Innovation, Quality & Honesty 700-C System Reference · securely clamped into position. A foot pedal activates the staple guns, which move vertically to attach the jambs to the header

Innovation, Quality & Honesty

700-C System ReferencePublished: 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 cus-tomers 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 (800) 553-5825 or fax (707) 762-0485. Outside the U.S. and Canada, call (707) 762-7367.

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 (800) 553-5825 or fax (707) 762-0485

Outside the U.S. and Canada, call (707) 762-7367 or fax (707) 762-0485

• 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: [email protected]

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 sugges-tions for improvement to [email protected]. (NOTE: This is not a way to get customer sup-port. For that, please refer to the Customer Service contact information above.) Thank you!

700-C a

b 700-C

Proprietary Notice ..................................................................................... .................... aContacting KVAL ....................................................................................... .................... a

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

Safety First! .........................................................................................................3Lock Out Procedure .................................................................................. .................... 4Lockout and Tagout Guidelines................................................................. .................... 5Follow the P-R-O-P-E-R lockout rule of thumb. ....................................... .................... 5

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

Initial Set up ........................................................................................................9Electrical Connections Overview.................................................................................. 11

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

Machine Tour.......................................................................................................15Quick Start...........................................................................................................17Turning the 700-C On and Off.............................................................................21

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

Control Panel ......................................................................................................22Main Control Panel.................................................................................. .................... 22Remote Control Panel (Optional) ............................................................ .................... 23Width Adjust ............................................................................................ .................... 24Length Adjust (Option D)......................................................................... .................... 26

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

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

Maintenance Schedule........................................................................................30 Lubrication Schedule..........................................................................................31

Lubrication Requirements ....................................................................... .................... 31Grease Points ......................................................................................... .................... 33

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

I/O for Normal Operation.....................................................................................38 Clamps and Rollers (Feed System) ...................................................................40

Tandem Cylinders ................................................................................... .................... 41Wheel Assist Cylinder ............................................................................. .................... 42Operation ................................................................................................ .................... 42

Staple Guns.........................................................................................................43Staple Gun Horizontal Positing ............................................................... .................... 44

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

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

KVAL 700-C Operation/Service Manual

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

Troubleshooting Electrical Problems...................................................................52 If the Power Stops During Normal Operation ......................................... .................... 52Troubleshooting with the Status Light Panel ........................................... .................... 53

Troubleshooting Photo Detectors........................................................................57Touch Screen Troubleshooting ...........................................................................59Getting Help from Kval ........................................................................................69

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

700-C 1

Introduction

2 700-C

Safety First!

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 DescriptionSafety 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 .

Electrical 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 electri-cal power supplying this machine.

When opening the cabinet you must first turn off the discon-nect 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

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 sys-tems. This should be done in accordance with the state and/or federal code require-ments.

Compliance with Codes and Regula-tions

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.

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 powerin OFF position

700-C 3

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 lockout, 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 tag-out guidelines below. (see picture below).

b. Turn the disconnect switch on the larger 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

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 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 regard-ing the safe operation of this machine.

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

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 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-

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 autho-rization.

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

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.

700-C 9

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

10 700-C

Initial Set up

Electrical Connections Overview

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 lay-out diagram from more information.

Neutral Hot Ground110Volt AC

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

Machine Tour

Feed Direction

InfeedEnd

OutfeedEnd

MovableFence

Main ControlPanel

FixedFence

Right HandMovable Side

Gun

Left HandMovable Side

Gun

Right HandFixed Side

Gun

Left HandFixed Side

Gun

TouchScreen

700-C 15

16 700-C

Quick Start

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

.

CONTROL CIRCUIT

OFF ON

STAPLE SEQUENCE

0

1

23 4

5

6

7

RESET 700-C

JAMB TYPE

REG. SPLIT

ENABLE FIXEDSIDE GUNS

OFF ON

ENABLE MOVABLESIDE GUNS

OFF ON

FIRE GUNSJAMB WIDTH JAMB WIDTH

WIDTH ADJUST

PUSHCLAMP

PULLRELEASE

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 doorHeader location

Right hand door Header location

Header Location Left or Right Hand

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

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

Firing Staple Guns and Nailer

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

20. Outfeed door.

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 GUNS16. 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.)

700-C 19

20 700-C

Turning the 700-C On and Off

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.

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.

CONTROL POWER

OVERLOAD RELAY

E-STOP

STOP

START

24VDC

700-C 21

Control Panel

Main Control Panel

• Control Circuit: Turns power on and off tho the machine.

• Reset 700-C: Returns the machine to the first sequence of operation.

• Staple Sequence: Selects one of seven user-pro-grammed staple patterns. See “Programming” on page 28. for staple programming instructions

Note: If Staple Sequence 0 is selected no staples will be fired.

• Select (Optional): This switch between the Main and Remote control panels. (See “Remote Control Panel (Optional)” on page 23.)

• Jamb type: Sets the machine up for regular or split jamb.

• Enable Fixed Side Gun: Enables the staple guns on the fixed fence side of the machine.

Note: If the machine has the optional remote control panel, both the main and remote panel Enable Fixed Side Gun switches must be in enable to enable the fixed side staple guns.

• Enable Movable side Guns: Enables the staple guns on the movable fence side of the machine.

Note: If the machine has the optional remote control panel, both the main and remote panel Movable Side Gun switches must be in enable to enable the movable side staple guns.

• Door Length: Sets the machine up for 6’8” door length or a 8’0” length door.

• Jamb Width buttons: These four buttons set the machine up for the jamb width indicated on each but-ton.

Note: Jamb width MUST be select for the machine to function.

• Fire Guns: Fires the enabled staple guns.

Note: Staple guns are enabled by the Enable Fixed Side Guns switch, the Enable Movable Side Guns switch, the LS-14 and LS-15 limit switches (See “Fixed Fence - Inside view” on page 74. for limit switch locations).

• Fire Side Nailer (Optional): Fires the side nailer guns.

• Width Adjust: Pulling this button releases the movable fence to adjust the fence for the disired door width. See “Width Adjust” on page 24. for width adjust information.

CONTROL CIRCUIT

OFF ON

STAPLE SEQUENCE

0

1

23 4

5

6

7

RESET 700-C

JAMB TYPE

REG. SPLIT


OFF ON


OFF ON


WIDTH ADJUST

PUSHCLAMP

FIRE SIDE NAILER

Door Length

6’ 8” 8’ 0”

SELECT

LOCAL REMOTE

PULLRELEASE

22 700-C

Control Panel

Remote Control Panel (Optional)

• Staple Sequence: Selects one of seven user-pro-grammed staple patterns. See “Programming” on page 28. for staple programming instructions

Note: If Staple Sequence 0 is selected no staples will be fired.

• Reset 700-C: R3eturns the machine to the first sequence of operation.

• Enable Fixed Side Gun: Enables the staple guns on the fixed fence side of the machine.

Note: Both the main and remote panel Enable Fixed Side Gun switches must be in enable to enable the fixed side staple guns.

• Enable Movable side Guns: Enables the staple guns on the movable fence side of the machine.

Note: Both the main and remote panel Movable Side Gun switches must be in enable to enable the movable side staple guns.

• Jamb Width buttons: These four buttons set the machine up for the jamb width indicated on each button.

Note: Jamb width MUST be select for the machine to function.

• Fire Guns: Fires the enabled staple guns.

