CONTROLLED AUTOMATION, INC.

CONSOLE TROUBLESHOOTING

+15VDC MACHINE INPUTS

The inputs for the limit switches, proximity switches, and photoelectric eyes operate at +15VDC. The input control wiring runs from the console to the input devices, which are mounted at various locations on the machine. A unique input relay number and a unique wire/tape color designate each input.

The input boards (OPTO-22 #PB32HQ or PB16HQ) have the white OPTO-22 #IDC5Q 10-30VDC input modules mounted on it (See DWG. #XXX-907A & XXX-907B for more detail). Each #IDC5Q has four inputs and a red LED to represent the status of each one. The + side of the +15VDC power supply is connected to the common terminals (C) on the terminal strip of the input board (yellow #16). There is a silver jumper strip that connects all the C terminals together. A yellow #16 jumper wire is used to connect the upper C terminals to the lower C terminals. A 5 amp picofuse, mounted on the input board in-line between the C terminal and the #IDC5Q input module, protects two of the four inputs. There are two fuses per #IDC5Q input module.

The input control wires are of some color other than black, yellow, or green and may be marked with colored tape. The return wire of the +15VDC power supply (RET) is black and is ran with the input control wire(s). Most of the input control wires are run from the console to the main DC input branch box mounted on the machine base. This run has several control wires, one black RET wire, and one yellow +15VDC wire for the proximity switches or photoelectric eyes. From this branch box, the control wire(s) and a RET wire are ran to each input device on the machine. Some of the control wires are run directly from the console to the input device. The inputs, outputs, wire colors, and relay numbers are listed on DWG. #XXX-964 thru XXX-970.

When an input is ON (red LED is lit), +15VDC can be measured across the C terminal and the input terminal on the input board (the input device contact is closed). When an input is OFF (red LED is not lit), no DC voltage will be measured across the terminals (the input device contact is open).

If the 5 amp picofuse is blown, the red LED will not indicate that the input is on. The input 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.

COMMON PROBLEMS

Shorted or open control wires

Bad limit switches, proximity switches, photoelectric eyes & reflectors

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

Loose RET jumper strip terminals

Limit switch arms and proximity switches not adjusted correctly

Photoelectric eyes and reflectors not aligned correctly

Blown 5 amp picofuse