11
troUBleshooting
chart:
this troubleshooting chart is a guide in identifying and correcting possible troubles
which may occur when operating this equipment.
not affiliated with this equipment, refer to power source owners manual.
proBleM
caUse
solUtion
pilot light is out
1.
Unit is not plugged in.
2.
switch is in off position.
3.
switch is faulty.
4.
light is burned out.
5.
circuit breaker is blown.
1.
plug in unit.
2.
turn switch to on position.
3.
replace switch.
4.
replace light.
5.
reset or replace circuit breaker.
drive indicator light does not
light when remote switch is
engaged
1.
light is burned out.
2.
remote switch is faulty.
3.
switch wire is damaged.
4.
amphenol plug is damaged.
5.
Motor control board is faulty.
6.
power to unit is off.
1.
replace light.
2.
replace remote switch.
3.
repair or replace switch wire.
4.
repair or replace amphenol plug.
5.
replace motor control board.
6.
turn power on.
loss of wire feed
1.
circuit breaker tripped.
2.
Motor control board is faulty.
3.
potentiometer is set at zero.
4.
Wire supply is exhausted.
5.
Wire feed cable tangled.
6.
Wire is bird nested.
7.
feeder is unplugged.
8.
feed cable is plugged.
9.
drive roll is misaligned.
10. drag is excessive.
11. Wire guide tube has worn out.
1.
reset circuit breaker.
2.
replace motor control board.
3.
set wire feed speed.
4.
resupply wire.
5.
straighten feed cable.
6.
loosen pressure roll / re-thread wire.
7.
plug in feeder to a 115v ac wall outlet.
8.
replace feed cable.
9.
align inlet and outlet guides with drive
roll.
10. adjust spool brake.
11. replace wire guide tube.
erratic wire feeding
1.
feed unit plug is connected to power
supply.
2.
Wire tangled on spool.
3.
Wrong or worn feed cable.
4.
Wrong or worn wire guide.
5.
Wrong drive roll groove.
6.
incorrect drive roll pressure.
7.
12v dc relay failed.
1.
Unplug then plug into 115v ac wall
outlet.
2.
remove tangled section and rethread.
3.
replace feed cable.
4.
replace wire guide.
5.
refer to chart on page 21.
6.
adjust pressure roll.
7.
replace relay.
faulty delay - retract
1.
potentiometer failed.
2.
toggle switch failed.
3.
12v dc relay failed.
1.
replace potentiometer.
2.
replace toggle switch.
3.
replace relay.
Motor will not turn off
1.
faulty trigger switch.
2.
switch control cable damaged.
3.
amphenol plug shorted.
4.
12v dc relay failed.
5.
logic board failed.
1.
repair or replace switch.
2.
repair or replace cable.
3.
repair or replace plug.
4.
replace relay.
5.
replace logic board.
Wire will not feed
1.
coiled feed cable - friction on wire.
2.
Wire is bent or curved.
1.
keep feed cable as straight as possible.
2.
keep wire straight as it enters feed
rolls.
loss of weld current
1.
Weld cables disconnected.
2.
power source contactor open.
3.
poor contactor connection.
1.
repair or replace cables.
2.
check contactor connections.
3.
Make proper connections.
erratic weld current
1.
poor ground connection.
2.
poor welding cable connection.
1.
Make proper connections.
2.
Make proper connections.
