In daily welding operations, the OTC DAIHEN CPVE250 welding machine is highly praised for its excellent arc stability and operational convenience. However, the equipment may occasionally experience abnormal conditions during long-term use. To help you quickly restore production, we have compiled the following common faults of the CPVE250 welder and their corresponding troubleshooting and treatment methods.
I. CPVE250 Welder Common Faults Troubleshooting Chart
When your welder experiences issues such as no wire feeding, no shielding gas, power breaker tripping, or no display on the control panel, please refer to the table below for preliminary fault diagnosis:
| No. | Fault Phenomenon | Cause of Fault or Abnormality | Troubleshooting Method | |
|---|---|---|---|---|
| 1 | Power switch trips | There may be an internal short circuit. If it cannot be re-energized, immediately cut off the power and contact the authorized agent. | ||
| 2 | Main power indicator (PL1) is OFF | Power switch ON, digital display is ON | Indicator (PL1) bulb fault | Check indicator PL1 |
| Power switch ON, digital display is OFF, fan not running | Distribution box switch not turned on | Check distribution box power status | ||
| Input cable connected loosely | Check input cable | |||
| 3 | Power switch ON, but digital display is OFF | Main power indicator (PL1) is OFF | Refer to No. 2 troubleshooting | |
| PL1 is ON | Control circuit fault | Check/replace circuit board P30110Q or P30110F | ||
| 4 | No shielding gas flows when torch switch is pressed | No gas when pressing “Gas Check” button | Cylinder valve is closed | Open the gas cylinder valve |
| Insufficient cylinder pressure | Check gas pressure | |||
| Gas solenoid valve SOL fault | Check solenoid valve SOL on the wire feeder | |||
| Gas flows when pressing “Gas Check” button | Torch switch cable broken or socket poor contact | Check wires No. 151, 152 | ||
| 5 | Continuous gas leaking | “Gas Check” LED is ON (normally open state) | Press “Gas Check” button to stop checking | |
| Gas solenoid valve SOL fault | Check solenoid valve SOL on the wire feeder | |||
| 6 | Gas flows when pressing torch switch, but no open-circuit voltage | Inverter main circuit fault | Turn off power, contact the authorized agent | |
| Control circuit fault | Check/replace circuit board P30110P or P30066S | |||
| 7 | Cannot set current, voltage | Control circuit fault | Check/replace circuit board P30110P | |
| Filter circuit fault | Check/replace circuit board P30179R | |||
| Remote control pendant fault | Check and replace cable, socket, or pendant body | |||
| Voltage detection abnormality | Check connection status of CN5 on P30110P | |||
| 8 | No wire feeding | Wire feeder side control cable poor contact or broken | Check/replace socket, cable | |
| Motor control circuit fault | Check/replace circuit board P30110Q | |||
| Filter circuit fault | Check/replace circuit board P30179R | |||
| 9 | WCR relay continuously acting | Current Hall sensor CT2 fault | Check Hall sensor CT2 | |
| WCR relay fault | Check/replace the relay on PCB P30110P | |||
| WCR circuit fault | Check/replace circuit board P30110P | |||