SIDE BELT NEST ASSEMBLY INSTRUCTIONS

Transcription

1 SIDE BELT NEST ASSEMBLY INSTRUCTIONS People. Products. Solutions.

2 TABLE OF CONTENTS SIDE BELT NEST PARTS ASSEMBLY FIXTURE NEST ASSEMBLY CONNECTING TROUGHS TO NESTS AND TABLE INSTALLING WALL COVERS SEWING BELT STARTUP INSTRUCTIONS TROUBLESHOOTING GUIDE TABLE PARTS BELT RETURN PARTS TABLE WIRING DIAGRAM PRODUCT WARRANTY PAGES VAL-CO recommends that you read the entire instruction manual before you begin assembling any parts. Order and method of assembly can greatly affect the quality and effectiveness of this product. For customer service, call Monday-Friday from 8:00am to 5:00pm EST. VAL-CO - Manual Page 1

3 8 SIDE BELT NEST PARTS VAL-CO - Manual Page 2

4 PARTS LIST & DRAWING KEY DETAIL # PART NUMBER QTY/ DESCRIPTION LEFT TOP ROOF SECTION RIGHT TOP ROOF SECTION BOTTOM ROOF SECTION ANTI-ROOST PLATE SUSPENSION BRACKET ANTI-ROOST SUPPORT BRACKET RIGHT PARTITION NARROW PLASTIC NEST BOTTOM NARROW EGG DEFLECTOR 5 GA. GALVANIZED ROD " WIRE ROD CLIP LEFT PARTITION 20H FRONT PARTITION BRACE PERCH BOARD PERCH BRACKET NEST TROUGH COVER NEST TROUGH BRACE TROUGH ASSEMBLY RH 8/20H TROUGH ASSEMBLY LH 8/20H LOOP HINGE TROUGH JOINER VAL-CO - Manual Page 3

5 HARDWARE PARTS LIST & DRAWING KEY 1 2 ½ (12.7 mm) 5/16 (7.9 mm) DETAIL # PART NUMBER QTY/ DESCRIPTION 1/4-20 NYLOCK NUT #10-24 HEX KEP LOCKNUT 1/4-20 X 2-1/4" HEX BOLT #10-24 X 1/2" UNLSOTTED HEAD MACHINE SCREW 7/64" X 3/4" COTTER PIN #62 X 3/16" ALL-ALUMINUM EASY RIVET #64 X 3/16" ALL-ALUMINUM EASY RIVET VAL-CO - Manual Page 4

6 WOOD ASSEMBLY FIXTURE (optional) We recommend the use of an assembly fixture of some kind. Below is an example of a simple fixture that can be used for holding the middle panel and partitions during assembly. Material List: (2) 2 x 4 x 96 Boards (1) 24 x 96 Plywood (20) Nails 2) Saw (9) 1/8 grooves across both boards to create (10) equal distant slots for partitions. (Approximately 9-9/16 ) 1} Lay (2) 2 x 4 x 96 boards parallel to plywood with approx. 1/8 gap between boards,to hold middle panel. Nail 2 x 4 s to plywood being careful not to place a nail where you are going to saw. VAL-CO - Manual Page 5

7 PARTITIONS TO MIDDLE PANEL Arrow pointing this way Partitions are marked L and R (1) L Partition & (10) R Partitions LEFT SIDE (1) R Partition & (10) L Partitions RIGHT SIDE Position middle panel in fixture and rivet (11) left partitions and (11) right partitions to panel as shown in diagram above. Be sure to note direction of arrow in middle panel. Use (3) rivets per partition. Partitions are identified with an L or R cutout for ease in assembly. (SEE PHOTO) One side (Left Side) gets (1) L partition and (10) R partitions the other side (Right Side) gets the opposite. When viewed from either end the L partition is always to the left-hand side and the R partition is to the right. Partitions can be riveted from either side. Be sure rivet is thru both partitions before riveting. Turn assembly on side to finish riveting bottom set of holes. (SEE PHOTO ON RIGHT) Remove assembly from fixture and rivet bottom set of holes as shown above. VAL-CO - Manual Page 6

