COMPONENT WORK SAMPLE 14 Integrated Peer Performance MAINTENANCE MANUAL

COMPONENT WORK SAMPLE 14 Integrated Peer Performance MAINTENANCE MANUAL

Copyright 2003 VALPAR International Corporation P.O. Box 5767 Tucson, Arizona 85703-5767 All rights reserved. No part of this manual may be reproduced or used in any form or by any means, electronic or mechanical, including photocopying or recording, or by any information storage or retrieval system without permission in writing from the publisher.

Table of Contents Section Title Page Introduction... 1 1A Determining if the VCWS14... 2 Functions Properly 1B Microswitch Check and Adjustment... 2 1C Wheel Position Check... 3 2 Trouble Shooting Table... 4 3A VCWS14 Control Box Removal... 5 and Installation 3B Microswitch Removal and Installation... 5 3C Motor Removal and Installation... 5 3D Set Screw Tightening Procedures... 7 Drawings 14.1 Work Sample Diagram... 8 14.2 Wiring Diagram Models from 1974 to 1985... 9 14.3 Wiring Diagram Models from 1985 to Present... 10 14.4 Wiring Diagram International Models 1985 to Present... 11 14.5 Microswitch Diagram... 12 i

INTRODUCTION: This VCWS14 Maintenance Manual is written as an aid for our Valpar VCWS14 customers. The VCWS14 Maintenance Manual covers all models of the VCWS14 built from 1974 to the present. The models of the VCWS14 can be divided into three categories: 1) models built from 1974 to 1985, 2) models built from 1985 to the present, 3) models built for international use. Please refer to the sections of this Maintenance Manual, which pertain to your VCWS14. Please note that this Maintenance Manual does not include information or wiring diagrams for the VCWS14 control box. Valpar considers this proprietary information. Any problems that may occur with the control box must be referred to Customer Service at Valpar International Corporation. The toll-free line is (800) 528-7070. Removal and installation of the control box is covered in section 3A of this manual. 1

1A DETERMINING IF THE VCWS14 FUNCTIONS PROPERLY Plug the work sample into a standard 110-volt wall outlet and turn the table on by moving the switch located on the front of the control box to its upward position. The control box should beep, and the table should rotate to the left within thirty seconds. If the table fails to beep, check the microswitch position and condition, refer to parts 1B and 1C. In the event this fails to solve the problem refer to part 2A of this guide. Approximately two to three seconds after the beep is heard, the table should rotate one station to the left. If the motor fails to come on, or the wheel does not turn, refer to part 2 of this guide for possible causes and solutions. After the table beeps and rotates, check the wheel for slippage. While the wheel is in motion exert downward pressure on it. If the wheel stops while the motor is running, the set screws on the motor shaft will need to be tightened. Refer to part 3D for these instructions. When the table functions properly, the total time between beeps should be about twenty four seconds. The motor will delay for about two seconds after the beep before turning the wheel. The test administration time is about twenty seconds, and is measured from the time the table stops turning until the next beep. These timing intervals are preset at the factory. If adjustment is needed the control box will need to be sent to the Valpar plant to be serviced by a qualified technician. The table should stop with the assembly sections in the center of the work stations. If the microswitch functions properly, the wheel speed alone will adjust the wheel stops. The knob in front of the control box is for speed adjustment. Turning this knob clockwise will increase the wheel speed. This will cause the assembly stations to move to the left. Turning the knob in the counter clockwise direction will have the opposite effect. Several attempts may be required for the wheel to stop correctly. After adjusting the speed, watch the table for several minutes to determine if it is skipping stations. Refer to section 2E for solutions to this problem. 1B MICROSWITCH CHECK AND ADJUSTMENT The microswitch is a small device, which controls the stops of the VCWS14 wheel. Refer to figure 14.3 for a drawing and description. The switch is mounted through the table so that the roller hits stops on the under side of the wheel. On models built from 1974 to 1985 the stops consist of slots cut into the bottom of the wheel. The slots are spaced so that the microswitch s small wheel drops into them as the table rotates. On models from 1985 to the present the stops consist of plastic strips which protrude from the bottom of the wheel. As the wheel turns, the microswitch strikes these stops. The wheel should then stop in the correct place on the table. The microswitch is a delicate electronic device and is easily damaged. Damage usually occurs when the table is moved. If the wheel is accidentally turned backwards (clock-wise) the microswitch will be damaged. To check for damage, remove the microswitch from the table. Refer to part 3B for the removal instructions. Check the microswitch arm (fig 14.3). The arm should be straight not bent. Sometimes straightening the arm will solve the problem. As a rule, the microswitch will need to be replaced. 2

