Troubleshootings 1. Plasma Cutter 1 The machine can not work at all and you find there is no spark in the discharging nozzle in the run-on tab Cause: The two parts are too far from each Solution: tight them 2 No gas from the torch Cause: the hose is broken Solution: change one hose 3 When the number on the display does not change Cause: the potentiometer is broken Solution: Change the potentiometer(It will not infulence your cutting result) TIG Welder Breakdown Trouble shoot Air switch can't be closed 1.Something wrong with quality of air switch; 2.Three-phase commutating bride is damaged and need to change; 3.Checking whether the inner of machine is short-circuited or not. The pilot light of power can't be on. No indication on the meter. Fan doesn't run. No current output. 1.Making sure whether the air switch opens or not; 2.Making sure whether the power of input electric cable has current; 3.Making sure whether the power lacks of phase or not. The pilot light of power is on. Indication of meter is normal. Fan runs. No welding output. 1.Checking whether the connection and plug lines in the machine contact well or not; 2.Checking whether the connection of output terminal opens, or contact well or not; 3.Control board is damaged (contact with salesmen or manufacturers). The pilot light of power is on. Abnormal pilot light is on. Indication of meter is normal. Fan runs normally. 1.IGBT is damaged. 2.Recovering the rectifier quickly; 3.Control board breaking down; 4.The feedback circuit is broken, and needed to contact to salesmen and manufacturers. Too large splash in the welding Unreasonable output polarity, change the polarity of output wire. In the welding, the output current is unstable or isn't controlled by the potentiometer. 1.Something wrong with quality of potentiometer, and potentiometer needs to change. 2.Weak contact of connecting section, especially the plugs, and check is needed. The pilot light of power is on. Abnormal pilot light isn't on. Indication of meter is normal. Fan runs normally. Argon welding has no high frequency, but the Arc-striking by contacting output current. 3.High voltage wrap is damaged. 4.High frequency relay is damaged. 5.Too long distance among high frequency discharge nozzle. ARC welder ARC160/200/230 breakdown phenomenon trouble shooting Electric source indicator doesnt light. Fan doesnt run. No welding output. 1. Check power switch. 2. Check input wires. Electric source indicator lights but the fan doesnt run or stop for a while. No welding output. 1. Connect with wrong electric source. Change the connection into single 220V. 2. 220V power system is unstable. 3. Power off or power on continuously in a short time and cause the over-voltage protection. 4. Wire which connects switch and electrical source is loose. Fix it again. 5. The 24V relay on main circuit is damaged or no a suction. Check the relay and replace it . Fan is running but output current is unstable or can not been controlled by potentiometer. 1. Potentiometer (1K) is bad; 2. Some connecting terminals arent fixed well. Fan runs but abnormal indicator doesnt light. No welding output. 1. Check all plug-ins are in good connection. 2. If the output terminals is in opening or loose connection. 3. Use multimeter to test voltage between MOS card and CN6 plug-in. It should be about DC 300V for WS-160/180/200 and DC 540V for WS-250/315/400. 1) Silicon Bridge is opening or its connecting wires are loose. 2) The big capacitor (about 470 F/450) on electrical card is in leakage. Replace it. 4. There is an auxiliary power supply on MOS card. If the green indicator isnt light that shows the auxiliary power doesnt work. Check where the fault is. 5. The controlling wire on TIG torch is broken. The abnormal indicator lights and fan runs but no welding output. 1. Over-current protected. Power off firstly and power on again. 2. Over-heat protected. I will get normal after waiting for 2 minutes to 3 minutes 3. It might be the malfunction of inverter circuit. Plug out the power supply plug (CN6) of main transformer on MOS card. Power on again: 1) If the indicator still lights, the problem is on the MOS card. Check and find out the bad FET to replace it. 2) Abnormal indicator doesnt light. The fault is on the rectifying card. Use the bridge measure the primary inductance value and Q value. Shunt transformer, L=1.2-2.0mH ,Q 40. If both the inductance and Q value are lower than the value, replace it: The second rectifier on transformer is bad. Replace it. 4 Feedback circuit is opening. ARC315/400/500 Fan dont work without output welding current 1. Make sure the air switch is perfect or off. 2. Make sure the electric net connected to the power supply has electricity. 3. The thermal resistor on the power board is damaged. 4. Bottom board (something wrong with the bottom board, no DC537V voltage output. 1) The silicone bridge is circuit broken, and the connectors are not well-connected. 2) The power board is somewhere burnt. Check the connectors from the air switch to the bottom board and that of the bottom board to the MOS board. Something wrong with the assistant power supply on the control board. Air switch turn off auto 1. Silicone bridge damaged, renew it 2. Air switch damaged, renew it. Fan works without output welding current 1. Check the connector assemblies are well connected or not. 2. The torch cable is broken or earth cable is broken. 3. Something wrong with the inverter circuit (abnormal LED is on). Please plug off one of the power plug (Somewhere near the VH-07) on the MOS board, and restart the machine. If abnormal LED doesnt show, there is a handicap in it or another one (1)The handicap is on , something wrong with main transformer board, main transformer may be damaged, measure it with electric bridge. Electric sense and Q value of single mains transformer L=1.2-2.0 Q 4 if L and Q is small, renew it. (2) It may be some rectifier on the main transformer board, check and it If the abnormal light is on, the MOSFET is broken, check and renew it. 4 The feedback circuit or the control circuit is break(abnormal LED is on), please contact the merchandisers Splash is big It is not reasonable to connect output polarities, exchange the output polarities. MIG Welding Machine phenomenon Reason Measure 01 After boot, the indicator light does not shine lack of power phase The back plate of the automatic air switch damaged Fuse within the power off check power change air switch Replacement of power within the fuse 2A 02 Connected to welding power, welding the back plate of the automatic air switch off automatically Automatic air switch damaged IGBT Module damage three-phase rectifier bridges damaged change air switch replacement of IGBT modules, and replacing the drive circuit board change 3-phase rectifier bridges 03 Welding process, welding power source behind the panel automatically switches off automatic air Long-term overload operation Air switch damaged load rate used in accordance with the welding machine change air switch 04 Can not adjust the size of welding current wire feeder control cable fault welding machine control circuit board bad welder in shunt at the two ends of broken wires change control cable change control board connect broken wires 05 Arc instability, big splash Specification is wrong Conductive serious wear mouth Change specification Change wear mouth 06 CO2 gas regulator is not heating CO2 gas regulator is damaged heating cable is broken change CO2 gas regulator repair heating cable 07 Hold down the torch switch, wire feed and normal, but gas is not normal. Control circuit board damage Solenoid valve damage Wire feeder control cable fault replacement control circuit board change solenoid change or repair wire feeder 08 Hold down the torch switch, wire feeder does not work, there is no no-load voltage directive Torch switch damage Wire feeder control cable fault Control circuit board damage replacement torch Repair wire feeder control cable replacement control circuit board