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On The Spot Precision Engineering.
Now that I have a complete idea in my head of how the machine should work, it is time to bring the machine back to square one in terms of the electric system. This is my favorite part of the job. I have been dealing with wires in Industrial Electric Systems for most of my life and I have done this type of job hundreds of times on both machines, and buildings. (Mostly for the HVAC equipment in the building)
What I do is restore the function of each circuit so that it achieves the desired result using the minimum amount of components. It turns out that this machine must have come from a place where they did not know how to find out what is wrong with a machine. Instead they would splice in all kinds of jumpers, and add devices to make it work. The picture above shows the left the diagram I made of the relays from my conversation with the service technician. On the right side the picture shows all of the wires and devices I pulled out of the machine to make it work again. The less components and wires you have in a machine the higher the reliability. I remember when cars had had a battery, a distributor with points, and an ignition switch. The system needed to achieve combustion was very simple. Cars were fixable back then. Today they have 30 to 70 microprocessors in them. Can you fix it when it breaks? Fortunately I can.