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1. Sensor position - The visible red beam should be 1" or less from the center line of the applicator head.
The lower edge of the aluminum sensor housing should be positioned 1-1/2" above the upper wood surface to be detected.
NOTE: If the wood blocks have much wane, it will be necessary to angle the sensor assembly so that the detection point is the LOWER leading edge of the block. Refer to the installation notes for more detail.
2. Manual Valve Operator - On the face of the control panel, locate the "TEST/FLUSH" switch. This switch has 3 positions: up (FLUSH), down (TEST), and the center position for automatic running. This switch must be in the center position.
3. Check that all three plug-in modules located inside the control panel are firmly in place.
With the on/off switch in the "ON" position and the door safety switch pulled out using insulated pliers, perform the following:
1. Remove the #821-23 timer module from its socket; grasp firmly at the lowest base edge of the module. Connect a positive meter lead to terminal (3) and the negative lead to terminal (A). About + 12VDC should appear across the terminals. If the proper power supply voltage does not appear, then the #821-26 power supply is defective.
2. Plug the timer module back into its socket. Connect the negative meter lead to terminal (A) (purple leads) of the timer base and the positive meter lead to terminal (7) (blue). Have an assistant hold the "FLUSH/TEST" switch down in the "TEST" position. The voltage should not exceed the voltage (+11VDC to + 12VDC) measured in the above Step 1. If it does, check to see if the following wires lead to the base terminals as follows:
Terminal A (lower) Double Purple
Terminal B (upper) Red
Terminal 7 (lower) Blue
3. Connect the positive meter lead to terminal (9) (orange) and the negative meter lead to terminal (A) (double purple). With the power turned "ON" and the "FLUSH/TEST" switch down in the "TEST" position, the voltage between (9) and (A) should not exceed 30 VDC. If greater, check to insure that: 1) Terminal (9) has a single orange lead connected to it, 2) Terminal (6) of the #806-2 base has an orange lead.
4. With timer module 23 installed, connect the negative meter lead to terminal (7) (blue) and the positive meter lead to terminal (B) (red). Turn power "ON" and depress the "FLUSH/TEST" switch down to "TEST". The voltage level should go from 12V to 1V. The LED that is located on the inside, upper left side of the #821-23 timer module will be lit. If these conditions are not met, replace the timer module.
5. The condition of relay #821-20 can be verified by observing that the voltage level is 12V between terminals (14) (blue) and (13) (red). This should occur when power is "ON" and the "FLUSH/TEST" switch is down to "TEST".
6. Relay #806-2 condition can be checked by observing the LED at the top of the module. It should be lit when power is "ON" and the "FLUSH/TEST" switch is depressed in the "TEST" position.
7. Relay #821-17 condition is satisfactory if the following conditions are met:
A. With power "ON", "TEST/FLUSH" switch in "TEST" position, a voltage level between terminals (3) and (4) should go from OV to 12V when a wood target is sensed.
B. With power "ON" and the "TEST/FLUSH" switch in "TEST position, the voltage level between terminals (1) and (2) should be about 115V.
8. Before checking the operation of the #822 sensor, check that the four cable leads are as follows:
Terminal 5 White
Terminal 6 Black
Terminal 7 Red
Terminal 8 Green
Then with power "ON", door safety switch pulled out and the "FLUSH/TEST" switch in the "TEST" position, bring a wood target within 1-1/2 inches of the sensor housing. When the wood is detected the red LED should go OUT. It should be lit only when wood is NOT being sensed. If this condition is not met, replace the sensor assembly.
Applicator Valve Assembly - The applicator valve assembly is composed of two sub-assemblies, the air cylinder and the valve body. The moving parts are the air piston and spool valve. The piston drives the spool valve towards the applicator head to open the valve and back to close the valve and create the sniffing action. The parts subject to wear in normal operation are the spool valve (part # 206-07) and the related seals.
If the valve leaks some adhesive in its "OFF" position, this is an indication that the seals are worn. If adhesive backs up into the air cylinder, this condition also indicates worn seals.
Adhesive in the air cylinder will cause valve operation to be sluggish, giving an indication of an electronic timing problem.
Take the valve apart and thoroughly clean all the pieces. Inspect the spool and seals, and replace parts which show wear. Use only APQUIP replacement seals and O-rings. Other seals, though they look the same, will not offer the same resistance to chemical attack or mechanical wear due to compound characteristics.
*****IMPORTANT NOTE*****
Observe the correct orientation of the #206-14 two-part seals that consist of a modified U-cup and O-ring expander. The "open side of the seal that contains the O-ring MUST fact toward the incoming adhesive pressure. The correct orientation of seals is well illustrated in drawing 268. Lubricate all parts with silicone grease which is available from Apquip. DO NOT USE PETROLEUM BASED GREASE.
Therefore, when installing the #206-14 seal in "inlet body" piece #206-5, the lips of the seal must enter the cavity first. However, for "mounting segment", body piece #258-4, the inner seal is installed with the "heel" of the seal entering first while for the outer seal, the lips are inserted first.
Related to the above consideration of seal orientation, note that the #258-24 seal for the air cylinder must have its "open side" face the incoming air pressure to seal effectively.
If the #206-7 valve spool is experiencing unusual wear because of its use with a filled or abrasive adhesive, then use of the ceramic coated version of the spool is recommended. This special spool is normally kept in stock.