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1-1

CHAPTER 1

Introduction to the MDA-6 and MDA-E

This chapter provides an overview of the

Kval MDA-6

and the

Kval MDA-E

machines and important

safety information to follow when operating the machine.

Chapter 1 at a Glance

TABLE 1- 1.

Section Name

Summary

Page

Safety!

IMPORTANT safety information is described in this section

Page 1-5

Zero-Energy to Start-Up

Procedure to power up your machine for the first time.

Page 1-12

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 center hours, and return

procedures

Page 1-14

Safety Sign-Off Sheet

A record to track operators that are trained on the machine.

Page 1-18

Summary of Contents for MDA-6

Page 1: ...Innovation Quality Honesty MDA E Operation Service Manual Published July 28 2021 MDA 6 Door Pre Hanging Machine With MDA E Brickmold Machine Operation and Service Manual ...

Page 2: ... or registered trademarks of their respective holders all rights reserved Reference to these products is not intended to imply affiliation with or sponsorship of Incorporated Contacting Customer Service For further information about this manual or other Incorporated products contact the Customer Support Department Mailing address Customer Support Department Incorporated 825 Petaluma Boulevard Sout...

Page 3: ...t your user experience with our product that is the manual the machinery the software etc What was easy or difficult to use or to learn If you could change something about the design what would it be Please email your comments and suggestions for improve ment to userexperience inc com NOTE This is not a customer support email link For that please refer to the Customer Service contact information a...

Page 4: ...KVAL MDA 6 Operation Manual ...

Page 5: ... Procedure 1 10 Pre Steps Before Lockout Tagout 1 10 Lockout Tagout Power 1 10 Lockout Tagout Air Supply 1 11 Start Maintenance 1 11 Post Maintenance Steps 1 11 Zero Energy to Start Up 1 12 Getting Help from Kval 1 14 Kval Return and Warranty Policy 1 15 Send the Item 1 15 Acceptance of Return 1 15 Refund Turnaround Time 1 15 Kval Errors 1 15 Customer Errors 1 16 Shipper Errors 1 16 Warranty Repla...

Page 6: ...ate the MDA 6 2 8 About the MDA E Brickmold Machine 2 9 Overview of the MDA E 2 9 Procedure to Process to Operate the MDA E 2 10 Chapter 4 Troubleshooting About a Typical Contactor Control 4 2 About Contactor Troubleshooting 4 3 Limit Switches 4 4 Troubleshooting Electrical Problems 4 5 If the Power Stops During Normal Operation 4 5 Troubleshooting with the Status Light Panel 4 7 ...

Page 7: ...ty information is described in this section Page 1 5 Zero Energy to Start Up Procedure to power up your machine for the first time Page 1 12 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 center hours and return procedures Page 1 14 Safety Sign...

Page 8: ...ated with an two electric foot pedal for up and down Much more heavy duty that the standard cylinder and required for 8 0 doors or doors heavier than 100lbs including frame and glass Option B Out swing Door Support Rollers and Delrin rails pivot up in seconds to transport inverted door frames from the light install station to the pivot table Standard Acrobat requires out swings to be lifted and ca...

Page 9: ...e wheels The inner gap between the wheels also accepts doors with lights installed up to 25 wide at the outside of the light frame The assembled door unit is then rolled into the next work station for finish packaging Available Options Option Title Description Option Z OutSwing Transfer Support UHMW plastic rails mounted to the machine frame to allow transference of outswing units by gliding on ra...

Page 10: ...s the following Chap ter Title Description 1 Introduction Descriptions of Machine Line and Safety Information 2 Operation Inter face Descriptions of how to power machine line and operator inter face user screens 3 Maintenance Maintenance steps for the machine line 4 Troubleshooting Troubleshooting tips and theory of operation ...

Page 11: ...amaged or illegible There are three types of warning labels or decals DANGER means if the danger is not avoided it will cause death or serious injury WARNING means if the warning is not heeded it can cause death or serious injury CAUTION means if the precaution is not taken it may cause minor or moderate injury Safety Guidelines In addition to the caution and warning labels affixed to this machine...

Page 12: ... down Never perform any maintenance unless machine is at zero state Never clean the machine while it is running Never walk away from the machine while it is running When the Machine is ON The compressed air system connected to this machine should have a three way air valve for shut off and pressure relief All cylinders on machine are under high pressure and can be very dangerous when activated Bef...

