-13-
M A C H I N E D O E S N O T O P E R AT E
SYMPTOM
CORRECT
FUNCTION
INDICATOR
POSSIBLE
PROBLEM
ACTION
No Power Indicator.
No display.
Power Indicator goes
on and off with main
power switch.
(A) Incoming
power supply.
(A) Check the incoming power (208-230VAC) L1 and L2 on the Power
Contactor in the Triangle Enclosure.
(B) Power
Contactor.
(B) In the Triangle Enclosure, check the voltage (24VAC approx.) at the coil of
the contactor. If the voltage is present, check the voltage (208-230VAC)
at terminals T1 and T2 on the contactor. If the voltage is present, the
contactor is good. Proceed to step (E). If the voltage at the coil is pres-
ent and T1 and T2 have no voltage, replace the contactor. If the voltage
at the coil is not present, proceed to the next two steps (C and D).
(C) Main Power
Switch.
(C) Check the Main Power Switch terminals B4 and B5 in the Control Con-
sole. Terminals B4 and B5 should have 24VAC approx. when the switch
is in the off position and 0 volts when the switch is in the on position.
If the voltage stays at 24VAC approx. replace the switch. If the voltage
stays at 0 volts proceed to step (D).
(D) 24VAC
Transformer.
(for Contac-
tor only)
(XSFMR-1).
(D) In the Triangle Enclosure, check the transformer primary input volt-
age (208-230VAC) at terminal L1 and L2 of the contactor. Check the
transformer secondary voltage (24VAC approx.) at the coil of contactor.
If the voltage at the coil is not present and step (C) is correct replace
the transformer. (This transformer is for the contactor only).
(E) 24VAC
Transformer.
low voltage
control
(XSFMR-2).
(E) ) In the Triangle Enclosure, check the transformer primary input volt-
age (208-230VAC) at terminal T1 and T2 on the contactor. Check the
transformer secondary voltage (24VAC approx.) at terminals #4T and
#5T. If the voltage at terminals #4T and #5T is not present replace
the transformer.
(This transformer is for all the low voltage control circuits except for
the coil of the contactor).
Power Indicator on.
Initiate Indicator
is not function-
ing.
Initiate Indicator goes
on with Actuator
and off after the
machine cycles.
Trigger
Actuator.
Check the voltage (24VAC approx.) at terminals #4 and # 8 in the Trol-
ley while depressing the trigger. This voltage reading should go from 0
to 24VAC. If this voltage reading is not correct replace or repair the
Trigger Actuator.
Power Indicator on.
Initiate Indicator
is functioning.
Weld Timer Indica-
tor is not func-
tioning.
Weld Timer Indicator
goes on and off
with every cycle.
Weld Timer.
Turn the weld time to the highest setting and check the voltage (24VAC
approx.) at terminals #8 and #9 in the Trolley. This voltage should come
on then go off every time the Trigger Actuator is depressed. If this volt-
age reading is not correct replace the Weld Timer. (0 – 24VAC – 0)
Power, Initiate, and
Weld Timer Indica-
tors are function-
ing.
Feed Reed Switch
indicator is not
functioning.
Feed Reed Switch
Indicator goes on
and off with every
cycle.
Feed Reed
Switch.
The Feed Reed Switch is a safety that will not allow the machine to operate
if the Feed Cylinder has not fully retracted. To test the Feed Reed Switch
jump terminals #7 and #9 in the Trolley. Now try to cycle the machine
with this jumper in place. If the machine operates this means that the
Feed Reed Switch is not functioning. This reed switch is located on the
Feed Cylinder and may be out of position. To check the position, turn the
power off (remove the jumper from the previous test) and loosen the set
screws on the reed switch. Now put an ohmmeter on terminals #7 and
#9. Slide the reed switch back and forth near the rear of the cylinder until
the meter reads continuity. Now lock the set screws. If this procedure
can not be accomplished replace the Feed Reed Switch.
Power, Initiate, Weld
Timer and Feed
Reed Switch Indi-
cators are func-
tioning.
Dwell Solenoid Indi-
cator is not func-
tioning.
Dwell Solenoid
Indicator goes on
and off with every
cycle. (Stays on
150 ms longer
than Feed Reed
Switch Indicator.)
Short Cycle
Relay.
Turn the weld time to the highest setting and check the voltage (24VAC
approx.) at terminals #7 and #8 in the Trolley. This voltage reading
should go from 0 to 24VAC and then back to 0 every time the Trigger
Actuator Switch is depressed. If this voltage reading is not correct
recheck the symptom. Now do the same procedure at terminals #8
and #12 in the Trolley. If this voltage reading is incorrect replace the
Short Cycle Relay.
Power, Initiate, Weld
Timer, Feed Reed
Switch and Dwell
Solenoid Indica-
tors are all func-
tioning.
All lights flash in
sequence.
(A) Air pres-
sure, Adjust-
able Exhaust
Mufflers and
Dwell Cylin-
der.
(A) Check the Air Regulator for proper setting (80psi). Now press the
test button located on the Dwell Solenoid body. If the Dwell Cylinder
does not operate check the Adjustable Exhaust Mufflers connected to
the Dwell Solenoid for proper adjustment. If either or both mufflers are
closed or restricted it will not allow the Dwell Cylinder to operate. Also
check the cylinder by turning the air off and then move the shaft up
and down. The shaft should move freely. If the mufflers (these mufflers
control the speed of the up and down motion on the cylinder) are properly
adjusted and have no restrictions and the Dwell Cylinder operates when
the solenoid test button is pressed proceed to step (B).
(B) Dwell
Solenoid.
(B) Turn the weld time to the highest setting and check the volt-
age (24VAC approx.) at terminals #8 and #12 in the Trolley. The voltage
reading should go from 0 to 24VAC and back to 0 every time the Trigger
Actuator Switch is depressed. If this voltage reading is correct replace
the Dwell Solenoid.
