOC-207-1-OP
ON-HD is a trademark of Kval Incorporated.
Copyright 2022 Kval Incorporated. All rights reserved.
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Contacting KVAL
Customer Service: For further information about this manual or other Kval Incorpo-
rated 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 [phone] or fax [phone]
Outside the U.S. and Canada, call [phone] or fax [phone]
• Business hours:
Technical Support:
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(Other sales related inquiries: http://www.kvalinc.com)
• Email: [email protected]

KVAL ON-HD Operation Manual
KVAL ON-HD Operation Manual
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KVAL ON-HD Operation Manual

Table of Contents
KVAL ON-HD Lift Manual
Chapter 1 Introduction to the ON-HD Lift
Overview of the ON-HD Lift ..................................................... 1-2
About this Manual.................................................................................1-3
Safety First!.............................................................................. 1-4
Safety Sheet Sign-Off Sheet.................................................................1-4
Safety Terminology of Labels................................................................1-4
Safety Guidelines..................................................................................1-4
Safety First!.............................................................................. 1-6
Safety Sheet Sign-Off Sheet.................................................................1-6
Safety Terminology of Labels................................................................1-6
Safety Guidelines..................................................................................1-6
Lockout-Tagout Guidelines ...................................................... 1-10
Follow the P-R-O-P-E-R lockout rule of thumb...................................1-10
Lockout Tagout Procedure....................................................... 1-11
Pre-Steps Before Lockout Tagout.......................................................1-11
Lockout Tagout Power ........................................................................1-11
Lockout Tagout Air Supply ..................................................................1-12
Start Maintenance...............................................................................1-12
Post Maintenance Steps.....................................................................1-12
Zero-Energy to Start-Up .......................................................... 1-13
Getting Help from Kval............................................................. 1-15
Kval Return and Warranty Policy............................................. 1-16
Send the Item .....................................................................................1-16
Acceptance of Return .........................................................................1-16
Refund Turnaround Time....................................................................1-16
Kval Errors..........................................................................................1-16
Customer Errors .................................................................................1-17
Shipper Errors.....................................................................................1-17
Warranty Replacement Parts..............................................................1-17
How to Download the Service Application ............................... 1-18
Download Application .........................................................................1-18
Safety Sign-Off Sheet .............................................................. 1-21
A Note to the Operator........................................................................1-21
Chapter 2 Operation of the ON-HD Lift
About the ON-HD Lift............................................................... 2-2
Initial Powering Operations for the ON-HD Lift ........................ 2-3

KVAL ON-HD Lift Manual
Table of Contents
How to Power Up the ON-HD Lift .........................................................2-3
Home the Machine Line........................................................................2-4
How to Power Down the Machine.........................................................2-4
About Emergency Shutdown and Recovery.........................................2-5
To Resume Normal Operation after an E-Stop.....................................2-5
Other Safety Controls ...........................................................................2-5
About Controls on ON-HD Lift ................................................. 2-6
ON-HD Lift Main Control.......................................................................2-6
Controls at the Main Panel ...................................................................2-6
Staging Area Controls.............................................................. 2-7
About the ON-HD Lift Process................................................. 2-8
Summary of the Interface ........................................................ 2-9
Machine Control and Calibration Screens ............................................2-9
Universal Controls ................................................................... 2-10
About Machine Status Feedback........................................................2-10
Request Access and Cancel Operation ..............................................2-10
About the Jump, Reset, and Home Buttons .......................................2-11
About the ON-HD Lift Main Screen.......................................... 2-12
About the ON-HD Lift Main Control Screen........................................2-12
About the ON-HD Lift Manual Operation Screen .................... 2-14
About the ON-HD Lift Manual Control Screen....................................2-14
About the ON-HD Lift Calibration Screen ................................ 2-16
The Calibration Screen.......................................................................2-16
Entering Calibration Offsets................................................................2-17
About the ON-HD Lift Diagnostic Screen................................. 2-20
About the ON-HD Lift Manual Control Screen....................................2-20
Description of the Light Tower ................................................ 2-21
About the Safety Curtain.......................................................... 2-22
If the Field is Broken...........................................................................2-22
To Resume Normal Operation after an Field is Broken ......................2-22
Location of Safety Curtain on the ON-HD Lift.....................................2-23
Chapter 3 Tour of the ON-HD Lift
Identification of Key Parts of the ON-HD Lift ........................... 3-2
ON-HD Lift Top View.............................................................................3-2
About the Lift Assembly ........................................................... 3-3
Boom Assembly ....................................................................................3-3
Carriage Assembly................................................................................3-4

Table of Contents
KVAL ON-HD Lift Manual
About the Grabber ................................................................................3-5
About the Feed Table............................................................... 3-6
About Controls on ON-HD Lift ................................................. 3-7
ON-HD Lift Main Control.......................................................................3-7
Staging Area Controls...........................................................................3-9
About the Safety Curtain.......................................................... 3-10
If the Field is Broken...........................................................................3-10
To Resume Normal Operation after an Field is Broken ......................3-10
Location of Safety Curtain on the ON-HD Lift.....................................3-11
About the Electrical Panels...................................................... 3-12
The Light Tower ..................................................................................3-13
About the Nodes.................................................................................3-13
Graphical Sample of Node Connections and Power Distribution .......3-14

