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Kval 777 Operation And Service Manual

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

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  • Page 1 Operation and Service Manual Published: May 14, 2019 Innovation, Quality & Honesty 777 Flat Back Bi-Fold Machine...
  • Page 2 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.
  • Page 3 Please email your comments and suggestions for improve- ment to userexperience@kvalinc.com. (NOTE: This is not a customer support email link. For that, please refer to the Customer Service contact information above.) Thank you! http://www.kvalinc.com KVAL 777 Operation/Service Manual...
  • Page 4 KVAL 777 Operation/Service Manual...

  • Page 5: Table Of Contents

    A Note to the Operator................1-16 Operation of the 777 Chapter 2 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...
  • Page 6 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 Maintenance of the 777 Chapter 3 Maintenance Schedule ............3-2 300 Cycle Maintenance Steps ..........
  • Page 7 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...
  • Page 8 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 KVAL 777 Operation/Service Manual...

  • Page 9: Chapter 1 At A Glance

    This section describes the method to contact page 1-13 Getting Help from KVAL 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 10: Overview Of The 777

    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.

  • Page 11: About This Manual

    Overview of the 777 About this Manual This manual contains operation information and service and maintenance information. It includes identification of machine assemblies, power-up and power-down steps, and informa- tion about using the user interface. The Troubleshooting and Maintenance sections are directed toward qualified ser- vice technicians only.

  • Page 12: Vsafety First

    See “Safety Sign-Off Sheet” on page 1-16. Safety Terminology of Labels In addition to the nameplate, KVAL machines may have other warning labels or decals that pro- vide safety information to operators. Safety labels should be clearly visible to the operator and must be replaced if missing, damaged, or illegible.
  • Page 13 Before performing any mainte- nance or repairs on this machine turn off the main air disconnect. Lockout and tagout this connection. See “Lockout Tagout Procedure” on page 1-9. KVAL 777 Operation/Service Manual...
  • Page 14 This should be done in accordance with applicable state and/or federal code requirements. Laser Warnings On some machines, laser indicators are used to set boundaries. Follow the manufacturers safety precautions. KVAL 777 Operation/Service Manual...
  • Page 15 First! Compliance with Codes and Regulations KVAL 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 regula- tions which apply in your geographic area.

  • Page 16: Lockout-Tagout Guidelines

    O..OFF! Shut off all power sources and isolating devices P..Place lock and tag E..ENERGY: Release stored energy to a zero-energy state R ..Recheck controls and test to ensure they are in the “OFF” state KVAL 777 Operation/Service Manual...

  • Page 17: Lockout Tagout Procedure

    Turn Switch to the Lock and Tag out Insert Lock into hole. OFF position Note: When multiple people are working on the machine, each person needs to have a lock on the handle in the extra holes provided. KVAL 777 Operation/Service Manual...

  • Page 18: Lockout Tagout Air Supply

    The lock and tag can now be removed (only by the person(s) who placed them), and the machine can be re-energized. The tags must be destroyed and the locks and keys returned to the lockout center. KVAL 777 Operation/Service Manual 1-10...

  • Page 19: Zero-Energy To Start-Up

    Replace Guards Replace all equipment guards. If part of equipment cannot be properly adjusted after start-up with guard on, contact the KVAL Service team. See “Getting Help from KVAL” on page 1-13. Check Controls Confirm that all switches are in the “OFF”...
  • Page 20 Be sure to follow the P-R-O- P-E-R lockout/tagout procedures, and that those around you do also. Close the Cage Gate Verify all cage gates are securely closed. Ensure all safety protocols are in effect. KVAL 777 Operation/Service Manual 1-12...

  • Page 21: Getting Help From Kval

    Ask about this procedure when calling are service team 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.
  • Page 22 • With what equipment is the unit interfaced? • What was the application? • What was the system environment (temperature, spacing, contaminants, etc.)? Call Kval customer support for a Return Material Authorization (RMA). When you call: • Have the packing slip or invoice numbers available.
  • Page 23 Getting Help from KVAL Page Intentionally Left Blank KVAL 777 Operation/Service Manual 1-15...

