14
ROCON LLC
TROUBLESHOOTING
Unit Will Not Power Up
1. Make sure the power cable is correctly plugged into the unit. The DeltaPoint Uno flowmeter display
shows a 3-digit number (bright-red digits). It may or may not be flashing.
2. Check the connector on J4 (see
) to ensure that the 6-pin receptacle is
plugged in correctly to the board.
3. If the power cable is plugged in correctly, and you have ensured that the 24 V is present, unit must be
replaced. Contact factory for RMA number, and a box for shipping if necessary.
Unit Will Not Start
**
The flowmeter requires a minimum of 1.5 LPM (0.4 GPM) to operate. If water flow is below minimum,
the display will blink 0.00 and send a fault alarm. The following tests determine the amount of water flow
available, if the hose or fittings are restricting water flow, or if the weld gun arms are faulty.**
Insufficient Water Flow
Suggested procedure to confirm amount of water flow available or if there is some restriction in the
circuit:
1. Turn water off by closing the water shut-off valves.
2.
Remove hoses “TO CELL” and “FROM CELL” from the unit and install a 5-foot hose loop
between them (the loop will be the same hose size and mating fitting).
3. Open the water shut-off valves.
4. Power up the unit. Does the flowmeter indicate water flow?
If yes, proceed to next step.
If not, contact supervisor.
**Unit indicates that water is present. The next step is to determine if there is a blockage or hose
dress problem between the unit and the weld gun arms.**
5. Close the water shut-off valves, remove the 5-foot hose loop, and reinstall the gun arm hoses to
the unit.
6. Remove the hoses at the manifold (or tee) just before they are divided into 2 separate hoses to
each weld gun arm.
7. Connect the supply and return hoses together and turn the water shutoff valves open.
8. Power up the unit. Does the flowmeter indicate water flow?
If yes, proceed to next step.
If no, inspect hose and fitting for a blockage, i.e. the fitting is not drilled through, or dirt is blocking
flow in hose or fitting, or hose is kinked.
**Unit indicates that water is present. The next step is to determine if there is a blockage in the weld
gun arms.**
9. Close the water shut-off valves. Connect the hoses to the manifold.
10. Turn the water back on.
11. Power up the unit. Does the flowmeter indicate water flow?
If yes, unit is working.
If no, inspect hose, fitting and weld gun arms for a blockage, i.e. the fitting is not drilled through or
dirt is blocking flow in hose or fitting. The hose dress may be incorrect. The water tubes are too
close to the caps, or the water tube is pinched, or the weld gun arms have never been tested for
water flow and must be disassembled.
Supervisor
: Above testing indicated no water flow from main header to hose drops to cell. Please
confirm that: (1) the number of pumps in operation is correct for a normal production day; (2) the headers
to zone in question are operational and no bypass valves are open; and (3) no shut-off valves have
closed, thus blocking the water flow through the header.
Check for air buildup in the cooling header circuit. Since electrode tips are replaced daily, small amounts
of air can leak into, and get trapped, in the piping. The rusty water that is observed in closed-loop cooling
systems is the result of this trapped air. Please note that trapped air can also damage the flow sensor.
The vortex flowmeter requires that there is continuous presence of water moving past the bluff body. If
there is any air in the line, water hammering can fracture the internal components of the sensor.