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Technical Support

NO

Problem

Probably the cause

Detection and solution

1

Generator can not be started: after press the start button, the generator starts and then stops at the same moment, the generator give out one voice “di”, the relay inside the generator acts and then returns at once.

1、The induction coil is not proper,

Please consult our technician;

2、Load is too heave, this means too much work piece inside the coil; or the power adjusted is too little.

  1. 1、 Less work piece should be put inside the coil when starting.
  2. 2、 To increase the power by adjusting the power knob on the front panel,

3、Short of the compensating capacitor

  1. 1、 Cut off the connection between coil and generator and the capacitor, to detect if the capacitor is short.
  2. 2、 Replace the whole capacitor or cut off the short part of the capacitor.

4、Loose of the connection between generator and capacitor, or between the capacitor and the coil.

1、Check all the connection.

5、Poor contact of the relay;

  1. 1、 Check the contact of the relay;
  2. 2、 Detect the output voltage from the filter capacitor inside the generator to be about 500VDC, when starting, this voltage should maintain the same value;
  3. 3、 Grinding the contacts of the relay or replace the relay;

6、Damage inside the generator

(1) Damage of the potentiometer on the front panel

1、Detect the voltage of the first pin from left of the S4 on the main card, when adjust the potentiometer, the voltage should be 2---5.1V continuously.

2、Replace the whole front panel or replace the potentiometer only.

(2) Damage of the main card or the driving cards or the voltage regulate card

Replace

(3) Damage of the feedback tester

Replace

(4) Damage of the over voltage sensor

Replace

(5) others

2

The “short circuit”LED on the front panel flash with buzzing.

1、Damage of the IGBT module used in voltage regulating part, or damage of the IGBT component on the auxiliary voltage regulate card.

  1. 1、 Using digital meter to Detect if the C2 and E2 or C2 and G2 of IGBT module is short; any short detected means IGBT module or the IGBT component on the auxiliary voltage regulating card is damaged;
  2. 2、 Remove the auxiliary voltage regulating card and detect again the IGBT module and the IGBT component on the auxiliary card respectively, to confirm the one of short.
  3. 3、 Replace the damaged IGBT module or damaged auxiliary card.

2、Damage of the short circuit sensor;

  1. 1、 When the main power is on , 100V can be detected between C2 and E2 of the voltage regulating IGBT module, but the LED of short circuit still light;
  2. 2、 Replace the short circuit sensor

3、Damage of the charging resistance

  1. 1、 Detect the resistance of 200Ω/20W, or measure the output voltage of the filter capacitor, the voltage should be about 500VDC.
  2. 2、 Replace the damaged resistance;

4、When repair, the main input power and the control input power is separated, and only the control power is turned on;

When repair, take off the S28 plug from the main card, and then short the two pins of the S28 socket , to stop the short circuit protection temporarily;

3

Over current happens every starting even at the smallest power or smallest current.

1、There is short or sparking between turns of the induction coil.

Make sure the insulation of the coil is good and complete , to recover the insulation if damaged;

2、The induction coil is not proper , too many turns or too little turns;

Please consult our technician;

3、Short of the compensating capacitor;

  1. 1、 Cut off the connection between coil and generator and the capacitor, to detect if the capacitor is short.
  2. 2、 Replace the whole capacitor or cut off the short part of the capacitor.

4、Damage of the inverting IGBT module or the regulating IGBT module or the Diode or the auxiliary voltage regulating card.

  1. 1、 Using digital meter to detect if the following components are short;
    1. (1) Two inverting IGBT module;
    2. (2) One Regulating IGBT module;
    3. (3) Diode module;
    4. (4) The IGBT and diode component on the auxiliary voltage regulating card;
  2. 2、 Replace the damaged components, it is suggested to be done by trained personal.

5、Damage of the voltage regulating card or damage of the driving cards;

  1. 1、 Check the LED on the driving cards or the voltage regulating card, the LED lights when damaged;
  2. 2、 Replace the damaged cards;

6、Damage of the driving power card.

  1. 1、 Check if the +5V、+20V , +12V and -12V is correct;
  2. 2、 If they are not correct, cut off the line between power card and main card or driving card, measure again;
  3. 3、 Replace the damaged card.

7、Damage of main control card.

Replace

8、others, such as sparks inside the generator.

NO

Problem

Probably the cause

Detection and solution

4

Water fail : the LED of water fail lights with continuous buzzing.

1、The pressure of the cooling water is not enough ---- there is one pressure relay inside the generator, and it is required the cooling water pressure is larger than 0.2Mpa.

  1. 1、 Make sure the pump is pressure pump, and the power is about 300--500W, and the pumping height is larger than 30 meters.
  2. 2、 Block the water outlet of the generator temporarily, to make the water pressure increase to start the pressure relay, recover the water out flow after the water fail disappears.

2、Damage of the pressure relay or the presetting value is too high .