8 PARTITION BRACE AND TROUGH ASSEMBLY Rivet partition brace to partitions as shown. Leave 2nd partition from both ends and the center partition open until trough and brackets are assembled, Align arrows on brace and middle panel before riveting Rivet partition brace to the third hole from bottom of each partition skipping the 2nd partition from both ends and the center partition. (SEE PHOTO ABOVE) After riveting partition brace to the partitions, slide assembly to edge of table so you can rivet trough assemblies to partitions. There is a right and left trough so be sure to align arrows on front trough panel with arrows on assembly. (SEE PHOTO ON RIGHT) Align these arrows. VAL-CO - Manual Page 7

9 TROUGH AND ROD ASSEMBLY Rivet trough assembly to the bottom hole in each partition. Rivet from the trough side as shown. Do not rivet end partitions until trough connectors are assembled to trough ends Rivet (2) rod clips to one end partition. Rivet from outside of partition and position clips to bottom of each J slot. (SEE PHOTO) These clips can be repositioned as needed later VAL-CO - Manual Page 8

10 TROUGH AND ROD ASSEMBLY Thread [2] rods thru partitions and back into clips. Place (2) more clips on other end of rods and rivet them to the slots in the other end partition same as first end. VAL-CO - Manual Page 9

11 NEST BOTTOMS, PADS AND DEFLECTOR ASSEMBLY Position nest pad in nest bottom so nap on pad is running toward egg trough and secure pad under tabs on sides of bottom. If using finger pads, use cable ties to secure pad to bottom. Place bottom in nest so lip on bottom fits into slot in trough. Bottom should slide between partitions and rest on previously installed rods. Position egg deflector behind partition brace and hook one ear under nest bottom. Pull other ear back and snap under nest bottom. Center deflector in opening and check that both ears are under nest bottom. VAL-CO - Manual Page 10

12 NEST BOTTOMS, PADS AND DEFLECTOR ASSEMBLY Align holes in deflector and brace and rivet secure from inside nest so rivet head is against plastic deflector VAL-CO - Manual Page 11

13 TROUGH BRACKETS TO TROUGH ASSEMBLY Place trough brace between partition and partition brace. Align holes and rivet all (3) braces secure with /2 (12.7 mm) long rivets. See drawing below. Place other end of brace inside front trough panel and rivet end braces secure with short rivets. Do not rivet center brace to trough at this time. Rivet trough braces to 2nd partition from both ends and center Long Rivet Short Rivet Long Rivet Leave Open Do not rivet Long Rivet Short Rivet VAL-CO - Manual Page 12

14 TROUGH COVER Place (3) hinges through openings in trough covers so flat side is against front panel as shown in photo. Position on nest and rivet as shown in drawing below. Use hole next to both end trough braces and rivet trough cover to nest using long rivets. Center trough brace and center hinge on trough cover are riveted to front panel at same time with (1) long rivet Assemble perch board to trough covers with (4) brackets, 1/4 x 2-1/4 bolts and 1/4 locknuts per side. Assemble bracket so legs are against perch board as shown in photos on next page. VAL-CO - Manual Page 13

15 PERCH BOARDS Assemble perch board to trough covers with (4) brackets, 1/4 x 2-1/4 bolts and 1/4 locknuts per side. Assemble bracket so legs are against perch board as shown in photos. VAL-CO - Manual Page 14

16 ROOF PANELS AND ANTI-ROOST BRACKETS Get (1) Right & (1) Left top panel and lay on top of partitions keeping arrows in top panels aligned with arrow in middle panel. Rivet (1) anti-roost bracket to both top panels and middle panel (2) rivets starting with hole to right of arrows as shown below. Rivet (4) more brackets to assembly on same side as first but skip every other set of holes. When all (5) brackets are riveted on one side, go to other and rivet (4) more brackets to remaining open holes. Finish riveting top panels to partitions with (2) rivets in each end partition and (1) rivet in each middle partition. After both top panels and (9) anti-roost brackets are assembled to nest get (2) bottom panels and place (3) hinges in each as shown in left picture. Bend hinge legs together and rivet to top panels with (1) rivet per hinge. Total (3) rivets per panel. VAL-CO - Manual Page 15

