16
©
2009
MIDWEST FASTENERS, INC.
— SureShot Welding System
Problem
Possible Cause
Corrective Action
Arc blow (all weld ma-
terial moves or “blows”
to one side).
Ground(s) not positioned properly.
Reposition ground clamp to “steer” weld material. Weld material will flow away from
the ground clamp.
Use double grounds, one on each side of the weld zone to balance current flow.
Welder turns on but
does not operate.
Broken ground cable or incomplete connection.
Make sure all cable connections are in good condition and are tightly secured.
Broken weld gun, weld cable or incomplete con-
nection.
Make sure all cable connections are in good condition and are tightly secured.
Broken control cable.
Verify continuity on all leads in the control cable (black and white only for contact weld
tools).
Shorted trigger switch (trigger LED always on).
Verify continuity on the trigger switch. Replace if defective.
Faulty trigger switch (trigger LED doesn’t light
when trigger pulled).
Verify continuity on the trigger switch. Replace if defective.
Faulty control board.
Replace control board.
Weld too hot regardless
of voltage setting.
Faulty control board.
Replace control board.
Green ready LED
doesn’t light.
Faulty control board.
Replace control board.
Unit detects trigger.
Check cables. Ensure trigger switch is not broken.
Unit detects contact.
Check cables. Ensure weld gun is not touching grounded work piece.
Green ready LED
blinks, welder doesn’t
operate.
Faulty control board.
Replace control board.
Yellow contact LED
doesn’t light when weld
gun is placed against
work.
Missing or faulty ground.
Make sure all cable connections are in good condition and are tightly secured.
Faulty control board.
Replace control board.
Red trigger LED doesn’t
light.
Broken control cable.
Verify continuity on all leads in the control cable (black and white only for contact weld
tools).
Control cable not fully connected.
Make sure all cable connections are in good condition and are tightly secured.
Faulty trigger switch.
Verify continuity on the trigger switch. Replace if defective.
Faulty control board.
Replace control board.
Breaker blows
each time unit is
powered on.
Shorted weld capacitor.
Use a capacitance meter to test weld capacitor. Visually inspect weld capacitor for obvi-
ous signs of damage. Replace defective weld capacitor.
Faulty control board.
Replace control board.
Welder doesn’t turn
on.
Not plugged in.
Plug in unit.
Panel breaker blown.
Reset breaker.
Faulty power switch.
Replace power switch.
Faulty control board.
Replace control board.
Welder shuts down
immediately.
Weld SCR shorted.
Check Error Code (E02
+
and E03
-
) take corrective action to replace weld SCR.
Faulty power switch.
Replace power switch.
Faulty control board.
Replace control board.
Welder shuts down
after a weld.
Weld SCR shorted.
Check Error Code (E02
+
and E03
-
) take corrective action to replace weld SCR.
Faulty power switch.
Replace power switch.
Faulty control board.
Replace control board.
