
41
TROUBLESHOOTING
SECTION 6
DISCONNECT primary power at wall
switch, or circuit breaker, before at-
tempting inspection or work inside the
power source.
6.0. TROUBLESHOOTING
If the power source is operating improperly, the following troubleshooting
information may be used to locate the source of the trouble.
Check the problem against the symptoms in the following troubleshooting
guide (Table 6-1.) The remedy for the problem may be quite simple. If the
cause cannot be quickly located, open up the unit and perform a simple visual
inspection of all the components and wiring. Check for proper terminal
connections, loose or burned wiring or components, blown fuses, bulged or
leaking capacitors, or any other sign of damage or discoloration.
CONDITION ACTION
Unit Inoperative A.
B.
C.
D.
E.
No input power. Check main line (user's) switch fuses -- replace if needed.
Poor or improper input (terminal board) connections.
Defective on/off switch on rear panel -- replace.
Thermal light on. Main transformer overheating. Also check for proper cooling,
proper primary hookup, or shorted turn on secondary.
Loss of primary phase. Find & replace defective fuse.
No Output -- Fan
Running
A.
B.
C.
D.
Poor or improper electrical input -- check input connections on TB.
Poor connections at output terminals/work station -- check, tighten or replace.
Main transformer overheating -- thermal switches tripped due to restricted cooling
air. Temperature light on front panel will be lit. Let unit cool down.
PC board defective or loose PC board connector(s) -- if loose, reinsert; if
defective, replace.
Limited Output or Low
Open-Circuit Voltage
A.
B.
C.
Input voltage jumper links on terminal board improperly set -- check for proper
voltage.
Poor output connections. Take apart, clean, and reassemble.
Panel-Remote switch in Remote position and remote voltage pot disabled.
Erratic Weld Current A.
B.
C.
D.
Welding cable size too small -- use correct cables.
Loose welding cable connection (will usually get hot) -- tighten all connections.
Improper wire feeder setup.
PC board defective -- replace.
High Output, No
Voltage Control
A.
B.
PC board defective or loose -- reset and/or replace board.
Shorted I.G.B.T. - Replace I.G.B.T. and check driver PCB.
No 115 Volt ac Output A. Circuit breaker tripped. Check 115V CB2 -- Reset.
Line Fuse Blows When
Power Source is First
Turned On
A.
B.
Shorted SCR in Main Bridge -- replace.
Shorted capacitor in Capacitor Bank.
Wire Feeder is
Inoperative
A.
B.
Loose feeder control cable -- Check and tighten all connections.
A Circuit Breaker tripped -- Check 42V CB1 -- Reset.
Table 6-1 Troubleshooting Table
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