4.2 Other Malfunctions
In the chart below, a number of malfunctions are described which can be diagnosed and remedied by trained
service technicians with relative ease. In case you cannot solve these problems yourself, contact our agent in
your neighbourhood or our customer service department. It is important that you give us details of the type and
serial number of your appliance, as well as an exact description of the malfunction.
Remedies and Explanations
The piston of the gun
does not respond to
triggering (applies for
gun ESP 10 S only)
Faulty connection in the con-
trol cable of the gun or in the
pistol
Test with ohmmeter: Normal resistance of the coil is
app. 11 Q. The magnet is connected to points 1 and
2, the trigger to points 3 and 4.
Next, check the plug-and-socket connections.
Try to move the piston by hand. There must not be any
unusual friction. The total piston stroke for the ESP 1 S
is approx. 7 mm and for the ESP 10 K approx. 11 mm.
Magnetic coil under continu-
ous current
Turn off the power source, then switch it back on,
watching the piston of the gun (do not trigger the gun).
The piston must remain unmoved. If the magnet at-
tracts it immediately, there is a defect in the control.
Note: The magnetic coil will burn out if kept under con-
tinuous current even for a short time. Therefore turn
off the power source again immediately!
Faulty welding results
in spite of correct pa-
rameter settings
Workpiece surface contami-
nated with oil, grease, rust, or
galvanized, painted, etc.
Movement of the piston ob-
structed
Clean the welding zone and the ground clamping
points of the workpiece. Best welding results are
achieved on clean bright metal surfaces.
Protective rubber cap has been wedged in
Welding results unreli-
able (sometimes good,
sometimes faulty)
Function of the piston
irregu- lar
Piston of the gun subjected to an excessive and fluctu-
ating amount of friction.
Clamping force of the spring insufficient.
In either case, have the gun repaired!
Arc blowing caused by difficult
workpiece geometry
Follow the instructions which can be found in the rele-
vant literature to reduce arc blowing. Make sure that
both ground clamps are connected to the workpiece.
Do not weld near a ground clamp!
The workpiece yields on the
impact of the stud.
Provide adequate support for the workpiece.
Unusually early power
source cut-out be-
cause of overheating.
Unusually strong heat-
ing at some points of
the welding circuit
Cable cross-sections reduced
by partial wire breakage
Scorching caused by loose
connections
Stop welding immediately! Replace cables.
Tighten all connections within the welding circuit!
Issue 4/2019 ver. 2.0 page 22 of 42
Köster & Co. GmbH • D-58256 Ennepetal • Spreeler Weg 32 • Tel. +49 2333 8306-0 • Fax +49 2333 8306-
38 Internet: http://www.koeco.net • E-Mail: koeco@koeco.net
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