Kval 700-C Operation And Service Manual

Innovation, Quality & Honesty

Operation and Service Manual

Published: September 26, 2022

700-C Frame Assembler

With Hand Controls

700-C Operation and Service Manual

KVAL 700-C Operation and Service 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 (800) 553-5825 or

fax (707) 762-0485.

Manual Name: 700-C Operation and Service Manual

Manual Revision: 46-MV100.1

700-C is a trademark of Kval Incorporated.

Beckhoff®, TwinCAT, and EtherCat® are registered trademarks and are licensed by Beckhoff

Automation GmbH

All other products are trademarks or registered trademarks of their respective holders, all rights

reserved. Reference to these products is not intended to imply affiliation with or sponsorship of

Kval Incorporated.

Contacting KVAL

For further information about this manual or other Kval Incorporated products, please contact us.

Mailing address:

Kval Incorporated

825 Petaluma Boulevard South

Petaluma, CA 94952

Phone and Fax:

call: (800) 553-5825

fax: (707) 762-0485

General Office Business Hours

Mon-Thu:6:00 AM - 4:00 PM PST

Fri: 6:00 AM - 3:30 PM PST

Parts

Contact us for all parts related needs, from orders to inquiries. Call, email, contact us on our web-

site at the “Contact Us” page.

email: pa[email protected]

KVAL 700-C Operation and Service Manual

Technical Service Support

For machinery support and troubleshooting. Call, email, contact us on our website at the “Contact

Us” page.

Mon-Fri:4:00 AM - 4:00 PM PST

email: [email protected]

Field Service Support

For any other inquiries or to schedule on-site service. Call, email, contact us on our website at the

“Contact Us” page.

email: [email protected]

Sales Support

For machinery information, specifications, and quotes. Call, email, contact us on our website at

the “Contact Us” page.

email: [email protected]

Kval Website

Learn about Kval, order parts, get information on our array of machines (including new machine

releases), learn about our machine software solutions, download machine documentation, view

videos of our machines in action, contact all the departments.

http://www.kvalinc.com

KVAL 700-C Operation and Service Manual

Table of Contents

700-C Operation and Service Manual

Proprietary Notice.................................................................................1-2

Contacting KVAL...................................................................................1-2

Kval Website.........................................................................................1-3

Proprietary Notice.................................................................................1-a

Contacting KVAL...................................................................................1-a

CHAPTER 1 .................................................................................Introduction 1-1

Safety First!.............................................................................. 1-3

Lockout and Tagout Guidelines ............................................... 1-5

Follow the P-R-O-P-E-R lockout rule of thumb. ...................................1-5

Zero-Energy State to Start-Up to Operating State................... 1-6

Lockout Tagout Procedure....................................................... 1-8

Pre-Steps Before Lockout Tagout.........................................................1-8

Lockout Tagout Power ..........................................................................1-8

Lockout Tagout Air Supply ....................................................................1-9

Start Maintenance.................................................................................1-9

Post Maintenance Steps.......................................................................1-9

Safety Sign-Off Sheet .............................................................. 1-11

A Note to the Operator........................................................................1-11

Initial Set up ............................................................................. 1-13

CHAPTER 2 .................................................................................... Operation 2-1

Machine Tour ........................................................................... 2-3

About the Electrical Box........................................................................2-4

Quick Start ............................................................................... 2-5

Load the Door into the Machine............................................................2-5

Getting the Door Ready to Process......................................................2-6

Summary of Hand Control Presses......................................2-7

Firing Staple Guns and Nailer..............................................2-7

End Process.........................................................................2-7

Turning the 700-C On and Off ................................................. 2-9

Powering Up the 700-C ........................................................................2-9

Powering Down the 700-C....................................................................2-9

Main Control Panel .................................................................. 2-10

Width Adjust............................................................................. 2-11

Length Adjust (Option D) ......................................................... 2-13

About the Touch Screen Interface ........................................... 2-15

700-C Operation and Service Manual

Table of Contents

Screen Paths ......................................................................................2-15

About the Main Screen .......................................................................2-16

About the Programming Screen .........................................................2-16

How to Set Staple Location ................................................................2-17

Staple Example...................................................................................2-17

About the Diagnostic Screen ..............................................................2-18

About the Manual Screen ...................................................................2-18

CHAPTER 3 ................................................................................Maintenance 3-1

Maintenance Schedule ............................................................ 3-2

Lubrication Schedule .............................................................. 3-3

Typical Lucubration Kit..........................................................................3-3

Lubrication Requirements........................................................ 3-4

Pillow Block Bearing Housings .............................................................3-4

Flange Bearing Housings .....................................................................3-5

Ball Rail Bearing ...................................................................................3-5

Grease Points.......................................................................................3-7

CHAPTER 4 ....................................................................Theory of Operation 4-1

Clamps and Rollers (Feed System)........................................ 4-2

Tandem Cylinders .................................................................................4-3

Wheel Assist Cylinder ...........................................................................4-4

Operation ..............................................................................................4-4

Staple Guns ............................................................................. 4-5

Staple Gun Horizontal Positioning........................................................4-6

CHAPTER 5 .......................................................................... Troubleshooting 5-1