1C WHEEL POSITION CHECK One problem exclusive to the present model VCWS14 table (1985 or later) is that the microswitch will get stuck on the stops. This usually occurs when the table is first turned on and is not warmed up. To determine if this is the problem, look between the red wheel and the table near the control box. The microswitch wheel should be visible. Look to see if it is resting on one of the stops. If the microswitch is stuck, the control box will never get the signal to reset its timing, and the red wheel will not rotate until it is repositioned. To reposition the red wheel, carefully push it about one inch in the counter clockwise direction. A click will be heard when the microswitch wheel drops off the stop. Turn the table off and on to reset the control box. If the microswitch gets stuck on the stop again, increase the wheel rotation speed. After the work sample begins to function correctly, refer to part 1A to correctly the wheel speed. 3

PART 2 VCWS14 TROUBLE SHOOTING TABLE 1/25/00 PROBLEM POSSIBLE CAUSE SOLUTION 2A VCWS14 WILL 1) BLOWN FUSE REPLACE FUSE NOT BEEP 2) DEFECTIVE CONTROL BOX CALL VALPAR CUSTOMER SERVICE 3) BREAK IN WIRES REWIRE VCWS14 REFER REFER TO FIGURE 14.2 4) MICROSWITCH IS REPOSITION WHEEL POSITIONED ON THE STOP REFER TO PART 1C 2B VCWS14 BEEPS BUT 1) BLOWN FUSE REPLACE FUSE DOES NOT RUN 2) DEFECTIVE CONTROL BOX CALL VALPAR CUSTOMER SERVICE 3) BREAK IN WIRES REWIRE VCWS14 REFER REFER TO FIGURE 14.2 4) DEFECTIVE MOTOR REPLACE MOTOR REFER TO PART 3C 5) MICROSWITCH IS REPOSITION WHEEL POSITIONED ON THE STOP REFER TO PART 1C 2C VCWS14 RUNS BUT THE 1) SPEED INCORECTLY CHECK WHEEL SPEED SPEED WILL NOT ADJUSTED ADJUSTMENT REFER TO ADJUST PART 1A 2) DEFECTIVE CONTROL BOX CALL VALPAR CUSTOMER SERVICE 3) DEFECTIVE MOTOR REPLACE MOTOR REFER TO PART 3C 2D VCWS14 RUNS BUT THE 1) LOOSE PEDESTAL TIGHTEN SET SCREWS WHEEL DOES NOT TURN SET SCREWS REFER TO PART 3D 2E VCWS14 RUNS BUT IT 1) DEFECTIVE CONTROL BOX CALL VALPAR SKIPS STOPS OR DOES CUSTOMER SERVICE NOT STOP IN THE RIGHT PLACE 2) BROKEN MICROSWITCH REPLACE MICROSWITCH 4

3A REFER TO PART 3B VCWS14 CONTROL BOX REMOVAL AND INSTALLATION If the control box needs to be returned for repair, it must first be removed from the table. It is also advisable to remove the microswitch and send it along with the control box to the Valpar plant. Refer to part 3B for instructions for removing the microswitch. On models made prior to 1985 there are two mounting screws, which go through the control box and into the table. On models made 1985 and later, there are four mounting screws on the lip of the control box. Unplug the work sample from the wall outlet. Pull out the plug in the back of the control box. Remove the mounting screws and the control box will come off the table. Reverse these steps to remount the control box after it has been repaired. 3B MICROSWITCH REMOVAL AND INSTALLATION The microswitch is located under the table about one inch behind the control box. Unplug the control box from the wall outlet. Disconnect the microswitch by loosening the terminal screws that connect the wires to the switch. Remove the two Phillips head mounting screws from the table. The microswitch should come loose. Remove the two machine screws that hold the microswitch to the angle bracket. Reverse the above steps to remount the microswitch to the table. Mount the microswitch to the angle bracket. Be sure the roller (small microswitch wheel) is to the left when the angle faces toward the front. On the VCWS14 manufactured prior to 1985, three wires will need to be connected to the microswitch. For units manufactured after 1985, only two wires are connected. On both models the red wire connects to the common terminal and the white wire connects to the normally open terminal. On the earlier models the black wire will connect to the normally closed terminal. 3C MOTOR REMOVAL AND INSTALLATION Unplug the VCWS14 from the wall outlet. When removing the motor, first remove the microswitch so it will not be damaged. Refer to part 3B for removal instructions. Turn the work sample upside down on a table or on the floor. 5