  • Page 24: Safety Sign-Off Sheet

    Note: It is recommended you make a copy of this sheet for new operators. If a copy is needed, you may download a PDF at the KVAL website (http://www.kvalinc.com). You may also contact our Service Department at (800) 553-5825 or email at service@kvalinc.com.
  • Page 25 CHAPTER 2 Operation of the 777 The content is geared to help operators understand the basic operation of the KVAL 777 Flat Back Bi-Fold Machine. Chapter 2 at a Glance Section Name Summary Page Illustrated summary of the operation of the machine...

  • Page 26: Kval 777 Process Summary

    Kval 777 Process Summary Kval 777 Process Summary Turn Power Pull Out Push in Start Machine Control Transformer Pre Set a) Load Doors b) Set Width Buttons a) Load Hinges b) Push the Hinges Loaded Button Push Both Start Sequence Buttons...

  • Page 27: Powering Operations For The 777

    • Shutting down the control power • Removing power from the entire system How to Power Up the 777 Ensure factory air is applied to machine and main air supply is turned on. Check that all E-Stop buttons are out and safety gate door s are closed.

  • Page 28: How To Power Down The 777

    Powering Operations for the 777 How to Power Down the 777 Reverse the steps in the “How to Power Up the 777” on page 2-3. Push the Stop Button Switch the green Control Transformer switch to the OFF position. KVAL also recommends that...

  • Page 29: Emergency Shutdown And Recovery

    Powering Operations for the 777 Emergency Shutdown and Recovery Important: Learn all safety precautionary controls on the machine. Depending on the model of machine, there are emergency shutdown (E- Stop) switches located at key points around the machine. The E-Stop switches are to be used when the machine is out of control or is about to damage personnel or equipment.

  • Page 30: About The Safety Curtain

    If the field is broken, the machine will shut down. This is safety feature performs the same func- tion as an Emergency Shutdown (E- Stop). To Resume Normal Operation after an Field is Broken Push the button on the operator's station START MACHINE KVAL 777 Operation/Service Manual...

  • Page 31: Quick Start

    See “Set the Width to the Door” on page 2-9 Power up the 777. See “How to Power Up the 777” on page 2-3. See “Powering Operations for the 777” on page 2-3 Turn ON Drills. Turn ON Screw Drop.
  • Page 32 Push the Start Sequence Buttons, at the same time. • The Heads lower and attach the hinges to the door. • The machine will unclamp automatically and feed the door out. • Repeat process for next door KVAL 777 Operation/Service Manual...

  • Page 33: Set The Width To The Door

    Line up the arrow to the desired width. Begin processing the doors. Locater Arrow How to Set the Width FIGURE 2- 3. KVAL 777 Operation/Service Manual...

  • Page 34: About The Hopper

    Any adjustment may cause timing issues with the operation of the Four Shooter. If you think problems are being caused by the cylin- ders, please contact the KVAL Service Department for direction. Important: Do not mix screw types in the Hopper. Different sizes, pitches can cause uneven application of the hinge.

  • Page 35: Pre Sets Drill Locations

    Indicates drill is at door drill- different thickness doors 8’.0” to 6’.8” Door Adjust: Back Limit Switch: Slide Drill Assembly to desired door Indicates assembly id ready length to drill Drill Pre Set Locations FIGURE 2- 4. KVAL 777 Operation/Service Manual 2-11...

  • Page 36: Adjusting Drill Height

    Note: A line is scribed to indicate normal door widths. Move until the arrow meets that scribe. Repeat for other three drills. Retrieve Tool Re-attach the cover. Reverse Lockout Tagout. Process doors. Loosen and move to desired location Reattach Covers KVAL 777 Operation/Service Manual 2-12...

  • Page 37: Adjust For The Length Of A Door

    • Adjust both Door Stops • Adjust all 4 Drill Assemblies • Automatic Adjustment of Heads 8’.0” to 6’.8” Door Adjust: Slide Drill Assembly to desired door length Stop Stop Length Assemblies to Adjust FIGURE 2- 5. KVAL 777 Operation/Service Manual 2-13...

  • Page 38: Adjust Drills For Door Length

    Reattach the cover. Reverse Lockout Tagout. Process doors. Slide to Reference Collar Note: In this sample we are moving to the 8 foot door position. Reverse steps to return to 6’ 8” posi- tion. Reattach Covers KVAL 777 Operation/Service Manual 2-14...

  • Page 39: Adjust The Stops To Different Door Length

    Process doors 6’8” Location 6’8” Location 8’0”Location 8’0” Location Left Hand Stop, align the front Right Hand Stop, align the edge of the plate to the mark rear edge of the plate to the mark KVAL 777 Operation/Service Manual 2-15...

