CIGWELD WeldSkill 4R Wirefeeder - 6.11 Advanced Troubleshooting

Troubleshooting 6-14 Manual 0-5186
WELDSKILL 250, 350 TROUBLESHOOTING
6.11 Advanced Troubleshooting
If the problem cannot be solved by the basic (external) troubleshooting guide, the Power Source covers and/or
the Wirefeeder covers will have to be removed. The advanced level of troubleshooting allows the technician with
a few common tools to remove the covers and analyse failures.
CAUTION
Never open the Power Source covers unless the Mains supply voltage to the Power Source is
disconnected from the Mains power point.
1 Test Equipment and Tools
•DigitalMultimeter
•DCclip-onammeter
•Screwdriverand8mmacrossatsnutdriver
•CRO(20Mhzbandwidth)&isolatingtransformer
2 Power Source or Wirefeeder Faults
CAUTION
Leave the Mains supply voltage disconnected from the Power Source during the visual inspection.
a) Wirefeeder
i) Remove all the case screws that fix the right hand panel to the Wirefeeder (the right hand panel as
seen from the front).
b) Power Source
i) Remove all the case screws that fix the left hand panel to the Power Source (the left hand panel as
seen from the front).
ii) Remove all the case screws that fix the right hand panel to the Power Source (the right hand panel
as seen from the front).
3 Visually Inspect
Visually inspect the inside of the Power Source or Wirefeeder. The levels of current present in these units can
cause burning or arcing of PCB, transformers, switches, rectifier or contactor when a failure occurs. Carefully
inspect all components within these units.
Look in particular for the following:
a) Loose or broken wires or connectors.
b) Burned or scorched parts or wires or evidence of arcing.
c) Any accumulation of metal dust or filings that may have caused shorting or arcing.
If any parts are damaged, they must be replaced. Refer to the Spare Parts section for a complete list of
components used in the Power Source.
Locate the faulty component(s) then replace where necessary.
At this point, apply voltage to the Power Source.
CAUTION
There are extremely dangerous voltage and power levels present inside these Power Sources. Do not
attempt to diagnose or repair unless you have had training in power electronics measurement and
troubleshooting techniques.