Manual 0463 413 001 TROUBLESHOOTING 6-13
6.03 LED Diagnostics
The unit has several LEDs that can assist in diagnosing problems.
POWER PCB2 / (15AP1)
D42 +24V_SEC OK +24VDC Supply on this pcb is present
D53 +18V_PRI OK +18VDC Supply on this pcb is present
CONTROL PCB3 / (20AP1)
D33 PWM IGBT Gate signals are enabled (Brightness depends on PWM demand)
D35 PS_OK +15VDC & -15VDC Supply on this PCB is present.
D36 3,3V_1 OK +3.3VDC Supply on this PCB is present
D40 +24V_1 LOW Problem: +24VDC Supply on this PCB is low
D43 BUS V ERROR Problem: Buss Voltage from PCB3 is less than 350VDC
D44 UI COM Communication from PCB1 is established
D45 uP OK If flashing, u processor. On this pcb is active
D85 10.3V_VB OK +10.3 VDC Supply on this PCB is present
D86 +5V_1 OK +5VDC Supply on this PCB is present
D87 MIG SOL ON Signal is active to turn on MIG gas solinoid
D88 TRIGGER ON Remote trigger is closed
D89 TIG SOL ON Signal is active to turn on TIG Solenoid (IF INSTALLED)
D90 FAN ON Fan control signal is on, fans should be running
6.04 Initial Power Up Test
Using Generators or Extension cords
If a problem is encountered while running on a generator or while using an extension cord, note the problem
and then plug the unit directly into a Mains Power Outlet. If the problem is no longer found, there is a problem
with the power from the generator or the extension cable is too long or wire gauge is too small to adequately
power the unit. Measure the incoming voltage at the units Mains Power Cable/Plug both before and while the
unit is under load to verify voltage does not drop under load conditions, especially when connecting to 120VAC.
Interconnections
When performing tests to determine failed component, check for open wires or poor connection between
components, pcbs, connectors, etc.
Wire Feedability Problems
Many welding problems, gun and consumable issues can be caused by improper wire feed set up, incorrect
or worn parts. Pay close attention to the following items:
Wire spool – Wire feeds smoothly o spool – no friction or wire cross over
Wire Spool Hub Brake Tension
Drive Roll - Size, style and condition
Wire Guides – Size and condition
Wire Tension Adjustment
Wire Liner (Conduit) - Size and condition
Contact Tip – Size and condition
Wire type
Gun Polarity
To Next Page