17 ROOF PANELS VAL-CO - Manual Page 16

18 ANTI-ROOST ANGLES Get (2) anti-roost angles and lay on top of each other with the peaks together. Align holes and place cotter pin through holes so that head of cotter pin is on side that will be up. Check that hole pattern in bottom angle will match anti-roost brackets previously assembled to nest. Bend legs on cotter pins outward and secure angles together. Place angles on brackets and rivet bottom angle to brackets with short rivets VAL-CO - Manual Page 17

19 SUSPENSION BRACKETS Assemble (1) suspension bracket to last two holes on top of each end. Use (2) #10-24 x 1/2 hex bolts and locknuts per bracket. Suspension Bracket VAL-CO - Manual Page 18

20 CONNECTING TROUGH BETWEEN NESTS Connect loose end of both trough joiners on ends of Right and Left trough assemblies to end partitions on nest with (1) long rivet per joiner. Be sure to attach joiners before setting nest so you can reach under trough easier After setting nest, you can now assemble connector troughs between nest. Rivet one end of connector trough to joiner on (1) nest with (2) rivets. Align nest with adjoining nest and rivet other end of connector. Rivet from inside of joiners when possible to prevent interference with belt. Rivet from inside of joiner VAL-CO - Manual Page 19

21 ATTACH CONNECTING TROUGH TO TABLE After attaching (1) end of connector trough to nest as described on previous page, remove table trough bracket from back of table and save hardware to reuse later. Fasten bracket to connecting trough with the (2) #10 bolts and nuts still on bracket. Slide trough and bracket back onto table keeping the trough lip above the table. Reattach bracket to table. VAL-CO - Manual Page 20

22 INSTALL WALL COVERS INSTALL WALL COVERS (2 PER COLLECTION TABLE) TO RESTRICT AIRFLOW Wall Covers are included with each collection table install as shown to restrict airflow through the oversized wall openings cut for the connector trough & cover assemblies. VAL-CO - Manual Page 21

23 SEWING BELT TOGETHER Thread belt through all nest troughs, connecting troughs, return assembly and table. See close-up on belt path through table in startup instructions. Begin splicing by removing slack from the belt. Pull the belt tight from the nest side until the belt tensioner is in the horizontal position, allowing 8 of overlap for splicing. Hold ends of belt tight by using C clamps and short 2 x 4 s to prevent damaging belt. Position the belt end from the table over the belt from the nest, making sure the edges are lined up and even. Apply a 1/4 bead of glue according to the glue pattern shown. Keeping the bead about 1/4 away from the edge of the belt. From the time you start to apply the glue you have approximately 15 seconds open time to complete the splice. Position the splice under a belt clamp or heavy object for approximately 2 minutes. Take the object off and allow the glue to harden for about 5 minutes more before sewing. Sew the belt according to the drawing starting on the outside of the glue around the edges. Now make an X in the middle of the splice. Run a 1/4 bead of glue along the cut edges to prevent fraying. Allow the glue to harden for about 5 minutes before running your system. The belt may stretch during operation making it necessary to periodically remove the excess and resplice as needed. TOP VIEW Belt from table Place on Top Belt from nest Place on Bottom SIDE VIEW Glue and Stitch Pattern 1/4 Glue Bead between belts. CAUTION The glue gun gets hot. The nozzle area temperatures reach 380 degrees. VAL-CO - Manual Page 22

24 STARTUP INSTRUCTIONS 1) Loosen all (3) bolts on both legs before adjusting height of table. Bolts must be loose enough to allow legs to slide. 2) Turn adjuster rod clockwise to lower table and counterclockwise to raise. Tighten side bolts securely after adjusting. 3) Run egg belt through table as shown on decal attached to back of access door. BELT PATH VAL-CO - Manual Page 23

25 4) Pull belt tight until counterweight is 2-3 links below sprocket. Mark belt and stitch secure as shown on previous page. 5) Plug power cord into proper outlet. Check that reset button is in on ground fault interrupter(gfi) CAUTION! BE SURE POWER IS OFF BEFORE CHANGING BELT DIRECTION TOGGLE SWITCH. 6) Flip belt direction toggle switch located below table up for belt to travel toward front of table (forward). Flip switch down to run belt away (reverse) VAL-CO - Manual Page 24

