JBC VPI SYSTEM I, II, III, IV SNAPON LOW DIGITAL BFH 1000 / 800 /800b /800c EEWB504A, EEWB503A, EEWB502A, EEWB516A, EEWB304A, EEWB519A, EEWB526A, EEWB526B, EEWB526C Service Manual VPI System II VPI System III VPI System IV Snapon Low Digital VPI System I December, 2007 All information contained or disclosed in this document is considered confidential and proprietary by Snap-on Equipment Company. All manufacturing, use, repro- duction, and sales rights are reserved by Snap-on Tools Company and the information contained herein shall not be used in whole or in part without the express written consent of Snap-on Tools Equipment. SNAP-on® is a registered trademark of Snap-on Incorporated. TABLE OF CONTENTS Table of Contents INTRODUCTION GENERAL........................................................................................................................................................... I FUNCTIONAL DESCRIPTION .............................................................................................................................. I BASIC BALANCER OPERATION .................................................................................................................. I WEIGHT APPLICATION ................................................................................................................................I ALLOY MODES............................................................................................................................................ I ALU-S MODE ............................................................................................................................................... I DISPLAY / CONTROL PANEL ...................................................................................................................... I GENERAL SPECIFICATIONS AND MACHINE FEATURES ................................................................................ II MAJOR FEATURES .................................................................................................................................... II SPECIFICATIONS ........................................................................................................................................ II IMPORTANT SAFETY INSTRUCTIONS ............................................................................................................. III LOCKOUT AND/OR TAGOUT SYSTEM PROCEDURE .....................................................................................IV ELECTRICAL SAFETY PRECAUTIONS ............................................................................................................IV SERVICE GUIDELINES / HANDLING STATIC SENSITIVE PCB’S ..................................................................... V CHAPTER 1 AC/DC POWER DISTRIBUTION LOCKOUT AND/OR TAGOUT SYSTEM PROCEDURE ................................................................................... 1-1 ELECTRICAL REQUIREMENTS ...................................................................................................................... 1-1 AC THEORY OF OPERATION ........................................................................................................................ 1-2 AC DISTRIBUTION .................................................................................................................................... 1-2 DRIVE MOTOR ......................................................................................................................................... 1-2 DC THEORY OF OPERATION ........................................................................................................................ 1-2 PROCESSOR BOARD ............................................................................................................................. 1-2 ENCODER BOARD .................................................................................................................................. 1-2 DISTANCE POTENTIOMETER (SYSTEM I,II,III,IV SOT LOW DIGITAL) ..................................................... 1-2 DIAMETER POTENTIOMETER (SYSTEM II,III,IV SOT LOW DIGITAL) ...................................................... 1-2 WIDTH POTENTIOMETER (SYSTEM III,IV) .............................................................................................. 1-3 TRANSDUCERS ....................................................................................................................................... 1-3 DISPLAY BOARD ..................................................................................................................................... 1-3 KEYPAD................................................................................................................................................... 1-3 AUTO STOP LOCK SWITCH (VPI III, IV) .................................................................................................. 1-3 ELECTROMAGNETIC BRAKE .................................................................................................................. 1-3 EMBEDDED PCB (SYSTEM IV, BFH) ...................................................................................................... 1-3 TROUBLESHOOTING ..................................................................................................................................... 1-4 PROCESSOR PCB ......................................................................................................................................... 1-7 KEYPAD SCHEMATIC (VPI SYSTEM III) ........................................................................................................ 1-7 KEYPAD SCHEMATIC (VPI SYSTEM I, II) ...................................................................................................... 1-8 KEYPAD SCHEMATIC (SNAPON LOW DIGITAL) ........................................................................................... 1-8 EMBEDDED PC (JBC SYSTEM IV) .............................................................................................................. 1-10 CHAPTER 2 THEORY OF OPERATION FUNCTIONAL DESCRIPTION .......................................................................................................................... 2-1 TERMINOLOGY JBC SYSTEM IV ................................................................................................................... 2-2 TERMINOLOGY JBC SYSTEM III ................................................................................................................... 2-3 TERMINOLOGY JBC SYSTEM I, II ................................................................................................................. 2-4 TERMINOLOGY SNAPON LOW DIGITAL ....................................................................................................... 2-5 BALANCER COMPONENTS ........................................................................................................................... 2-6 MAIN PROCESSOR PCB......................................................................................................................... 2-6 POWER SUPPLY PCB ............................................................................................................................ 2-6 KEYPAD................................................................................................................................................... 2-6 Effective 05/2007 TABLE OF CONTENTS DISPLAY PCB .......................................................................................................................................... 2-6 TEMPERATURE SENSOR ....................................................................................................................... 2-6 DRIVE MOTOR ......................................................................................................................................... 2-6 TRANSDUCERS ....................................................................................................................................... 2-6 SAPE (SEMI-AUTOMATIC-PARAMETER-ENTRY) ................................................................................... 2-7 ENCODER ................................................................................................................................................ 2-7 VIBRATORY SYSTEM .............................................................................................................................. 2-8 ELECTROMAGNETIC BRAKE .................................................................................................................. 2-8 AUTO STOP LOCK SWITCH (JBC SYSTEM III, IV) .................................................................................. 2-8 CHAPTER 3 CHECKOUT, CALIBRATION AND MAINTENANCE GENERAL....................................................................................................................................................... 3-1 SHAFT IMBALANCE, WHEEL ADAPTER TO SHAFT REMOUNT TEST ......................................................... 3-1 BALANCER DIAGNOSTICS (TROUBLESHOOTING) ....................................................................................... 3-1 TROUBLESHOOT USING CORRECT DIAGNOSTICS PROCEDURES ............................................................ 3-2 TOOLS REQUIRED WHEN SERVICING THE Y2K BALANCERS ................................................................... 3-2 FUNCTIONS OF SNAPON / JBC VPI BALANCERS .....................................................................................