Kval 700-C System Reference Manual

Innovation, Quality & Honesty

700-C System
Reference

Published: 3/8/18

Proprietary Notice

This document contains confidential and trade secret information, which is proprietary to Kval, Inc.
(“Kval”), and is protected by laws pertaining to such materials. This document, the information in this
document, and all rights thereto are the sole and exclusive property of Kval, are intended for use by cus­tomers and employees of Kval, and are not to be copied, used, or disclosed to anyone, in whole or in
part, without the express written permission of Kval. For authorization to copy this information, please
call Kval Customer Support at [phone] or fax [phone]. Outside the U.S. and Canada, call
[phone].

Copyright 2015 Kval Incorporated. All rights reserved.

KVAL 2012 and 700-C are trademarks of Kval, Incorporated.
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

Customer Service: For further information about this manual or other Kval Incorporated products,
contact the Customer Support department

• http://www.kvalinc.com/customer_service.html (lists all the representatives, including email
addresses and phone numbers)

• 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: 4:00 AM to 4:30 PM Pacific Standard Time, Monday through Friday
Parts & Service Sales: 6:30 AM to 4:30 PM Pacific Standard Time, Monday through Friday
(Other sales related inquiries: http://www.kvalinc.com/contact_us.html)

• Email: [e-mail]

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 [e-mail]. (NOTE: This is not a way to get customer sup­port. For that, please refer to the Customer Service contact information above.) Thank you!

700-C a

b 700-C

Proprietary Notice ..................................................................................... .................... a

Contacting KVAL ....................................................................................... .................... a

CHAPTER 1

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

Safety First!.........................................................................................................3

Lock Out Procedure.................................................................................. .................... 4

Lockout and Tagout Guidelines................................................................. .................... 5

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

Zero-Energy Start-Up..........................................................................................6

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

Initial Set up ........................................................................................................9

Electrical Connections Overview...................... ... .... ... ... ... .... ... ... ... ... .... ... ........... ... .... ... 11

CHAPTER 2

.............................................................Operation of the 700-C 2-13

Machine Tour.......................................................................................................15

Quick Start...........................................................................................................17

Turning the 700-C On and Off.............................................................................21

Powering Up the 700-C.............................. ... ... ... .... ... ... .......................... ....... .... ... ... ... 21

Powering Down the 700-C...................................................................... .................... 21

Control Panel ......................................................................................................22

Main Control Panel.................................................................................. .................... 22

Remote Control Panel (Optional)............................................................ .................... 23

Width Adjust........................................... ....................................... ... .... ... .................... 24

Length Adjust (Option D).................. ... ... .... ... ... ... .................................... .................... 26

Touch Screen Interface.......................................................................................27

CHAPTER 3 ..............................................................................Maintenance 3-29

Maintenance Schedule........................................................................................30

Lubrication Schedule..........................................................................................31

Lubrication Requirements....................................................................... .................... 31

Grease Points ......................................................................................... .................... 33

CHAPTER 4

..................................................................Theory of Operation 4-37

I/O for Normal Operation .....................................................................................38

Clamps and Rollers (Feed System)...................................................................40

Tandem Cylinders .................................. .... ... ... ... .... ... ... ... .... ... ................ .............. ... ... 41

Wheel Assist Cylinder............................................................................. .................... 42

Operation ................................................................................................ .................... 42

Staple Guns.........................................................................................................43

Staple Gun Horizontal Positing ............................................................... .................... 44

CHAPTER 5

........................................................................ Troubleshooting 5-49

Troubleshooting the Air Cylinders.......................................................................50

KVAL 700-C Operation/Service Manual

Adjusting Cylinder Extension Speed:...................................................... .................... 51

Adjusting Cylinder Retraction Speed: ..................................................... .................... 51

Troubleshooting Electrical Problems...................................................................52

If the Power Stops During Normal Operation......................................... .................... 52

Troubleshooting with the Status Light Panel........................................... .................... 53

Troubleshooting Photo Detectors........................................................................57

Touch Screen Troubleshooting ...........................................................................59

Getting Help from Kval........................................................................................69

Product Return Procedure ...................................................................... .................... 69

Part Locations.....................................................................................................71

Control Panel .......................................................................................... .................... 77

700-C

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 moun ted 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.

