No Weld Output; Operating Panel Failure" (Led's Do Not Light Properly Or Welding Setting Cannot Be Established.) - Thermal Arc ARCMASTER 200 TS Service Manual

3.3 "No weld output"

When in High Frequency TIG (HF TIG) mode, if the
High Frequency is not generated (present), refer to
"High Frequency Output Failure". Refer to the page
11-7.
Cause
Occurs when the remote connector (CON1) or
associated circuitry is defective, damaged, or the
TIG torch cable is defective.
Verification/Remedy
CAUTION
Read and understand this entire section before
proceeding. Extreme personal harm and test
equipment damage will occur if the procedures are
not performed accurately.
a) Verify the remote connector (CON1). (Applies
to LIFT TIG and High Frequency TIG (HF TIG)
mode.)
 Verify a secure between the remote connec-
tor (CON1) and the TIG torch cable.
 Verify a secure connection of the harness
and the connections between the remote
connector (CON1) and CN1 on PCB1 (WK-
5713) are all correct and there are no open
circuits.
 Contact the manufacture if you find any bro-
ken connectors or damaged wiring har-
nesses.
 Verify the proper pins-outs of the remote con-
nector at the TIG Torch side. (Refer to section
in the Operating Manual.)
 Verify that there is no open circuit on the
remote connector at TIG Torch side.
 In equipment for remote control use, Verify
the pin specification of a connector. (Refer to
section in the Operating Manual.)
b) Verify the condition and connections of the
welding cable, the stick rod holders and the
ground clamp. (Applies to all welding modes.)
 Verify a secure connection of the welding
cable, stick rod holders, ground clamp and
dense connectors and there are no open cir-
cuits.
c) Verify the no-load voltage (OCV). (Applies to
STICK, High Frequency TIG (HF TIG) mode.)
11
200TS
 Refer to the section "Verification of No-load
voltage (No OCV)" in the page 11-13.
 If performing the "No-Load Voltage Failure"
procedure does not rectify the failure, per-
form the following tests in the sequence
below. Replace any defective components
found.
1) Secondary diode (D2-D3)
 Verification. Refer to the page 11-12.
 Replacement. Refer to the page 12-15.
2) Coupling coil (C.C.) and Reactor (FCH1)
 Replacement C.C. Refer to the page 12-
15.
 Replacement FCH1. Refer to the page
12-15.
3) Transformer (T1)
 Replacement T1. Refer to the page 12-
10.
4) Primary IGBT (Q1A-Q4C)
 Verification. Refer to the page 11-12.
 Replacement. Refer to the page 12-13,
14.
5) Hall C.T. (CT1)
 Replacement CT1. Refer to the page 12-
17.
3.4 "Operating Panel Failure"
(LED's do not light properly
or welding setting cannot be
established.)
Cause
Occurs when there is a connection failure among
PCB1 (WK-5713), PCB5 (WK-5448), PCB6 (WK-
5460) and PCB1 or PCB5 or PCB6 are defective.
Verification/Remedy
a) Verify the harness connection between CN101
on PCB1 (WK-5713) and CN1 on PCB4 (WK-
5499).
 Verify a secure connection of the harness
and the connections between CN101 on
PCB1 and CN1 on PCB5.
 Contact the manufacture if you find any bro-
ken connectors or damaged wiring har-
nesses.
11 – 6
ADVANCED TROUBLESHOOTING