4. Examine the main contactor:
a. Look for black or rough surfaces that are difficult to remove.
b. Make sure that the contactor closes immediately after the Start command is applied.
5. If the contactor is defective, replace it.
6. Examine the pilot-arc relay to make sure that it closes.
7. Examine the wiring to make sure that the coil receives 24 VDC.
8. Examine the start circuit PCB, and replace it if it is defective.
9. Do a torch lead test: Do a test for continuity between the nozzle and workpiece on page 301.
Troubleshooting for a pilot arc timeout
Diagnostic code 521
Diagnostic code 521 identifies a problem with the pilot arc.
Symptoms
Code Symptoms XPR models XPR action Code cancels with...
521 • No current is found on the work cable for
500 milliseconds after the pilot arc current is
established.
• For a minimum of 3 milliseconds, the sensor in the
work cable cannot measure current greater than
the transfer reference value.
All models End of cycle • Start process
• Set process
• Remote on-off
Corrective action
1. Make sure that the transfer height is correct.
2. Examine the consumables.
3. Replace consumables that have damage or excess wear.
Verification
Do a torch lead test. Refer to Do a test for continuity between the nozzle and workpiece on page 301.
Diagnostics and Troubleshooting
8
321811530Instruction ManualXPR460
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