CIGWELD WeldSkill 200AC/DC - Troubleshooting; Basic Troubleshooting - Power Source Faults

TROUBLESHOOTING WELDSKILL
200AC/DC INVERTER
Manual 0-5206 6-1 Troubleshooting
6.01 Basic Troubleshooting-Power Source Faults
The following table is a guide for analyzing problems and making repairs to the Power Source.
Fault Possible Cause Remedy
1 There is no weld
output and all front
panel displays are off
A
B
C
D
E
F
G
The main Power Switch is set to OFF
Control fuse is blown
The main Power Switch is faulty
Loose connection to EMC board
Faulty Power Inverter board
Faulty Control board
Faulty Display board
A
B
C
D
E
F
G
Set main Power Switch to ON
Replace Line fuse
Replace main Power Switch
Tighten connections
Replace Power Inverter board
Replace Control board
Replace Display board
2 There is no weld
output and all front
panel displays are off
or flickering on & off
A The internal protection circuit to shut
the unit down if the mains supply
voltage is too high has operated
A Check to see if mains supply
voltage is >274VAC. A
generator with poor voltage
regulation may cause a supply
voltage in excess of 274VAC.
Connect Power Source to a
supply voltage <274VAC.
3 There is no weld
output and the yellow
over temperature light
is on
A
B
C
Unit has overheated
Airflow inlet or outlet ducts are
blocked
Fan does not operate
A
B
C
Allow unit to cool with
fan running until over
temperature light extinguishes
Remove blockages from
airflow ducts
Replace fan. Check fan wiring
is not damaged
4 Mode switch does not
change welding mode
A Faulty Display board A Replace Display board
5 No HF output when
HF mode is selected
A
B
Points gap too large
Faulty HF board
A
B
Use Feeler gauge to set points
gap
Replace HF board
6 A welding arc can
be established but
the weld is erratic or
inconsistent
A
B
C
D
E
F
G
H
Work Lead cable too small
Loose welding connections
Loose earth clamp
Incorrect weld polarity selected
No shielding gas
Wind blows shielding gas away
Incorrect TIG tungsten electrode
Poorly prepared or worn TIG
tungsten
A
B
C
D
E
F
G
H
Use correct weld cable size
Tighten welding connections
Tighten earth clamp
Correct weld polarity.
Refer to weld consumable
manufacturers recommended
polarity
Connect shielding gas
Shield welding area from
draughts
Use correct tungsten type
Regrind tungsten to correct
shape
Table 6-1: Power Source Faults
SECTION 6:
TROUBLESHOOTING