26 8) Turn power on 7) Turn controller dial to 0 9) Slowly turn dial up to desired speed. 10) To adjust tracking of belt loosen {4} nuts on drive roll bearing 11) Turn adjuster knob until belt runs true. Retighten nuts. VAL-CO - Manual Page 25

27 TABLE TROUBLESHOOTING GUIDE PROBLEM Table will not run and overhead light does not turn on. Motor runs but one or both rollers do not turn. Belts running in wrong direction Belts slipping on drive rolls Belts not tracking straight SOLUTION Test button is set on ground fault receptacle. Push reset button. Controller is not turned on. Be sure switch is in on position. Check fuse in controller. Replace with 8 amp fuse if needed. Belt direction toggle switch under table is not engaged. Be sure switch is either up or down. Lovejoy couplers are not engaged. Slide couplers to end of shaft. Place spider between couplers and tighten set screws on coupler. Chain is not tight. Loosen bolts on chain tensioner and pull tensioner up until chain is tight. Retighten bolts. Belt direction toggle switch under table is in wrong direction. Flip switch to opposite direction. Not enough pressure on pinch rollers. Adjust nuts on pinch roll spring tensioner brackets. Belt tensioner weight is loose due to normal stretching of belt. Cut belt and restitch. Drive rollers need adjusting. Loosen bolts on outside bearings and turn adjustment knob on front of table until belt tracks straight. VAL-CO - Manual Page 26

28 COLLECTION TABLES CAT # DESCRIPTION /2 HP, 110V /4 HP, 110V /2 HP, 220V (Int l) /4 HP, 220V (Int l) VAL-CO - Manual Page 27

29 SIDE BELT COLLECTION TABLES KEY # PART NO. DESCRIPTION QTY. KEY # PART NO. DESCRIPTION QTY V DC CONTROLLER ROLLER SHAFT CONTROLLER MOUNT /8" DRIVE ROLLER ADJUSTER KNOB HOUSING TIE FRONT PANEL ACCESS DOOR GFI RECEPTACLE IDLER SPROCKET RECEPTACLE BOX /2" LOCKING COLLAR DRIVE SHAFT SPROCKET SHAFT COUPLER SPIDER 2 34A COUNTER WEIGHT " FLEX COUPLER #40 ROLLER CHAIN 19" /4 X 1/4 X 1" KEY #40 MASTER LINK " FLANGE BEARING TENSIONER BASE DRIVE ROLLER SPROCKET TENSIONER SHAFT /4 X 1/4 X 1" KEY TENSIONER BACK ROLLER CHAIN TIGHTENER TENSIONER ROLLER IDLER SPROCKET SHAFT TENSIONER SLIDE PLATE /2" LOCKING COLLAR EGG GUIDE BRACKET TENSIONER HANDLE NEST - TABLE BRACKET LEFT CHAIN HOUSING FRT. EGG GUIDE BRKT #40 ROLLER CHAIN 54" ROLLER COVER #40 OFFSET LINK PINCH ROLL BRACKET #40 MASTER LINK SPRING RT. CHAIN HOUSING LEFT HOUSING CHAIN HOUSING BASE RIGHT HOUSING ELECTRIC BOX DRIVE ROLL RPM GEARBOX LEG TIE PLATE /2HP ELECTRIC MOTOR /2" THRD ROD W/NUT RIGHT BASE CHANNEL LIGHT FIXTURE LEFT BASE CHANNEL LIGHT BULB RIGHT LEG RIGHT LEG BASE /2" CASTLE NUT MOTOR MOUNT LEFT LEG LEFT LEG BASE /8" X 3/4" ROLL PIN EGG PLATE FOOT PAD LEFT RACK ARM SUPPORT SCRAPER SUPPORT SCRAPER BRACKET BRUSH RETAINER RACK TOP RACK BASE RACK ARM BELT SCRAPER LOCKING SPRING PLUNGER 5" BRUSH RT RACK ARM SUPPORT RACK ARM SUPPORT TABLE TOP BRUSH BRACKET TABLE MAT /16" X 1/2" CLEVIS PIN EGG GUIDE COTTER PIN MOUNT PLATE LITTER DRAWER DRIVE SHAFT LITTER DRAWER RETAINER /4 X 1/4 X 5 KEY PINCH ROLL SHAFT 2 65& WALL COVER 2 VAL-CO - Manual Page 28

