1
APPENDIX B
FIG 1: STUD POLARITY SET-UP PROCEDURE
•Open the door to the DCE control and examine which configuration of Power Supply you have by using the pictures
below (NOTE THE POSITION OF THE BUS BAR; determine if stud is Neg. or Pos. Polarity; proceed to FIG. 2
on next page).
Polarity Jumpers
X22, X23
Bus Bar is across
the SCR’s
Positive Stud Bus Bar is above
the SCR’s
Negative Stud
2
FIG 2: STUD POLARITY JUMPERS X22 AND X23
•The polarity determined from FIG. 1 (on previous page) should dictate the jumper positions
* Note: polarity changes are not effective until DCE is powered down for 30 seconds then powered back on
X 23 Jumper
“Positive” stud = pins 5,6 and 7,8
“Negative” stud = pins 1,2 and 3,4
X 22 Jumper
“On” indicating stud “Positive”
3
“Off” indicating stud “Negative”
FIG 3: FEEDER BOARDS AND FUSE LOCATIONS
•Remove cover of ETF Feeder control box (JIC Box)
LM Amplifier Pcb
ETF CPU Pcb (large
Motor Driver Pcb Note fuses
motherboard)
(See Fig. 4 for F1 and F2
details)
ETF CPU Pcb
Fuses F2-F5
F5
F4 F2
Feeder Transformer F1
F3
F1T1 Taps
F2 F1
Filter Board
MEASUREMENT
LINE Fuse F1
4
FIG 4: FEEDER MOTOR BOARDS FOR E12, E13, E52 FEEDERS
ETF 52
ETF 12, ETF 13
P2 – Hopper Vibration Adjust
F1
F1
P1 – Bowl Vibration Adjust
P1 – Bowl Vibration
Adjustment.
Adjust so that studs/nuts ride up
the bowl ramp smoothly without
“dancing”.
5
FIG 5: FEEDER STYLE AND DESIGNATION NUMBERS
ETF 12, ETF 13 ETF 90
IDENTIFY YOUR
FEEDER
Then proceed with the
steps indicated in the
troubleshooting guide
ETF 52
6
ZCPU and Interface Boards FIG 6: Interface Board Location Expander
Board
DCE Welder Controller Plug in ASSIST
Module here
Parallel Interface
Plug in ASSIST
Module here
Device Net Interface or RS485 Interface
7
FIG 7: Location of K1 and K2 Relays and Fuse Bank
F4 F5 F6 F7 F8 F9 F10
F1 F2 F3
RAM Module
RAM Module
Release Button
DCE Welder Controller
Fuse Bank
K2
K1
K1-SMPS-Relay
K2-Feeder- Relay
DCE ZCPU
8
FIG 8: ETF 90 FEEDER
Rail Kicker Assembly
Remove Side Cover Knife Assembly Air Cylinder
Feeder Rail
9
FIG 9: Negative Polarity and Measurement Line
PWM Board
Temperature
Probe
Ω For Measurement Line Checks: Ω
Measurement Line up.
Be sure all cables are still hooked up.
(Blue) Read 0 Ω on ohm-meter
Weld Power Connector Bus Bar Common Measurement 10
Line
FIG 10: Positive Polarity and Measurement Line
PWM Board
Temperature
Probe
Measurement Line Ω For Measurement Line Checks:
(Blue) up.
Be sure all cables are still hooked up.
