CIGWELD WeldSkill 4R Wirefeeder - SECTION 6: TROUBLESHOOTING; 6.01 Power Source; Wirefeeder Faults

TROUBLESHOOTING WELDSKILL 250, 350
Manual 0-5186 6-1 Troubleshooting
SECTION 6:
TROUBLESHOOTING
6.01 Power Source / Wirefeeder Faults
The following table is a guide for analysing problems and making repairs to the Power Source/Wirefeeder.
FAULT CAUSE REMEDY
1 Mains supply voltage
is ON. Indicator light
is not lit and welding
arc can not be
established.
A
B
Primary fuse is blown.
Broken connection in primary
circuit.
A
B
Replace primary fuse.
Have an Accredited CIGWELD
Service Provider check primary
circuit.
2 Mains indicator
light is not lit but
welding arc can be
established.
Burnt out Indicator light. Have an Accredited CIGWELD
Service Provider replace Indicator
light.
3 Mains supply
voltage is ON and
power Indicator
is lit however unit
will not commence
welding when the
torch trigger switch is
depressed.
A
B
Faulty torch trigger
Circuit breaker tripped
A
B
Repair or replace torch trigger
switch/leads
Reset Circuit Breaker(s)
4 Mains supply voltage
is ON, no wire feed
but gas flows from
the MIG Torch when
the torch trigger
switch is depressed.
A
B
Electrode wire stuck in conduit
liner or contact tip (burn-back
jam).
Faulty control PCB
A
B
Check for clogged / kinked MIG
Torch conduit liner or worn
contract tip. Replace faulty
components.
Have an Accredited CIGWELD
Service Provider investigate the
fault.
5 Wire feeds when
the torch trigger
switch is depressed
but arc cannot be
established.
A
B
Mig torch polarity lead is not
connected into a welding output
terminal.
Poor or no work lead contact.
A
B
Connect the MIG torch polarity
lead to either the positive welding
output terminal or negative output
terminal as required.
Clean work clamp area and ensure
good electrical contact.
6 Inconsistent wire feed A
B
C
D
Worn or dirty contact tip
Worn feed roll.
Excessive back tension from wire
reel hub.
Worn, kinked or dirty conduit liner
A
B
C
D
Replace if necessary.
Replace if necessary.
Reduce brake tension on spool
hub
Clean or replace conduit liner
7 No gas flow A
B
C
D
Gas hose is cut.
Gas passage contains impurities.
Gas regulator turned off.
Empty Cylinder
A
B
C
D
Replace or repair.
Disconnect gas hose from the rear
of Power Source or wirefeeder
then raise gas pressure and blow
out impurities.
Turn on.
Replace cylinder.