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7-4. Troubleshooting
Trouble
Wire does not feed; open-circuit voltage
available.
Wire feeds erratically.
Motor runs slowly.
Unit does not switch out of Soft Start.
Wire feeds when Jog switch is pressed
but not when gun trigger is pressed.
Wire feeds when Jog switch is pressed
but not when gun trigger is pressed.
Wire stubbing on low end using a con-
stant current power source or feeder re-
sets.
Gas does not flow or does not stop flow-
ing; wire feeds.
OM-278792 Page 28
Check power switch S1 and connections, replace if necessary.
Check supplementary protector CB1. Reset CB1.
Unit overheated. Allow unit to cool.
Check sensing lead connection.
Check gun trigger plug connection.
Check gun trigger. See gun Owner's Manual.
Check Resonant Coupler PC23 and connections, replace if necessary.
Check DIP switch settings on Meter Board PC22 (see section 5-12)
Have Factory Authorized Service Agent check Control board PC1.
Readjust hub tension (see section 5-10).
Readjust drive roll pressure (see section 5-10).
Clean or replace dirty or worn drive roll (see Section 5-5).
Remove weld spatter around nozzle opening.
Replace contact tip or liner (see gun Owner's Manual).
Change to correct size and type drive roll (see Section 5-5)
Check that DIP switches on Motor Control Board (PC 1) are set correctly (see section 5-12)
Have Factory Authorized Service Agent check control board PC1.
When soft start is on, motor will run slow until weld current is sensed by HD1.
Readjust hub tension (see Section 5-10).
Check if wire speed dual schedule switch is activated (if applicable, see Section 6-3)
Check and replace contact tip or liner if necessary (see gun Owner's Manual).
Check that DIP switches on Motor Control Board (PC 1) are set correctly (see section 5-12)
Have Factory Authorized Service Agent check Control board PC1.
Check transducer HD1 and connections, and replace if necessary.
Check gun trigger connection at wire feeder. Check gun trigger leads and trigger switch. See gun Owner's
Manual.
Check DIP switch settings on Meter Board PC22 (see section 5-12)
Have Factory Authorized Service Agent check Control board PC1.
Ensure that CC/CV switch in feeder is in CC position (see Section 6-1).
Increase power source inductance setting if available.
Increase output setting of power source or decrease wire feed speed.
Clear blockage in gas hose or replace hose.
Clear blockage in welding gun.
Clear blockage in filter (see Section 7-3).
Check gas valve.
Check coil voltage and connections of gas valve GS1. Check continuity of coil. Replace GS1 if necessary.
Have Factory Authorized Service Agent check Control board PC1.
Remedy