Kval 777 Quick Start

Brand
Kval
Model
777
Type
Quick Start
777 QUICK START
2. Ensure factory air is applied to all
machines.
3. Verify that all E-Stop buttons are
OUT and Gates are CLOSED.
4. Turn the Electrical Disconnect to the ON
positions on each Electrical Cabinet in
the production line.
1. Verify the area of operation is clear
and safe to process doors
5. Turn the Control Circuit Switch to the
ON position. (Approximately 3 minute
boot-up)
6. Initiate the Start Button.
7. All Six Light Indicators Should be ON
See reverse side for 6 Lights Description
Power-UP
777 Quick Stat rev 1
Quick Start
2-7
KVAL 777 Operation/Service Manual
Quick Start
Ensure factory air is present at the
machine and the main air supply valve is
turned on.
Make sure Hoppers are loaded.
Confirm all mechanical presets.
Attach the Hinges, knuckles side
up, to each Hinge Applicator
Turn ON Drills.
Turn ON Screw Drop.
Turn ON Screw Drivers.
Reverse Screw Drivers OFF.
Adjust the width of the door.
Set Door Length (Stops must
be moved when switching
between door lengths).
Quick Start
2-7
KVAL 777 Operation/Service Manual
Quick Start
Ensure factory air is present at the
machine and the main air supply valve is
turned on.
Make sure Hoppers are loaded.
Confirm all mechanical presets.
Attach the Hinges, knuckles side
up, to each Hinge Applicator
Turn ON Drills.
Turn ON Screw Drop.
Turn ON Screw Drivers.
Reverse Screw Drivers OFF.
Adjust the width of the door.
Set Door Length (Stops must
be moved when switching
between door lengths).
1. Load both doors parallel to each other.
2. Push the doors all the way to the back stop,
slightly tugging the door back to create a gap
between the doors.
Note: If not satisfied with
the alignment, press the
Unclamp Button on the
machine control panel.
Reset the alignment. Press
Unclamp Button again to
clamp.
Push the Hinges Loaded Button, the Hinge
Applicator will turn 180° and place he hinges over
the gap of the doors.
Push the Start Sequence Buttons,
at the same time.
• The Heads lower and attach
the hinges to the door.
• The door will unclamp auto-
matically and feed the door
out.
• Repeat process for next door
Quick Start
KVAL 777 Operation/Service Manual
2-8
Push the Hinges
Loaded Button,
the Hinge
Applicator will
turn 180° and
place he hinges
over the gap of
the doors.
Push the Start Sequence Buttons,
at the same time.
• The Heads lower and attach
the hinges to the door.
• The door will unclamp auto-
matically and feed the door
out.
• Repeat process for next door
Quick Start
KVAL 777 Operation/Service Manual
2-8
Push the Start Sequence Buttons,
at the same time.
• The Heads lower and attach
the hinges to the door.
• The door will unclamp auto-
matically and feed the door
out.
• Repeat process for next door
Quick Start
KVAL 777 Operation/Service Manual
2-8
Start Summary
Stat
This light turn on when
the Machine Stat buton is
pressed and the ACR Relay is
latched.
Stop
This light will be on if
Machine Stop buton is deac-
tivated.
.
E-Stop
If the light is NOT on,
ensure gates are closed and all
E-Stops are not activated
24VDC
Light turns on once the
ACR is latched and the 24VDC
Power Supply is working.
Powers the PLC.
Tips
Light NOT ON Steps to Ty
Control Power Check Main Power to the machine
Ensure the Control Circuit Buton is ON
Tech: (Lock/Tagout) Ensure the Disconnect Switch in the Panels is ON
Tech: (Lock/Tagout) Check Control Transformer
Over Load Relay Tech: (Lock/Tagout) Check Overload Relays on Contactors
E-Stop Ensure ALL E-Stops are in the OUT position.
Ensure ALL Safey Gates are closed and Light Cutain feedback is error free.
Tech:(Lock/Tagout) Check resistance of E-Stop circuit
Stop Ensure Stop Buton is not stuck
Tech: (Lock/Tagout) Check resistance of Stop circuit
Stat Ensure Stat Buton is making connection
Tech: (Lock/Tagout) Check ACR Circuit
24VDC Tech: (Lock/Tagout) Check voltage into and out of the 24VDC power supply
About the 6-Lights
Control Power
The overload circuit is working when
light is on.
verload Relay
High Voltage may cause injury or death.
Troubleshooting checks must be performed
by a Qualied Electrical Technician.
For Technicians: Get detailed troubleshooting information on the 6 Lights. (See a video ,Download a PDF)
Video (6-LightsTroubleshooting): htps://www.kvalinc.com/videos/training
PDF (6-Lights Troubleshooting): htps://www.kvalinc.com/machine-suppot
Adjust for the Length of a Door
2-13
KVAL 777 Operation/Service Manual
Adjust for the Length of a Door
There are some mechanical adjustments to match the length of an 8’.0” or 6’.8” door’
• Adjust both Door Stops
• Adjust all 4 Drill Assemblies
• Automatic Adjustment of Heads
8’.0” to 6’.8” Door Adjust:
Slide Drill Assembly to desired
door length Stop
Stop
FIGURE 2- 5. Length Assemblies to Adjust
Adjust for the Length of a Door
KVAL 777 Operation/Service Manual
2-14
Adjust Drills for Door Length
Adjust all the drills by sliding the assembly to per-determined collars.
1. Lockout Tagout Machine.
2. Remove the cover. (10-32 bolts X4)
3. Locate the adjusting bolt
at the base of the drill
assembly.
4. With a 1/2” wrench, loosen the bolt. (Do not
remove)
5. Slide the assembly to the desired collar.
6. Re-tighten the bolt
7. Repeat for other three drills.
8. Reattach the cover.
9. Reverse Lockout Tagout.
10. Process doors.
Note: Adjust All 4 Drills.
Note: In this sample, we are moving to the 8’0” door
position. Reverse steps to return to 6’ 8” posi-
tion.
6’ 8” Reference8’ 0” Reference
Loosen Bolt
Slide to Reference Collar
Remove Covers
Reattach Covers
Note: In this sample we are moving to the 8 foot door
position. Reverse steps to return to 6’ 8” posi-
tion.
Adjust for the Length of a Door
2-15
KVAL 777 Operation/Service Manual
Adjust the Stops to Different Door Length
Adjust all the stops by unbolting the stop assemblies and moving to the marked locations.
1. Lockout Tagout Machine.
2. For the Right Hand Stop, unbolt the 4 bolts and
move to the
marked location.
3. For the Left Hand Stop, unbolt the 2 bolts and
move to the marked location
4. Secure all bolts.
5. Reverse Lockout Tagout
6. Process doors
See photos below for the
stop locations.
Right Hand Stop, align the
rear edge of the plate to the
mark
Left Hand Stop, align the front
edge of the plate to the mark
6’8” Location
6’8” Location
8’0”Location
8’0” Location
Adjusting Drill Assemblies Adjusting Stops
Adjusting Machine for Door Length
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Kval 777 Quick Start

Brand
Kval
Model
777
Type
Quick Start
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