Tweco Weld Sequencer - Manual (Page 35)

Manual 0-2023 29 Section Name
SECTION 5:
CUSTOMER/OPERATOR
SERVICE
5.01 Introduction
This Section provides service diagnostics for the Weld
Sequencer, allowing the Technician to isolate any faulty
Subassemblies. Refer to Subsection 5.05, Parts Replace-
ment Procedures, for parts replacement instructions.
Under no circumstances are field repairs to be attempted
on Printed Circuit Boards or other Subassemblies of this
unit. Evidence of unauthorized repairs will void the fac-
tory warranty.
NOTE
The troubleshooting contained in this manual is
for the Weld Sequencer only. Troubleshooting other
parts of the system is covered in the separate manu-
als for that product.
5.02 Transformer Connections
The main transformer in the Weld Sequencer Enclosure
is compatible with input voltages of 115 and 230VAC. Se-
lection is made on the terminal strip on the rear panel of
the Enclosure using two jumper terminals. Figure 5-1
shows the jumper locations for the different voltages.
230 Volt Jumpers
TB4 Terminal Strip
A-02404
1 2 3 4 5 6 7
115 Volt Jumpers
TB4 Terminal Strip
A-02405
1 2 3 4 5 6 7
Figure 5-1 Input Voltage Terminal Locations
5.03 Troubleshooting Guide -
General Information
WARNING
There are extremely dangerous voltage and power
levels present inside this unit. Do not attempt to
diagnose or repair unless you have had training in
power electronics measurement and troubleshoot-
ing techniques.
A. Troubleshooting
This manual provides troubleshooting and parts replace-
ment. In most cases, it requires Weld Sequencer disas-
sembly and live measurements.
Troubleshooting and repair of this unit is a process which
should be undertaken only by those familiar with high
voltage high power electronic equipment.
If major complex subassemblies are faulty, the faulty sub-
assembly must be returned for repair.
NOTE
Follow all instructions as listed and complete each
in the order presented.
Malfunctions may be due to faulty connections rather than
a faulty component. Check all connections to the com-
ponents that appear to be malfunctioning. The trouble-
shooting guide is arranged in the normal operating se-
quence of the Weld Sequencer (refer to Appendix VI or
VII) for easy reference. Before troubleshooting is started,
the Weld Sequencer should be isolated from the system
to confirm that the problem exists in the Weld Sequencer
and not another part of the system. If a problem is in the
power supply, welding console, or other component of
the system, check their respective Manuals supplied with
that product.
The Weld Sequencer contains accessory components of
the welding system and consists of individual modules.
It is important to isolate the area of the trouble should
problems occur. The quickest way to identify whether
the problem is in the Weld Sequencer or one of the other
components of the welding system is to take the Weld
Sequencer out of the system by running GS1 GAS FLOW
up to the maximum flow desired, then shutting the GS1
module OFF. If CS1 and/or CP1 are connected they also
must be turned OFF. Try a weld. If the problem is cor-
rected the fault is in the Weld Sequencer. If it doesn’t
correct the problem, the fault is probably in the welding
console, power supply or RP1 Remote Control. RP1 can
be isolated by switching the welding console and power
supply out.