  • Page 40: Adjust The Heads To Different Door Length

    The two outside Heads will move to 8’0” Doors: towards the ends of the machine. : The two outside Heads will move towards 6’8” Doors the center of the machine. The middle Head remains stationary 8’0”Location 6’8” Location 8’0”Location KVAL 777 Operation/Service Manual 2-16...

  • Page 41: Tour Of The Machine

    Drives screws into the door Width Adjust Motor: Push both buttons at the same time to begin the process. Feed Motor: Note: Some Options include a Moves door out of the Safety Light Curtain. machine. KVAL 777 Operation/Service Manual 2-17...

  • Page 42: About The 4 Shooters

    These tubes receive the ens, and aligns them. screws from the hopper by way of plastic tubes Flip Cylinder: Flips applicator 180° to put the hinge in place to attach to the door Hinge Applicator KVAL 777 Operation/Service Manual 2-18...

  • Page 43: About The Hopper

    Any adjustment may cause timing issues with the operation of the Four Shooter. If you think problems are being caused by the cylin- ders, please contact the KVAL Service Department for direction. Important: Do not mix screw types in the Hopper. Different sizes, pitches can cause uneven application of the hinge.

  • Page 44: Controls

    Emergency Stop selected length door. If safety issues occur, press this button. Removes power from Note: Door Length. Drills and entire machine. stops must also be moved for door length changes. KVAL 777 Operation/Service Manual 2-20...

  • Page 45: Machine Control Box

    If safety issues occur press this assembly. button. Removes power from the entire machine. Start Sequence Buttons After the door is loaded and properly set, press the at the same time. Sequence Buttons KVAL 777 Operation/Service Manual 2-21...

  • Page 46: The 777 Main Electrical Panel

    The 777 Main Electrical Panel The 777 Main Electrical Panel Figure below, is an overview of the location of assemblies in the panel. Warning: High Voltage is present in this panel at the top of the Three Phase Input even with the disconnect off. If working on the panel, follow safety protocol as described in Chapter 1.

  • Page 47: Description Of The Six Light Panel

    24VDC – light E-Stop – The back comes on once the gate is closed and Frame E-stop is not acti- ACR is latch and the vated when this light is on. 24VDC power Supply is working KVAL 777 Operation/Service Manual 2-23...
  • Page 48 Description of the Six Light Panel KVAL 777 Operation/Service Manual 2-24...
  • Page 49 This chapter describes preventative maintenance steps for KVAL 777 Flat Back Bi-Fold Machine. The content is geared to guide technicians to keep a regular maintenance schedule for your KVAL machine. Keeping your KVAL machine maintained is an important piece for successful operation of your door production process.

  • Page 50: Maintenance Schedule

    This should be done in accor- dance with applicable state and/or federal code requirements To view a video of the maintenance process, visit the KVAL website. Select the Video Tab to view videos. http://www.kvalinc.com/...
  • Page 51 Clean inside hopper with WD-40 and a 3M Scotchbrite pad. Wipe dry with a clean dry rag 72,000 Cycles Inspect Inspect all nuts and bolts for tightnesses Tighten is necessary. Clean Wash filter and lubricator bowls with soapy water. KVAL 777 Operation/Service Manual...

  • Page 52: 300 Cycle Maintenance Steps

    Use pressured air to blow off dust and debris on entire machine. Use a clean rag to clean areas not affected by pressurized air. Also blow out any dust collection units. Check vertical bearings for loose screws. Loose screws could cause bearing damage. KVAL 777 Operation/Service Manual...

  • Page 53: 600 Cycle Maintenance Steps

    Maintenance) Inspect Air Filter Water Traps. Empty trap if necessary Slide locking switch down to unlock twist trap to remove. Reverse action when installing trap. Inspect Tooling Inspect the Tooling for wear, (Screw Driver Bits) KVAL 777 Operation/Service Manual...

  • Page 54: Lubricate Inside Of Hopper

    600 Cycle Maintenance Steps Lubricate inside of Hopper Lubricate the inside of the Hoppers with a light coat of dry silicone spray. Lubricate the input to the screw drop hoses. Provides an easier screw drop. Do not over-spray oil. KVAL 777 Operation/Service Manual...