Get Live Technical Help .......................................................... 5-2

Troubleshooting the Air Cylinders............................................ 5-3

Adjusting Cylinder Extension Speed:....................................................5-4

Adjusting Cylinder Retraction Speed: ..................................................5-4

Troubleshooting Electrical Problems ....................................... 5-5

If the Power Stops During Normal Operation ......................................5-5

Troubleshooting with the Status Light Panel ........................................5-6

Trouble shooting Table..........................................................................5-6

Adjusting Limit Switches ......................................................... 5-8

Troubleshooting Photo Detectors ............................................ 5-9

Table of Contents

700-C Operation and Service Manual

CHAPTER 6 ...............................................................Getting Help from Kval 6-1

Getting Help from KVAL........................................................... 6-2

KVAL Return and Warranty Policy ........................................................6-3

Send the Item .......................................................................................6-3

Acceptance of Return ...........................................................................6-3

Refund Turnaround Time ......................................................................6-3

Kval Errors............................................................................................6-3

Customer Errors ...................................................................................6-3

Shipper Errors.......................................................................................6-4

Warranty Replacement Parts................................................................6-4

700-C 1-1

CHAPTER 1 Introduction

The KVAL 700-C Frame Assembly Machine is generally used in-line with the Commander or 990

Series of machines.

The operation includes placing the strike jamb and header into the machine and clamping into place.

The door, with hinge jamb installed, is then moved into position, gently lowered into place, and then

securely clamped into position. A foot pedal activates the staple guns, which move vertically to attach

the jambs to the header. The door is then raised and rolled out of the machine to the next station to the

packaging station.

The 700-C is adjustable for doors from 18" to 4', wide with a standard length capacity of 6'8" or an

optional capacity for 7'0" and 8'0" doors. The 700-C can have up to four staple guns mounted on four

corner brackets. Staple guns are not included.

SPECIFICATIONS

Footprint Size: 10' x 6'

Crated Dimensions: 120"L x 80"W x 53"H

Shipping Weight: 1,200 lbs.

{UL} Electrical panel is built according to Underwriter's Laboratories specifications and the UL label is

applied.

Prices FOB KVAL Plant in Petaluma, CA.

Safety First!

700-C 1-3

Safety First!

The 700-C 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 damage to equipment and/or seri-

ous injury to personnel.

Safety Guidelines

In addition to the caution and warning labels affixed to the 700-C system, follow the guidelines below

to help ensure the safety of equipment and personnel.

Guideline Description

Safety Training 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.

Protective Gear Never operate the machine without proper eye and ear protection.

Entering the Safety Cage When the machine is on:

• Never reach hands beyond safety cage. If the machine has servo

motors can unexpectedly move quickly and out of control.

• Do not clear slugs out of the machine while it is running.

• Never perform any maintenance while machine is running.

• Never clean the machine while it is running.

• Never walk away from the machine while it is running.

Compressed Air The compressed air system connected to this machine should have a three-way air

valve for shut-off and pressure relief. The air supply line providing the pressure to

this machine also has a three-way air valve. All cylinders on the machine are under

high pressure and can be very dangerous when activated. Before performing any

maintenance or repairs on the machine, turn the main air disconnect off. Lock-out

and tag-out this connection.

1-4 700-C

Electrical

Do not open the cabinets without High Voltage training or without permission

from a supervisor.

Electrical circuitry on this machine is protected by an

approved lockable disconnect circuit or a Lever style

power switch. In addition to this equipment, you must

install an approved disconnect for the electrical power sup-

plying this machine.

Disconnect Machines: 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 dis-

connect switch. All maintenance and repairs to electrical

circuitry should only be performed by a qualified electri-

cian.

Lever Style Electrical Panels: Lever style panels have a

lock system that can be unlocked to allow access to electrical

penal that still has power applied. High Voltage may cause

injury or death.

Before Conducting

Maintenance

Prior to performing any maintenance, repairs, cleaning or when clearing jammed

debris, you must disconnect, tag-out and lock-out the electrical and air pressure

systems. This should be done in accordance with the state and/or federal code

requirements.

Compliance with Codes

and Regulations

KVAL Inc. advises that you request an on-site state safety review of your installa-

tion of this machine. This is to ensure conformance to any additional specific

safety and health regulations which apply in your geographic area.

Other Hazard Control

Action

If you believe any part or operation of this machine is in violation of any health or

safety regulation, it is your responsibility to immediately protect your employees

against any such hazard and bring the matter to our attention for review and cor-

rection, if deemed advisable.

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.

Still has power

in OFF position

Lockout and Tagout Guidelines

700-C 1-5

Lockout and Tagout Guidelines

• Place a tag on all padlocks. On the tags, include your

name and date.

• These locks are only to be removed by the person

whose name is on the tag.

• If more than one person is working on the machine,

then each additional person places a lock and tag on

each disconnect.

• You may only remove your own lock and tag.

NOTE: When many people are working on the same

machine, a multiple lockout device is necessary.

