CONTROLLED AUTOMATION, INC.

CONSOLE TROUBLESHOOTING

115VAC MACHINE OUTPUTS

The outputs for the control relays, the hydraulic valves, air valves, and motor contactors operate at 115VAC 60Hz. The output control wiring runs from the console to the output devices, which are mounted at various locations on the machine. A unique output relay number and a unique wire/tape color designate each output.

The output boards (OPTO-22 #PB32HQ) have the black OPTO-22 #OAC5Q 115VAC output modules mounted on it (See DWG.#XXX-907A & XXX-907B for more detail). Each #OAC5Q has four outputs and a red LED to represent the status of each one. The L1 leg of the machine control voltage (9L1) is connected to the common terminals (C) on the terminal strip of the output board (black #16). There is a silver common jumper strip that connects all the C terminals together. A black #16 AWG jumper wire is used to connect the upper C terminals to the lower C terminals. A 5 amp picofuse, mounted on the output board in-line between the C terminal and the #OAC5Q output module, protects two of the four outputs. There are two fuses per #OAC5Q output module.

The output control wires are of some color other than black, white, or green and may be marked with colored tape. The L2 wire of the machine control voltage (9L2) is white and is ran with the output control wire(s). Most of the output control wires are run from the console to the main AC output branch box mounted on the machine base. This run has several control wires, two white 9L2 wires, and a green ground wire that is connected to the chassis of the branch box. From this branch box, the control wire(s) and a 9L2 wire are ran to each output device on the machine. Some of the control wires are ran directly from the console to the output device. The inputs, outputs, wire colors, and relay numbers are listed on DWG. #XXX-964 thru XXX-970.

When an output is ON (red LED is lit), 115VAC can be measured across the coil of the output device (between output terminal and 9L2). When an output is OFF (red LED is not lit), no AC voltage will be measured across the coil.

If the 5 amp picofuse is blown, the red LED will still indicate that the output turns on and off correctly, but 115VAC will not be measured across the coil. The output that shares the same fuse will not work either. To check or replace the fuse, turn off all power to the console (TURN OFF BOTH FUSED DISCONNECTS ON SIDE OF CONSOLE), use needle-nose pliers to remove and install the fuse from its two pin socket.

If 115VAC is measured across the coil all the time, even if output is off (red LED not lit), there is probably an open coil or an open in the wiring to the coil. Since the output modules are solid state and there is no mechanical connection or disconnection, there is a small leakage current through the output module. This leakage current is not enough to turn on a coil, but with no load, 115VAC will be measured.

COMMON PROBLEMS

Shorted or open control wires

Shorted or open coils in valves

Loose connections at console terminals, branch box terminals, & output devices

Loose 9L2 jumper strip terminals at console & branch box

Blown 5 amp picofuse