Kval 700-C User manual

Innovation, Quality & Honesty

Service Manual

Published: October 18, 2023

700-C Frame Assembly Machine

700-C Service Manual

KVAL 700-CService 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 Service Manual

Manual Revision: 46-CS1-MV101.1, 46-CS1-MV100.2

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: [email protected]

KVAL 700-CService Manual

Technical Support

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

Us” page.

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

email: [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-CService Manual

Access Manuals and Videos Easily

You can easily access a range of resources including downloadable PDF manuals, Quick Start

guides, Maintenance Summaries, links to instructional videos, and Electro-Mechanical Maps. To

access these valuable materials, simply follow these steps:

1. Visit https://kvalinc.com/machine-support or scan the QR code provided in this sec-

tion.

2. Hover your cursor over the Support option located at the top bar of the website.

3. From the drop-down menu that appears, select Machine Support.

Once you've reached the Machine Support page:

1. Enter either the machine model name or the machine serial number.

2. This will take you to the document page related to your specific machine.

3. From there, you can easily select and download the desired files and resources.

This streamlined process ensures you have quick and convenient access to the information you

need for your machine

.

FIGURE 1-1. Machine Support Page

QR Code

https://kvalinc.com/machine-support

Table of Contents

Introduction and Safety...Chapter 1

About the 700-C ........................................................................................1-1

Table Options ..............................................................................................1-1

About this Manual ....................................................................................1-3

Service Manual ...........................................................................................1-3

Quick Start ...................................................................................................1-3

Safety First! .................................................................................................1-4

Safety Sheet Sign-Off Sheet ....................................................................1-4

Safety Terminology of Labels ...................................................................1-4

Safety Guidelines .....................................................................................1-5

Training ........................................................................................................1-5

Protective Gear ...........................................................................................1-5

When the Machine is Powered and Running ........................................1-5

Lockout/Tagout Guidelines ...................................................................1-6

Follow the P-R-O-P-E-R lockout rule of thumb. ....................................1-6

Lockout/Tagout Procedure ...................................................................1-7

Before Lockout/Tagout: Inspect the Machines ......................................1-7

Lockout/Tagout Power ...............................................................................1-7

Lockout/Tagout Air Supply ........................................................................1-8

Start Maintenance ......................................................................................1-8

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

Zero-Energy to Start-Up ........................................................................1-10

Inspect ........................................................................................................1-10

Clean Up ....................................................................................................1-10

Replace Guards ........................................................................................1-10

Check Controls .........................................................................................1-10

Remove Locks ..........................................................................................1-10

Perform Visual Checks ............................................................................1-10

Close the Cage Gate ...............................................................................1-11

Getting Help from Kval ...........................................................................1-12

Kval Return and Warranty Policy .......................................................1-13

Send the Item ............................................................................................1-13

Acceptance of Return ..............................................................................1-13

Refund Turnaround Time ........................................................................1-13

Kval Errors .................................................................................................1-13

Customer Errors .......................................................................................1-14

Shipper Errors ...........................................................................................1-14

Warranty Replacement Parts .................................................................1-14

Safety Sign-Off Sheet .............................................................................1-16

Table of Contents

A Note to the Operator ..........................................................................1-16

Maintenance of the 700-C...Chapter 2

Maintenance Schedule ..........................................................................2-1

Lubrication Schedule ..............................................................................2-3

Kval Lubrication Kit ....................................................................................2-4

About Bearings ..........................................................................................2-5

About Pillow Block Bearing Housings .............................................2-6

About Flange Bearing Housings ..............................................................2-6

About Ball Rail Bearings .......................................................................2-7

Machine Lubrication Map ......................................................................2-8

Greasing Staple Gun Carriage Bearings .......................................2-9

Recommended Tools .................................................................................2-9

Staple Carriage Greasing Procedure ......................................................2-9

Staple Carriage Grease Point Locations ................................................2-9

Greasing the Movable Fence Bearings ..........................................2-11

Recommended Tools ...............................................................................2-11

Movable Fence Greasing Procedure ....................................................2-11

Movable Fence Grease Point Locations ..............................................2-11

Greasing the Rack and Pinion Bearings ........................................2-13

Recommended Tools ...............................................................................2-13

Rack and Pinion Greasing Procedure ..................................................2-13

Rack and Pinion Grease Point Locations .............................................2-13

Description of Air Input System ..........................................................2-15

Air Input with Lubrication ........................................................................2-15