Note: Staple guns are enabled by the Enable Fixed Side Guns switch, the Enable Movable Side Guns switch, the LS-14 and LS-15 limit switches (See “Fixed Fence - Inside view” on page 74. for limit switch locations).

• Width Adjust: Pulling this button releases the movable fence to adjust the fence for the desired door width. See “Width Adjust” on page 24. for width adjust information.

• Fire Side Nailer (Optional): Fires the optional side nailer guns.

STAPLE SEQUENCE

0

1

23 4

5

6

7

RESET 700-C

ENABLE FIXEDGUSIDE GUNS

OFF ON


OFF ON


WIDTH ADJUST

PUSHCLAMP

PULLRELEASE

FIRE SIDE NAILER

700-C 23

Width Adjust

The following describes adjusting the 700-C to accommodate different door widths. The picture below shows the location of the width adjust system components.

To adjust the width of the 700-C:

1. If necessary set the Thick Jamb spacers 1 and 2.

To adjust the Thick Jamb spacers:

a. Use the T-handle to loosen the inner collars for Thick spacer.

b. Slide the outer collar up agents the collar bar bracket for a narrow jamb. Or away from the collar bar bracket to allow for the Thick Jamb spacer.

Thick Jamb spacer positions:

c. Put the Thick Jamb spacer in the disired position.

d. Push the inner collar up agents the collar bar bracket and tighten the T-handle, securing the col-lar bar.

Use the above process for both Thick Jamb spacer 1 and Tick Jamb spacer 2.

CollarBars

“Pickle”Fork locations

Width Adjustbutton

MeasuringTape

Location

Movable Fence

Thick JambSpacer 1

Thick JambSpacer 2

T-Handle

Inner CollarThick JambSpacer

Collar barBracket

Collar BarTravel

Outer Collar

Thick Jamb Thin Jamb

24 700-C

Control Panel

2. Pull up the width adjust button located on the main control panel or the (optional) remote control panel. This will retract the pickle forks freeing the movable fence for positing.

3. Slide the movable fence to the disired location indicated by the measuring tape located on the main frame of the machine. This will retract the pickle forks.

4. Push down the width adjust button. This will cause the pickle forks to extend capturing a collar and locking the position of the movable fence.

Note: The “pickle fork” must capture a collar for proper operation.

The Collar bar

The collar bar has factory positioned collars set for door widths of 18”, 20” 22”, 24”, 26”, 28”, 30”, 32”, 34”, 36”, 42”and 48”. There are two additional collars for user settable positions.

Measuring Tape

Pickle Fork(Shown in the retracted position)

Pickle Fork(Shown in the extended position)

18” 20” 22” 24” 26” 28” 30” 32” 34” 36” 48” Spares42”

700-C 25

Length Adjust (Option D)

The following describes adjusting the 700-C to accommodate different door lengths.

FIGURE 1. Adjustment End Clamps

End Clamp set at 6’8”

Adjustment Pin

7’0” 8’0”

There are 2 adjustment end clamps at each end of the machine. Adjust all 4 end clamps.

To adjust the end clamps for 6’8”, 7’0”, or 8’0” doors, pull the pins and move clamps to the appro-priate length. Secure pin in the adjustment hole. See the figure below.

26 700-C

Touch Screen Interface

Touch Screen Interface

The following is an overview of the touchscreen functions for basic machine operation.

Main Screen

Maintenance

See “Maintenance Screen” on page 59.

Programing screens

See See “Programming” on page 28. (below)

700-C 27

Programming

Programming Buttons

The programming buttons determine where staples will be fired into the jamb. For all pro-grams a staple is fired approximately 1/2” below the top of the jamb in reference to how the jamb is oriented in the 700-C. The programming buttons are used to toggle other staple locations.

For example:

If staples where desired at 1/2”, 2” and 3 1/4”, programming buttons 6 and 11 would be pushed.

• 1/2: A staple is always fired at this location.

• 2”: This location requires button 6 pressed.

• 3 1/4”: This location requires Button 11 pressed.

Note: All programming button locations have a tolerance of +/- 1/4”

ProgramNumber

ProgramingButtons

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

3/4”

1”

1 1/4”

1 1/2”

1 3/4”

2”

2 1/4”

2 1/2”

2 3/4”

3”

3 1/4”

3 1/2”

3 3/4”

4”

4 1/4”

4 1/2”

4 3/4”

5”

5 1/2”

5 1/2”

5 3/4”

6”

6 1/4”

6 1/2”

6 3/4”

7”

7 1/4”

6

11

28 700-C

CHAPTER 3 Maintenance

This chapter describes how to maintain the 700-C system. This chapter contains the following informa-tion:

• Maintenance schedule.......................page 30

• Lubrication requirements...................page 31

700-C 29

Maintenance

Maintenance Schedule

KVAL recommends the following maintenance schedule to ensure that the machine operates properly. Refer to this section for steps to perform maintenance.

Daily Preventive Maintenance

Op Operation Description

Clean Blow off dust from the entire machine.Wipe down the outside of the machine with a clean dry cloth.

Check Check tooling for wear.

Clean Wipe off the photo eyes with a clean dry cloth, and check to ensure that all fastening nuts are snug.

Check Check the air pressure to make sure it is set at 80 psi to100 psi.

Clean Empty any Dust Collection Units.

Check Check for obstructed flow when excessive sawdust appears.

Check Check the air filter water trap. Empty if full.

Weekly Preventive Maintenance


Check Check the machine for smooth motion through a complete door cycle

Clean Clean linear bearings and the chrome shaft with a clean dry cloth, then lubricate.

Check Check all air lines & electrical wiring for kinks or rubbing.

LUBE Refill lubricator with an ISO 32 standard hydraulic oil (KVAL part# SYSLUBG)

Six Month Preventive Maintenance


Clean Wash filter and lubricator bowls with soapy water.

LUBE Grease all bearings and tighten all bolts. Access to some grease fittings is difficult and will require a special needle point grease tip (supplied with your system).

Clean Clean and lubricate all slides and cylinder rods with dry silicone spray.

Tighten Tighten all bolts.

Back-up Backup computer software.

LUBE Lubricate linear bearings and chrome shafts with silicone.

30 700-C

Lubrication Schedule


KVAL recommends the following lubrication schedule to ensure that the machine operates prop-erly.

Lubrication Requirements

This section describes the parts of the machine that require periodic lubrication, and specifies the lubri-cants. In addition, it explains how to maintain the lubrication systems on the machine.

Linear Bearings

If the bearing is equipped with a grease fitting, it should receive 1 Gram (one pump from grease gun) of Dura-Lith Grease (KVAL P/N Lube EP-2) every 30 days. Bearings without grease fittings have been pre-lubricated at the factory and do not require fur-ther lubrication.

Flange Bearing and Pillow Blocks

Use Dura-Lith grease: 1 gram every 60 days.

Approved Lubrication Products for Lubricators

Chevron AW Hydraulic Oil 32 – or KVAL P/N SYSLUBG or G-C lubricants light AW R&O or Mobile DTE 24 or Shell Tellus32 or Gulf Harmony 32.

TABLE 3-1. Recommended Lubrication Schedule

Type of Assembly Recommended Schedule Recommended Lubrication Type

Linear Bearing

Every 250 Hours of Machine Operation Dura-Lith Grease (KVAL P/N Lube EP-2)Pillow Block Bearing

Flange Block Bearing

Ball Screw Every 80 Hours of Machine Operation

Air Line Lubricator One drop of oil every 2 or 3 cycles

Check the lines every week to two weeks

Either lubricant listed below is approved to use.

