OM-212296 Page 34
10-3. Troubleshooting Table
Trouble
Remedy
Unit is completely inoperative.
Check circuit breaker CB1, and reset if necessary (see Section 10-2).
Wire does not feed during jogging.
Place Power Switch S1 in On position (see Section 6-3).
Check 115 volts ac input power and be sure it is energized.
Check circuit breaker CB1, and reset if necessary (see Section 10-2).
Jog Speed Control set too low; increase Jog Speed setting (see Section 6-6).
Check wire feed motor, and repair or replace if necessary.
Check Inch Up push buttons PB3 and Inch Down push button PB4, and replace if necessary (see
Section 6-3 and Parts List).
Have Factory Authorized Service Agent check control board PC1, and replace if necessary.
Wire feeds wrong direction during jog-
ging.
Change Wire Drive Motor Direction setting in the Auxiliary Menu (see Section 6-10).
Wire only feeds down whether Inch
Down or Up button is pressed.
Have Factory Authorized Service Agent check control board PC1, and replace if necessary.
Wire does not feed after Start button is
pressed (ensure that all wire feed jog-
ging functions are operating properly
before checking this problem).
Check Start switch PB1, and replace if necessary.
The unit will not start if in a menu screen, indicated by a blinking light.
No wire feed speed control with Wire
Speed control during welding. Wire
Speed remains at the Run−In Wire
Speed setting.
Check current feedback signal. This signal, +1 volt DC per 100 amperes, can be measured on termi-
nal strip TB1, terminal F, with respect to terminal D (see Section 5-5). HDC 1500DX needs a signal of
greater than 1.5 volts DC i.e. > 150 amps) for the unit to go from run−in to weld parameters.
Have Factory Authorized Service Agent check control board PC1, and replace if necessary.
No contactor control for welding power
source (ensure that welding power
source is working properly and that all
connections are correct).
Check for contact closure from pin A to pin B. This can be measured on terminal block TB1, terminal
A, with respect to terminal B (see Section 5-5).
No output control for welding power
source.
Check command signal on pin E of 14-pin receptacle. This signal can be measured on terminal block
TB1, terminal E, with respect to terminal D. Signal should go from 0 to +10 volts DC as Output control
is turned from min. to max.
Unit displays BUTN EROR.
Check the push buttons, and replace if necessary (see Section 6-3 and Parts List). (On power up the
HDC 1500DX checks the push buttons to see if any are stuck.) Turn the unit off for 10 seconds to
clear the error message.
Unit displays TACH EROR.
Check connection from HDC 1500DX to motor. Turn the unit off for 10 seconds to clear the error mes-
sage. This error is displayed because the HDC 1500DX is not receiving a tach signal from the motor.
Make sure the motor being used matches the one selected in the Auxiliary Menu (see Section 6-10).
(The motor may not have a tach.)
Make sure motor cable is not routed with weld cable. (If inching works properly, noise may be corrupt-
ing the tach signal.)
Unit displays MOTR EROR.
Make sure the motor being used matches the one selected in the Auxiliary Menu (see Section 6-10).
Turn the unit off for 10 seconds to clear the error message.
Inspect motor for damage. (see motor Owner’s Manual). (Motor draws excessive amount of current.)
Erratic weld and no control of output.
Check remote voltage sense lead polarity, (see Section 5-3) for correct sense lead connections.
