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Kval MDA-6 Operation & Service Manual

Door pre hanging machine
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Operation/Service Manual
Published: July 28, 2021
Innovation, Quality & Honesty
MDA-6 Door Pre Hanging Machine
With MDA-E Brickmold Machine
MDA-E

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Summary of Contents for Kval MDA-6

  • Page 1 Operation/Service Manual Published: July 28, 2021 Innovation, Quality & Honesty MDA-6 Door Pre Hanging Machine With MDA-E Brickmold Machine MDA-E...
  • Page 2 (800) 553-5825 or fax (707) 762-0485. Outside the U.S. and Canada, call (707) 762- 7367. Manual Part Number: DOC-114-017-1-OPSRV MDA-6 and MDA-E are trademarks of Incorporated. Copyright 2021 Incorporated. All rights reserved. All other products are trademarks or registered trademarks of their respective holders, all rights reserved.
  • Page 3 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 above.) Thank you! http://www.inc.com KVAL MDA-6 System Operation/Service Manual...
  • Page 4 KVAL MDA-6 Operation/Manual...

  • Page 5: Table Of Contents

    Table of Contents Introduction to the MDA-6 and MDA-E Chapter 1 Overview of the MDA-6 and MDA-E ........1-2 MDA-6....................1-2 Available Options..................1-2 MDA-E ....................1-3 Available Options..................1-3 About this Manual .................1-4 Safety First!................1-5 Safety Sheet Sign-Off Sheet..............1-5 Safety Terminology of Labels..............1-5 Safety Guidelines..................1-5...
  • Page 6 Table of Contents Powering Operations of the MDA-6 ......... 2-6 How to Power Up the Machine .............2-6 How to Power Down the Machine............2-7 Process to Operate 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......
  • Page 7 Procedure to power up your machine for the first time. Page 1-12 Zero-Energy to Start-Up This section describes the method to contact the KVAL service center Page 1-14 Getting Help from KVAL for help. The section includes how to get information from the speci-...

  • Page 8: Overview Of The Mda-6 And Mda-E

    (https://kvalinc.com) for contact information. MDA-6 A door is rolled into the MDA-6 Pre-Hanging Machine on non-marking wheels. The door is then ready to have exterior casing applied as well as the finish packaging. The table design supports doors ranging from 2'6" up to 3'0" on parallel rows of urethane wheels.

  • Page 9: Mda-E

    Overview of the MDA-6 and MDA-E MDA-E is designed to make it easy to apply brickmold casing to the exterior of the door unit. MDA-E A door is rolled into the machine on non-marking wheels. For ergonomic reasons, the door is then lowered approximately 5".

  • Page 10: About This Manual

    Overview of the MDA-6 and MDA-E About this Manual includes the following: Operation and Service Manual Chap- Title Description Introduction Descriptions of Machine Line and Safety Information. Operation Inter- Descriptions of how to power face machine line, and operator inter- face user screens.

  • Page 11: Safety First

    See “Safety Sign-Off Sheet” on page 1-18. 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 12 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 1-10. KVAL MDA-6 Operation/Service Manual...
  • Page 13 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 MDA-6 Operation/Service Manual...
  • Page 14 Safety 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 15: 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 MDA-6 Operation/Service Manual...

  • Page 16: 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 MDA-6 Operation/Service Manual 1-10...

  • Page 17: 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 MDA-6 Operation/Service Manual 1-11...

  • Page 18: 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 1-14. Check Controls Confirm that all switches are in the “OFF”...
  • Page 19 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 MDA-6 Operation/Service Manual 1-13...

  • Page 20: Getting Help From Kval

    • 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, Friday KVAL MDA-6 Operation/Service Manual 1-14...

  • Page 21: Kval Return And Warranty Policy

    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 days of purchase or without a Kval Inc. issued RMA number will not be accepted.

  • Page 22: Customer Errors

    Kval provides a warranty to products that are deemed defective. Within 30 days of discovery of said defect, please notify Kval, but no more than one (1) year after delivery will the product be covered under Warranty. The repair, replacement, or payment in the manner described above shall be the exclusive remedy of Buyer for breach of Kval’s warranty or for claims based upon failure...
  • Page 23 Kval Return and Warranty Policy Page Intentionally Left Blank KVAL MDA-6 Operation/Service Manual 1-17...

  • 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 Operation of the MDA-6 and MDA-E CHAPTER 2 This chapter describes components, assemblies, and the user interface of the Kval MDA-6 Kval and the The content is geared to help operators understand the basic operation of the MDA-E. machine. Chapter 2 at a Glance...

  • Page 26: Operator's Tour

    Controls: Controls are located at this end to activate and deac- tivated the Pop-ups Holster Foot Switch: Controls the Lift Electrical Motor: Lifts the table up and down Option I: Width Cylinders Locations FIGURE 2- 1. KVAL MDA-6 Operation/Service Manual...

  • Page 27: The Main Electrical Panel

    High Voltage Section Control Trans- former • Disconnect • PDR • Fuses 24VDC and 120Vac Terminal Block Pump Contactor Relays and Thermal Over- load Circuit Overview of Main Electrical Panel and High Frequency Panel FIGURE 2- 2. KVAL MDA-6 Operation/Service Manual...

  • Page 28: About Limit Switches

    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 KVAL MDA-6 Operation/Service Manual...

  • Page 29: Description Of The Six Light Panel

    Description of the Six Light Panel Description of the Six Light Panel The six lights on this panel indicate the status of the MDA-6 system. The Sequence that the lights activate is as follows: Control Power Overload Relay E-Stop Stop...