• KVAL P/N SYSLUBG

• Chevron AW Hydraulic Oil 32

• G-C lubricants light AW R&O

• Mobile DTE 24

• Shell Tellus32

• Gulf Harmony 32

Gear Box 2000 Hours of Machine Operation or six months of operation

• AGMA #8 gear lube

• MOBILUBE HD 80 W-90

• or equivalent

700-C 31

Maintenance

Gear Motor Lubrication Requirements

Oil change is recommended after 2000 hours or six months of operation. Use AGMA #8 gear lube or MOBILUBE HD 80 W-90 or equivalent

Adjusting the Air Line Lubricator (not available on all machines)

Using the knob on the top of the lubricator, adjust until one drop per every other cycle is used (as observed through sight glass.)

Priming the Air Line Lubricator

New and used machinery run out of oil from time to time. It is a good practice to check your machine lubricator to insure that it is putting the proper dose of oil in the air lines. Usually 1 drop of oil every other cycle is a good rule of thumb.

To prime the lubricator, find an air line on the carriage section of the machine that is energized, and dis-connect it, allowing the air stream to bleed air pressure away from any persons. Direct the air stream at the machine so you can see when there is an oily film blowing out of the air hose. Repeat this same pro-cedure for the back section and other trouble areas.

Check the lines every week to two weeks.

NOTE: The Lubricator is not installed on all machines.

(Sight glass). Drop will form at end of cane shaped tube visi-ble inside glass.

(Adjustment knob). When the oiler has run dry, open the knob all the way until flow begins. Once you have a steady flow, tighten knob back down until you have one drop per every other cycle.

Lubricator

Regulator Filter

Set bottom valve to 90 psi

Set top valve to 100psi

Sight Glass. Check rate: 1 drop for ever two door cycles.

Adjustment Knob

32 700-C


Grease Points

Top View

700-C 33

Maintenance

Heads

34 700-C


700-C 35

Maintenance

36 700-C

CHAPTER 4 Theory of Operation

700-C 37

Theory of Operation

I/O for Normal Operation

The following describes the I/O of the 700-C during normal operation:

1. Insert head jamb - No I/O activity.

2. .Insert strike jamb - No I/O activity.

3. Insure head and strike jamb corners meet.

4. Manually pull in door - No I/O activity.

5. Swing hinge jamb down.- No I/O activity.

6. Push Sequence Forward foot switch - PLC input I004.

a. Brings in movable side guns and strike jamb clamps - PLC output Q000

b. Header clamps extend - PLC output Q016.

c. PLC checks header sense switches: to find the header. Input I014 for right hand door (LS-14), input I015 for left hand door (LS-15). See “Fixed Fence - Inside view” on page 74. for limit switch locations.

7. Appropriate staple guns and clamps are raised into position.

• If Right hand door: PLC output Q006.

• If Left hand door: PLC output Q007.


a. Lowers in feed wheels dropping door into proper alignment with head and strike jamb - PLC output Q001

9. Insure hinge jamb overlaps head jamb - No I/O activity.


a. PLC output Q003 goes high which Brings in fixed (hinge) side guns/clamps.

b. PLC output Q17 goes high which the activates the Fixed side in close cylinder.

c. When fixed side guns and clamps move to the proper position limit switch LS-17 activates causing PLC input I017 to go high.


a. PLC output Q005 goes high causing the end clamps to push both the strike and hinge jamb into the header which reference to the corner reference. This should square the jambs and header.

b. PLC output Q010 goes high which raises the outfeed wheels raising the door assemble into stapling position.

c. PLC output Q004 goes high causing the bottom jamb clamps raise, push frame up from the bottom.

d. Fixed side in close cylinder is retracted, extended then retracted again. This tightens, loosens and tightens the fixed side clamps, a process called burping. This burping action aligns and squares the head, strike, and hinge jamb against the reference stops.

12. Insure door, head jamb and strike jamb are clamped square - No I/O activity.

13. Press Fire Guns PLC input Q002 goes high causing the staple guns to fire.

a. For Right Movable gun PLC output Q012 goes high firing the gun.

b. For Left Movable gun PLC output Q013 goes high firing the gun.

c. For Right Fixed gun PLC output Q014 goes high firing the gun.

d. For Left Fixed gun PLC output Q015 goes high firing the gun.

14. Staple guns start to drop (De-energize Raise Left or Right Staple Guns)

38 700-C

I/O for Normal Operation

a. PLC output Q006 goes low causing the Right Staple Guns to drop.

b. PLC output Q007 goes low causing the Left Staple Guns to drop.

15. As the Staple guns drop the through beam is counting slots, when the slot (the slots are ¼” apart) counts equals a preset value a staple is fired (PLC outputs Q012 trough Q015).

16. Press Fire Side nailer (Optional). Air single only - No I/O activity.


a. PLC output Q000 goes low causing Nailers, staple guns and clamps move away from door.

b. PLC output Q016 goes low causing header clamps to release.

4.Right OR Left hand door de-energized

• If Right hand door PLC output Q006 goes low.

• If Left Hand door PLC output Q007 goes low.

6.Press Reset - PLC input I001

a. PLC output Q010 goes high causing the Out feed Wheels to move up causing the door to move to the position for outfeed.

18. .Manually feed door to next process - No I/O activity.

700-C 39

Theory of Operation

Clamps and Rollers (Feed System)

The door transport subsystem provides a mechanism for in and out feed of the door and assists in clamping. There are two sections, one a mirror image of the other. One section is located on the fixed side of the 700-C, the other on the movable side. Each section consists of a set of tandem pneumatic cyl-inders for the main drive, a pneumatic cylinder for wheel assist, a rack and pinion, three levers, three in feed wheels and two out feed wheels. The tandem cylinders are connected to the rack, which turns the pinions, which turns the levers, which change the elevation of the wheels (see illustration below).

Outfeed Wheels (silver)

TandemCylinders

Wheel AssistCylinders

Infeed Wheels(green) Rack

&Pinion

Outfeed Wheels (silver)

Infeed Wheels

Wheel assist

Rack and Pinion

Outfeed Wheels Tandem Cylinders

40 700-C

Clamps and Rollers (Feed System)

Tandem Cylinders

The tandem cylinders consist of two pneumatic cylinders which share a common piston rod (see Illus-tration below). One cylinder has 1.5” travel, the other a 2.5” travel. This arrangement allows for four different stroke lengths of 0”, 1.5”, 2.5” and 4” (see Table 1:). Each cylinder is activated by a dual acti-vation control valve. The dual activating control valves are located in the main valve bank.

Tandem Cylinder Stroke length

* The dual activated control valves are latching. A control voltage pulse of approximately 0.5 seconds to input of the control valve will cause the valve to change state and latch in that state until another con-trol voltage pulse is received.

TABLE 4.

Position VisualStroke Length

1.5” Cylinder

2.5” Cylinder

PLC Outputs*

1 0” Retracted Retracted Q011, Q002

2 1.5” Extended Retracted Q010,Q002

3 2.5” Retracted Extended Q011, Q001

4 4” Extended Extended Q010, Q001

B

A

B

A

PLC output Q011

PLC output Q010

1.5” Cylinder 2.5” CylinderCommon Shaft

PLC output Q002

PLC output Q001

Main Air Supply

Dual ActivatedControl Valves

(Retract)

(Extend)

(Retract)

(Extend)

700-C 41

Theory of Operation

Wheel Assist Cylinder

The wheel assists cylinder's function is to provide extra lift for the out-feed wheels. The wheel assist is a pneumatic cylinder that when activated pushes a bracket mounted on the rack. This cylinder is activated by a control valve located in the main valve bank. The wheels assist control valve is activated by PLC output Q20.