Page 13: ...ocated at different locations Before performing any repairs or mainte nance lockout and tagout must be installed at all locations All maintenance and repairs to electrical circuitry should only be per formed by a qualified electrician Still has power in OFF position Electrical Prior to performing any maintenance repairs cleaning or when clearing jammed debris you must disconnect tag out or lock ou...

Page 14: ...dent If you believe any part or operation of this machine is in violation of any health or safety regulation STOP pro duction It is your responsibility to immediately protect your employees against any such hazard Additional detailed safety guidelines are included in the operating instructions of this manual KVAL will be pleased to review with you any questions you may have regarding the safe oper...

Page 15: ...ck and tag on each disconnect Only each operator may remove their own lock and tag Important When many people are all working on the same machine you will need a multiple lockout device such as the one shown here 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 ...

Page 16: ...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 Turn off machine See Chapter 2 for power down and power up procedures 5 Turn the disconnect switches on ALL electrical and frequency panels to the OFF position Then push the red tab to po...

Page 17: ...tc are completely removed and that all guards and safety devices are installed 10 Before removing the locks and tags the person who attached them shall inspect the equipment to ensure that the machine will not be put in an unsafe condition when re energized 11 The lock and tag can now be removed only by the person s who placed them and the machine can be re energized 12 The tags must be destroyed ...

Page 18: ...ally when energy is restored Remove Locks Each operator must remove his or her own lock and tag This will ensure that all oper ators are in a safe place when the equipment is started Perform Visual Checks If the equipment is too large to see all around it station personnel around the area and sound the personnel alarm before starting the equipment If your operation is more complex your company s c...

Page 19: ...the key to your lock Proper lockout tagout can save lives limbs and money Help make your work environment safe for you and your fellow workers 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 ...

Page 20: ...d record the serial number 3 phase volts electrical print number and air print number 2 Contact our customer support team 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 service Kvalinc com Hours 6 00 AM to 4 00 PM Pacific Standard Time Monday through Thursday 6 30 AM to 1 30 PM Pacific Standard Time Frid...

Page 21: ...ton RMA _______________ Send the Item Return the item to this address Kval Inc RMA ______ Kval Parts 825 Petaluma Blvd South Petaluma CA 94952 USA Acceptance of Return We can only accept items for a return if they are still in their original packaging and in undam aged resalable condition Returns are accepted within 45 days of purchase and with an RMA number issued by Kval Inc Returns after 45 day...

Page 22: ...val s warranty or for claims based upon failure of or defect in the products regardless of when the failure or defect arises and whether a claim however described is based upon contract warranty indemnity tort extra contractual liability including negligence strict liability or otherwise Normal wear and tear and deterioration during use shall not constitute a defect in material or manufacture unde...

Page 23: ...Kval Return and Warranty Policy 1 17 KVAL MDA 6 Operation Service Manual Page Intentionally Left Blank ...

Page 24: ...follow my company s safety procedures I have read and understand these guidelines Machine Safety Concerns I have been given a tour of the machine and understand all the safety labels E Stops and the actions to take in case of an emergency I will make sure all guards are in place before operation I will turn off the compressed air before loading hardware staples screws etc I will turn off the elect...

Page 25: ...E The content is geared to help operators understand the basic operation of the machine Chapter 2 at a Glance Section Name Summary Page About the MDA 6 Descriptions of the operation of the parts and assemblies of the machine Page 2 2 Powering Operations Descriptions of power up power down homing and emergency stops Page 2 6 About the MDA E Description of the operation of the MDA E Page 2 9 ...

Page 26: ... This section describes controls and assemblies on the MDA 6 FIGURE 2 1 Electrical Motor Lifts the table up and down Foot Switch Controls the Lift Controls Controls are located at this end to activate and deac tivated the Pop ups Option I Width Cylinders Locations Holster ...

Page 27: ...sent 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 FIGURE 2 2 Overview of Main Electrical Panel and High Frequency Panel Main Electrical Panel Control Trans former 24VDC and 120Vac Terminal Block High Voltage Section Disconnect PDR Fuses Pump Contactor and Thermal Over load Circuit Relays ...

Page 28: ...ripped to identify the maximum and minimum limit of the lift The Limit Switch is activated by an assembly moving a switch arm Depending on the model of limit switch the amount of pre travel amount of movement from the arms resting position is either 5 or 20 degrees before the limit switch actuates Clicks Switch Arm ...

