Related Manuals for Kval MDA-66
Summary of Contents for Kval MDA-66
- Page 1 Operation and Service Manual Published: 5/17/18 Innovation, Quality & Honesty MDA-66 Inspection Table MDA-11 Door Pre-Hanging Machine MDA-66 MDA-11...
- 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 KVAL MDA-6 Operation/Service Manual 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.
- Page 4 KVAL MDA-6 Operation/Service Manual...
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Page 5: Table Of Contents
Operating the MDA-11 ..................2-3 About the MDA-66 ..................... 2-5 Assemblies on the MDA-66 ................2-5 The MDA-66 Main Electrical Panel ..............2-6 Description of the Five Light Panel ..............2-7 Powering Operations MDA-66 ................2-8 How to Power Up ..................2-8 How to Power Down.................. - Page 6 Table of Contents Pulley and Idler Shafts................... 3-6 Description of Air Input System ................3-7 Air Input with Lubrication ................3-7 Air Line Without Lubricator ................3-8 Chapter 4 Troubleshooting About a Typical Contactor Control..............4-2 About Contactor Troubleshooting ..............4-3 Limit Switches .....................
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Page 7: Introduction
Procedure to power up your machine for the first time. Page 1-10 Zero-Energy to Start-Up This section describes the method to contact the KVAL service center Page 1-12 Getting Help from KVAL for help. The section includes how to get information from the speci-... -
Page 8: About This Manual
About this Manual 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. KVAL Operation/Service Manual... -
Page 9: Safety First
See “Safety Sign-Off Sheet” on page 1-15. 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 10 All cylinders on machine are under high pressure and can be very dangerous when activated. 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 1-8. KVAL Operation/Service Manual...
- Page 11 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 Operation/Service Manual...
- Page 12 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.
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Page 13: 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 Operation/Service Manual... -
Page 14: 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 Operation/Service Manual... -
Page 15: 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 Operation/Service Manual... -
Page 16: 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 1-12. Check Controls Confirm that all switches are in the “OFF”... - Page 17 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 Operation/Service Manual 1-11...
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Page 18: 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 19 • 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 20 Getting Help from KVAL Page Intentionally Left Blank KVAL Operation/Service Manual 1-14...
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Page 21: 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 22 Safety Sign-Off Sheet KVAL Operation/Service Manual 1-16...
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Page 23: Operation
CHAPTER 2 Operation This chapter describes components, assemblies, and the operation of the KVAL MDA-66 and MDA-11. The content is geared to help operators understand the basic operation of the machine. Chapter 2 at a Glance Section Name Summary Page... -
Page 24: About The Mda-11
This machine is the first part of the process to assemble the doors. Assemblies on the MDA-11 Pickle Fork Shaft Assembly Pickle Fork Air Cylinder Movable Fence Movable Fence Fixed Fence Jamb Shelves Pickle Fork Air (3 each side) Pickle Fork Air Cylinder Controls KVAL Operation/Service Manual... -
Page 25: Operating The Mda-11
Note: Both the fixed fence and the movable fence will move in-tandem. 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. Pickle Fork (Shown in the extended position) KVAL Operation/Service Manual... - Page 26 Attach hinges/jam to the door. Attach Hinges Jam on the Shelf Pull Up the width adjust button. This will cause the pickle forks to retract. Move the fences apart to free doors. Move doors out to the machine. KVAL Operation/Service Manual...
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Page 27: About The Mda-66
About the MDA-66 About the MDA-66 On the MDA-66, double door units roll in from a KVAL door and frame assembly station.The pri- mary support rolls are 30” wide to accept two 1’4” door panels contained in frame door unit. -
Page 28: The Mda-66 Main Electrical Panel
The MDA-66 Main Electrical Panel The MDA-66 Main Electrical Panel Figure 2- 1 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. -
Page 29: Description Of The Five Light Panel
Description of the Five Light Panel Description of the Five Light Panel The six lights on this panel indicate the status of the MDA-66 system. The Sequence that the lights activate is as follows: Control Power Overload Relay E-Stop Stop Start Stop –... -
Page 30: Powering Operations Mda-66
Powering Operations MDA-66 Powering Operations MDA-66 This section describes how to power up and to power down the MDA-66. 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
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: Operating The Mda-66
Operating the MDA-66 Operating the MDA-66 Follow the steps below to operate the MDA-66. Slide doors into machine. While the door is on the table, perform packing, adding trim or work required. If needed. use the Pop-Up Foot pedal to Note: raise the 39.0”... -
Page 33: Chapter 3 Maintenance
This chapter describes preventative maintenance steps for KVAL MDA-66. 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 pro- duction process. -
Page 34: Maintenance Schedule
Maintenance Schedule Maintenance Schedule KVAL recommends the following maintenance schedule to ensure that the machine operates properly. Daily, Monthly, Six Month Maintenance Daily Preventive Maintenance Operation Description Clean Blow off dust from the entire machine.Wipe down the outside of the machine with a clean dry cloth. -
Page 35: Lubrication Schedule
Lubrication Schedule Lubrication Schedule KVAL recommends the following lubrication schedule to ensure that the machine operates prop- erly. Recommended Lubrication Schedule TABLE 3-2. Type of Recommended Schedule Recommended Assembly Lubrication Type Linear Bearing Pillow Block Bearing Every 250 Hours of Machine Operation... -
Page 36: 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 3-2. KVAL MDA-6 Operation/Service Manual... -
Page 37: 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 3-4. KVAL MDA-6 Operation/Service Manual... -
Page 38: Pulley And Idler Shafts
Breakout of Pulley Assembly Pulley in Action Grease IN Note: It is important not to overfill the Idler Shaft. Avoid get- ting excess grease on the Grease Out belts Idler Shaft KVAL MDA-6 Operation/Service Manual... -
Page 39: 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 40: Air Line Without Lubricator
Usually 1 drop of oil every other cycle is a good rule of thumb. The approved list of oil for lubricators is as follows: • KVAL P/N SYSLUBG • Chevron AW Hydraulic Oil 32 • G-C lubricants light AW R&O •... - Page 41 Description of Air Input System KVAL MDA-6 Operation/Service Manual...
- Page 42 Description of Air Input System KVAL MDA-6 Operation/Service Manual 3-10...
- Page 43 Troubleshooting 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.
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Page 44: About A Typical Contactor Control
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 4- 7. KVAL MDA-6 Operation/Service Manual... -
Page 45: 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 46: 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 47: 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 48 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...
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Page 49: 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 50 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 51 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 52 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 53 12 power up 8, 9 return material authorization (RMA) 12 dura-lith grease, bearing lube 3 returning the product to Kval 12 electrical panel 6 safety guidelines 3 e-stop light Safety Sign Off Sheet description 7...
- Page 54 Index locations 4 zero-energy start-up clean up 10 inspect 10 KVAL MDA-Series Manual...
- Page 56 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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