Operation

TABLE 5.

Position Visual DescriptionPLC

Outputs*

1 Both cylinders deactivated Q011 Q002

2 1.5” cylinder activated Q010 Q002

3 2.5” cylinder activated Q011 Q001

4 Both 1.5” and 2.2” cylinders activated

Q010 Q001

5 1.5”, 2.2” plus wheels assist cylinders activated

Q010 Q001 Q020

Wheels assistcylinder

0”

1.5”

2.5”

3.7”

3.7”Extended

42 700-C

Staple Guns

Staple Guns

The staple guns inserts staples into the desired locations in the door frame. There are four staple guns. Two on the fixed side and two on the movable side of the 700-C labeled Right Hand-Movable Side, Left Hand-Movable Side, Right Hand-Fixed Side, Left Hand-Fixed Side (see illustration above). Each staple gun assembly consists of a staple gun, a control valve, an air cylinder coupled to an air over oil cylinder and a through beam with a trigger bar. (see illustration below).

Right HandMovable Side

Left HandMovable Side

Right Hand Left HandFixed SideFixed Side

TriggerBar

ThroughBeam

ControlValve

StapleGun

AirCylinder

Staple GunAir Input

Air over Oilcylinder

Fire Guns

ControlValve

Drop Guns

700-C 43

Theory of Operation

Staple Gun Horizontal Positing

The horizontal staple gun positioning subsystem consists of a two control valves, two oil canisters and four transport cylinders and four oil flow regulators, The two control valves are located in the main valve bank. The two oil canisters are located on the lower frame rail, one at each end of the 700-C. The staple gun transport cylinders and oil flow regulators are located under the four staple gun carriages. Both right hand-movable and right hand-fixed staple guns share a common control valve and oil canis-ter, as do both left hand-movable and left hand-fixed staple guns

Staple Gun Transport Operation

A +24 volt signal from the PLC activates the control valve which pushes compressed air into the top of the oil canister which pushes oil into the lower section of the horizontal cylinder causing the staple gun to raise into the firing position. When the PLC removes the +24 volt signal from the control valve the air in the top of the oil canister is coupled to the exhaust port and compressed air is forced into the upper portion of the transport valve allowing the staple guns to drop. The drop rate is controlled by the oil flow regulator. Each of the two control valves is controlled by a dedicated PLC output as shown in the table above.

Air over OilCanister

ControlValve

“Drop Guns”

Oil FlowRegulators

Oil Line

HorizontalCylinders

To AirExhaust

From MainAir Supply

B A

TABLE 6. PLC Raise Guns Outputs

Location PLC Output

Fixed Fence side Q006

Movable Fence side Q007FromPLC

44 700-C

Staple Guns

Firing the Staple Guns.

Each of the four staple guns is connected to the main air supply through an air Tee. One output of the air Tee is sent to the staple drive input of the staple gun, the other to a control valve. The output of the control valve is connected to the staple gun trigger (see illustration at right). A +24 volt single from the PLC activates the control valve which allows air to flow to the staple gun trigger causing the sta-ple gun to fire. Each of the four staple guns is controlled by a dedicated PLC output.

Through Beam Circuit

The through beam sub-system is an incremental linear optical encoder. Its function is to measure mechanical motion. There is a through beam circuit for each of the four staple gun carriage. Each through beam circuit consists of an emitter, a receiver and a trigger bar all of which are mounted to the staple gun carriages See illus-tration at right.

From MainAir Supply

To other Staple Guns

Control Valve

Input

Output

Staple Gun Trigger

PLC Outputs for firing Staple Guns

Staple Gun PLC Output

Right Hand Movable Q012

Left hand Movable Q013

Right Hand Fixed Q014

Left Hand Fixed Q015

To PLCOutput

AirTee

+24 Volts (Brown wire)

-24 Volts (Blue wire)

Single - To PLC (Black wire)

Through Beam

Trigger Bar

700-C 45

Theory of Operation

Through Beams

The emitter is a visible light source. The receiver is a light sensor. The receiver is aimed at the emitter. When the receiver senses the light from the emitter, the receiver will output a Low (0 Volt). If the emit-ter beam is blocked, the receiver will output a High (+24 volts). See illustration below. Each of the four through beam outputs is connected to a dedicated PLC input.

Trigger Bar

The trigger bar is a plate with 1/8” slots at ¼” increments and is mounted to the main frame. The trigger bar passes between the through beam’s emitter and receiver. As the receiver and emitter move down the trigger bar the light sensor outputs a Low for every slot in the trigger bar. The “Lows” are counted by the PLC. See the illustration at right.

TABLE 7.

Through Beam Output PLC Input

Right Hand Movable I006

Left Hand Movable I006

Right Hand Fixed I010

Left Hand Fixed I011+24 Volts

-24 Volts

+24 Volts

-24 Volts

To PLC input(O Volts)

+24 Volts

-24 Volts

+24 Volts

-24 Volts

To PLC input(+24 Volts)

Beam Sensed Beam Blocked

EmitterAnd Receiver

TriggerBar

46 700-C

Staple Guns

Staple Gun and Through Beam Operation

At the start of the Staple sequence, the staple gun is approximately 1/2” from the top of the jamb. When the Fire Guns button is pressed, the staple gun fires a staple. The staple gun transport cylinder is deacti-vated which causes the staple gun carriage to drop. As it drops the through beam sub-system counts the slots in the trigger bar. Whenever the trigger bar slot count equals a number in the staple pattern, a staple is fired.

Example:

For this example let’s say the selected staple gun pattern contains slot numbers 7 and 12. When the “Fire Guns” button is pressed, the staple gun fires, and this puts a sta-ple approximately 1/2” from the top of the jamb. The Staple gun carriage drops and the computer counts trig-ger bar slots. When the trigger bar slot count reaches 7 a staple is fired. Then when the trigger bar slot count equals 12 the staple gun would fire. The result would be 3 staples in the jamb at 1/2”, 2 1/4” and 3 1/2”. See the illustration at right.

Staple Fired

Slot 1 3/4”

Slot 2 1”

Slot 3 1 1/4”

Slot 4 1 1/2”

Slot 5 1 3/4”

Slot 6 2”

Slot 7 2 1/4”

Slot 8 2 1/2”

Slot 9 2 3/4”

Slot 10 3”

Slot 11 3 1/4”

Slot 12 3 1/2”

Slot 13 3 3/4”

Slot 14 4”

Slot 15 4 1/4”

Slot 16 4 1/2”

Slot 17 4 3/4”

Slot 18 5”

Slot 19 5 1/4”

Slot 20 5 1/2”

Slot 21 5 3/4”

Slot 22 6”

Slot 23 6 1/4”

Slot 24 6 1/2”

Slot 25 6 3/4”

Slot 26 7”

Slot 27 7 1/4”

1/2” Here

Staple FiredHere

Staple FiredHere

700-C 47

Theory of Operation

48 700-C

CHAPTER 5 Troubleshooting

700-C 49

Troubleshooting

Troubleshooting the Air Cylinders

Most cylinders have an extend and retract port. To adjust the extend motion of a cylinder you must adjust the flow control on the retract port; this regulates the air flow exhausting from the cylinder and the opposite is true for the retract motion.

