8 TROUBLESHOOTING 8-1 Causes and remedies Fault Cause
Contents
1. sequencer turns on when the FEED TEST button is switched on and off Replace if found to be faulty Check the solenoid valves in manual mode and replace them if found to be faulty Check the input of the sequencer comes on when the selector switch is turned on and off Replace the switch if found to be faulty Adjust the air pressure to within the range of 0 4 MPa to 0 6 MPa Check the input of the sequencer comes on when the selector switch is pushed Replace the switch if found to be faulty Check and replace the relay if found to be faulty Page57 B OCT a la ia ley ie n E 8 2 6 Solenoid valve operation in manual Solenoid valve assembly installation Contact your local dealer 8 2 9 Sequencer LED lamp layout 8 2 6 Solenoid valve operation in manual Solenoid valve assembly installation Contact your local dealer 8 2 9 Sequencer LED lamp layout 9 4 2 Air supply pressure check Contact your local dealer 8 2 9 Sequencer LED lamp layout 8 2 9 Sequencer LED lamp layout 7 8 Relay installation2. Replace the chute track if no improvement is observed Adjust the air blow timer Check if air is supplied Adjust the air pressure to within the recommended range of 0 4 MPa to 0 6 MPa Repair a deformed vinyl bolt feed tube or replace it if damaged Check solenoid motion in manual mode and if the solenoid cannot be activated replace it Adjust the timer setting Turn the air supply off and check the air cylinder motion by hand Replace the cylinder if these motions are not smooth Replace the separator if wear or deterioration is noticed Contact your local dealer to check and correct the program Paged3 B OTETI PISIS e 3 ghee 8 2 3 Removal of the vinyl tube from the separator assembly 8 2 1 Chute track A procedure Air supply pressure check 8 2 6 Solenoid valve operation in manual mode 7 5 Solenoid valve assembly installation procedure Contact your local dealer Contact your local dealer Contact your local dealer DENGENSHA EUROPE LTD Unit 8 Birchbrook Industrial Park Shenstone Staffordshire WS14 ODJ United Kingdom ana nI ei S a ea waa dale d Eie AUTOMATIC Ne ie eae Ot ERATE el eg Re Faut cause _______ pemesy____reteronco Vinyl bolt feed tube bent or Adjust the vinyl bolt feed tube 5 3 21 broken or replace it Vinyl bolt feed tube installation Wear of vinyl bolt feed tube Replace the vinyl bolt feed 8 2 3 scratched dented tube Removal of the vin
3. DENGENSHA EUROPE LTD Unit 8 Birchbrook Industrial Park Shenstone Staffordshire WS14 ODJ United Kingdom Ro oe ea Es ah i CIE WELDING AU TO M AT IC NED ie oe OE t PAT I3 LED i3 igh oe 8 TROUBLESHOOTING 8 1 Causes and remedies Faut_ cause Remedy Roterence Main isolator not Turn main isolator 5 3 30 switched on switch to ON position Power on Power supply wires Connect the power 5 3 29 not connected supply wires Power supply wire connection Power not supplied Check if power is supplied Ce Sequencer PLC protection Inspect F5 fuse in the fuse fuse blown and no power box and replace if it is blown supplied to the sequencer The fuse used is a 250V 2A glass fuse Inspect F1 and F2 fuse in the fuse box and replace if they are blown Turn the air supply off and pull the spindle out to the stroke end then make the alignment Correct the bolt feed unit mounting angle Correct angle is 30 No power supplied to the DC stabilizing power supply unit because of blown fuse Spindle jaws not correctly aligned with guide pin in lower electrode 5 3 11 Feed unit bolt supply position adjustment 5 3 11 Feed unit bolt supply position adjustment inwitcorect bots oats trom he vbratoy bowl in with correct bolts bolts from the vibratory bowl Large swing due to bolt feed _ Mount the universal bracket 5 3 11 unit resonance supporting the bolt feed unit Feed unit bolt as parallel as possible to the
4. Supply position weld machine adjustment Impossible to place a bolt onto the guide pin of the lower electrode Bolt feed unit mounting angle not appropriate No vibrations of the bulk hopper Air pressure outside the recommended range 0 4 MPa to 0 6 MPa Level switch failure Check if air is supplied Adjust the air pressure to within the recommended range of 0 4 MPa to 0 6 MPa No power supplied Check power is supplied Se Replace level switch No vibrations generated by the Replace the vibrator Page52 9 4 2 Air supply pressure check 7 6 Vibratory bowl level switch installation 7 5 Bulk hopper vibrator installation Mees lS AZN Cre No bolt supply to the chuck assembly Separator not working as required WEL DIN G Vinyl bolt feed tube broken Bolts stick in the chute track A because of oil in the track Air blow time too short bolts are staying in the vinyl bolt feed tube Air pressure outside the recommended range 0 4 MPa to 0 6 MPa Vinyl bolt feed tube in bad condition or damaged Valve malfunction Incorrect timer setting Broken or damaged cylinder Wear or deterioration of the inner surface of the separator causing bolts to stick Sequencer program modified DENGENSHA EUROPE LTD Unit 8 Birchbrook Industrial Park Shenstone Staffordshire WS14 ODJ United Kingdom a o TO MEAs NUT amp Replace or repair the vinyl bolt feed tube Remove the oil
