Kval 777 Operation manual

Innovation, Quality & Honesty
Operation and Service Manual
Published: May 14, 2019
777 Operation and Service Manual
777 Flat Back Bi-Fold Machine

KVAL 777 Operation/Service Manual
Proprietary Notice
This Manual is confidential and contains proprietary information and intellectual
property of KVAL Inc., and is to be used solely by Customer as an operating manual
for KVAL Inc. machines. Neither this Manual nor any of the information contained
herein may be reproduced or disclosed under any circumstances without the express
written permission of KVAL Inc. For authorization to copy this information, please
call Kval Customer Support at [phone] or fax [phone]. Outside the
U.S. and Canada, call [phone].
Manual Part Number: DOC_76_2-OPSR
777 is a trademark of Kval Incorporated.
Copyright 2018 Kval Incorporated. All rights reserved.
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KVAL777 Operation/Service Manual
KVAL 777 Operation/Service Manual
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KVAL 777 Operation/Service Manual

Table of Contents
KVAL 777 Hinge Application System
Chapter 1 Introduction to the 777
Chapter 1 at a Glance...........................................................................1-1
Overview of the 777................................................................. 1-2
Available Options..................................................................................1-2
About this Manual .................................................................................1-3
vSafety First!............................................................................ 1-4
Safety Sheet Sign-Off Sheet.................................................................1-4
Safety Terminology of Labels................................................................1-4
Safety Guidelines..................................................................................1-4
Lockout-Tagout Guidelines ...................................................... 1-8
Follow the P-R-O-P-E-R lockout rule of thumb.....................................1-8
Lockout Tagout Procedure....................................................... 1-9
Pre-Steps Before Lockout Tagout .........................................................1-9
Lockout Tagout Power ..........................................................................1-9
Lockout Tagout Air Supply ..................................................................1-10
Start Maintenance...............................................................................1-10
Post Maintenance Steps.....................................................................1-10
Zero-Energy to Start-Up........................................................... 1-11
Getting Help from KVAL........................................................... 1-13
On-Line Help.......................................................................................1-13
Product Return Procedure ..................................................................1-13
Safety Sign-Off Sheet .............................................................. 1-16
A Note to the Operator........................................................................1-16
Chapter 2 Operation of the 777
Kval 777 Process Summary .................................................... 2-2
Powering Operations for the 777 ............................................. 2-3
How to Power Up the 777.....................................................................2-3
How to Power Down the 777 ................................................................2-4
Stabilizing Heads at the End of Shift.....................................................2-4
Emergency Shutdown and Recovery ...................................................2-5
To Resume Normal Operation after an E-Stop .....................................2-5
Other safety controls can include: ........................................................2-5
Typical E-Stop Locations ......................................................................2-5
About the Safety Curtain.......................................................... 2-6
If the Field is Broken.............................................................................2-6
To Resume Normal Operation after an Field is Broken ........................2-6
Quick Start ............................................................................... 2-7

KVAL 777 Operation/Service Manual
Table of Contents
Set the Width to the Door ........................................................ 2-9
About the Hopper..................................................................... 2-10
Hopper Process..................................................................................2-10
Pre Sets Drill Locations ........................................................... 2-11
Adjusting Drill Height ..........................................................................2-12
Adjust for the Length of a Door................................................ 2-13
Adjust Drills for Door Length...............................................................2-14
Adjust the Stops to Different Door Length ..........................................2-15
Adjust the Heads to Different Door Length .........................................2-16
Tour of the Machine ................................................................. 2-17
Front View...........................................................................................2-17
Rear View ...........................................................................................2-17
About the 4 Shooters ............................................................... 2-18
4 Shooter ............................................................................................2-18
About the Hopper..................................................................... 2-19
Hopper Process..................................................................................2-19
Controls ................................................................................... 2-20
Main Control Box ................................................................................2-20
Machine Control Box ..........................................................................2-21
Start Sequence Buttons......................................................................2-21
The 777 Main Electrical Panel................................................. 2-22
Description of the Six Light Panel ........................................... 2-23
Chapter 3 Maintenance of the 777
Maintenance Schedule ............................................................ 3-2
300 Cycle Maintenance Steps ................................................. 3-4
Clean, Clean, Clean!.............................................................................3-4
600 Cycle Maintenance Steps ................................................. 3-5
Check Air Gauges and Inspect Water Traps ........................................3-5
Inspect Tooling......................................................................................3-5
Lubricate inside of Hopper....................................................................3-6
3,000 Cycle Maintenance Steps .............................................. 3-7
Inspect Feed Belts................................................................................3-7
Inspect Screw Drop Tubes on 4 Shooter..............................................3-7
Inspect all Photo Eyes ..........................................................................3-7
Inspect Limit Switches ..........................................................................3-8
Inspect Screw Receiver Parts...............................................................3-8

