Red-D-Arc D502K 5+4 Technical Manual page 41

Trouble
High weld output.
Electrode sticks to the workpiece more
frequently during low voltage (short arc
length) conditions.
Low weld output.
Low open-circuit voltage.
No remote fine amperage or voltage
control.
Wire feeder does not work with welding
generator.
Low CV weld output.
Min or max CV weld output only.
B. Auxiliary Power
Trouble
No auxiliary power output; weld output
okay.
D502K 5+4
Check position of Amperage Range switch S3 and Voltage/Amperage Adjust control R1.
Check engine speed, and adjust if necessary (see Section 7-5).
Check field current regulator board PC1 and connection, and replace PC1 if necessary (see Section
10-7).
Circuit breaker CB4 may be open. CB4 automatically resets when the fault is corrected (see Section 7-8).
Check transformer T1 for signs of winding failure. Check continuity across windings, and check for
proper connections. Check secondary voltages. Replace T1 if necessary.
Check integrated rectifiers SR4 and SR5, and replace if necessary.
Check engine speed, and adjust if necessary (see Section 7-5).
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.
Check field current regulator board PC1 and connection, and replace PC1 if necessary (see Section
10-7).
Clean slip rings, and install new brushes if necessary (see Section 10-11).
Disconnect leads 105 and 108 from the rotor, and check continuity across slip rings. Replace rotor if nec-
essary.
Check engine speed, and adjust if necessary (see Section 7-5).
Place Voltage/Amperage Adjust Control switch S5 in Weld Terminals Remotely Controlled position.
Check and secure connections to Remote 14 receptacle RC14 (see Section 4-9).
Repair or replace remote control device.
Reset circuit breaker CB5 or CB6 (see Section 7-8).
Check and secure connections to Remote 14 receptacle RC14 (see Section 4-9).
Repair or replace wire feeder.
Set Amperage Range switch S3 to highest range.
Check position of Voltage/Amperage Adjust control R1 and Voltage/Amperage Adjust Control switch S5.
Repair or replace remote control device.
Check field current regulator board PC1 and connection, and replace PC1 if necessary (see Section
10-7).
Max CV weld output only: disconnect leads 19 and 30 at PC3 and check voltage feedback circuit. Feed-
back voltage should be the same as weld terminal open circuit voltage (see Section 10-2).
Reset receptacle circuit breakers.
Check resistance of auxiliary power windings between leads 81 and 84. Replace exciter stator (aux. sta-
tor) if necessary.
Remedy
Remedy
TM-4412 Page 37