Page 29: ...ght illuminates when the Control Transformer is pulled out and the power is working on secondary side of transformer Overload Relay The overload circuit is working when light is on E Stop The back gate is closed and Frame E stop is not acti vated when this light is on 24VDC light comes on once the ACR is latch and the 24VDC power Supply is working Stop This light will be on if Machine Stop button ...

Page 30: ...ing power from the entire system How to Power Up the Machine 1 Ensure factory air is applied to machine and main air supply is turned on 2 Make sure the electrical disconnect the electrical cabinet is turned to the ON posi tion 3 Pull the green CONTROL TRANSFORMER button out to the ON position It should light up 4 Push the green START MACHINE button to initialize the machine 5 The Six Lights will ...

Page 31: ... Panel 2 Push the green CONTROL TRANSFORMER switch to the OFF position 3 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 electri cal storms Step 3 Turn Off Disconnect Step2 Push In the Control Transformer Button Step 1 Press the Red Stop Button ...

Page 32: ...cated at the front of the machine Note If processing a door with raised moulding press switches to engage the cylin ders Optional MDA 6 may not have this feature 1 Roll the door into the machine 2 Operate the foot switch to bring the door to the vertical position 3 Remove door to start the next process step Width cylinder controls ...

Page 33: ... the exterior of the door unit The table is designed to support doors ranging from 2 6 up to 3 0 on parallel rows of urethane wheels The inner gap between the wheels also accepts doors with lights installed up to 25 wide at the outside of the light frame Note The MDA E is a fully pneumatic operated machine No electrical wiring is needed Overview of the MDA E ...

Page 34: ... E 1 Roll a door into the machine on non marking wheels 2 Operate the pneumatic switch once to lower the door Approximately 5 3 Place the brickmold onto the exterior side of the unit and fasten it into place 4 Operate the pneumatic switch again to raise the door 5 Roll the door to the next work station for finish packaging ...

Page 35: ...ur door production process Chapter 3 at a Glance Maintenance Schedule This section describes the assemblies to schedule for maintenance Daily Weekly 5 Six Month Checkups Page 3 2 Lubrication Requirements This section describes the lubrication requirements for the machine including types of lube to use This section includes Linear Bearings Flange Bearing and Pillow Blocks Gear Motor Lubrication Req...

Page 36: ... Check the air filter water trap Empty if full Weekly Preventive Maintenance Op Operation Description 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 SYS...

Page 37: ... Pillow Block Bearing Flange Block Bearing Ball Screw Every 80 Hours of Machine Operation Idler Shafts Pulley Monthly Tapered Bearing One Pump 4 Times a Year Air Line Lubricator One drop of oil every 2 or 3 cycles Check the lines every week to two weeks Note Some CNC Machines drop every 5 10 cycles Either lubricant listed below is approved to use KVAL P N SYSLUBG Chevron AW Hydraulic Oil 32 G C lu...

Page 38: ...The Zerk fitting is basically a valve that opens under pressure to allow lubricant to pass through a channel and be forced into the voids of the bearing When the pressure stops the ball returns to its closed position The ball excludes dirt and functions as a check valve to prevent grease escaping back out of the fitting The ball is almost flush with the surface of the fitting so that it can be wip...

Page 39: ...nd align the bearing Flanges are also used with bearings on external housings used to mount a bearing unit A mounted bearing unit acts as a system to position the bearing securely for reliable operation FIGURE 3 3 Flange Bearings Greasing Flange Bear ing Bearing Housings Approximatively 1 Gram one pump from grease gun of Dura Lith Grease KVAL P N Lube EP 2 Every 250 hours of operation Lip ...

Page 40: ...nance For recom mended greasing schedule see Lubrication Schedule on page 3 3 Note Some bearings may be difficult to get access to Use an extender to reach tight areas 1 Perform Lockout Tagout 2 Identify zerk fittings and apply EP 2 grease See Figure 3 4 3 After lubrication is completed reverse Lockout Tagout FIGURE 3 4 MDA 6 Lubrication Points Shaft Assembly X2 ...

Page 41: ...ecom mended greasing schedule see Lubrication Schedule on page 3 3 Note Some bearings may be difficult to get access to Use an extender to reach tight areas 1 Perform Lockout Tagout 2 Identify zerk fittings and apply EP 2 grease See Figure 3 4 3 After lubrication is completed reverse Lockout Tagout FIGURE 3 5 MDA E Lubrication Points Shaft Assembly X2 Opened Pillow Block X4 ...

