Customer complaint (has help #1 alarm) Help 1 “Indicates a malfunction in the primary power circuit” removed sheet metal and conducted pre-power checks. Only issue is that R1 and R8 are reading out of tolerance, should be around 37-39kohms but have a reading over 1megaohms. Powered on unit and have a significant imbalance on capacitors, 360 and 560 vdc, should be 460 each. Board needs to be either replaced or repaired. Did pit welder under load I did not get a Help 1 as stated. But the likely reason for code is cap imbalance. Max voltage is 500 and exceeding limits can result in components failure. Could need capacitors as well. 

Customer opted to get the board repaired, along with ordering new caps in case theory is correct. 

After installing the board, welder was powered on. Initially capacitors held a 6% difference which is tolerable, but then gradually grew out of the tolerance of 10% Shutdown unit and removed caps, installed new, tested and have near perfect balance. Under load perfect balance. Re-assembled, wipedown.

Project Type: Circuit Board Installation Cincinnati, Ohio…

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About Dupont Welder Services

Over the past 30 years Dupont Welder Services has assisted over 1,300 customers by servicing and repairing their welding equipment. Our expert technicians service welding machines in both gas-driven and electrical models for the industry’s leading manufacturers. We provide service and repair for owners with one machine to large manufacturing facilities with over a hundred.