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M. Over Current Error
OVER
CRNT
Indicates one or more of the inverter engines has latched with an over-current. Signal is sent from engine module(s) (RC6,
Pin 11, on inverter control board PC1) to process control module PC4 (J2, Pin 6).
The over-current circuit monitors the inverter high frequency transformer primary current. Normal welding will never trip
this circuit, only a fault will cause an over-current condition. LED4 will be lit on the inverter control board, and power must
be cycled to clear this error.
S
The most likely fault to trip this circuit is an open 940 volts DC bus bleeder resistor, either R1 or R8 on the interconnect
board. An open resistor will cause the bus, which is split between two series capacitors, to become unbalanced. The
capacitor with the open resistor will go to approximately 340 volts DC. The other capacitor will go to approximately 600
volts DC. Normally, both capacitors are at approximately 470 volts DC. The unit will weld like this most of the time. A
16 uF balancing capacitor in series with the transformer can keep the transformer from saturating under these adverse
conditions. Occasionally, the inverter transformer will saturate, and when this happens, it draws a huge amount of
current and trips the over-current circuit. This condition locks off the inverter control board and eventually the bus ca-
pacitors will fail. A change to a different resistor eliminated this situation and the problem is no longer an issue.
S
A shorted output diode will cause an over-current error and no weld output will be available.
N. Release Trigger Error
REL
TRIG
Indicates a timed weld has expired, but the trigger is still active. Press Jog/Purge button to clear error.
This error occurs after a timed weld expires and the trigger is not released. A PDA with File Management/WaveWriter
software can be used to set up timed welds. This is strictly an informational
−
type error.
O. Trigger Stuck Error
TRIG
STUK
Indicates the welding power source was turned on and the trigger signal attempted to weld. Turn welding power source off
and back on again to clear the error.
This error indicates a trigger source was activated while the power source was being powered up. If the trigger source is
removed, the error can be cleared.
S
Use a PDA with ServicePak software and view the Comm Diagnostics screen to see the source of the contactor or
trigger command.
S
If LED2 is lit on RIO board PC10, a contactor signal is being sent from the robot.
P. Wire Feed Speed Error
ERR
WFS
Indicates a wire feed speed error. Press Jog/Purge button to clear error.
This error indicates actual wire feed speed does not match wire feed speed command.
Q. Stop Error
ERR
STOP
Indicates an arc stop error. Press Jog/Purge button to clear error.
This error occurs as a result of obstructions in the wire feed system or a faulty wire drive system. Check wire feed and
wire drive system.
R. Flow Error
ERR
FLOW
Indicates a gas flow error. Press Jog/Purge button to clear error.
This error occurs when there is no gas flow to the gun. Check shielding gas system and reestablish gas flow to the gun.