KVAL ON-HD Lift Manual
Table of Contents

KVAL ON-HD Operation Manual
1-1
CHAPTER 1 Introduction to the ON-HD Lift
Chapter 1 at a Glance
The following information is available in this chapter:
TABLE 1- 1. Summary of Chapter
Section Name Summary Page
Overview of the ON-HD
Door System
This section provides an overview of the
machine. It includes a general description
and a table of available options
page 1-2
Safety First! IMPORTANT safety information is described
in this section
page 1-6
Lockout-Tagout Guidelines Procedures describing Lockout Tagout. page 1-10
Zero-Energy to Start-Up Procedure to power up your machine for the
first time.
page 1-13
Getting Help from KVAL This section describes the method to contact
the KVAL service center for help. The section
includes how to get information from the
specification plate tor provide to KVAL, ser-
vice center hours, and return procedures
page 1-15
Safety Sign-Off Sheet A record to track operators that are trained
on the machine.
page 1-21

Overview of the ON-HD Lift
KVAL ON-HD Operation Manual
1-2
Overview of the ON-HD Lift
The ON-HD Lift is a vacuum lifting system
that is combined with AC servo motors for
vertical and horizontal movement which
ensures accurate and smooth positioning.
The power conveyor tables feature pop-up
jump belt systems to properly align doors
against edge guides for in-feed and re
stacking.

Overview of the ON-HD Lift
KVAL ON-HD Operation Manual
1-3
About this Manual
This manual is part of a package delivered with the machine line.
Integration Package includes the following:
Operation Manual
Service Manual
Chapter Title Description
1Introduction Descriptions of Machine Line and
Safety Information.
2
Operation
Interface
Descriptions of how to power
machine line, and operator inter-
face user screens.
3Tour A Tour of the machine.
Chapter Title Description
1Introduction Descriptions of Machine Line and
Safety Information.
2IT System Descriptions of the PLC.
4Maintenance Maintenance steps for the
machine line
5Troubleshooting Troubleshooting tips and theory
of operation.

Safety First!
KVAL ON-HD Operation Manual
1-4
Safety First!
Safety Sheet Sign-Off Sheet
At the end of this chapter, there is a safety sign-off sheet. It lists personnel and machine safety cri-
teria to understand before operating the machine. It is highly recommended that personnel operat-
ing, 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 1-21.
Safety Terminology of Labels
In addition to the nameplate, KVAL machines may have other warning labels or decals that pro-
vide safety information to operators. Safety labels should be clearly visible to the operator and
must be replaced if missing, damaged, or illegible.
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.
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!
KVAL ON-HD Operation Manual
1-5

Safety First!
KVAL ON-HD Operation Manual
1-6
Safety First!
Safety Sheet Sign-Off Sheet
At the end of this chapter, there is a safety sign-off sheet. It lists personnel and machine safety cri-
teria to understand before operating the machine. It is highly recommended that personnel operat-
ing, 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 1-21.
Safety Terminology of Labels
In addition to the nameplate, KVAL machines may have other warning labels or decals that pro-
vide safety information to operators. Safety labels should be clearly visible to the operator and
must be replaced if missing, damaged, or illegible.
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.
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!
KVAL ON-HD Operation Manual
1-7
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 mainte-
nance or repairs on this machine turn off the
main air disconnect. Lockout and tagout
this connection.
See “Lockout Tagout Procedure” on
page 1-11.
Compressed Air

Safety First!
KVAL ON-HD Operation Manual
1-8
Electrical circuitry on this
machine is protected by an
approved lockable disconnect
circuit. In addition to this equip-
ment, 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 mainte-
nance, lockout and tagout must be installed at all locations
All maintenance and repairs to electrical circuitry should only be per-
formed 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 ON-HD Operation Manual
1-9
KVAL advises that you request an on-site state
safety review of your installation of this
machine. This is to ensure conformance to any
additional specific safety and health regula-
tions which apply in your geographic area.
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 pro-
duction. 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 proce-
dures to follow.

Lockout-Tagout Guidelines
KVAL ON-HD Operation Manual
1-10
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

Lockout Tagout Procedure
KVAL ON-HD Operation Manual
1-11
Lockout Tagout Procedure
This policy is required by OSHA regulation 1910.147 and Cal OSHA’S
SB198 ruling of July 1991.
Use the following lockout procedure to secure this machine while it is
powered down. During a lockout, you disconnect all power and shut
off the air supply. Be sure to use the tagout guidelines noted below.
Pre-Steps Before Lockout Tagout
Lockout Tagout Power
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.
Turn Switch to the
OFF position
Lock and Tag out

Lockout Tagout Procedure
KVAL ON-HD Operation Manual
1-12
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.
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.