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 establish, insure and achieve a zero-energy state

R ...... Re-check controls and test to ensure they are in the “OFF” position

1-6 700-C

Zero-Energy State to Start-Up to Operating State

Starting the equipment properly is just as important as the lock-out/tag-out procedure in terms of safety.

Start-up

• Inspect

• Clean up

• Replace guards

• Check controls

• Remove locks

• Perform visual checks

Inspect

When work is finished, the equipment must be inspected for proper adjustment before starting equip-

ment.

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, leave only that guard off.

Check Controls

Confirm that all switches are in the “OFF” position. In some cases, the machine can start automatically

when energy is restored.

Remove Locks

Each person must remove his or her own lock and tag. This will ensure 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 person-

nel alarm before starting the equipment. If your operation is more complex, having many pieces of

equipment and a lot of people, a comprehensive lock-out/tag-out procedure may involve additional

steps. You will need to ask your supervisor about these procedures. A specific lock-out procedure may

be posted at each machine. On larger or long-term maintenance or installation projects, the procedures

should be explained to all participants and a copy of the procedures should be posted on-site for the

duration of the work. Provisions which ensure protection during shift changes when contractor or out-

side help is used must also comply with the lock-out/tag-out procedures. Comprehensive lock-out/tag-

out may use a gang box or other system to ensure that locks are secure and not removed without autho-

rization.

Zero-Energy State to Start-Up to Operating State

700-C 1-7

Remember, lock-out/tag-out procedures work because you are the only one with the key to your lock.

Proper lock-out/tag-out can save lives, limbs, and money. Help make your work environment safe for

yourself and your fellow workers. Be sure to follow the P-R-OP-E-R lock-out/tag-out procedures, and

that those around you do also.

1-8 700-C

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.

https://www.osha.gov/

Pre-Steps Before Lockout Tagout

1. Evaluate the equipment to fully understand all energy sources (multiple electrical sup-

plies, 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.

Lockout Tagout 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.

4. Turn the Main Power on ALL electrical panels to the OFF position.

a.Lever style Electrical Panels: ensure the lever is in the down position, insert lock and tag

into the lever hole making sure the lever cannot move, lock as per the tagout guidelines. (see

illustration below).

b.Disconnect style Electrical Panels: 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 illus-

tration below).

Lockout Tagout Procedure

700-C 1-9

Lockout Tagout Air Supply

5. Turn all air valves to the OFF position and place a padlock through the hole (see illustration below).

NOTE: Place your tag on the padlock, as per the tagout guidelines.

Start Maintenance

6. Once the locks and tags are in place and all personnel are clear, attempt to operate the machine to

ensure equipment will not operate.

7. Maintenance or repairs may started.

Post Maintenance Steps

8. 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.

9. 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.

10. The lock and tag can now be removed (only by the person(s) who placed them), and the machine can

be re-energized.

11. The tags must be destroyed and the locks and keys returned to the lockout center.

Insert Lock into hole.

Turn Switch to the

OFF position

Lock and Tag out

1-10 700-C

YOUR LIFE MAY DEPEND ON IT.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, I will stop production and

immediately 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 man-

ner 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.

Initial Set up

700-C 1-13

Initial Set up

Your new Kval machine arrives at your plant crated, banded, taped, with painted set collars on all shafts,

keeping all of the precision moving parts secure during shipping.

1. To protect against damaging the machine with the forklift, move the machine as close as possible to

the area where it will be stationed before removing it from the crate

2. Use caution when removing the machine from the crate. Any time the machine is lifted to remove the

skids, there is a chance that the machine could drop suddenly, which could damage the machine or

injure people near the machine.

3. Remove all painted set collars from the shafts. Almost every shaft on the machine has set collars to

secure the moveable assembly mounted to the shafts.

4. Remove any tape securing the various buttons, switches and knobs. Level your Kval machine by put-

ting metal shims underneath the corners of the base. Leave a clear shot from the bolt holes in the foot

pads to your shop floor.

5. Once the machine is level, anchor it to the floor so that it won't move across the floor during opera-

tion. Kval recommends a ½-inch Red Head, Trubolt anchor in each of the foot pads.

Trubolt Wedge Anchor

INSTALLATION INSTRUCTIONS

1.Drill a ½-inch hole, minimum of 6-inch depth. Clean hole.

NOTE: Kval recommends drilling completely through the slab. If in the

future the machine needs to be moved, remove the Red Head nut and

pound the bolt flush with the floor surface.

2.Assemble anchor with nut and washer so that the top of the nut is flush

with the top of the anchor. Drive anchor through material to be fastened so

that nut and washer are flush with surface material.

3.Expand anchor by tightening nut 3 to 5 turns (torque requirement 55 ft.

lbs. for a ½-inch Red Head Trubolt.

700-C 2-1

CHAPTER 2 Operation

Machine Tour

700-C 2-3

Machine Tour

Feed Direction

Infeed

End

Outfeed

End

Movable

Fence

Main

Control

Panel

Fixed

Fence

Right Hand

Movable Side

Gun

Left Hand

Movable Side

Gun

Right Hand

Fixed Side

Gun

Left Hand

Fixed Side

Gun

Touch

Screen

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Kval 700-C Operation And Service Manual

Kval 700-C Operation And Service Manual

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