1. Problem Description
A customer reported a High Temperature Hardware Error on an wave soldering machine.
The machine had been powered off for two days. Upon restarting, the error occurred when attempting to start the solder pot.
Initial troubleshooting revealed:
Solder pot thermostat was checked and appeared to be functioning.
Contactor CON-02 was not activating.
No voltage was present at the CON-02 contactor coil.
Electrical schematic checks did not initially identify an obvious problem.
Further troubleshooting ultimately identified a faulty Digital I/O card. Replacing the Digital I/O card resolved the issue.
2. Troubleshooting Procedure
Step 1 – Verify Temperature Offset
Before troubleshooting the hardware circuit, verify that the alarm is not being triggered by an actual high-temperature condition or an incorrect temperature reading.
Navigate to the Solder Pot Module window through the Troubleshooting Tab.
Check the temperature offset.
The acceptable offset should not exceed ±5°F.
If the offset exceeds this range, recalibrate the solder pot temperature or investigate the cause of the excessive offset.
Step 2 – Verify High Temperature OK Input
The machine monitors the high-temperature safety circuit before activating the heaters.
Navigate to the DI/O screen through the Modules Menu.
Locate the input labeled Solder/Hot Knife High Temp. OK.
Verify that the input is ON.
This input requires a DC common signal to be present for the machine to recognize that the high-temperature safety circuit is satisfied.
If the input is OFF, troubleshoot the circuit using the machine's electrical schematics.
Step 3 – Inspect the Safety Circuit
The DC common signal is routed through the safety devices installed on the machine. The number and type of devices depend on the machine configuration.
Follow the electrical schematics to determine where the DC common signal is being interrupted.
A common issue is oxidized contacts inside the TS-01 thermostat, which can prevent the DC common signal from passing through.
Inspect the TS-01 thermostat contacts.
If the thermostat contacts are oxidized or faulty, replace the thermostat.
Replacement Part:
Part Number: 3-0606-462-01-1
Description: SWITCH, THERMAL, MOD SWITCH
The thermostat is located beneath the rear cover of the solder pot, above the drain valve.
3. Additional Troubleshooting – Digital I/O Card
The customer ultimately identified a faulty Digital I/O card.
Corrective Action:
Replace the faulty Digital I/O card.
Verify that the High Temperature Hardware Error has cleared.
Confirm that the solder pot contactor activates properly.
Verify normal solder pot operation.
Result: The customer confirmed that replacing the Digital I/O card resolved the problem.
4. Important Notes
Always verify the actual solder pot temperature before proceeding with hardware alarm troubleshooting.
Temperature offset should remain within ±5°F.
Use the machine-specific electrical schematics when tracing the high-temperature safety circuit.
Check the TS-01 thermostat for oxidized contacts.
If the safety circuit and thermostat are functioning correctly, investigate the Digital I/O card and its associated inputs.
Important Safety Notice: Never bypass or permanently defeat any temperature safety device. Any diagnostic testing involving safety circuit connections must be performed by qualified personnel in accordance with approved service procedures. Restore all safety connections before returning the machine to operation.