12 --- Some Common Electrical Problems.
Note, This Section Only Applies to Custom 18/30, Custom 30/30, Super 30/30,
Custom 30/40, and Super 30/40 Machines that were the Most Common SAF's made.
It does Not Apply to Hydraulic Machines like Super 30/40 HD and Super 36/75.
Trouble-Shooters also need to Understand that SAF's were made for over 40 Years,
and there are Many Variations in Electrical Wiring, Electrical Components, and Mechanical Components used. You will need to Understand how it Works to Fix it!!!
You will Need a Maintenance Manual, Which has the Electrical Schematic in it,
to do any Trouble-Shooting. Manual also has More Trouble-Shooting Charts & Theory.
As a Rule, an Electrical Device Fails in 1 of 2 Ways;
--- It "Shorts" or "Short-Circuit" meaning Very-Low or No-Resistance. --- It "Opens" or "Open-Circuit" meaning Very-High or Infinite-Resistance.
12A --- Fuse Blows when you Try to Punch in Single or Nibble Mode. Caused by Shorted Punch Solenoid Coil or wiring, Normal Coil Resistance is about 15 ohms.
12B --- No Punch in Single or Nibble Mode.
--- Caused by Open Punch Solenoid Coil, Normal Coil Resistance is about 15 Ohms.
--- Caused by Broken-Wire "Open" going to the Solenoid Coil.
--- Caused by Tool Handle Lock-Switch or Lock-Switch Wiring being Open.
--- Caused by Open Footswitch or Wiring to switch.
12C --- Machine will Punch with Tool Handle Open and Not Locked-In.
Caused by Tool Handle Lock-Switch being Shorted.
12D --- Punches OK in Nibble, but Blows Fuse 4FU and won't Punch in Single Mode.
Caused by Control Relay CR1 Coil Short, Normal Resistance is about 250 Ohms.
12E --- Punches OK in Nibble, No Punch in Single. Some Causes;
--- Limit Switch LS1 Open. LS1 is Normally-Open & Closes when Activated!
--- Limit Switch LS2 Open. LS2 is Normally-Closed & Opens when Activated!
--- Control Relay CR1 Coil Open, Normal is About a Couple Hundred Ohms.
--- LS1 or LS2 Wired Wrong. LS1 is Normally-Open, LS2 is Normally-Closed.
12F --- Varying Short to Normal Stroke in Single, Normal Operation in Nibble.
Caused by Limit Switch LS1 Short. LS1 is Normally-Open & Closes when Activated!
12G --- Starts Nibbling when Punch in Single Mode, must Turn-Off Machine to Stop.
Caused by Limit Switch LS2 Short. LS2 is Normally-Closed & Opens when Activated!
12H --- Fuse 4FU Blows as Punch Ram starts to move down in Single or Nibble.
Caused by Control Relay CR2 Coil Short, Normal Resistance is About 2000 Ohms.
12i --- Machine continues to Punch in Single as long as Foot Petal is Depressed.
Caused by Control Relay CR2 Open, Normal Resistance is About 2000 Ohms.
12J --- No Punch in Single, but Nibble Punches Without Depressing Footswitch.
Caused by Limit Switch LS3 Short. Note! Early Machines do Not have this LS3 Switch
which was Added to Eliminate Possibility of Double Punching in Singe-Punch Mode.
12K --- Constant Nibble Punching in Single Mode, Normal Operation in Nibble Mode.
Caused by Limit Switch LS3 Open.
12L --- 1 Punch at Power-On. Punching in Nibble without depressing Footswitch.
Caused by Shorted Footswitch.
12M --- 3-Phase Fuses Blow. Caused by;
--- Wrong A.C. voltage to machine or motor & transformer not wired for correct voltage
--- Bad (Shorted) Press-Drive Motor
--- Stalled Motor from Bad Crankshaft Bearings or from Old Hardened Grease
--- Shorted / Melted Step-Down Transformer. Caused by Wrong A.C. Voltage to Machine or Big-Loads Plugged-In to 110 VAC Machine Power Socket, like a Cooling Fan. This External Power-Socket was made Only for a 60 Watt Work-Light!
I sometimes Disconnect this Socket to Prevent this Common Problem.