POWERMASTER 500, 500P, 350, 350P
6-2
March 17, 2006
6.03 Troubleshooting Guide
This guide should be used as an aid to determine the cause
of a system malfunction or failure. It should be
remembered that in most welding situations there can be
a large number of variables which can affect the overall
system performance. These variables often include several
pieces of equipment, interconnect cables, weld cables,
shielding gas systems, grounding, consumable wire or
electrodes, part preparation, etc. It is important to check
all aspects of the welding system and environment when
troubleshooting a problem or malfunction.
Explanation of front panel lights:
OUTPUT CONTACTOR ON – GREEN
This light indicates that either the OUTPUT CONTACTOR
switch on the front panel is on, or the remote GUN SWITCH
is on via either the 14 pin or 19 pin remote receptacle.
Whenever this green light is on, the machine should be
producing output.
OVERTEMPERATURE – AMBER
This light indicates that the machine has overheated and
shut itself off. When this light is on, the machine will be
disabled and not produce any output. After the machine
has cooled, this light will automatically turn off and the
machine will no longer be disabled.
The following guide lists several potential problems and
lists a number of items to check or possible causes.
DANGER:
ELECTRIC SHOCK CAN KILL
Open the main wall disconnect switch or
breaker, before removing any covers or access
panels on the welding machine. Live voltage
is still present even with the front panel control
switch OFF. Wait at least three full minutes
after power has been removed before
removing any covers or access panels to allow
adequate time for internal capacitors to
discharge.
1. Unit is completely inoperative – digital display is
off, fans are off, no output.
A. Check for blown input fuse or fuses.
B. Check to make sure that voltage setting on
changeover board is correct
1) Check all of the LINKS to make sure they are
set right.
2) Check fuse on the rear panel.
C. Check wiring to the input terminal block and ground
screw.
D. Is front panel CONTROL POWER switch/circuit
breaker ON?
E. With CONTROL POWER switch ON and power
applied to the machine check for 120 VAC power
on the rear duplex.
F. Check the following internal to the machine.
1) All connections to the control boards.
2) Wiring to the small control transformer mounted
underneath the control board.
G. Possible defective circuit breaker switch on front
panel.
H. Possible defective main control board.
I. Possible defective display board.
2. Machine blows input fuse as soon as power is
applied.
A. Check wiring to input terminal block and ground
screw.
B. Check to make sure that voltage setting on
changeover board is correct.
1) Check the LINKS to make sure they are set right.
2) Check fuse on the rear panel.
C. Check internal wiring to terminal block, input
rectifier, IGBTs, contactors and changeover board.
D. Possible defective input rectifier module and/or
suppressors. (See how to check the input rectifier
module below).
E. Possible defective IGBT modules. (See how to
check IGBT module below).
F. Possible defective capacitor board/s.
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