Section 6: Troubleshooting; Basic Troubleshooting-Power Source Faults - Thermal Arc 181i FABRICATOR Service Manual

TROUBLESHOOTING

6.01 Basic Troubleshooting-Power Source Faults

The following table is a guide for analysing problems and making repairs to the Power Source.
Fault
1 There is no weld
output and all front
panel displays are off
2 There is no weld
output and all front
panel displays are off
or flickering on & off
3 There is no weld
output and the yellow
over temperature light
is on
4 Mode switch does not
change welding mode
5 The wirefeed motor
and the weld output
do not operate when
the torch trigger
switch is depressed
6 The wirefeed motor
does not operate
when the torch trigger
switch is depressed
7 The wirefeed motor
operates at maximum
speed and cannot be
adjusted.
Manual 0-5152
SECTION 6:
TROUBLESHOOTING
Possible Cause
A The main Power Switch is set to OFF
B Line fuse is blown
C The main Power Switch is faulty
D Loose connection to EMC board
E Faulty Power Inverter board
F Faulty Control board
G Faulty Display board
A The internal protection circuit to shut
the unit down if the mains supply
voltage is too high has operated
A Unit has overheated
B Airflow inlet or outlet ducts are
blocked
C Fan does not operate
A Faulty Display board
A Internal wiring fault
B Over temperature light is on
C Power Source set to REMOTE
D Trigger wires shorted to weld voltage
inside torch
E Trigger wires or torch switch faulty
F Faulty Power Inverter board
G Faulty Control board
H Faulty Display board
A Power Source set to TIG or STICK
mode
B Wirefeeder motor wiring has become
loose
C Trigger wires or torch switch faulty
D Faulty Power Inverter board
A Faulty Power Inverter board
B Faulty Display board
Table 6-1 Power Source Faults
A Set main Power Switch to ON
B Replace Line fuse
C Replace main Power Switch
D Tighten connections
E Replace Power Inverter board
F Replace Control board
G Replace Display board
A Check to see if mains supply
voltage is <274VAC. A
generator with poor voltage
regulation may cause a supply
voltage in excess of 274VAC.
Connect Power Source to a
supply voltage <274VAC.
A Allow unit to cool with fan
running until over temperature
light extinguishes
B Remove blockages from
airflow ducts
C Replace fan. Check fan wiring
header is plugged securely
into Control board. Check fan
wiring is not damaged
A Replace Display board
A Check continuity of internal
wiring from Torch adaptor
through to boards
B Allow unit to cool
C Set switch to LOCAL
D Repair trigger wires in torch
E Check & Repair
F Replace Power Inverter board
G Replace Control board
H Replace Display board
A Set power Source to MIG mode
Check motor wiring
B Check & Repair
C Replace Power Inverter board
D
A Replace Power Inverter board
B Replace Display board
6-1
FABRICATOR 181i
Remedy
Troubleshooting