  • Page 55: 3,000 Cycle Maintenance Steps

    • cracks • wear from rubbing • Ensure tube clamps are tight Inspect all Photo Eyes Inspect all photo eyes secure and tight. Check Nut that attaches Photo Eye to Machine Check Connection to Photo Eye KVAL 777 Operation/Service Manual...

  • Page 56: Inspect Limit Switches

    5 or 20 degrees before the limit switch actuates. Inspect Screw Receiver Parts Inspect screw receiver parts on six shooters for cracks or breaks. Inspect: Screw Receiver Spring Split Shell Steel Ring Rubber Ring Steel Ring Replace any parts that are broken. KVAL 777 Operation/Service Manual...

  • Page 57: Inspect Airlines

    Refill Lubricators Ensure Air is turned off. Refill all lubricators. Replace fluid if milky or discolored. Use ab ISO 32 stan- dard hydraulic oil (KVAL PN: SYS- LUBEG). Slide locking switch down twist bowl and remove. Refill bowl. Reverse action when installing trap.

  • Page 58: Grease Ball Screw Bearings

    Grease ball screw bearings (if applicable). For a table of lubrication types to use, Lubrication Schedule. For locations to lubricate, See Grease Ball Screw Bearings Clean Bearing Shafts Clean all bearing shafts with clean, dry cloth. Spray shaft with silicone oil and clean build up grime and dirt. KVAL 777 Operation/Service Manual 3-10...

  • Page 59: 12,000 Cycle Maintenance Steps

    Inspect all air cylinders for air leaks. Replace the cylinder if seal is leaking. Symptoms include a cylinder not extracting or retracting to the limits. Cylinders not holding their position. Inspect Ball Rail Shafts and Ball Screws Inspect ball rail shafts for pitting or abrasions. Example of a Pitted Ball Rail KVAL 777 Operation/Service Manual 3-11...

  • Page 60: Clean And Lubricate Slides, Cylinder Rods And Bearing Shafts

    Clean and lubricate all slides and cylinder rods with dry silicone spray. Clean Inside Hopper Clean inside hopper with dry sili- ® cone oil and a 3M ScotchBrite pad (or equivalent). Wipe dry with a clean dry rag KVAL 777 Operation/Service Manual 3-12...

  • Page 61: 72,000 Cycle Maintenance Steps

    Wash filter and lubricator bowls with soapy water. • Slide lock down to unlock. • Twist bowl to remove it. • Remove filter from Air filter assembly. Inspect and clean or replace if necessary. • Clean bowls and reas- semble. KVAL 777 Operation/Service Manual 3-13...

  • Page 62: Tool Changing Schedule

    Changing and inspecting the tooling on a regular basis keeps the door machining process running accurately and efficiently. KVAL recommends using the tables below for reference to change or inspect the machine tooling. Note: Depending on Machine or Option, some of these tools may vary.

  • Page 63: Lubrication Schedule

    Lubrication Schedule Lubrication Schedule KVAL recommends the following lubrication schedule to ensure that the machine operates prop- erly. Recommended Lubrication Schedule TABLE 3-3. Type of Recommended Schedule Recommended Assembly Lubrication Type Linear Bearing Pillow Block Bearing Every 250 Hours of Machine Operation...

  • Page 64: Lubrication Requirements

    Closed Pillow Block Hub Style Opened Pillow Block parallel perpendicular mount Greasing Approximatively 1 Gram (one pump from grease gun) of Dura-Lith Grease (KVAL P/N: Lube EP-2). Every 250 hours of operation. Pillow Block Bearings FIGURE 3-6. KVAL 777 Operation/Service Manual 3-16...

  • Page 65: Flange Bearing Housings

    X,Y, or Z direction. Greasing Ball Rail Bearing Approximatively 1 Gram (one pump from grease gun) of Dura-Lith Grease (KVAL P/ Every 250 hours N: Lube EP-2). of operation. Ball Rail Bearings FIGURE 3-8. KVAL 777 Operation/Service Manual 3-17...

  • Page 66: Pulley And Idler Shafts

    Note: It is important not to overfill the Idler Shaft. Avoid getting excess grease on the belts Grease Out Approximatively 1 Gram (one pump from grease gun) of Dura-Lith Grease Idler Shaft (KVAL P/N: Lube Monthly EP-2). KVAL 777 Operation/Service Manual 3-18...