700-C 1

Introduction

2 700-C

Safety First!

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.

Still has power

in OFF position

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 seri­ous 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

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

Cage

Compressed Air .

safety precautions posted on the machine and are trained to operate thi s ma chine in a
safe manner.

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.

Electrical 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. All maintenance and
repairs to electrical circuitry should only be performed by a
qualified electrician.

Before Conducting
Maintenance

Compliance with
Codes and Regula­tions

700-C 3

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.

KVAL Inc. 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.

Other Hazard Control

When multiple people are
working on the machine, each
person needs to have a lock on
the handle in the extra holes
provided.

Action

Lock Out 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 the 700-C while it is powered down. During a locko ut,

disconnect all power and shut off the air supply. Be sure to use the tag-out guidelines noted below.

To lock out the 700-C

1. Assess 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. Disconnect power.

NOTE:Always lock out electrical disconnects on both electrical cabinets

a. Turn the disconnect switches on the main electrical panel to the OFF position. Then pull out

the red tab and place a padlock through the hole. Place your tag on the padlock, as per the tag­out guidelines below. (see picture below).

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 matte r to our attention for review and correction,
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.

b. Turn the disconnect switch on the lar ger high-frequency panel to the OFF position. Then pull

out the red tab and place a padlock through the hole. Place your tag on the padlock, as per the
tag-out guidelines below

4 700-C

Safety First!

5. Turn the main air valve to the OFF position and place a

padlock through the hole (see illustration).
NOTE: Place your tag on the padlock, as per the tag-out
guidelines below.

6. Insure the machine will not operate.

7. When maintenance or repairs are completed, the person

who performed the work must ensure all tools, spare parts,
test equipment, etc., are completely removed and that all
guards and safety devices are installed.

8. Before removing the locks and tags, the person who

attached them shall inspect the equipment to ensure that
the machine will not be put into an unsafe condition when
re-energized.

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

be re-energized.

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

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

700-C 5

Zero-Energy Start-Up

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 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, 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 person­nel 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 additi onal
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 out­side help is used must also comply with the lock-out/tag-out procedures. Comprehensive lock-out/tag-

6 700-C

Zero-Energy Start-Up

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

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.

YOUR LIFE MAY DEPEND ON IT.

700-C 7

8 700-C

Initial Set up

Initial Set up

Y our 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.

700-C 9

Trubolt Wedge Anchor

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

INSTALLATION INSTRUCTIONS

10 700-C

Initial Set up

The main electrical power is connected to the disconnect,
located in the large electrical panel.

The 700-C requires 110 Volt AC. Typically this voltage is
pulled from the previous machine. Refer to the plant lay­out diagram from more information.

Neutral Hot Ground

110Volt AC

Electrical Connections Overview

700-C 11

12 700-C

CHAPTER 2 Operation of the 700-C

700-C 13

Operation of the 700-C

14 700-C

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

Machine Tour

700-C 15

16 700-C

Quick Start

CONTROL CIRCUIT

OFF ON

STAPLE SEQUENCE

0

1

2

3

4

5

6

7

RESET 700-C

JAMB TYPE

REG. SPLIT

ENABLE FIXED

SIDE GUNS

OFF ON

ENABLE MOVABLE

SIDE GUNS

OFF ON

FIRE GUNS

JAMB WIDTH JAMB WIDTH

WIDTH ADJUST

PUSH
CLAMP

PULL

RELEASE

FIRE SIDE NAILER

Door Length

6’ 8”

8’ 0”

SELECT

LOCAL REMOTE

2. Select the Jamb Type. See “Main Control

Panel” on page 22.

3. Select Door Length (Optional). See “Main Con-

trol Panel” on page 22.

