Common Faults and Solutions
1.4.0T welder works with single-phase small current and strikes arc slowly/delayedly.
a.Check if the network voltage (single-phase power supply) or voltage fluctuation is violent (generator power supply);
b.check if the electrode is wet and if the workpiece is clean;
c. check if the input cable or output holder wire accords with international specifications;
d.check if the welder output is normal, and if there is no-load voltage.
e. If the above is normal, please contact with our customer service center to give you a solution.
2.LED panel displays nothing, but the welder works normally.
a.Check if LED header wire is inserted well (pull out the wire or shake it) or if the wire lead drops out.
b.If no, please replace LED panel.
3.LED panel displays nothing, without any no-load voltage, and the welder does not work normally.
a.Check if the input network voltage is normal, and if the three-phase input power wire is connected well.
b.Check if the control transformer connecting line is connected well.
c.Check if the control transformer outputs 22V power source (see the Detection Method 4). If it is normal, the LED panel is faulted, please replace the LED panel. If there is no 22V voltage, the control transformer is faulted, please replace the control transformer.
d.If the above faults are removed, LED panel yet displays nothing, and the welder does not work normally, the intelligent control module is faulted, replace it.
4.In case of switch-on failure or switch trip
a.firstly, check if the rectifier bridge is broken down (see Detection Method 3). If yes, please replace the rectifier bridge components;
b.secondly, check if the IGBT inverter components are broken down (see Detection Method 10), if yes, check if the drive voltage of the intelligent control module is normal (see Detection Method 8). If the drive voltage of the intelligent control module is wrong, please replace the intelligent control module and IGBT inverter components.
c.Check if the electrolytic capacitor component is shorted or cracked (old welders before the year 2008),
d.check if the circuit breaker is normal (See Detection Method 5)
5.LED panel displays current value, without any fault code, but the welder has no output.
a. Check if the rectifier tube of the output rectifier and freewheel components is opened (Its detection method is the same as that in EE32, the 6th part).
b. Check if the intelligent control panel is damaged (to check the drive voltage, see the Detection Method 8).
c.Check if the output high-frequency transformer secondary is shorted.
d. If the above is normal, the intelligent control module is faulted, replace it.
6.The welding current is not adjustable.
a. Check if the welder's no-load voltage is normal with a multimeter (Detection Method 1). If it is normal, the encoder is broken or the connecting wire is broken or connected virtually.
b.If there is no no-load voltage, the intelligent control module is faulted, replace it.
7.Upon welding, the current drops sharply and suddenly, so it fails to strike arc.
a.Check if there is any fault code,
b.if the quick coupler of the output end is connected virtually,
c.and if the socket of the IGBT drive is connected virtually.
d.Check if the current transformer is in poor contact (Upon welding, the welder component makes "sizzle" sounds.
8.If the welding current is relatively small, less than the welding current value,
a.the network voltage is less than the welder's under-voltage point (according to the welder models, under-voltage points are between 290V～310V),
b.the output cable is in poor contact to cause the increase of consumption,
c.the sectional area of the output cooper cable is less than 35 square meters or the aluminum cable is used,
d.increase the welding current,
e.check if the quick coupler of the output end is connected virtually.
9.If it is hard to strike arc,
a.check if the quick coupler of the output end is connected virtually;
b.check no-load voltage; if it is less than 80V,
c.check if the arc ignition circuit is normal, if the output wire is too long or the aluminum cable is used,
d.if the surface of the welding workpiece is not clean,
e. if the electrode is wet,
f.if the network voltage is less than the welder's under-voltage point (according to the welder models, under-voltage points are between 290V～310V)
10.The welding molding is not good,
a.the network voltage has big fluctuation,
b.the generator power supply and voltage fluctuation are too big,
c.electrode is wet,
d.the welding current is over-big,
e.the wire connection is wrong.For example, when the basic electrode is used, the positive electrode is connected with the workpiece, while the negative electrode is connected with the electrode holder.
11.In case of big welding spatter
a.tune down the welding current
b.weld at the short arc as far as possible
c.the workpiece surface is not clean
d. adjust the correction mode of the output end.
12.In case of arc interruption,
a.check if the quick coupler of the output end is connected virtually;
b.the network voltage is less than the welder's under-voltage point or the three-phase network voltage is not balanced;
c.to share power supply with other alternating current machines simultaneously, it will cause the arc interruption due to the voltage attenuation of the DC machine;
d.the electrode is wet,
e the network voltage does work normally, or the machine is over-heated because of long-time operation,
f.the machine appears the arc interruption due to instantaneous protection. Over-long cable or aluminum cable is used;
g.if the cellulose electrode must be used in PS model, other models are easy to cause the arc interruption.
13.In case of arc bias,
a.adjust the welding method and use short arc welding,
b.adjust the direction of ground electrode.
c.Pay attention to wind direction upon welding outdoor;
d.adjust the correction mode of the output end, e.g.: J422 (ordinary electrode, acidity), the welder's output negative electrode is connected with the electrode holder, and the positive electrode is connected with the workpiece.
14.There are some abnormal sounds, when the welder works.
a.Fan abnormal sound: when the fan is damaged or has some foreign matters, the fan makes some abnormal sounds. Please replace the fan or remove the foreign matters.
b.High-frequency transformer abnormal sound: the magnetic core of the high-frequency transformer is misplaced, loosened or cracked, the abnormal sound appears (if it fails to weld, please replace the high-frequency transformer.)
c.If the intelligent control module makes abnormal sound, the intelligent control module is faulted, replace it.