  • Page 67: Sample Of Grease Locations For 777

    Sample of Grease Locations for 777 Sample of Grease Locations for 777 This machine is a powerful electro-mechanical Caution motion control system. If servicing this machine, fol- low the safety guidelines. Failure to do so can result in damage to equipment and/or serious injury to person- nel.
  • Page 68 Sample of Grease Locations for 777 Grease Locations Head Identify zerk fittings and apply EP-2 grease. Use an extender to reach tight areas. Make sure to Lockout/Tagout before maintenance. For recommended greasing schedule, see “Lubrication Schedule” on page 3-15. Head Vertical Axis: Moves...

  • Page 69: Grease Locations 4-Shooter Bearings

    Sample of Grease Locations for 777 Grease Locations 4-Shooter Bearings Identify zerk fittings and apply EP-2 grease. Use an extender to reach tight areas. Make sure to Lockout/Tagout before maintenance. For recommended greasing schedule, see “Lubrication Schedule” on page 3-15.

  • Page 70: Description Of Air Input System

    Description of Air Input System Description of Air Input System There are two types of air inputs on KVAL machinery. Not all machines have lubricator option installed. Check your machine or Air prints to verify installation. Air Input with Lubrication The air input system takes in shop air and supplies clean dry air (CDA) and lubricated air to the machine.

  • Page 71: Air Line Without Lubricator

    The air input system takes in shop air and supplies clean dry air (CDA). Shop Air Clean Dry Air (CDA) to Input Blow Off Air On- Off Knob Muffler Filter (purge) Pressure Gauge with adjust Air Distribution Block Air Filter without Lubricator FIGURE 3-13. KVAL 777 Operation/Service Manual 3-23...

  • Page 72: Remove And Replace The Screw Driver Bits

    .To insert screwdriver bit, reverse step 5 above, push bit holder back toward Six- Shooter assembly and hold while inserting new bit. Release holder to secure bit. Remove Driver Bits Bit Holder Lock Slide Bit Holder lock Back Slide Bit Out KVAL 777 Operation/Service Manual 3-24...
  • Page 73 Troubleshooting the 777 This chapter describes troubleshooting steps to help technicians solve issues that may occur with your KVAL machine. If help is needed, call or contact our KVAL Service team at (800) 553-5825 or http://www.kvalinc.com. Refer to the Air and Electrical drawings provided with delivery of the machine.

  • Page 74: About A Typical Contactor Control

    Control Circuit circuitry to the Common DC - Thermal Control Coil for OverLoad 120 Vac. Should measure Line Voltage here Motor Schematic Drawing of Contactor and Thermal Overload Block Diagram of a Common Contactor Circuit FIGURE 1-1. KVAL Operation/Service Manual...

  • Page 75: About Contactor Troubleshooting

    Rerun the machine and verify that motor runs without tripping the circuit. If the same overload keeps tripping, verify condition. Follow circuit path using the E-Drawing as a reference. a.Common issues: Check for bad wire, bad motor, or if load is too great for cur- rent draw. KVAL Operation/Service Manual...

  • Page 76: About Typical Vfd Motor Drive Control

    An adjustable-speed drive is used to control the motor speed and torque by varying motor input frequency and voltage. A variable-frequency drive (VFD) is used in KVAL machinery to accu- rately drive motors for machining or moving product through the machine. The figure below shows a block diagram of a typical motor drive circuit.

  • Page 77: About The Vfd

    The output voltage is then sent to the motor. For a block diagram, see Figure 1-3 on page 1-4 VFD models vary in KVAL machines depending on where it is used, voltage requirements and type of PLC used. This is a general view on the VFD. See the machine’s Electrical Print for detailed information.

  • Page 78: About Vfd Troubleshooting

    Note: The number of reset buttons depends on the machine type and option. The fig- ure above shows a machine with 11 VFDs The VFD manuals are located in the Electrical Panels. On some machines, documentation can be found in the operation station in the documen- tation folder. KVAL Operation/Service Manual...

  • Page 79: About A Typical Pneumatic Circuit

    Schematic Drawing of Pneumatic Circuit Note: In this sample set-up, Port A is nor- mally open and Port B is nor- mally closed. If power is OFF, air should be on Port B. Block Diagram of a Pneumatic Circuit FIGURE 1-6. KVAL Operation/Service Manual...