Adjusting the Air Line Lubricator ...........................................................2-15

Priming the Air Line Lubricator ...............................................................2-16

Air Line Without Lubricator .....................................................................2-16

Troubleshooting the 700-C...Chapter 3

Get Live Technical Help .........................................................................3-1

About a Typical Pneumatic Circuit ....................................................3-2

Typical Pneumatic Assembly ....................................................................3-3

About the Coil (Solenoid) ..........................................................................3-3

About Cylinder Operation ..........................................................................3-4

How the Pneumatic System Works ..................................................3-5

Important Notice about Adjusting Cylinder Speed ................................3-7

Table of Contents

Adjusting Cylinder Extend Speed ............................................................3-7

Adjusting Cylinder Retraction Speed ......................................................3-7

Pneumatic Assembly Locations .........................................................3-8

Description of the Light Tower ...........................................................3-9

Bottom Light (Control Power) ..............................................................3-10

Bottom Light Conditions ..........................................................................3-10

If the Bottom Light is OFF .......................................................................3-10

If the Bottom Light is ON .........................................................................3-10

Top Light (Machine Status) ..................................................................3-11

Top Light Conditions ................................................................................3-11

If the Top Light is OFF .............................................................................3-11

If the Top Light Flashing White ...............................................................3-11

If the Machine Status Light is Red .........................................................3-12

If the Machine Status Light is Yellow .....................................................3-13

If the Machine Status Light is Blue ........................................................3-13

If the Machine Top is Solid Green ..........................................................3-13

About the Three Light Panel ................................................................3-14

Control Power Light .................................................................................3-14

Start Light ..................................................................................................3-15

About Switches and Sensors ..............................................................3-16

Using Sensors to Trouble Shoot ............................................................3-17

1-2

Door Transfer System Service Manual

CHAPTER 1 Introduction and Safety

This chapter provides an overview of the Kval Door Transport System (DTS) and important safety

information to follow when operating the machine.

Chapter 1 at a Glance

Section Name Summary Page

Overview of the DTS

System

This section provides an overview of the DTS This

section includes a general description and a table

of available options.

page 1-1

Safety! IMPORTANT safety information is described in this

section.

page 1-5

Zero-Energy to Start-

Up

Procedure to power up your machine for the first

time.

page 1-10

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, service center hours, and

return procedures.

page 1-12

Safety Sign-Off Sheet A record to track operators that are trained on the

machine.

page 1-16

About the 700-C

1-1

About the 700-C

The Kval 700-C Frame Assembly Machine is generally used in-line with the Commander 3 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. Two-Hand control Palm Buttons activate the clamping

sequence and vertically move staple guns into position to attach the jambs to the header. Activat-

ing staple gun "fire" sequence is initiated with one palm button and the "fire guns" push-button on

the control panel on machine. The door is then raised and rolled out of the machine to the next sta-

tion 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. Spot Nail Staple guns, with 7/16” crown staples are supplied with machine

as standard.

Table Options

Each table or conveyor is assigned an option.

TABLE 1-1. 700-C Options

Option Table Description

B: Reverse Feed Direction Normal direction is left to right. For right to left, add this

option.

54X: 5/4 Spacers for Thick Jambs Spacers for frame width adjust bars to accommodate

both 11/16" thick jambs and 5/4" thick jambs.

D: 7’0” and 8’.0” Door Frame Allows operator to quickly adjust end clamps from 6'8" to

7'0" or 8'0" doors. Quick changeover time of approxi-

mately one minute required.

G: 7’0” Door Frame Allows operator to quickly adjust end clamps from 6'8" to

7'0" doors. Quick changeover time of approximately one

minute required.

I: Leg Extensions For variable height applications. Customer to specify

height.

J: End Clamp Spacers For use on 6’6” doors. Jamb spacer blocks connect to

the end clamp pads. Four spacers required.

N: End Clamp Spacers For use on 6’6” doors. Jamb spacer blocks connect to

the end clamp pads. Four spacers required.

N: Narrow Jamb Via removable spacer blocks and increased cylinder

stroke, operator is able to reduce minimum jamb width

from 4-1/4" to 3-1/2".

About the 700-C

1-2

A: Duplex Edge Nailers Not recommended for MDF jambs. This option includes

and utilizes two(2) Stanley Bostich F28WW Round Head

Framing Nailer's (nails 2" to 3 1/2" in length) with remote

fire valves

SG1: Custom Staple Gun Mounts Customer requests to utilize their own staple guns and

remote fires which differ from the outlined standard engi-

neered models in Option SG. Note: Not all staple guns

can be applied to the 700-C machine.