I) Models Built Prior to 1985 On models built prior to 1985 the motor is mounted with an angle bracket. Remove the three bolts that fasten the motor to the angle bracket. Loosen the Allen set screws located on the pedestal between the motor and the red wheel. Cut the wires about three inches from the motor. The motor should slide straight up. Slide the new motor on the pedestal. Fasten the motor to the angle bracket using the same three bolts. Tighten the Allen set screws. Strip about one half inch of insulation from the blue and yellow wires that are still connected to the control box. Connect these wires to the same colored wires on the motor using the wire nuts provided. Turn the table over and remount the microswitch. Refer to part 1A to prepare the work sample for use. II) Models built between 1985 and 1987 Models built in this period use a wooden box for the motor mount. Take the top off the box by removing the four screws. The motor is suspended in the box with two nylon bolts with rubber ends. Use a 9/16" wrench to loosen the nuts on both bolts. The motor is now held in place with two Allen set screws located on the pedestal between the motor and the red wheel. The set screws can only be accessed from the front opening of the motor mount box. Turn the red wheel until one of the set screws is lined up with the front opening. Loosen the set screw using a 1/8" Allen wrench. Turn the red wheel until the other set screw can be loosened. Cut the wires between the motor and control box on the outside of the motor mount box. Slide motor out of the pedestal and out of the motor mount box. Strip about 1/2 inch of insulation from the yellow, blue, and green wires from the control box. Install the new motor by first sliding the three wires connected to it through the motor mount box. Connect the three wires from the new motor to the appropriate colored wires on the control box, using the wire nuts provided. Slide the new motor on the pedestal and tighten both Allen set screws. Tighten both motor suspension bolts until the rubber ends are very snug against the motor housing. Check for play in the motor by rocking the red wheel back and forth. If the motor also rocks, the nylon bolts need to be tightened. After the motor is secure in the box, remount the top of the motor mount box. Turn the table over and remount the microswitch. Refer to part 1A to prepare the work sample for use. 6

III) Models Built from 1987 to Present The present model VCWS14 motor is suspended from the table and is fastened with a metal bracket. Two nylon bolts with rubber ends pass through the bracket and fasten tightly against the back of the motor housing. Loosen the nuts on both nylon bolts with a 9/16" wrench. Remove the motor bracket from the table using a 7/16" wrench. The motor is now held in place with two Allen set screws located on the pedestal between the motor and the red wheel. Loosen both set screws using an 1/8" Allen wrench. Cut the blue, yellow, and green wires about half way between the motor and control box. Slide the motor out of the pedestal. Strip about 1/2 inch of insulation from the three cut wires from the control box. Connect these wires to the same colored wires on the new motor with the wire nuts provided. Slide the new motor into the pedestal and tighten the Allen set screws. Remount the motor bracket rotating the red wheel as necessary to line up the motor. Tighten the nylon bolts against the motor housing. Check for play in the motor by rocking the red wheel back and forth. If the motor also rocks, the nylon bolts need to be tightened. After the motor is secure, turn the table over and remount the microswitch. Refer to part 1A to prepare the work sample for use. 3D SET SCREW TIGHTENING PROCEDURES If the red wheel slips it is necessary to tighten the pedestal set screws. To find the pedestal look under the table. The motor is connected to the red wheel with the pedestal. Two set screws fasten the pedestal to the motor shaft. Turn the red wheel counter clock-wise until one of the set screws can be accessed. Tighten the set screw with an 1/8" Allen wrench. Turn the table on and let the wheel rotate until the other set screw can be accessed. Turn the table off and tighten the second set screw. Refer to part 1A to check the wheel for slippage. Repeat the above procedure until the wheel stops slipping. 7

Figure 14.1 8

Wiring Diagram MODELS FROM 1974 TO 1985 Figure 14.2 9

Wiring Diagram MODELS FROM 1985 TO PRESENT Figure 14.3 10

Wiring Diagram INTERNATIONAL WIRING FROM 1985 TO PRESENT Figure 14.4 11

Figure 14.5 12