1. Check the air pressure to the machine.

2. Check the flow controls to see that they are adjusted correctly and to the proper specifications.

3. Check for any obstructions to the cylinders such as screws or a mis-placed tool etc. FOLLOW ALL SAFETY GUIDELINES AND SIGNS DURING THIS PROCESS.

4. Check the solenoid air valves:

a. The solenoid valves can be manually operated by pushing the red manual override button on the end of the valve.

b. If the valve seems to be leaking, the seals may be dry or contaminated with water or it maybe that the cylinder “O” rings are damaged and air is passing from one side to the other side of the cylinder which means the air is exhausting through the solenoid valve. It maybe is necessary to purchase a rebuild kit or a new cylinder.

c. If the valve is not receiving an electrical signal, for instructions. It might be necessary to call in a specialist or check with KVAL customer service at 1-800-553-5825.

5. If an Air Leak is coming from an exhaust port on the solenoid air bank:

Manual over-ride button

CAUTION: Once activated, The valve will allow full pressure to cylinder. Make sure you are clear of all moving parts.

50 700-C

Troubleshooting the Air Cylinders

a. Check the solenoid for the manual override. If the solenoid has a manual override you can push each of the buttons one at a time. When the air leak stops or weakens it usually means that one or more of the cylinders that the solenoid is operating are faulty.

Adjusting Cylinder Extension Speed:

Adjusting Cylinder Retraction Speed:

700-C 51

Troubleshooting

Troubleshooting Electrical Problems

The electrical component systems are designed to expedite the troubleshooting process and minimize “down time”. In general, component systems have the input or feed functions at the top. Output or load functions are positioned at the bottom. Most two-voltage electrical panels are designed with the LOW VOLTAGES on the LEFT, and the HIGH VOLTAGES on the RIGHT. The majority of the system com-ponents are labeled with numbers that correspond with the electrical prints included in the electrical box door.

Computer controlled machines have signals on the computer that light up when the input or output func-tions are energized, respectively. Computer controlled as well as non-computer controlled machines have white 120V control power terminal strips. This will indicate power supply from the respective cir-cuits.

Idec controllers also have lights on them for the input and output functions. You can easily find out which circuits are failing by watching the lights turn on or off. Compare the lights on the IDEC control-ler to the electrical print to determine what systems are being affected.

If the Power Stops During Normal Operation

1. Check that the input power disconnect switch is not turned off.

2. Check that all of the emergency stop buttons are in the normal position.

3. Lock Out and Tag Out the main power source.

4. Turn the panel disconnect switch in the off position, open the electrical panel door.

5. Observe the disconnect switches. Look for loose or broken wires at the disconnect then at all of the components.

6. Check for continuity of all fuses with an OHM meter.

7. Check motor overloads by pressing each white button (usually at the bottom of the panel) in SEQUENCE,. If one is tripped there will be a slight resistance to touch and a “click” sound as it is reset.

WARNINGThe following checks require the electrical panel to be energized. These troubleshooting checks MUST BE PERFORMED BY A QUALIFIED ELECTRICAL TECHNICIAN.

1. Remove lock and tag outs on the main power sources.

2. Manually close disconnect switches and energize the control circuit or transformer with its respective switch. Observe that the numbers 1, 3 & 4 are lit on the white lighted terminal strip. This tells you that there are no overloads or emergency stops tripped.

3. Most electrical problems are related to mechanical malfunction (e.g., stuck motors, jammed chain, non tripped limit switches, etc.) The most common failure is an improperly adjusted limit switch. To check a limit switch, manually operate the limit switch. If the computer terminal strips lights, the switch needs to be re-adjusted. For more information on the limit switch specifications, see the manu-facturer’s information. For limit switch adjustment procedures, refer to.

4. If a solenoid valve is suspected, and not cleared in the air checks section (see), it can be electrically jumped to check operation.

THE FOLLOWING SHOULD ONLY BE ATTEMPTED BY TRAINED ELECTRICAL PERSONNEL.

52 700-C


Troubleshooting with the Status Light Panel

The Status List Panel is located on the front of the Operator’s Station, below the work surface area. It has six lights that are all illuminated when the system is in proper working order. If one or more lights are OFF, follow the process below to ascertain the cause.

NOTE: Be sure to proceed down the table, starting with the CONTROL POWER light.

CONTROL POWER

OVERLOAD RELAY

E-STOP

STOP

START

24VDC

700-C 53

Troubleshooting

Light If ON: If OFF:CONTROL POWER

Go to OVER-LOAD RELAY

• Check to see if the Control Transformer button is pulled out.

• Is the Disconnect switch on the main electrical cabinet set to ON?

• Is there 208, 220, 440, or 575 VAC to the top side of the Control Transformer (E3)? If not, check the fuses at the Fuse Block (E5), and the contacts on the Control Transformer button on the switch panel.

• Is there 110 VAC between #1 & #2 on the110 VAC Terminal Strip? If not, check the fuse on the output side of the Control Transformer. If fuse is good, check power coming out of Control Transformer. If no power on the output side, and there is power going into the top of the Control Transformer, replace the Control Transformer. If there is power at the Control Transformer, check the wiring of the black and white wire going from the Control Transformer to the 110 VAC Terminal Strip.

OVERLOAD RELAY

Go to E-STOP

• There is No over-load relay on this machine. If there is power to the Status Light panel this light will be lit.

E-STOP Go to STOP • Check to see the E-Stop button(s) is pulled out.

NOTE: Location and quantity of E-Stop buttons varies depending on customer need. Typical locations for E-Stop buttons are near the Rear Access Gate and near the Tool Changer Access Gate

• For Single E-Stop button machines: Check for 110 VAC between #2 and #4. If no voltage, check to see if the E-Stop but-ton is pulled out. If the E-Stop button is pulled out and E-Stop light is OFF check the wiring. If no fault is found in the wiring turn off the DL-NCB main power and check for continuity across the pulled out E-Stop switch.

• For multiple E-Stop Button machines: With on side of the meter on #2 check for 110 VAC on #4 through #5. If at any point no volt-age is found trace the wires to find the associated E-Stop button and check to see if that button is pulled out. If the E-Stop button is pulled out and the E-Stop light is OFF check the wiring. If no fault is found in the wiring turn off the DL-NCB main power and check for continuity across the pulled out E-Stop switch.

• Check to see if the Back Gate is closed.

• Check to see if the Disconnect switch on the high-frequency electrical cabinet is ON.

• Check for 110 VAC between #2 and #3A on the 110 VAC Termi-nal Strip. If there is 110VAC, go to next step: If the Disconnect switch on the high-frequency electrical cabinet is OFF (closed) and there is not 110 VAC between #2 and 3A, check the wiring.

• Check for 110 VAC between #2 and #3B. If there is 110 VAC, go to next step: If the contact on the Rear Access Gate is closed and there is no power between #2 and #3B, check for wiring prob-lems.

STOP Go to START • Check for 110 VAC between #2 and #6. If there is voltage, press the Start button. If no voltage, check the Stop button to make sure it is all the way out and not stuck in, then check the contact to make sure it is closed. If still no voltage, check the wiring.

START Go to 24VDC • Push the Start button. If the Start light remains unlit, push in the Start button and hold it in while a second person checks for volt-age between #2 and #7. If there is 110 VAC, replace the ACR relay. If there is no voltage while the button is held in, check the wiring.