Read 0 Ω on ohm-meter
Ω Ω
Common Measurement
Weld Power Connector Bus Bar 11
Line
FIG 11: DCE SAFETY BOARD
H4 H5 H6
H1 H2 H3
LEDS H1-
H1-H6
SEE “DCE SAFETY BOARD TRUTH TABLE pages 13 and 14”
12
FIG 12: DCE SAFETY BOARD TRUTH TABLE
H1 H2 H3 H4 H5 H6 Condition / Possible Problem
ON ON ON ON ON ON !Weld Mode: (Not in OP-Stop or E-
Stop modes) SMPS Relay -K1 and
Feeder Relay K2 should be
energized
ON ON ON ON ON OFF !Bad Safety Board ***
!Bad Op-Stop switch / wiring***
***
ON ON ON ON OFF ON !Bad Safety Board
!Bad Op-Stop switch / wiring***
***
!OP-Stop Mode: Feeder Relay K2
is de-energized
ON ON ON ON OFF OFF
!Bad Op-Stop switch / wiring ***
!Bad Safety Board
ON ON ON OFF NA NA !Bad Safety Board
ON ON OFF NA NA NA !Bad Safety Board
!Bad E-Stop switch / wiring***
***
ON OFF ON NA NA NA !Bad Safety Board
!Bad E-Stop switch / wiring***
***
“NA” = Does not matter ***SEE PAGES 15 AND 16 FOR FURTHER INFORMATION
13
Truth Table Continues on next page
FIG 13: DCE SAFETY BOARD TRUTH TABLE
H1 H2 H3 H4 H5 H6 Condition / Possible Problem
ON OFF OFF OFF OFF OFF !E-Stop Mode: SMPS Relay -K1
and Feeder Relay K2 should be de-
energized
!Bad ZCPU
!Bad SMPS Relay-K1
!Bad Feeder Relay-K2
{
!Bad Safety Board
!Bad E-Stop switch / wiring
SEE PAGES 15 AND 16 FOR FURTHER INFORMATION !Op-Stop bypass switches (Live-
Man and Door-Switch) both “ON”
at Power Up
OFF NA NA NA NA NA !Bad ZCPU
{
!24VDC is not being provided on
DCE cabinet connector X2 pins A2
SEE PAGES 15 AND 16 FOR FURTHER INFORMATION or A3 or 0 VDC is not being on X2
pin A8 or A4
!Bad Safety Board
!Bad A2 Aux. Board onside DCE
door
!DCE Control is not powered up
!480VAC input power problem
“NA” = Does not matter 14
X2 CONNECTOR LOCATION
E-STOP/OP-STOP
SEE NEXT PAGE FOR SCHEMATIC
A PINS
B PINS
15
X2 CONNECTOR SCHEMATIC
CUSTOMER CONTROL
E-STOP 1-1 *** B10
X2
E-STOP 2-1 *** B12
E-STOP 2-2 *** A12
E-STOP 1-2 *** A10 DCE
OP-STOP 1-1 *** A5 WELDER
CONTROL
OP-STOP 2-1 *** B6
CABINET
OP-STOP 2-2 *** A6
OP-STOP 1-2 *** B5
+24V EXTERNAL A1
0 24V EXTERNAL A7
STATUS E-STOP B9
STATUS E-STOP A9
STATUS OP-STOP B11
STATUS OP-STOP A11
+24V SI-MODULE *** A2
0 24V SI-MODULE *** A8 *** MAKE THESE
E-STOP CHANNEL SP A3 CONNECTIONS
ON DUMMY PLUG
E-STOP CHANNEL SN A4 FOR HAND-
HAND-GUN
ONLY
LIVE MAN SWITCH 1-1 B2 APPLICATIONS.
LIVE MAN SWITCH 1-2 B8
+24V INTERNAL *** B1
0 24V INTERNAL *** B7
16
FIG. 14: WELD TOOL STICKOUT ADJUSTMENT
Weld Tool must be plugged into ETF Feeder and Air Supply
should be on. Move Flash Shield or Probe to attain the
dimensions shown in drawing below.
Loosen Collar
Flash Shield Probe
Loosen Adjustment Screws Loosen Adjustment Screws
On each side
Stick-
Stick-Out Stick-
Stick-Out
Gauge Gauge
.080” or 2mm 17
.080” or 2mm
FIG. 15: X11 ON ETF FEEDER CPU BOARD
STUD
LEVEL
DETECT
PROX.
1 4 7 10 13
BRN BRN
2 5 8 11 14
BLU BLU
3 6 9 12 15
BLK BLK
FEED RAIL
LEVEL
DETECT
DRUM DOOR PROX.
JUMPER WIRE 18
FIG. 16: Air Pressure Detection
Refer to Fig. 5 of this appendix to identify your feeder. Remove the side cover of the ETF Feeder Control Box.
ETF 12, ETF13, ETF52 ETF 90
Air Pressure Switch LED. Should be on at 60psi and above. Turn the small adjustment screw
next to the LED to adjust the switch to detect 60psi and above.
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