  • Page 30: Powering Operations Of The Mda-6

    Powering Operations of the MDA-6 Powering Operations of the MDA-6 This section describes how to power up and to power down the MDA-6 Powering up the system includes: • Applying power to the entire system • Starting the Control Circuit Powering down the system includes: •...

  • Page 31: How To Power Down The Machine

    Push the green switch to the OFF position. CONTROL TRANSFORMER 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 1: Press the...

  • Page 32: Process To Operate The Mda-6

    Pneumatic control switches are located at the front of the machine. : If processing a door with raised moulding, press switches to engage the cylin- Note ders. (Optional, MDA-6 may not have this feature) Width cylinder controls Roll the door into the machine.

  • Page 33: About The Mda-E Brickmold Machine

    25" wide at the outside of the light frame. : The is a fully pneumatic operated machine. No electrical wiring is Note MDA-E needed. Overview of the MDA-E KVAL MDA-6 Operation/Service Manual...

  • Page 34: Procedure To Process To Operate The Mda-E

    Place the brickmold onto the exterior side of the unit and fasten it into place. Operate the pneumatic switch again to raise the door. Roll the door to the next work station for finish packaging. KVAL MDA-6 Operation/Service Manual 2-10...
  • Page 35 Maintenance of the MDA-6 and MDA-E CHAPTER 3 This chapter describes preventative maintenance steps for The con- Kval MDA-6 Kval MDA-E tent is geared to guide technicians to keep a regular maintenance schedule for your machine. Kval Keeping your machine maintained is an important piece for successful operation of your Kval door production process.
  • Page 36 Clean linear bearings and the chrome shaft with a clean dry cloth, then lubricate. Clean Check all air lines & electrical wiring for kinks or rubbing. Check Refill lubricator with an ISO 32 standard hydraulic oil (KVAL part# SYSLUBG) LUBE Six Month Preventive Maintenance Operation Description Wash filter and lubricator bowls with soapy water.
  • Page 37 R&O • Mobile DTE 24 • Shell Tellus32 • Gulf Harmony 32 Typical Lucubration Kit Part Number: LUBEKIT Kval Hydraulic Oil Silicone Spray Grease Gun EP-2 Multi-FAK Extension Adapter Grease Needle Nozzle E Adapter Needle Nozzle KVAL MDA-6 Operation/Service Manual...
  • Page 38 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 3-2. KVAL MDA-6 Operation/Service Manual...
  • Page 39 Bearing Flange Bear- Greasing Housings Approximatively 1 Gram (one pump from grease gun) of Dura-Lith Grease (KVAL P/ Every 250 hours N: Lube EP-2). of operation. Flange Bearings FIGURE 3-3. KVAL MDA-6 Operation/Service Manual...
  • Page 40 Some bearings may be difficult to get access to. Use an extender to reach tight Note: areas. Perform Lockout/Tagout. Identify zerk fittings and apply EP-2 grease. (See Figure 3- 4 ) After lubrication is completed, reverse Lockout/Tagout. Shaft Assembly (X2) MDA-6 Lubrication Points FIGURE 3- 4. KVAL MDA-6 Operation/Service Manual...
  • Page 41 Some bearings may be difficult to get access to. Use an extender to reach tight Note: areas. Perform Lockout/Tagout. Identify zerk fittings and apply EP-2 grease. (See Figure 3- 4 ) After lubrication is completed, reverse Lockout/Tagout. Opened Pillow Block (X4) Shaft Assembly (X2) MDA-E Lubrication Points FIGURE 3- 5. KVAL MDA-6 Operation/Service Manual...
  • Page 42 Once you have a steady flow, tighten knob back down until you have one drop per every other cycle. Drop will form at end of cane shaped tube visible inside glass. KVAL MDA-6 Operation/Service Manual...
  • Page 43 The air input system takes in shop air and supplies clean dry air (CDA). Shop Clean Dry Air (CDA) to Air Blow Off Input Air On- Off Knob Muffler Filter (purge) Pressure Gauge with adjust Air Distribution Block Air Filter without Lubricator FIGURE 3-7. KVAL MDA-6 Operation/Service Manual...
  • Page 44 Description of Air Input System KVAL MDA-6 Operation/Service Manual 3-10...

  • Page 45: Chapter 4 Troubleshooting

    CHAPTER 4 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 46: About A Typical Contactor Control

    Control Circuit Common DC - Control Coil for Thermal OverLoad 120 Vac. Should measure Line Voltage here Motor Schematic Drawing of Contactor and Thermal Overload Block Diagram of a Common Contactor Circuit FIGURE 4- 2. KVAL MDA-6 Operation/Service Manual...

  • Page 47: 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 MDA-6 Operation/Service Manual...

  • Page 48: Limit Switches

    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. KVAL MDA-6 Operation/Service Manual...

  • Page 49: 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. Warning The following checks require the electrical panel to be energized.
  • Page 50 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. KVAL MDA-6 Operation/Service Manual...

  • Page 51: Troubleshooting With The Status Light Panel

    STEP 4: Stop (Amber) If light is OFF go to item Page 4-9. STEP 5: Start (Amber) If light is OFF go to item Page 4-10. STEP 6: 24VDC (Green light is OFF go to item Page 4-10. KVAL MDA-6 Operation/Service Manual...
  • Page 52 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 MDA-6 Operation/Service Manual...
  • Page 53 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 MDA-6 Operation/Service Manual...
  • Page 54 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 MDA-6 Operation/Service Manual 4-10...
  • Page 55 10 power up troubleshooting 5 powering up and down machine 6 RKG-3 Entry Door 9 safety guidelines 5 Safety Sign Off Sheet Safety Concerns 18 sensors types 4 six light panel description 5 MDA-6 and MDA-E Operation and Service Manual...
  • 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 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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