While checking for loose connection and dry solder etc.

, Switch off the machine, otherwise IGBT

will be permanently damaged. ~

, ;

1. Of-Over Temperature Indication 1. Check if fans are working.

2. Check fan voltage.
3. Remove dust from the Heat Sink.
4. Check Thermistor resistance
approx. 280 ohms.
5. Replace Control PCB.
6. Replace Thermistors.

2. SP - Single Phasing Indication 1. Check incoming line voltage,

fuses, etc.
2. Check MCB.
3. Check for wires removed at MCB,
EMI or spike protector PCB.
4. Check IC of the SP card.
5. Check for loose connection.

3. UV - Under Voltage Indication 1. Check in put Voltage 330V.

4. OV - Over Voltage Indication 1. Check in put Voltage 46SV.

5. OC - Over Current Indication 1. Check out put Diodes.

2. Change U3 in Drive PCB.
3. Check Gate, Emitter and Collector
wires from Drive PCB.
4. Check the loose connection and
dry solder.
5. Check Drive PCB
6. Change Drive PCB if faulty.
7. Check IGBT
8. Change lGBT if Failed.

6. MCB Tripping 1. MCB defective

2. Check EMil Spike protector PCB.
3. Check MOV.
4. Check for phase-to-phase short
circuit.
Sr.
No. PROBLEM SOLUTION

7. OCV (Open circuit Voltage) not present. 1. Check input voltage.

2. Check out put resistance.
\
3. Check out put diodes.
4. Check IGBT and Drive PCB.
5. Check indicating lamp and take
corrective.

8. Out put Current in not stable while welding. 1. Check base current-Potentiometer.
2. Check Normal I Pulse switch
position.
3. Keep peak current potentiometer
at min.
4. Check for control PCB from Dust,
Oil and Grease etc.
5. Check for loose connection of
shunt wire in control PCB.

9. Loud Bang 1. Check MOV.

2. Replace MOV.

10. No Welding Current 1. Check Open Circuit Voltage.

2. Check input voltage.
3. Check out put resistance.
4. Check output diodes.
5. Check IGBT and Drive PCB.
6. Check indication lamps and take
corrective actions.
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ZAICAP INV CAPACITOR 0.1 mfd 1000 VDC

ZAICPCB INV CONTROL PCB

ZAICPOT INV CONTROL POTENTIOMETER

ZAICT INV CONTROL TRANSFORMER

ZAIDPM INV DIGITAL PANEL METER

ZAIDPCB INV DRIVE PCB

ZAIELCAP INV ELECTROLYTIC CAPACITOR

ZAIESPCB INV EMI/SPIKE PCB THREE PH.

ZAIFAN INV FAN 6" NADI

ZAIIC124J INV IC LM 124J

ZAIIC339 INV IC LM 339

ZAIIC2526 INV IC UC 2526

ZAIIC316J INV IC HCPL 316J

ZAIIGBT INV IGBT 400 AMP

ZAIIPBRIDGE INV INPUT BRIDGE 400 AMP

ZAIPCHOKE INV INPUT CHOKE

ZAIMCB INV 400 AMP MCB

ZAIMOV INV 400 AMP MOV

ZAIOPCHOKE INV OUTPUT CHOKE

ZAIDIODE INV DIODE 150EBU04

ZAIOPT INV OUTPUT TERMINAL

ZAIPT INV POWER TRANSFORMER

ZAIRSSW INV RESET SWITCH

ZAIRCSW INV ROCKER SWITCH

ZAISPCB INV SNUBBER PCB

ZAITB INV TERMINAL BLOCK

ZAITHR INV THERMISTER

ZAIWH INVWHEELS

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