SGS4: Stanley Bostitch Staple

Guns-1/2” Crown

Replaces the standard staple guns with four(4) Stanely

Bostitch SB650S4 (1/2" crown) staple guns and remote

fires necessary to fasten wood jambs, headers, and sills

on 700 series framing machines.

SGS5: Stanley Bostitch Staple

Guns-7/16” Crown

Replaces the standard staple guns with four(4) Stanely

Bostitch SB650S5 (7/16" crown) staple guns and remote

fires necessary to fasten wood jambs, headers, and sills

on 700 series framing machines.

SGMAX: MAX Staple Gun-7/16”

Crown

Replaces the standard staple guns with four(4) MAX TA

551B/16 (7/16" crown) staple guns and remote fires nec-

essary to fasten wood jambs, headers, and sills on 700

series framing machines.

TABLE 1-1. 700-C Options

Option Table Description

About this Manual

1-3

Auto Cross Transfer System Operation and Service Manual

About this Manual

This manual is part of a package delivered with the machine line.

Note: Manuals and Quick Starts are available on line to download. Videos are avail-

able to view. See “Access Manuals and Videos Easily” at the beginning of this

manual.Operation Manual

Service Manual

This Manual.

Quick Start

A one page laminated sheet to aid in operating the machine.

Chapter Title Description

1Introduction Descriptions of Machine Line and Safety Information.

2Operation Descriptions of how to power machine line, and operator

user screens.

3Tour Descriptions of the Table Options of the 700-C.

Chapter Title Description

1Introduction Descriptions of Machine Line and Safety Information.

2Maintenance Descriptions of Calibration Routines and how to use the

interfaces

3Troubleshooting Common troubleshooting Tips.

700-C QUICK START

Power-Down

Power-UP

Verify Area is safe, power and air are applied,

E-Stops are out and Fence Gates are closed.

1. At the Electrical Box, turn the Electrical Dis-

connect to the ON position.

2. Turn the Control Circuit Switch to the ON

position.

(Approximately 3 minute boot-up)

3. Push the Stat buton.

All the 3 lights should be illuminated. See re-

verse side for the 3-Light Description.

1. Push the Stop buton.

2. Turn the Control Circuit Switch to the OFF

position.

3. Turn the Electrical Disconnect to the OFF

position on the Electrical Cabinet.

Note: Some of these setings are options and may not be

located on your machine.

• Ensure the proper guns are enabled and staples are

loaded.

• Adjust the machine for the desired Door Width.

• Adjust the machine for Door Lenth.

• Adjust the machine for Jamb Width.

• Adjust the machine for Jamb Thickness.

Mechanical Setup

Before processing the door, set-up the following mechani-

cal adjustments.

Note: See the back of this Quick Stat for information on

these setings.

Main Panel Controls

Stage the door for framing.

1. Inset the Header Jamb

ĻIdentiy the hand of the door. (See back

for hand location.)

ĻPatially pull the door into the 700-C.

ĻPlace the header jamb into Head Jamb

Clamp.

2. Inset the Strike Jamb

ĻPlace strike jamb into the machine and

pull the door in all the way in.

ĻMake sure the strike jamb aligns to the

header.

ĻFlip the hinge jamb down.

ĻRoughly align the hinge jamb to the

header jamb.

Power Controls

Reset.

• Brings 700- C to stating position

Turn On or OFF Staple Guns

Select Jamb Type (Reg or Split)

Select the Staple Syle Se-

quence.

• Select A = 0-3.

• Select B= 4-7.

• Sequence REV and FWD.

• Rev= Step back Clear Hands

Control.

• FWD = Go foward from Rev Step.

Width Butons:

• Select Jamb Width-Butons.

• Select Door Width-Black buton

control. Manually move fence to

door width position.

Stage the Door

Frame the Door

1. Bring in the Movable Heads and Header Clamps

ĻPress both Hands Free Butons simultaneously.

ĻThe movable side staple guns and strike jamb clamps

move close to the door.

ĻThe header and swing clamps extend.

ĻStaple guns and clamps are raised into position.

2. Drop Down the Door to Align

ĻPress both Hands Free Butons simultaneously.

ĻThe infeed wheels lower to align the door to the header

and strike jambs.