5. check 9 4 7 Bolt quantity in the vibratory bowl check Increase the bolt quantity in the vibratory bowl Adjust the variable resistor on control panel Check the vibrator wires are connected correctly 5 3 28 Vibratory bowl wire connection Page55 DENGENSHA EUROPE LTD Unit 8 Birchbrook Industrial Park Shenstone Staffordshire WS14 ODJ United Kingdom RESISTANCE WELDING e AUTOMATIC NUT amp BOLT F la la es l gt in RS taut cause remeay feterenes Power not supplied Checkpoweris supped S Check the vibrator wires are connecte coreey No power supplied to the Inspect F3 or F4 fuse in the vibratory bowl due to a blown fuse box and replace if blown fuse The fuse used is a 250V 5A glass fuse Malfunction of the variable Replace the printed circuit Contact your local resistor on the printed board dealer circuit board or the card Malfunction of the vibrator Check the input on the 8 2 9 relay sequencer is activated when Sequencer LED lamp a nut comes right under the layout proximity switch and the out 7 8 put turns on after its preset Relay installation time Check operation of relay Replace the relay if found to be faulty Vibrator malfunction Overhaul or replace the Contact your local vibrator dealer Proximity switch failure Replace the proximity switch Contact your local dealer continuously AUTO switch on the feed Check and correct the AUTO 8 2 7 unit not in correct position switch positi
6. n adjusting variable resistor disabling the vibration adjustment Malfunction of the printed Replace the printed circuit Contact your local circuit board board dealer Bolts coated in oil which gathered in the vibratory bowl Weak vibrations due to too many bolts in the vibratory bowl Strong vibrations due to too few bolts in the vibratory bowl Change in the setting of the circuit board Wiring check Inadequate power supply Check power is supplied to voltage or frequency the feeder correctly A U TO Meats NUT amp variable resistor on the printed the printed circuit board in the DENGENSHA EUROPE LTD Unit 8 Birchbrook Industrial Park Shenstone Staffordshire WS14 ODJ United Kingdom B OTETI PAT I3 LED Es 53a 9 4 9 Removal of oil dust etc in the vibratory bowl 9 4 7 Bolt quantity in the vibratory bowl check Remove the oil and dust from the inside of the vibratory bowl and the bolts 9 4 8 Support frame play and tilt check Check the support frame position for level and stability Visually check If no bolt travels up the track overhaul the bowl only Replace the vibration adjustment variable resistor Contact your local dealer Contact your local dealer Remove the oil and dust 9 4 9 from the inside of the vibratory Removal of oil bowl and the bolts dust etc in the vibratory bowl Reduce the bolt quantity in the 9 4 7 vibratory bowl Bolt quantity in the vibratory bowl
7. on AUTO switch position correction procedure Start initiation wire broken Check input 4 of the Contact your local Feeder sequencer comes on and dealer does not goes according to the state 8 2 9 start the of the initiation Repair the Sequencer LED lamp spindle initiation circuit if its layout does not actuation has a failure extend Sequencer program modified Ask your local dealer to check the feeder Malfunction of the feed unit Check solenoid valve motions 8 2 6 start switch soleneoid valve in manual mode and replace Solenoid valve is turned the valve if found to be faulty operation in manual mode ON 7 5 Solenoid valve assembly installation Air pressure source not Check if air is supplied 5 3 19 available Primary air supply Page56 A2e S Ss eA aN eC ce No bolt fed by the separator even when The spindle fails to extend and retract even when button Is actuated functions work normally WELDING Malfunction of the solenoid valves for separator and air blow Malfunction of the solenoid valve for the feed unit Malfunction of the selector switch Air pressure outside recommended range of 0 4 MPa to 0 6 MPa Malfunction of the selector switch Malfunction of the spot welding start relay DENGENSHA EUROPE LTD Unit 8 Birchbrook Industrial Park Shenstone Staffordshire WS14 ODJ United Kingdom AUTOMATIC N U T Check the solenoid valves in manual mode and replace them if found to be faulty
8. yl bolt feed tube from the tube clamp block 5 3 21 Vinyl bolt feed tube installation into feed unit Air pressure outside the Check if air is supplied 9 4 2 recommended range Adjust the air pressure to Air supply 0 4 MPa to 0 6 MPa within the recommended pressure check range of 0 4 MPa to 0 6 MPa Sequencer program Contact your local dealer to Contact your local modified check and correct the dealer program Bolts sticking together and are Remove the oil and dust 9 4 9 not being fed from the inside of the vibratory Removal of oil No bolts bowl and the bolts dust etc in the being vibratory bowl supplied to Vibratory bowl outlet and Visually check the alignment 7 4 the Chute chute track A inlet are not and adjust if needed Chute track A track A aligned assembly maintenance invitvcorectbots bottom tho vibratory bow in with correct bolts bolts from the vibratory bowl Bolts caught and stuck inthe Adjust the wiper 8 2 4 wiper located in the vibratory Wiper adjustment bowl Page54 pe ea Es ah i CIE Bolts caught and stuck in the Vibratory bowl vibrations too strong or too weak WELODIN G Bolts coated in oil which gathered in the vibratory bowl Too many or not enough bolts in the vibratory bowl Tilt or play of the support frame Overlapping bolts Separate the bolts Contact your local dealer Bolts caught and stuck in the vibratory bowl due to track wear Malfunction of the vibratio
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