Advertisement
Section 5
DANGER
Problem
Error Code E01
A ground fault has been detected.
Error Code E02
The positive (+) side weld SCR is bad.
Error Code E03
The negative (-) side weld SCR is bad.
Error Code E04
The positive (+) phase, high charge SCR is bad.
Error Code E05
The positive (+) phase, low charge SCR is bad.
Error Code E06
The negative (-) phase, high charge SCR is bad.
Error Code E07
The negative (-) phase, low charge SCR is bad.
Error Code E08
The discharge FET is bad.
Error Code E09
The discharge resistors are bad.
Error Code E11
Stud did not lift during gap weld.
Error Code E12
No earth ground.
All Other Error Codes
Poor surface condition.
Poor ground connection.
Broken or loose cables.
Use of center punch or witness marks.
Loose collet or chuck.
Poor Weld
Dirt in weld tool preventing smooth operation.
Cables are coiled.
Voltage incorrect for size stud to be welded.
Studs or pins are not perpendicular to the work surface.
Arc Blow (all weld material moves or "blows" to one
side).
Incorrect plunge setting.
Incorrect spring rate.
Weld voltage too high.
Gap too small when using gap process.
Weld is too hot.
Plunge too small.
Spring pressure too low.
Weld is too cold.
Weld voltage too low.
Gap too large when using gap process.
Plunge too large.
Spring pressure too high.
This guide references components inside the welding power supply. Working inside a capacitor
discharge (CD) power supply is inherently dangerous. Do not attempt to service components inside
a CD power supply unless you have been trained in the proper safety and service procedures. If you
have questions, consult your distributor or the factory directly.
Possible Cause
Trouble Shooting
Corrective Action
Verify that the outlet and other cables are wired correctly.
Have a qualified service tech check and replace the + weld SCR.
Have a qualified service tech check and replace the - weld SCR.
Replace control board.
Replace control board.
Replace control board.
Replace control board.
Replace control board.
Have a qualified service tech check and replace the discharge resistors.
Check control cable connection. Check gap weld tool settings.
Check power cords and outlets.
Call for service to have a qualified service tech assess problem.
Properly prepare the weld surface. Make sure it is free of contaminants such as dirt and
oil. If there is heavy oxide (rust for steel or aluminum oxide for aluminum) it must first
be removed.
Make sure all cable connections are in good condition and tightly secured.
Make sure all cable connections are in good condition and tightly secured.
Do not use center punch/witness marks to locate CD weld studs. They effectively
reduce the tip length degrading weld performance.
The collet should have a firm hold on the weld stud. If you are able to easily (with no
real resistance) pull the stud out of the collet then the collet is worn. Replace collet.
If the inside of the collet looks like there are threads in it then the collet is worn out and
should be replaced.
Service weld tool per your weld tool's Operation Manual.
Uncoil weld and ground cables.
Check the weld parameter table on page 15 to ensure that you are using the correct volt-
age for the size stud you are trying to weld.
If the operator can not suitably hold the welding tool perpendicular to the work surface,
then a template or fixture may be required.
Use double grounds, one on each side of the weld zone to balance current flow.
Move ground connections away from weld zone.
Space ground connections evenly around the weld zone.
Adjust plunge per weld tool's Operation Manual.
Adjust spring pressure per weld tool's Operation Manual.
Decrease weld voltage.
If using a gap weld tool, increase the weld gap per weld tool's Operation Manual.
Increase the plunge per weld tool's Operation Manual.
Increase the spring pressure per weld tool's Operation Manual.
Increase weld voltage.
If using a gap weld tool, decrease the weld gap per weld tool's Operation Manual.
Decrease the plunge per weld tool's Operation Manual.
Decrease the spring pressure per weld tool's Operation Manual.
1
Advertisement