54 700-C


Adjusting Limit Switches

If a machine suddenly stops in mid cycle, check the limit switches. A worn limit switch arm or a misadjusted limit switch is more than likely the cause. (Another potential cause is faulty photo eyes – for details.)

Depending on the model of limit switch on your machine, the pre-travel (amount of movement from the limit switch arm’s resting position to the position at which the switch actuates – with a “click”) is either 5 or 20 degrees. The DL-NCB has

24VDC Home the 700-C (see)

Check between DC+ and DC- for 24VDC. If no DC voltage, disconnect the + Brown/Red and - Blue/Black wires from the 24VDC power supply and check for DC voltage where those wires were disconnected.

If no voltage: • Check the input side for 110 VAC. If no 110 VAC, check the fuse. If there is 110 VAC and no 24VDC, replace the 24VDC Power Supply.

If there is 24VDC:• Reconnect the + Brown/Red and - Blue/Black wires to the 24VDC power supply.

• Trace the + Brown/Red wire to the DC terminal block.

• Disconnect all brown wires from the + DC from the DC terminal block except the + Brown/Red wire form the + 24VDC power sup-ply.

• Check for +24VDC at between any –DC and +DC terminal on the DC Terminal block.

• Reinstall the + brown wires one by one checking for +24VDC after installing each + brown wire. If at any point no voltage is found trace the last reinstalled wire and check for shorts.

700-C 55

Troubleshooting

five limit switches that have 5 degrees of pre-travel (3 on the X axis and 2 on the Y axis), and two switches that have 20 degrees of pre-travel (on the Cutter head).

If the arm is moved to the full extent of its travel and you do not hear the limit switch “click”, the switch needs to be adjusted. Use the set screw on the limit switch arm and adjust the arm to activate at the desired degree of rotation (see illustrations below).

Examples of Limit Switches:

56 700-C

Troubleshooting Photo Detectors

Troubleshooting Photo Detectors

Another cause of improper machine operation is a faulty or dirty photo detector.

There are two types of photo detectors, Through Beams and Photo Eyes.

• Through Beam Detectors consist of an emitter and detector. The emitter sends a light beam that is sensed by the detector. The detector then sends 0VDC to the PLC. If the beam is broken the detector sends 24VDC to the PLC.

• Photo Eye Detectors contain both emitter and receiver. If an object is within the Photo Eye’s sensing field light from the emitter is reflected from the object back to the receiver. The Photo Eye then sends 24VDC to PLC. If no object is sensed the Photo Eye sends a 0VDC to the PLC.

If the photo detector is dirty, it will falsely sense the presence of a door, or other obstruction, and stop the machine operation. If a suspected Photo Detector is clean check for the proper DC Voltage.

700-C 57

Troubleshooting

58 700-C

Touch Screen Troubleshooting


Maintenance Screen

TABLE 8.

Title Notes

Reg/Split Shows status of Jamb type switch (SW00):

• Reg. = OFF

• Split = ONSee “Control Panel” on page 77. for switch location.

Reset Shows status of Reset switch (PB01 & (OPTIONAL) PB01A):

See “Control Panel” on page 77. for switch location.

Fire Shows status of Fire Guns switch (PB02 & (OPTIONAL) PB02A):


Forward Shows status of Forward foot switch. (FS1)

See “Fixed and Movable Fence” on page 71. for location

Reverse Shows status of Seq. Reverse foot switch (FS2).


Enable movable Shows status of Enable Movable Guns switch (SW12 & (OPTIONAL) SW12B):.


Enable fixed Shows status of Enable Fixed Guns switch (SW13 & (OPTIONAL) SW13A):


Right header Shows status of Infeed head in place in place limit switch (LS14).

See “Moveably Fence - Inside view” on page 75.

Moves to screen PLC output screens. See “PLC Output 00-17” on page 65.

Moves to screen PLC output input screens. See “PLC Input 00-17” on page 61.

700-C 59

Left header Shows status of Outfeed head in place limit switch (LS15).


Guns in Shows status of Guns In limit switch (LS-17).

See “Fixed Fence - Inside view” on page 74.

Program Local 1

Program Local 2

Program Local 4

Program Local 8

. Shows status of Staple Sequence switch (SW30,SW31,SW32,SW33) See “Main Control Panel” on page 77. for location. The Sta-ple Sequence switch converts the decimal Staple Sequence number to it’s binary equiv-lant. See the truth table at right.

Note: At present Program Local 8 is not used.

Program Remote 1

Program Remote 2

Program Remote 4

Program Remote 8

Shows status of Staple Sequence switch (SW20,SW21,SW22,SW23) See “Remote Control Panel (Optional)” on page 78. The Staple Sequence switch converts the decimal Staple Sequence number to it’s binary equivalent. See “Staple sequence switch truth table” above

Jamb Width A Shows status of the Jamb Width A switch (SW34 & (Optional) SW34A). See “Main Con-trol Panel” on page 77.

Jamb Width B Shows status of the Jamb Width B switch (SW35 & (Optional) SW35A). See “Main Con-trol Panel” on page 77.

Jamb Width C Shows status of the Jamb Width C switch (SW36 & (Optional) SW36A). See “Main Con-trol Panel” on page 77.

Jamb Width D Shows status of the Jamb Width D switch (SW37 & (Optional) SW37A). See “Main Con-trol Panel” on page 77.

TABLE 8.

Title Notes

TABLE 9. Staple sequence switch truth table

Program Location

1

Program Location

2

Program Location

3

Staple Sequence

OFF OFF OFF 0

ON OFF OFF 1

OFF ON OFF 2

ON ON OFF 3

OFF OFF ON 4

ON OFF ON 5

OFF ON ON 6

ON ON ON 7

60 700-C


PLC Input 00-17

TABLE 10.

Title Notes

SS-00 Split-jamb Shows status of Jamb type switch (SW00):

• Reg. = OFF

• Split = ONSee “Control Panel” on page 77. for switch location.

PB-01 Reset Shows status of Reset switch (PB01 & (OPTIONAL) PB01A):


PB-02 Fire guns Shows status of Fire Guns switch (PB02 & (OPTIONAL) PB02A):


SS-03 RH/LH Not used.

FS-04 Seq. FWD Shows status of Forward foot switch. (FS1)


FS-05 Seq. REV Shows status of Seq. Reverse foot switch (FS2).


PE-06 Movable right Shows status of Movable right through beam (THRU06)

See “Heads” on page 73. for location.

PE-07 Movable left Shows status of Movable left through beam (THRU07)


PE-10 Fixed right Shows status of Fixed right through beam (THRU010)


PE-11 Fixed left Shows status of Fixed left through beam (THRU011)


SS-12 Enable movable guns Shows status of Enable Movable Guns switch (SW12 & (OPTIONAL) SW12B):.


700-C 61

SS-13 Enable fixed guns Shows status of Enable Fixed Guns switch (SW13 & (OPTIONAL) SW13A):


LS-14 Infeed head in place Shows status of Infeed head in place in place limit switch (LS14).


LS-15 Outfeed head in place Shows status of Outfeed head in place limit switch (LS15).


PE-16 Door in machine Shows status of Door in Machine photo eye (PE16).

See “Fixed and Movable Fence” on page 71. for location.

LS-17 Guns in Shows status of Guns In limit switch (LS17).

See “Fixed Fence - Inside view” on page 74.

