TABLE OF CONTENTS (continued)
TABLE OF CONTENTS
SECTION 5:
SERVICE .............................................................................................. 5-1
5.01 Routine Maintenance ...................................................................................... 5-1
5.02 Maintenance Diagram ..................................................................................... 5-2
5.03 Basic Troubleshooting .................................................................................... 5-3
5.04 TIG Welding Problems ................................................................................... 5-4
5.05 Stick Welding Problems ................................................................................. 5-6
5.06 Power Source Problems ................................................................................. 5-9
5.07 Power Source Error Codes ........................................................................... 5-11
5.08 Voltage Reduction Device (VRD) .................................................................. 5-13
SECTION 6:
ADVANCED TROUBLE SHOOTING ................................................................. 6-1
6.01 System-Level Fault Isolation .......................................................................... 6-1
6.1.1 Opening the Enclosure .......................................................................... 6-1
6.02 Verification and Remedy to the Indicated Error Codes ................................... 6-3
6.2.1 E01 "Over-Temperature at the primary side" .......................................... 6-3
6.2.2 E02 "Over-Temperature at the secondary side" ...................................... 6-3
6.2.3 E03 "Primary Over-Current Failure" ........................................................ 6-4
6.2.4 E94 “Thermistor malfunction” ............................................................... 6-4
6.2.5 E99 “Initial Power Receiving” ................................................................ 6-4
6.2.6 E04 "Torch Cable Failure" ....................................................................... 6-5
6.2.7 E93 "Memory Chip (EEPROM) error." .................................................... 6-5
6.03 Verification and Remedy to Failures without Indication Codes ....................... 6-6
6.3.1 "Cooling Fan (FAN1) Failure" (Fan is not rotating.) ................................. 6-6
6.3.2 "Gas Valve Failure" (No Gas flow through unit) ...................................... 6-7
6.3.3 "No Weld Output" ................................................................................... 6-7
6.3.4 "Operating Panel Failure" ........................................................................ 6-7
6.3.5 "High Frequency Output Failure" ............................................................ 6-8
6.04 Fault Isolation Tests ........................................................................................ 6-9
6.4.1 Preparation ............................................................................................ 6-9
6.05 Verification of the Power Input Circuitry ......................................................... 6-9
6.5.1 Verification of the AC Input Voltage using an AC Voltmeter ................... 6-9
6.5.2 Verification of Power Supply Voltage ................................................... 6-10
6.5.3 Verification of the Cooling Fan, FAN1, Drive Circuitry .......................... 6-11
6.5.4 Verification of the Gas Valve, SOL1, Drive Circuitry ............................. 6-12
6.5.5 Verification of the primary Diode (D1) ................................................. 6-12
6.5.6 Verification of the secondary Diode (D2, D3) ...................................... 6-13
6.5.7 Verification of the primary IGBT (Q1A-Q4C) ........................................ 6-13
6.5.8 Verification of No-load Voltage (OCV) ................................................. 6-14