Section 10 - Troubleshooting; Troubleshooting Tables - Red-D-Arc D502K 5+4 Technical Manual

SECTION 10 – TROUBLESHOOTING

10-1. Troubleshooting Tables

A. Welding
Trouble
No weld output; auxiliary power output
okay.
No weld output or auxiliary power output. Disconnect equipment from auxiliary power receptacles during start-up.
Erratic weld output.
TM-4412 Page 36
Place Process/Contactor switch S6 in a Weld Terminals Always On position, or place switch in a Weld
Terminals Remotely Controlled position and connect remote contactor to optional Remote 14 receptacle
RC14 (see Sections 4-9, 5-3 and 5-4).
Check position of Amperage Range switch S3.
Check position of optional Polarity/AC Selector switch S13.
Reset circuit breaker CB11 (see Section 7-8).
Reset circuit breaker CB5 (see Section 7-8). Check for faulty remote device connected to RC14.
Check fuse F2, and replace if open (see Section 7-8).
Check and secure connections to Remote 14 receptacle RC14 (see Section 4-9).
Check connector board PC6 and connections, and replace PC6 if necessary (see Section 10-5).
Clean slip rings, and install new brushes if necessary (see Section 10-11).
Check field current regulator board PC1 and connections, and replace PC1 if necessary (see Section
10-7).
Disconnect leads 105 and 108 from rotor, and check continuity across slip rings. Replace rotor if neces-
sary.
Reset circuit breaker CB12 (see Section 7-8).
Check fuses F1 and F2, and replace if open (see Section 7-8).
Check integrated rectifier SR1, and replace if necessary.
Check capacitor C9, and replace if necessary.
Clean slip rings, and install new brushes if necessary (see Section 10-11).
Disconnect leads 105 and 106 from the rotor, and check continuity across slip rings. Replace rotor if nec-
essary.
Disconnect stator excitation leads 100 and 101, and check continuity between leads. Replace stator if
necessary.
Check resistance and connections of resistor R3; full resistance of R3 (end to end) is 10 ohms
Replace R3 if necessary. If R3 is replaced, adjust R3 (see Section 10-12).
Check field current regulator board PC1 and connection, and replace PC1 if necessary (see Section
10-7).
Use dry, properly stored electrodes.
Be sure connection to work piece is clean and tight.
Remove excessive coils from weld cables.
Check and tighten connections inside and outside unit.
Clean slip rings, and install new brushes if necessary (see Section 10-11).
Check main rectifier SR3, and replace if necessary.
.
See Section 10-2 for test points and
values and Section 14 and following
for parts location.
Remedy
±
10%.
D502K 5+4