30 BELT RETURN 26 CONNECTING TROUGHS ORDERED SEPERATELY KEY PART NO. QTY. DESCRIPTION KEY PART NO. QTY. DESCRIPTION RETURN BACK PANEL BELT SHIELD BELT COVER CLEVIS PIN RIGHT CASE RETURN TROUGH BRKT LEFT CASE /16" NYLOK NUT ROLLERS /16" FLAT WASHER BRUSH BRACKET /16" X 3/4" HEX BOLT RT. ADJUSTER BRKT /16" LOCK WASHERS LEFT ADJUSTER BRKT /16" FLANGE NUTS ADJUSTER KNOBS /16" X 1-1/4" BOLT BRUSHES /16" NUT BRUSH RETAINERS #8 X 3/8" TAP SCREW LOCKING PLUNGER /16" POP RIVET DBL THREAD SHAFT COTTER PIN SGL THREAD SHAFT /8" HEX NUT VAL-CO - Manual Page 29

31 110 VOLT TABLE WIRING DIAGRAM VAL-CO - Manual Page 30

32 VAL PRODUCTS, INC. WARRANTIES VAL-C0 MANUFACTURED PRODUCTS OTHER THAN EXTENDED WARRANTY PRODUCTS Val Products, Inc. (Val Products) warrants to the original purchaser that Val Products manufactured products (other than the products subject to an extended warranty set forth below) will be free of defects in material and workmanship for a period of one (1) year from and after the date of original purchase and when used in a usual and customary fashion. If Val Products is notified that such a defect exists within one year of the original purchase date and, upon inspection, agrees that the product is defective, Val Products will, at its option, (a) repair or replace (FOB Val Products plant) the defective product, or (b) refund to the original purchaser the original purchase price paid for the defective product less any installation, shipping, or other charges associated with the original purchase. All defective products must be returned to a Val Products designated location for evaluation. Val Products determination as to whether the product is defective is final. See the General Conditions and Limitations set forth below. NIPPLE DRINKERS EXTENDED WARRANTY Val Products, Inc. (Val Products) agrees to the following extended warranty with respect to VR Series and VL Series Nipple Drinkers manufactured by Val Products: VR Series and VL Series Nipple Drinkers that prove to be defective in workmanship or material and become unusable within a period of five (5) years from and after the date of original purchase will be repaired or replaced, at Val Products option, at no charge (excluding labor of removal and installation), FOB Val Products plant. VR Series and VL Series Nipple Drinkers which prove to be defective in workmanship or material and become unusable after five (5) years but within ten (10) years of the date of original purchase will be repaired or replaced, at Val Products option, at a pro rated cost basis (excluding labor of removal and installation) to the original purchaser, FOB Val Products plant, on the following basis: Year six (6), customer pays 50% of the current price, year seven (7), customer pays 60% of the current price, year eight (8), customer pays 70% of the current price, year nine (9), customer pays 80% of the current price, and year ten (10), customer pays 90% of the current price. All defective Nipple Drinkers must be returned to a Val Products designated location for evaluation. Val Products determination as to whether the product is defective and unusable is final. See the General Conditions and Limitations set forth below. FIBERGLASS FAN HOUSINGS EXTENDED WARRANTY Val Products, Inc. (Val Products) agrees to the following extended warranty with respect to the fiberglass fan housings manufactured by Val Products on VAL-CO PMC Power Miser 12, 16, 21, 24, 36, 48, and 50 Fiberglass Fans that prove to be defective in workmanship or material and become unusable over the life of the structure where the VAL-CO Fiberglass Fan was originally installed after original purchase, provided that the fan has remained undisturbed in its original installation location, will be repaired or replaced, at Val Products option, at no charge (excluding labor of removal and installation and shipping), FOB Val Products plant. All defective fan housings must be returned to a Val Products designated location for evaluation. Val Products determination as to whether the product is defective and unusable is final. See the General Conditions and Limitations set forth below. VAL-CO - Manual Page 31