Table of Contents
KVAL 777 Hinge Application System
Inspect Airlines .....................................................................................3-9
Refill Lubricators ...................................................................................3-9
Grease Ball Screw Bearings...............................................................3-10
Clean Bearing Shafts..........................................................................3-10
12,000 Cycle Maintenance Steps ............................................ 3-11
Inspect Chains for Proper Tension......................................................3-11
Inspect Air Cylinders...........................................................................3-11
Inspect Ball Rail Shafts and Ball Screws ............................................3-11
Clean and Lubricate Slides, Cylinder Rods and Bearing Shafts.........3-12
Clean Inside Hopper ...........................................................................3-12
72,000 Cycle Maintenance Steps ............................................ 3-13
Inspect Nuts and Bolts........................................................................3-13
Electrical .............................................................................................3-13
Wash Filter and Lubricator Bowls .......................................................3-13
Tool Changing Schedule.......................................................... 3-14
Lubrication Schedule ............................................................... 3-15
Typical Lubrication Kit.........................................................................3-15
Lubrication Requirements........................................................ 3-16
Pillow Block Bearing Housings ...........................................................3-16
Flange Bearing Housings ...................................................................3-17
Ball Rail Bearing .................................................................................3-17
Pulley and Idler Shafts........................................................................3-18
Sample of Grease Locations for 777 ....................................... 3-19
Grease Locations on Frame of 777 ....................................................3-19
Grease Locations 4-Shooter Bearings................................................3-21
Description of Air Input System ............................................... 3-22
Air Input with Lubrication ...................................................................3-22
Air Line Without Lubricator .................................................................3-23
Remove and Replace the Screw Driver Bits............................ 3-24
Chapter 4 Troubleshooting the 777
About a Typical Contactor Control ........................................... 4-2
About Contactor Troubleshooting .........................................................4-3
About Typical VFD Motor Drive Control................................... 4-4
About the VFD ......................................................................................4-5
About VFD Troubleshooting .................................................................4-6
About a Typical Pneumatic Circuit ........................................... 4-7
Typical Pneumatic Assembly ................................................................4-8

KVAL 777 Operation/Service Manual
Table of Contents
About the Coil (Solenoid)......................................................................4-8
About Cylinder Operation .....................................................................4-9
How the Pneumatic System Works ......................................................4-9
Important Notice about Adjusting Cylinder Speed ..............................4-11
Adjusting Cylinder Extend Speed .......................................................4-12
Adjusting Cylinder Retraction Speed .................................................4-12
Using Sensors to Trouble Shoot.............................................. 4-13
Troubleshooting Electrical Problems ....................................... 4-14
If the Power Stops During Normal Operation......................................4-14
Troubleshooting with the Status Light Panel ........................... 4-16

1-1
KVAL 777 Operation/Service Manual
CHAPTER 1 Introduction to the 777
This chapter provides an overview of the KVAL 777 Flat Back Bi-fold Machine.
Included is important safety Information and Lockout Tagout procedures.
Chapter 1 at a Glance
The following information is available in this chapter:
TABLE 1- 1. Summary of Chapter
Section Name Summary Page
Overview of the 777 This section provides an overview of the
machine. It includes a general description and
a table of available options
page 1-2
Safety First! IMPORTANT safety information is described in
this section
page 1-4
Lockout-Tagout Guidelines Procedures describing Lockout Tagout. page 1-8
Zero-Energy to Start-Up Procedure to power up your machine for the
first time.
page 1-11
Getting Help from KVAL This section describes the method to contact
the KVAL service center for help. The section
includes how to get information from the speci-
fication plate tor provide to KVAL, service cen-
ter hours, and return procedures
page 1-13
Safety Sign-Off Sheet A record to track operators that are trained on
the machine.
page 1-16

Overview of the 777
KVAL 777 Operation/Service Manual
1-2
Overview of the 777
KVAL's Model 777 Flat Back Bi-Fold Machine is
designed to install flat back hinges on bi-fold doors. This
machine has a structural frame with four drill stations and
three hinge application stations. The basic machine
includes set up for 6’8” and 6’6” doors with hinge appli-
cation units set on fixed centers.
Door width is adjustable from 8-3/4” to 24”. Thickness is
adjustable from 1-1/6” to 1-3/8”.
The 777 includes spring loaded wheels to support the pan-
els as they are fed into the machine. Dual off-feed belts
are provided to move finished doors out of the machine,
so the next pair can be inserted.
Method of operation includes placing a pair of doors in machine and clamping them. Hinges can
be placed in machine during cycle operation so they are in position when machine is actuated.
Four drills move in to drill for pivot hardware. Hinges are manually placed and screws are auto-
matically dispensed to attach hinges simultaneously. The machine then releases the doors and
another operator removes them manually from the off-feed side. Factory service trip included in
the price.
Available Options
TABLE 1-2. Options
Options Title Descriptions
Option A 8'0" Door Capacity To make machine adjustable to drill for the top and bottom pivot
holes in door up to 8'-0", and adjustment of the two outside screw-
driver units to change center-to-center distance of hinges to
attach three hinges on doors up to 8’0" in length. Option also
includes upgrade to linear bearing slides and adjustment for end
drilling units.
Option E Extra Screwdriver
Head
A fourth screwdriver head to add 8'0" door capability.