4. Select the Local or Remote control box

(Optional). See “Main Control Panel” on
page 22.

5. Select a Jamb Width. See “Control Panel” on

page 22.

6. Select a Staple Sequence. See “Control Panel” on

page 22.

Left hand door

Header location

Right hand door

Header location

Header Location

Left or Right Hand

10. Insert Strike Jamb and insure head and strike jamb corners meet

Quick Start

Set the door width and length before starting the process. See “Width Adjust” on page 24. See “Length Adjust

(Option D)” on page 26.

1. Power up the 700-C. See “Powering Up the 700-C” on page 21.

7. Insure the proper staple guns are enabled and staples are loaded. See “Control Panel” on page 22.

8. Adjust the machine for the desired door width. See “Width Adjust” on page 24.

9. Insert the jambs

.

700-C 17

11. Pull in the door.

12. Swing the hinge jamb down.

13. Use the Foot Pedal to control the process. First Activate the Foot Pedal (Option).

14. Each press of the Sequence Forward operates the machine in a predetermined process. Press the

Sequence Reverse switch to go back 1 step to fix errors or recheck setup. Press the Sequence
Forward

to continue to where you left off.

• Push the

Sequence Forward foot switch (brings in movable

side staplers).

• Push the

Sequence Forward foot switch again (drops door to

lower position).

• Ensure the hinge jamb is in the correct position in relation to
the head jamb.

• Push the

Sequence Forward foot switch a third time (brings in the fixed side staple guns).

• Push the

Sequence Forward foot switch a fourth time (clamps the door).

NOTE:

Some 700-C machines have dual switches that must be activated to use the

Foot Pedals. The

switches are located next to the

Control Panel. If these switches are not installed bypass these

instructions and go to step 14

Press both switches to activate the Foot Pedal. Both switches must me
maintained to operate the Foot Pedal. If one or both switches are not

pressed, the foot pedal will not operate.

If a hand is taken of the switch during process, there is a 2 second delay
before the process can be resumed.

With both switches maintained, go to step 14 to continue using the Foot
Pedal

Dual Switches

18 700-C

Quick Start

15. For 700-C machines that have dual switches, simultane-

ously hold the switch located next to the

Control Panel

and Press Fire Guns

Note: If a hand is taken of the switch during process, there is

a 2 second delay before the process can be resumed.

If these switches are not installed, bypass these instructions
and go to step 16

FIRE GUNS

16. Press Fire Guns (See “Control Panel” on page 22.)

Fire Side Nailer

17. For 700-C machines that have dual switches,

simultaneously hold the switch located next to
the

Control Panel and Fire Side Nailer

Note: If a hand is taken of the switch during pro-

cess, there is a 2 second delay before the process
can be resumed.

If these switches are not installed, bypass these
instructions and go to step 18

18. Press Fire Side Nailer (Optional) (See “Control Panel” on page 22.)

RESET

21. Press Reset. (Returns machine to start position) (See “Control Panel” on page 22.)

Firing Staple Guns and Nailer

19. Push the Sequence Forward foot switch (un-clamps door).

20. Outfeed door.

700-C 19

20 700-C

Turning the 700-C On and Off

POWER

RELAY

E-STOP

STOP

START

Turning the 700-C On and Off

Use the procedures below for powering up and powering down the 700-C.

Powering Up the 700-C

Powering up the system includes:

• Applying power to the entire system

• Starting the Control Circuit

To Power Up the 700-c

1. Make sure the electrical disconnect the electrical cabinet is turned to the ON position.

2. Turn the CONTROL TRANSFORMER switch located on the main control panel to the ON position.

It should light up.

3. All lights on the status light panel on the electrical box should be illuminated.

CONTROL

OVERLOAD

24VDC

Powering Down the 700-C

Powering down the system includes:

• Shutting down the control power

• Removing power from the entire system

To Power Down the 700-C

1. Turn the CONTROL TRANSFORMER switch to the OFF position. This kills power to the machine.

All status lights should be off.

2. Kval 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.

700-C 21