TABLE 10.

Title Notes

62 700-C


PLC Input 20-37

TABLE 11.

Title Notes

SS-20 Remote Sel-1

SS-21 Remote Sel-2

SS-22 Remote Sel-4

SS-23 Remote Not-8

Shows status of Staple Sequence switch (SW30,SW31,SW32,SW33) See “Remote Control Panel (Optional)” on page 78. for location. The Staple Sequence switch converts the deci-mal Staple Sequence number to it’s binary equivalent. See the truth table Figure 12, “Staple sequence switch truth table,” on page 64


SS-25 Metal Sill Not used

SS-26 Manual / Auto Shows status of 6’8”/8’0 switch

See “Main Control Panel” on page 77. for location.

CR-27 Remote hand info Not used

700-C 63

SS-30 Local Sel-1

SS-30 Local Sel-2

SS-30 Local Sel-4

SS-30 Local Not-8

. Shows status of Staple Sequence switch (SW30,SW31,SW32,SW33) See “Main Control Panel” on page 77. for location. The Sta-ple Sequence switch converts the decimal Staple Sequence number to it’s binary equiva-lent. See the truth table at right.


SS-34 Jamb size A

SS-34 Jamb size B

SS-34 Jamb size C

SS-34 Jamb size D

Shows status of Staple Sequence switch (SW20,SW21,SW22,SW23) See “Remote Control Panel (Optional)” on page 78. The Staple Sequence switch converts the decimal Staple Sequence number to it’s binary equivalent. See “Staple sequence switch truth table” above

TABLE 11.

Title Notes

TABLE 12. Staple sequence switch truth table

Program Location

1

Program Location

2

Program Location

3

Staple Sequence

OFF OFF OFF 0

ON OFF OFF 1

OFF ON OFF 2

ON ON OFF 3

OFF OFF ON 4

ON OFF ON 5

OFF ON ON 6

ON ON ON 7

64 700-C


PLC Output 00-17

TABLE 13.

Title Notes

SV-00 Move side clamp Shows status of control valve SV-00 (See “Control Valves” on page 76.)

which controls PC32 and PC35 (See “Heads” on page 73.)

SV-01 Infeed wheels up Shows status of control valve SV-01 (See “Control Valves” on page 76.)

which controls PC6 and PC26 (See “Infeed and Outfeed Wheels” on page 72.)

SV-02 Infeed wheels down Shows status of control valve SV-02 (See “Control Valves” on page 76.)

which controls PC6 and PC26 (See “Infeed and Outfeed Wheels” on page 72.)

SV-03 Fixed side clamp Shows status of control valve SV-03 (See “Control Valves” on page 76.) which controls PC39 and PC36 ((See “Heads” on page 73.)

SV-04 Bot. Jamb clamp Shows status of control valve SV-04 (See “Control Valves” on page 76.) which controls PC13, PC23 (See “Fixed Fence - Inside view” on page 74.) and PC14, PC24 (See “Move-ably Fence - Inside view” on page 75.)

SV-05 Right end clamp Shows status of control valve SV-05 (See “Control Valves” on page 76.)

SV-06 Raise right guns Shows status of control valve SV-06 (See “Control Valves” on page 76.) which controls PC33 and PC38 (See “Heads” on page 73.)

SV-07 Raise left guns Shows status of control valve SV-07 (See “Control Valves” on page 76.) which controls PC34 and PC37 (See “Heads” on page 73.)

SV-10 Outfeed wheels up Shows status of control valve SV-10 (See “Control Valves” on page 76.) which controls PC7 and PC7 (See “Infeed and Outfeed Wheels” on page 72.)

SV-11 Outfeed wheels down Shows status of control valve SV-11 (See “Control Valves” on page 76.) which controls PC7 and PC7 (See “Infeed and Outfeed Wheels” on page 72.)

SV-12 Fire right movable Shows status of control valve SV-12 which control SG1 (See “Heads” on page 73.)

SV-13 Fire left movable Shows status of control valve SV-13 which control SG2 (See “Heads” on page 73.)

SV-14 Fire right fixed Shows status of control valve SV-14 which control SG3 (See “Heads” on page 73.)

SV-15 Fire left fixed Shows status of control valve SV-15 which control SG4 (See “Heads” on page 73.)

700-C 65

PLC Output 20-37

SV-16 Head clamp Shows status of control valve SV-16 (See “Control Valves” on page 76.) which controls PC3, PC4, PC5, PC9, PC10 bad PC11 (See “Moveably Fence - Inside view” on page 75.)

SV-17 Fixed guns in close Shows status of control valve SV-17 (See “Control Valves” on page 76.)

TABLE 14.

Title Notes

SV-20 Outfeed Assist cyl Shows status of control valve SV-20 (See “Control Valves” on page 76.) which controls PC28 and PC8 (See “Infeed and Outfeed Wheels” on page 72.)

SV-21 3/4” Ret. Shows status of control valve SV-21 (See “Control Valves” on page 76.) which retracts PC15, PC21 (See “Fixed Fence - Inside view” on page 74.) and PC16, PC22 (See “Move-ably Fence - Inside view” on page 75.)

SV-22 3/4” Ext. Shows status of control valve SV-22 (See “Control Valves” on page 76.) which extends PC15, PC21 (See “Fixed Fence - Inside view” on page 74.) and PC16, PC22 (See “Move-ably Fence - Inside view” on page 75.)

SV-23 2” Ret. Shows status of control valve SV-23 (See “Control Valves” on page 76.) which retracts PC15, PC21 (See “Fixed Fence - Inside view” on page 74.) and PC16, PC22 (See “Move-ably Fence - Inside view” on page 75.)

SV-24 2” Ext. Shows status of control valve SV-24 (See “Control Valves” on page 76.) which extends PC15, PC21 (See “Fixed Fence - Inside view” on page 74.) and PC16, PC22 (See “Move-ably Fence - Inside view” on page 75.)

SV-25 Left end clamp Shows status of control valve SV-25 (See “Control Valves” on page 76.)

PL-26 No jamb error Shows status of 6’8”/8’0 switch. See “Main Control Panel” on page 77. for location.

Q-27 Not used

Q-30 Not used

Q-31 Not used

Q-32 Not used

Q-33 Not used

TABLE 13.

Title Notes

66 700-C


Q-34 Not used

Q-35 Not used

Q-36 Not used

CR-37 OK to feed door in Shows status of PLC output 37

TABLE 14.

Title Notes

700-C 67

68 700-C

Getting Help from Kval

Getting Help from Kval

Before you seek help, first try the troubleshooting procedures in.

If you are still not able to resolve the problem, contact our customer support engineers:

• In the U.S and Canada, call (800) 553-5825 or fax (707) 762-0485

• Outside the U.S. and Canada, call (707) 762-7367 or fax (707) 762-0485

• Email address is [email protected]

Technical Support business hours are 4:00 AM to 4:30 PM Pacific Standard Time, Monday through Fri-day.

Product Return Procedure

If you’ve contacted Kval for help and it is determined that a return is necessary, use the procedure below to return the machine or part.

Note: Non-Warranty returns are subject to a 15% restocking charge.

1. Obtain the packing slip and/or invoice numbers of the defective unit, and secure a purchase order number to cover repair costs in the event the unit is determined to be out of warranty.

2. Reason for return: Before you return the unit, have someone from your organization with a technical understanding of the 700-C system and its application include answers to the following questions:

• What is the extent of the failure/reason for return? What are the relevant error messages or error codes?