3. Bring in the Fixed Heads

ĻPress both Hands Free Butons simultaneously.

ĻFixed side staple guns move in.

4. Raise the Door and Frame into Stapling Position

ĻPress both Hands Free Butons simultaneously.

ĻOufeed wheels raise the door into position.

ĻBotom jamb clamps rise, pushing the frame up from the

botom.

ĻEnd jamb clamps move in.

ĻEnsure that door, header jamb, strike jamb are clamped

square.

5. Fire Staple Guns

ĻPress the let Hands Free Buton and the green Fire But-

ton simultaneously.

ĻOufeed wheels move down and the swing clamps

retract.

ĻStaple guns ire to the programmed patern.

ĻStaple guns will ire when dropping

5a. Fire Nail Guns (Option)

ĻPress the right Hands Free Buton and the Yellow Fire

Buton simultaneously.

ĻNail guns ire.

Note: The Nail Guns are an option and are not installed on all

700-C machines.

6. Unclamp the Door

ĻPress both Hands Free Butons simultaneously.

ĻAll guns move away from the door.

ĻAll clamps retract.

ĻOufeed wheels move up.

ĻManually move the door out of the 700-C.

7. Reset 700-C

ĻPress both Hands Free Butons simultaneously.

ĻLast step before pulling in another door or shuting down

the machine.

Note: Pressing the Reset Buton on the Main Control Panel is

an alternate way to reset the 700-C.

Ater the door is pulled in and the hinge and strike jambs

are aligned, use the Hands Free controls to staple the

frame to the door.

If a step needs to be reversed, move the Main Control

panel Sequence switch to REV. Press the Hands Clear but-

tons to go back a step. Ater the issue is resolved, set the

Sequence switch to back to FWD and continue process-

ing the door.

Hands Free

Green Fire Button

Yellow Fire Button

Hands Free

Align

Staple Guns Fired

1: Headers/Movable Fence In Close

Nail Guns Fired

5a: Fire the Nail Guns

7: Reset the 700-C

5: Fire the Staple Guns

6: Unclamp the Door and Frame

4:Raise the Door and Frame

3: Bring in the Fixed Head Side

2: Align the Door

Hands Free (X2)

Download Manuals and Access Videos

htps://kvalinc.com/machine-suppot

At the web page, enter the 700-C serial

number in the search box. Access to the

manuals and videos will be available.

Hands Free (X2)

Safety First!

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 1-16.

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.

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.

Safety Guidelines

1-5

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.

Note: Different versions of the stickers may have been applied to the machine. The

intent of safety is the same.

Training

Ensure that all employees who operate this machine are aware of and adhere to all safety precau-

tions posted on the machine and are trained to operate this machine in a safe manner. Figure 1-1

below shows a sample of safety labels addressing training.

FIGURE 1-1. Read the Manual Labels

Protective Gear

Never operate the machine without proper eye and ear protection. Figure 1-2 below shows a sam-

ple of safety labels addressing safety gear.

FIGURE 1-2. protective Gear Labels

When the Machine is Powered and Running

Serious injury or death could occur if these general rules are not followed.

•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.

Lockout/Tagout Guidelines

1-6

Lockout/Tagout Guidelines

Follow these Lockout/Tagout guidelines,

• Place a tag on all padlocks. On the tag, each operator must put their own name and

date. (These locks are only to be removed by the person who signs the tag)

• 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

1-7

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/

Before Lockout/Tagout: Inspect the Machines

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 shut-

down.

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).

Lockout/Tagout Procedure

1-8

b.Disconnect style Electrical Panels: push the red tab to pop it out. Place a pad-

lock through the hole. Place your tag on the padlock, as per the tagout guide-

lines below. (see illustration below).

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.

Insert Lock into hole.

Turn Switch to the

OFF position Lock and Tag out

Lockout/Tagout Procedure

1-9

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.

Zero-Energy to Start-Up

1-10

Zero-Energy to Start-Up

Starting the equipment properly is just as important as the Lockout/Tagout guidelines in terms of

safety.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 Technical Support. See “Getting Help from Kval” on page 1-12.

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 com-

pany’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.

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-O-P-E-R Lockout/Tagout proce-

dures, and that those around you do also.

Zero-Energy to Start-Up

1-11

Close the Cage Gate

Verify all cage gates are securely closed. Ensure all safety protocols are in effect.

Page is loading ...

Kval 700-C User manual

Kval 700-C User manual

Related papers