  • Page 80: Typical Pneumatic Assembly

    About a Typical Pneumatic Circuit Typical Pneumatic Assembly Pneumatic assembly setups vary in KVAL machines depending on where it is used and air requirements.This is a general overview of a pneumatic assembly. See the machine’s Air Print for detailed information.

  • Page 81: About Cylinder Operation

    Router applies the control voltage to the which directs com- Control Valve pressed air to extend port of the Cylinder are extended deactivating the Cylinder Router Retract Sensor fully extends activating the Router Extend Sensor. KVAL Operation/Service Manual...
  • Page 82 Control Valve Cylinder. retract deactivating the Cylinder Router Extend Sensor When the are fully retracted, the is activated. Cylinder Router Retract Sensor senses the voltage from the completing the process Retract Sensor KVAL Operation/Service Manual 1-10...

  • Page 83: Important Notice About Adjusting Cylinder Speed

    However, sometimes machine settling, mechanics be “broken in” may be cause to slightly adjust extend and retraction speed. If more than 1/2 turn on adjustment knobs are needed, call in a specialist or check with KVAL customer service at 1-800-553-5825. KVAL Operation/Service Manual 1-11...

  • Page 84: Adjusting Cylinder Extend Speed

    Adjusting Cylinder Extend Speed Adjusting Cylinder Retraction Speed Tip: If Installing a new flow control assembly, shut down the flow control and back out 4 to 5 turns. this position is a good starting point for kine adjust. KVAL Operation/Service Manual 1-12...

  • Page 85: Using Sensors To Trouble Shoot

    • Check output voltages of the sensors in the active mode. The voltage should effec- tively equal 0 VDC • Check the output voltages of the sensors in inactive mode.The voltage should effec- tively equal 24 VDC KVAL Operation/Service Manual 1-13...

  • Page 86: Troubleshooting Electrical Problems

    Refer to Air and Electrical Schematics provided with delivery of the machine. Schematics are located in the Electrical Panel. If copies NOTE: are unavailable, contact the KVAL Service Department. Have model number and serial number of machine readily available. Prior to performing any maintenance, repairs, cleaning or when clearing jammed debris, you must disconnect, tagout, or lockout the electrical and air pressure systems.
  • Page 87 Note: Most electrical problems are related to mechanical malfunction (e.g., stuck motors, jammed chain, blocked photo sensors etc.) Note: If a solenoid valve is suspected, and not cleared in the air checks section (see), it can be electrically jumped to check operation. KVAL Operation/Service Manual 1-15...

  • Page 88: Troubleshooting With The Status Light Panel

    STEP 4: Stop (Amber) If light is OFF go to item page 1-18. STEP 5: Start (Amber) If light is OFF go to item page 1-19. STEP 6: 24VDC (Green light is OFF go to item page 1-19. KVAL Operation/Service Manual 1-16...
  • Page 89 X1 and X2. If no power is measured it is a bad transformer. b.If there is power at X1 and X2, check the other side of the fuse. If now power, replace the fuse. KVAL Operation/Service Manual 1-17...
  • Page 90 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. KVAL Operation/Service Manual 1-18...
  • Page 91 Check for +24VDC at between any –DC and +DC terminal on the DC Terminal block. Reinstall the (+ 24V positive) wires one by one, checking for +24VDC after installing each. If at any point no voltage is found trace the last reinstalled wire and check for shorts. KVAL Operation/Service Manual 1-19...
  • Page 92 Troubleshooting with the Status Light Panel KVAL Operation/Service Manual 1-20...
  • Page 93 2-23 start machine button KVAL 3-15 power up KVAL Part Number status light panel LUBEKIT 3-15 description 4-16 KVAL, getting help 1-13 use as troubleshooting key 4-16 stop light description 2-23 KVAL 777 Operation / Service Manual...
  • Page 94 4-16 zerk fittings 3-16 locations 3-16 zero-energy start-up clean up 1-11 inspect 1-11 KVAL 777 Operation / Service Manual...
  • Page 96 Contacting KVAL Customer Service Phone and Fax: Mailing address: In the U.S and Canada, call (800) 553-5825 or fax Customer Support Department (707) 762-0485 Kval Incorporated Outside the U.S. and Canada, call (707) 762-7367 825 Petaluma Boulevard South or fax (707) 762-0485 Petaluma, CA 94952 Email: service@kvalinc.com...

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