• How long did it operate?

• Did any other items fail at the same time?

• What was happening when the unit failed (e.g., installing the unit, cycling power, starting other equipment, etc.)?

• How was the product configured (in detail)?

• Which, if any, cables were modified and how?

• With what equipment is the unit interfaced?

• What was the application?

• What was the system environment (temperature, spacing, contaminants, etc.)?

3. Call Kval customer support for a Return Material Authorization (RMA). When you call:

• Have the packing slip or invoice numbers available.

• Have the documented reason for return available.

4. Send the merchandise back to Kval.

• Make sure the item(s) you are returning are securely packaged and well protected from shipping damage

• Include the packing slip or invoice numbers.

• Include the documented reason for return.

• Include the RMA number with the parts package.

700-C 69

70 700-C

Part Locations

Part Locations

Fixed and Movable Fence

FixedFence

In Feed

Out Feed

Key:Reference Designator - I/OI/O Description

FS4 - I004Seq. Forward

FS5 - I005Seq. Reverse

Movable FencePE16 - I016

Door In Machine

700-C 71

Infeed and Outfeed Wheels

FixedFence

In Feed

Out Feed


Movable Fence

PC26:

PC27:

PC28 - Q020Assist Cylinder

Q001 - RetractInfeed wheels upQ002 - ExtendInfeed wheels down

Q010 - Retract Q011 - ExtendOutfeed wheels down

Outfeed wheels up

PC6:

PC7:

PC8 - Q020Assist Cylinder

Q001 - RetractInfeed wheels upQ002 - ExtendInfeed wheels down

Q010 - Retract Q011 - ExtendOutfeed wheels down

Outfeed wheels up

72 700-C

Part Locations

Heads

In Feed

Out Feed

Movable Fence

FixedFence

Right HandMovable Head

Left HandMovable Head

Right HandFixed Head

Left HandFixed Head


PC33 - Q006Raise Right Guns

PC38 - Q006Raise Right Guns

PC34 - Q007Raise Left Guns

PC37 - Q007Raise Left Guns

Through Beam Junction Box

Through Beam Junction Box

SG1 - Q012Fire Right Movable

SG3 - Q014Fire Right Fixed

SG2 - Q013Fire Left Movable

SG4 - Q015Fire Left Fixed

THRU06 - I006Movable Right

THRU07 - I007Movable Left

THRU10 - I010Fixed Right

THRU11 - I011Fixed Right

PC32 - Q000Movable Side Clamp

PC35 - Q000Movable Side Clamp

PC39 - Q003Fixed Side Clamp

PC36 - Q003Fixed Side Clamp

SV1 - Q012Fire Right Movable

SV2 - Q013Fire Left Movable

SV3 - Q015Fire Left Fixed

SV4 - Q014Fire Right Fixed

700-C 73

Fixed Fence - Inside view

FixedFence

In Feed

Out Feed


PC13 - Q004:Bottom Jamb Clamp

LS-17 - I017Guns In

PC25 - Q028Head Clamps(Inner)

LS14 - I014Right Head

PC1 - Q026Head Clamps(Outer)

In Place



LS-15 - I0015Outfeed headIn Place

PC15:

Q021: Retract 3/4” Cylinder

Q024: Extend 2” Cylinder

PC17:Q023: Retract 2” Cylinder

Q022: Extend 3/4” Cylinder

PC21:



PC19:Q023: Retract 2” Cylinder


PC23:Q004: Bottom Jamb Clamp



74 700-C

Part Locations

Moveably Fence - Inside view

Movable Fence

In Feed

Out Feed







PC16:



PC18Q023: Retract 2” Cylinder

PC2 Manually operatedWidth Lock

PC12



Manually operatedWidth Lock


PC22:



PC20Q023: Retract 2” Cylinder



700-C 75

Control Valves


SV-16 - Q016Head Clamps

SV-17 - Q017Fixed Guns In Close

SV-25 - Left End Clamp

SV-20 - Q020Assist Cylinder

SV-21 - Q021Retract 3/4”

SV-22 - Q022Extend 3/4”

SV-23 - Q023Retract 2”

SV-24 - Q024Extend 2”

Cylinder

Cylinder

Cylinder

Cylinder

SV-11 - Q011Outfeed Wheels Down

SV-07 - Q007Raise Left Guns

S-06 - Q006Raise Right Guns

SV-05 - Q005Right End Clamp

SV-04 - Q004Bottom Jamb Clamp

SV-03 - Q003Fixed Side Clamp

SV-00 - Q000Movable Side Clamp

SV-02 - Q002Infeed Wheels Down

SV-10 - Q010Outfeed Wheels up

SV-01 - Q001Infeed Wheels Up

76 700-C

Part Locations

Control Panel

Main Control Panel


PB01 - I001Local & Remote Reset

SW26 - I026 (Optional)6’8/8’0

SW00 - I000Jamb Reg/Split

PB02 - I002 Local & Remote Fire

PB34 - I034Jamb Width A

SW13 - I013Enable Fixed Guns

PB36 - I036Jamb Width C

PB37 - I037Jamb Width D

PB35 - I035Jamb Width B

SW30,SW31,SW32,SW33:I030: Program Select -Local Select #1

I033: Program Select -Local Select #8



SW1 Control Circuit Power

CONTROL CIRCUIT

OFF ON

STAPLE SEQUENCE

0

1

23 4

5

6

7

RESET 700-C

JAMB TYPE

REG. SPLIT


OFF ON


OFF ON


WIDTH ADJUST

PUSHCLAMP

PULLRELEASE

FIRE SIDE NAILER

Fire Side Nailer (Optional)Nematic button

Width AdjustNematic button

Door Length

6’ 8” 8’ 0”

SW12 - I012Enable Movable Guns

SELECT

LOCAL REMOTE

SW24 - I024SELECT LOCAL/REMOTE (OPTIONAL)

700-C 77

Remote Control Panel (Optional)


SW12A - I012Enable Movable Guns

SW4A - I002 Local & Remote Fire

SW34A - I034Jamb Width A

SW13A - I013Enable Fixed Guns

SW36A - I036Jamb Width C

SW37A - I037Jamb Width D

SW35A - I035Jamb Width B

SW20,SW21,SW22,SW23:I030: Program Select -Remote Select #1

I033: Program Select -Remote Select #8



STAPLE SEQUENCE

0

1

23 4

5

6

7

RESET 700-C

ENABLE FIXEDGUSIDE GUNS

OFF ON


OFF ON


WIDTH ADJUST

PUSHCLAMP

PULLRELEASE

FIRE SIDE NAILER

Fire Side Nailer (Optional)Nematic button

Width AdjustNematic button

SW1A - I001Local & Remote Reset

78 700-C

Part Locations

Head Jamb Stapling (Optional)

Infeed

Outfeed

700-C 79

80 700-C

http://www.kvalinc.com

Customer Service

Mailing address:

Customer Support Department

Kval Incorporated

825 Petaluma Boulevard South

Petaluma, CA 94952

Contacting KVAL

Phone and Fax:

In the U.S and Canada, call (800) 553-5825 or fax (707) 762-0485

Outside the U.S. and Canada, call (707) 762-7367 or fax (707) 762-0485

Email: [email protected]

http://www.kvalinc.com

Documents

Innovation, Quality & Honesty 700-C System Reference · securely clamped into position. A foot pedal activates the staple guns, which move vertically to attach the jambs to the header