Troubleshooting; Basic Troubleshooting - Thermal Arc 201 TS Service Manual

TROUBLESHOOTING

6.01 Basic Troubleshooting

Symptom
ON/OFF Switch "ON"
Power Indicator OFF
Over Temp Indicator on
Power Indicator ON, Fan
does not run
No Gas Flow In Lift Tig /
HF Tig Mode
ON/OFF Indicator blinks
Cannot adjust Weld
Current
No Open Circuit voltage
Low Weld output
High Weld Output
No HF in HF TIG mode
Manual 0-5148
SECTION 6:
TROUBLESHOOTING
Check power supply input
Check ON/OFF switch continuity (See 6.06.7)
Check Inrush Resistor (see 6.06.6)）
Check control PCB2 J8 connector and front panel PCB3 J24 connector to make sure
they are properly inserted.
Replace front panel PCB3
Duty Cycle has been exceeded. Reduce weld time and allow Power Supply to cool.
Check thermostat wire connections. If the connection is properly inserted and
Over Temp Indicator is still on after short-circuit thermostat, replace control panel,
otherwise replace thermostat. (the value of thermostat is 75ºC).
Check fan for obstruction.
Check whether J12connector on main board PCB1 is plugged in properly. Check for
+24V±10% on pins 1 and pin 2 of J12 connector.
If both above are ok, replace fan.
Check process switch on front panel to determine whether it is functioning properly.
And put it to Lift Tig or HF Tig mode.
Make sure pin3 and pin4 of J12connector on main board PCB1 is +24V±10%
Replace gas solenoid
Step 1. Make sure the voltage between pin 1 and pin2 of J11 connector on main
power PCB1 is - 24VDC±10%, and the voltage between pin 2 and 3 is +24VDC±10%.
Step 2. If above voltage is correct, please replace front panel PCB3.
Step 3. If above voltage is incorrect, disconnect the harness of J11 connector and
re-measure according to step 1. If still incorrect replace Main Power PCB 1
Check Control panel PCB 3 J26 connector and Remote control PCB4 J27 connector
to make sure they are properly inserted.
Check Current Control Potentiometer for an adjustment of 0 to 4.8vdc from Min to
Max on Front Panel PCB3. Pin1=Min, Pin2=Wiper, Pin3=Max. If adjustment cannot
be made correctly replace Front Panel PCB3.
Check process switch on front panel to determine whether it is functioning properly.
Check the Bus voltage on Main Power PCB1 . It should read 385VDC (see 6.05)
Turn Powersupply off and remove Mains Power. Check Input IGBT's and Output
Diodes (see 6.06.2 and 6.06.5). If it is incorrect, replace main power PCB1.
If above is OK, replace control PCB2.
If input mains is 230VAC and output is limited to 125Amps output, check Front panel
PCB3 J25 connector and Main Power PCB1 J16 connector . If they are properly
inserted, replace Control PCB2
If input is 115V, output is near 160A, check whether it is shorted between pin1 and
pin 3 on IN JC connector on main power board. If it is not, replace control board.
Make sure the process switch is functioning properly, and put it to HF TIG mode.
Check TIG torch Switch for continuity. Also check wire harness on 8 pin remote
connection. If OK, measure on (PCB1) J17 pins1 and 3 for 15vdc when troch switch
is depressed.
Check the wire of HF arc starter is connection properly.
Replace the main power PCB1
THERMAL ARC 161STL, 201TS
Inspection Methods
6-1 Troubleshooting