Page 42: ... delivers the lubricated air to valve banks and air cylinders FIGURE 3 6 Typical Air Line Filter and Lubrication System Adjusting the Air Line Lubricator Using the knob on the top of the lubricator adjust until one drop per every other cycle is used as observed through sight glass Shop Air Input Air On Off Knob Muffler Filter purge Pressure Gauge with adjust Clean Dry Air CDA to Air Blow Off Lubri...

Page 43: ... Harmony 32 To prime the lubricator find an air line on the carriage section of the machine that is energized and disconnect 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 procedure for the back section and other trouble areas It is recommended to chec...

Page 44: ...Description of Air Input System KVAL MDA 6 Operation Service Manual 3 10 ...

Page 45: ...or Control Describes a typical contactor control circuit Page 4 2 Limit Switches Troubleshooting Limit Switches Page 4 4 Troubleshooting Electrical Problems Includes voltages in the electrical panels using the Status Light panel to troubleshoot Page 4 5 Refer to the Air and Electrical drawings provided with delivery of the machine The drawings are normally located in the Electrical Panel If copies...

Page 46: ... 2 Block Diagram of a Common Contactor Circuit High Voltage may cause personnel injury or death Troubleshooting checks must be performed by a Qualified Electrical Technician PLC Output Fuse s Line Voltage Power Contactor Control Coil Input Power Input Power Output Control Circuit Common ON Should measure Control Voltage 120 VAC here Should measure Line Voltage here Should measure Line Voltage here...

Page 47: ...e circuit See Troubleshooting with the Status Light Panel on page 4 7 1 Open the Main Electrical Cabinet to find the Contactor Thermal Overload Assem bly 2 Press each Green Reset button on the Thermal Overload An audible click will be heard on the tripped circuit Take note of tripped circuit 3 Once the overloads are reset verify LED s are on 4 Rerun the machine and verify that motor runs without t...

Page 48: ... than likely the cause Depending on the model of limit switch you receive the amount of pre travel amount of movement from the arms resting position is either 5 or 20 degrees before the limit switch actuates Clicks If the arm is moved to the full extents of its travel and you do not here the limit switch Click the switch needs to be adjusted here is how you adjust it follow the following drawings ...

Page 49: ...atching the lights turn on or off Compare the lights on the IDEC or Beckhoff controllers 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 Check the Six Lights on the Electrical Panel See Troublesh...

Page 50: ...emergency stops tripped 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 it can be electrically jumped to check operation 4 With the power off check for motor overloads by pressing each reset button usu ally at the bottom of the panel in SEQUENC...

Page 51: ...e the cause NOTE Be sure to proceed down the table starting with the CONTROL POWER light STEP 1 Control Power Amber If light is OFF go to item A on Page 4 8 STEP 2 Overload Relay Amber If light is OFF go to item B on Page 4 9 STEP 3 E Stop Amber If light is OFF go to item C on Page 4 9 STEP 4 Stop Amber If light is OFF go to item D on Page 4 9 STEP 5 Start Amber If light is OFF go to item E on Pag...

Page 52: ...ck the wiring of the black and white wire going from the Control Transformer to the 120 VAC Terminal Strip 7 If there is no power between 1 and 2 check the secondary side of the trans former a Check between 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 2 Is the Disconnect Switch on the main ...

Page 53: ...est or Stop Trip Indicator Factory Set Current Rating Adjust E Stop Light OFF Check if any E Stop buttons are 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 Stop Light OFF Check for 120 VAC between 2 and 4 If there is voltage press the Start button If ...

Page 54: ...eck for DC voltage where those wires were disconnected If no voltage Check the input side for 120 VAC If no 120 VAC check the fuse If there is 120 VAC and no 24VDC replace the 24VDC Power Supply If there is 24VDC Reconnect the V wire to the 24VDC power supply Trace the output wire to the DC terminal block Disconnect all 24V positive wires from the DC from the DC terminal block except the output wi...

Page 55: ...2 overload relay light description 5 P PLC location in main electrical panel 3 power lock out procedure 10 power up troubleshooting 5 powering up and down machine 6 R RKG 3 Entry Door 9 S safety guidelines 5 Safety Sign Off Sheet Safety Concerns 18 sensors types 4 six light panel description 5 sequence list 5 start light description 10 start light description 5 start machine button power up 6 stat...

Page 56: ...Index MDA 6 and MDA E Operation and Service Manual ...

Page 57: ...Notes ...

Page 58: ...Index MDA 6 and MDA E Operation and Service Manual ...

Page 59: ...Notes ...

Page 60: ...partment 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 service kvalinc com http www kvalinc com ...

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