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OM-216 655 Page 12
5-2. Troubleshooting
Problem Solution
Unit is completely inoperative. Check continuity of Power switch S1, and replace if necessary.
Reset circuit breaker CB1 if open.
Check input power source. See welding power source Technical Manual.
Wire does not feed, unit completely inop
-
erative.
Turn Power switch On.
erative.
Check 14−pin receptacle connections.
Check input power or the CB
Wire does not feed. Check gun trigger connection at wire feeder. Check gun trigger leads and trigger switch. See gun Owner’s
Manual.
Have Factory Authorized Service Agent check drive motor and control board PC1.
Wire feeds erratically. Readjust hub tension and drive roll pressure.
Use correct size drive roll (see Parts List).
Clean or replace dirty or worn drive roll.
Remove weld spatter around nozzle opening.
Replace contact tip or liner. See gun Owner’s Manual.
Have Factory Authorized Service Agent check drive motor and control board PC1.
Wire feeds when Jog switch is pressed
but not when gun trigger is pressed.
Check gun trigger connection at wire feeder. Check gun trigger leads and trigger switch. See gun Owner’s
Manual.
Wire does not feed with Jog button S2B
pressed.
Check continuity of Jog button S3, and replace if necessary.
pressed.
Check motor control board PC1 and connections, and replace if necessary
Electrode wire feeding stops or feeds
erratically during welding.
Realign drive rolls.
erratically during welding.
Check hub assembly (see Parts List).
Wire feeds as soon as power is applied. Check gun trigger. See gun Owner’s Manual.
Wire does not feed until trigger is
pressed but continues to feed after trig-
ger is released.
Check for short between gun trigger leads and weld cable. Repair or replace gun trigger leads.
Gas valve rattles loudly and wire feeds
slowly or erratically.
Check for short between gun trigger leads and weld cable. Repair or replace gun trigger leads.
Gas does not flow; wire feeds. Check gas valve and flowmeter.
Wire feeds, but gas does not flow with
gun trigger pressed.
Check coil voltage and connections of gas valve GS1. Check continuity of coil. Replace GS1 if necessary.
gun trigger pressed.
Check continuity of Purge switch S2A, and replace if necessary.
Wire feeds, but gas does not flow with
Purge switch S2 pressed.
Check continuity of Purge switch S2A, and replace if necessary.
Purge switch S2 pressed.
Check coil voltage and connections of gas valve GS1. Check continuity of coil. Replace GS1 if necessary.
Wire feeds and electrode wire is ener
-
gized, but gas flow is irregular.
Check coil voltage and connections of gas valve GS1. Check continuity of coil. Replace GS1 if necessary.
gized, but gas flow is irregular.
Clear blockage in gas hose or replace hose.
Clear blockage in gun. See gun Owner’s Manual.
Motor runs at full speed. Check motor control board PC1 and connections, and replace if necessary.
Check resistance and connections of active wire speed potentiometers and replace if necessary.
Wire drive motor coasts (no brake at trig-
ger release).
Check motor control board PC1 and connections, and replace if necessary.
Meter does not work properly. Check optional meter board PC2 and connections, and replace if necessary