  1. 1、 Open the generator, adjust the preset on the pressure relay to about 0.15MPa.

2、 Replace the pressure relay.

3、Damage of the main control card.

Very little possibility.

5

Over temperature: The LED of over temperature lights with continuous buzzing

1、The temperature inside the compensating capacitor is too high;

  1. 1、 Take off the 2P line from generator to capacitor box, if the over temperature warning disappears, this means the capacitor box is over temperature; if the warning continues, the generator is over temperature.
  2. 2、 This problem can be solved by Decreasing the temperature of the cooling water,

2、The temperature of the water cooled base inside the generator is too high;

3、Damage of the thermometer.

  1. 1、 According to procedure described above, check which one of the generator or the capacitor box is over temperature, if the actual temperature is below 55℃, the thermometer may go wrong;
  2. 2、 Replace it.

4、Damage of the main control card;

Replace.

6

Input over voltage: The LED lights with continuous buzzing.

1、The input voltage is higher than 420V;

  1. 1、 Using digital meter to measure the input voltage to be in the range of 340 --- 420V;
  2. 2、 If the input voltage exceeds the range above, please contact our technician.

2、Presetting of the potentiometer on the main card is not correct.

Adjust the RP2 multi-turn potentiometer on the main card to reset the value for over input voltage control; the voltage will increase 10 volts when adjust one turn reverse to clock direction.

3、Damage of power card or main control card.

Replace.

7

Output over volt: The LED of output over volt lights with continuous buzzing.

1、Damage of voltage sensor module;

Replace

2、Damage of main control card;

Replace

3、When the output over volt happens together with over current, solve the problem of over current at first, sometimes, output over volt disappears after the over current problem be solved.

8

Pressing the start button can not start the generator, at the same time , the relay does not act.

1、Damage of the relay;

  1. 1、 measure the resistance of the coil of the relay to see if it is OK.
  2. 2、 Replace the damaged relay.

2、Damage of the main control card;

1、The relay is OK, but does not act when pressing the start button. In this case , the main control card may have problem.

3、others

9

Over current happens when operating at large output power , but it is normal at small output power.

1、Input voltage is too low or the capacity of the input power is not enough;

To Improve the input power or use the machine at lower power.

2、Induction coil is not proper.

To Improve the coil.

3、problem of generator

(1) Problem of main control card or other cards.

(2) Spark inside the generator or poor insulation status.

10

Over currents happens after a long time working at large output power.

1、Temperature inside the generator is too high , this may caused by high surrounding temperature.

Improve the ventilation.

2、Input voltage waves greatly, especially the input voltage is too low.

Improve the input power or use the machine at lower output power.

3、The input switch outside the generator has a poor quality or the model is not proper, or the input wire is too thin to cause too much heat.

Replace with good quality switch and select the switch and wire according to the instruction.

11

Main switch or input switch jumps off every time, the power can not be turned on.

  1. 1、 short of the rectifier bridge ,

Replace

  1. 2、 The contacts of the relay have been stuck together.

Replace or repair the relay.

  1. 3、 Short of other parts or lines

Check

12

Main switch jumps off when using at large output power , or after long time working.

  1. 1、 Main switch is getting poor.

Replace

2、Wire connected to the switch loose, poor electrical contact.

Hold all the wire tight.

3、Over heat of the wire due to poor contact or too thin of the wire

13

Input switch is easy to jump off , or the input fuse is easy blown.

1、Rated current of switch is too low,

To select proper switch according to our instruction.

2、The quality of switch is poor or got poor after ling timer use.

Replace

14

Control fuse blows easily

1、Short of fans or short between fan and frame.

Replace or insulate

2、Short of control transformer or control switch

Replace

3、Short between fuse and generator frame.

Replace the whole set of fuse.

15

Output power is still low even the adjusting knob is at maximum position

  1. 1、 The induction coil is not proper or the compensate capacitor is not matching.

Improve the coil or the matching

  1. 2、 problem of the generator

NO

Problem

Probably the cause

Detection and solution

16

Heating starts as soon as the power is on, and the heating can not be stopped by stop button.

  1. 1、 The front panel circuit is too dirty;

Clean it with alcohol or acetone.

  1. 2、 Problem of foot switch or remote control box.

Replace

17

No power: the power LED and the digital meter on the front panel does not light.

1、The main switch or the control switch is off

Turn on all the switch

2、The control fuse is blown

Check the fuse on the back panel

  1. 3、 The main switch or the control switch is damaged;

Replace new ones

  1. 4、 No input power

Check the input circuit;

  1. 5、 Damages inside the generator

(1) Control transformer is damaged;

Detect if the output of 15V is correct;

(2) main power card is damaged;

Detect the DC output on the power card;

18

Electric Leakage

1、poor insulation between fuse and generator frame;

2、leakage between fans and the generator frame.

3、others

Guangyuan inverter electronic equipment manufacturing Co. Ltd
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