33 FIBERGLASS FAN MOTORS EXTENDED WARRANTY Val Products, Inc. (Val Products) agrees to the following extended warranty with respect to the fiberglass fan motors included as original equipment on VAL-CO PMC Power Miser 12, 16, 21, and 24 Fiberglass Fans manufactured by Val Products that prove to be defective in workmanship or material and become unusable within a period of two (2) years from and after the date of original purchase will be repaired or replaced, at Val Products option, at no charge (excluding labor of removal and installation and shipping), FOB Val Products plant. All defective fan motors must be returned to a Val Products designated location for evaluation. Val Products determination as to whether the product is defective and unusable is final. See the General Conditions and Limitations set forth below. General Conditions and Limitations Applicable to All Val Products, Inc. (Val Products) Warranties, Including Extended Warranties The Product must be installed and operated in accordance with instructions published by Val Products or the warranty will be void. Warranty will be void if all components of the product or system are not original equipment supplied by the manufacturer. Products not manufactured by Val Products and supplied by outside manufacturers (such as, but not limited to, certain electrical motors, certain controls, gas valves, etc.) are warranted separately by the respective manufacturer and only to the extent of the manufacturer s warranty. Warranty applies only to products used in applications as originally intended by Val Products other applications in industry or commerce are not covered by the Warranty. Val Products products are expressly not designed or authorized for use in any applications where intended to sustain or support human life or any other application where the failure of the product could result in personal injury or death. Malfunctions resulting from misuse, abuse, mismanagement, negligence, alteration, accident, lack of proper maintenance, lightening strikes, electrical power surges, or electrical power interruption shall not be considered defects under the Warranty. Corrosion, material deterioration and/or equipment malfunction caused by or consistent with the excessive additions of chemicals, minerals, sediments or other foreign elements with the product shall not be considered defects under the Warranty. VAL PRODUCTS WILL NOT, UNDER ANY CIRCUMSTANCES, BE LIABLE FOR ANY KIND OF SPECIAL, INCIDENTAL, CONSEQUENTIAL, OR CONTINGENT DAMAGES INCLUDING, BUT NOT LIMITED TO, LOST OR DAMAGED PRODUCT, GOODS OR LIVESTOCK, COSTS OF TRANSPORTATION, LOST SALES, LOST ORDERS, LOST INCOME, INCREASED OVERHEAD, LABOR AND INCIDENTAL COSTS AND OPERATIONAL INEFFICIENCIES. IN NO EVENT SHALL THE WARRANTY LIABILITY EXCEED THE INVOICED PRICE OF THE PRODUCT TO THE ORIGINAL PURCHASER. THE WARRANTIES SET FORTH ABOVE CONSTITUTE VAL PRODUCTS ENTIRE AND SOLE WARRANTY. VAL PRODUCTS EXPRESSLY DISCLAIMS ANY AND ALL OTHER WARRANTIES INCLUDING, BUT NOT LIMITED TO, ANY AND ALL OTHER EXPRESS OR IMPLIED WARRANTIES AS TO THE MERCHANTABILITY, FITNESS FOR A PARTICULAR PURPOSE OR USE, DESCRIPTION OF QUALITY OF THE PRODUCT FURNISHED, AND ANY OTHER WARRANTY ARISING BY OPERATION OF LAW, CUSTOM OR USAGE. Val Products denies any authorization of any distributor, dealer, agent, or employee to modify, extend, or otherwise alter the conditions of any warranty in addition to, or in lieu of, those conditions and terms expressly stated above. Any exceptions not noted in the body of the Warranty must be authorized in writing by an officer of Val Products. Val Products reserves the right to change or delete models, or change specifications at any time without notice or obligation to improve previous products. VAL-CO - Manual Page 32

34 PEOPLE. PRODUCTS. SOLUTIONS. CUSTOMER SERVICE USA & CANADA VAL-CO 210 E. Main St. P.O. Box 117 Coldwater, OH USA Toll Free: Phone: Fax: INTERNATIONAL VAL-CO P.O. Box 958 Lancaster, PA USA Phone: Fax: VAL-CO - Manual Page 33