SECTION 5: TROUBLESHOOTING

Refer to the corresponding wiring diagram as a supplement to the troubleshooting chart when tracing an
electrical problem. Check supplementary drawings for options you may have received with the unit.

Table 5-1. TROUBLESHOOTING GUIDE

Trouble Probable Cause Remedy

No line voltage at 1. External fused 1. Turn on external fused disconnect switch.

all. Red POWER disconnect switch off.
ON light not on. 2. Replace fuse. Check for shorts if fuse
2. Fuse in external continues to blow.
fused disconnect
switch blown. 3. Replace fuse 4FU. Check for shorts if fuse
continues to blow.
3. Fuse 4FU blown.
4. Replace lamp.
4. POWER ON lamp
burned out.

No convenience Fuse 6FU blown. Replace fuse 6FU. Check for shorts if fuse
outlet power. continues to blow.
Internal power on.

Pump motor does 1. Fuse 8FU blow.

1. Replace fuse 8FU. Check for shorts if fuse
not operate. 2. Relay 2CR not
continues to blow.
functioning.
2. Check 115v on wire 4
NOTE: Pump is external.

Headstock does not 1. Air supply not 1. Connect air supply to inlet.
extend to clamp properly connected.
part.
2. Defective foot switch 2. Check Input 0 lamp on PLC. If it doesn’t
cable and plug. light when Footswitch pressed, replace foot
switch cable and/or plug.

3. Defective solenoid 3. Check that Output lights 4 and 5 on PLC

valve SOL B. toggle with Footswitch. If so, replace
solenoid valve SOL B coil or complete
solenoid valve.

4. Fuse 5FU 4. Replace fuse

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 Table 5-1. TROUBLESHOOTING GUIDE

Trouble Probable Cause Remedy

Current Flow with 1. Insulators worn or 1. Check headstock drawing for insulator
nothing clamped missing locations and repair/replace as needed.
2. SCR(s) shorted 2. Check SCRs

Headstock does not 1. Air supply not 1. Connect air supply to inlet.
retract to release properly connected.
part. 2. Check per Headstock doesn’t clamp
2. Defective foot switch procedure above.
cable and plug.
3. Replace solenoid valve SOL A coil or
3. Defective solenoid complete solenoid valve.
valve SOL A.

Irregular clamping 1. Dirty or defective 1. Clean or replace pressure

action at headstock. pressure regulator. regulator.

2. Dirty air filter. 2. Clean air filter.

Magnetizing current Incorrect setting POT 0 in Adjust POT 0 in PLC

shot too long or too PLC
short.

No output current at Thermo shutdown. Turn off disconnect, wait until unit cools.
Contacts, Coil.

Continuous mag Shorted SCR. Call Authorized Service Center.

shot on coil and/or
contact.

Main fuse to unit Shorted SCR Call Authorized Service Center.

blown.

No output current or 1. Loose connection at 1. Clean connections and tighten hardware.

irregular current bus bars or cable
through contacts joints. 2. Replace fuse 5FU. Check for shorts if fuse
continues to blow.
2. Fuse 5FU.
3. Swap relays 5CR and 6CR.
3. Defective relay if
occurs on COIL only 4. Check outputs on PLC and see if Output 6
or CONTACTS only. is on during COIL mag shot and Output 7 is

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 Table 5-1. TROUBLESHOOTING GUIDE

Trouble Probable Cause Remedy

on during CONTACTS shot. Check
4. Defective harnesses. harnesses and replace or repair as
necessary.

5. Defective SCRs. 5. Call Authorized Service Center

No output current or 1. Loose connection at 1. Clean connections and tighten hardware.

irregular current bus bars or cable
through Coils. joints. 2. Replace fuse 5FU. Check for shorts if fuse
continues to blow.
2. Fuse 5FU blown.
3. AC firing board or relay 7CR.
3. Mod AC(option) NO
AC 4. Swap with 6CR and see if problem switches
to CONTACTS.
4. Defective relay 5CR
5. Check harnesses and replace or repair as
5. Defective harnesses. necessary.

6. Defective SCRs. 6. Call Authorized Service Center

7.

Low output current 1. Impedance of part 1. Check equipment output with a central
at higher current exceeds the conductor (optional accessory). If
control settings. equipment equipment output is within specifications,
capabilities. part cannot be tested with this equipment.

2. Low line voltage. 2. Check line voltage. Correct if possible or try

another line
3. Loose connection at
bus bars or cable 3. Clean connections and tighten hardware
joints.
4. Adjust per instructions above
4. Wrong voltage range
on current controls 5. Check SPAN and BIAS adj. on AC firing
board.
5. MOD AC(Optional)
only

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 Table 5-1. TROUBLESHOOTING GUIDE

Trouble Probable Cause Remedy

Maximum current 1. Check inhibit light operation.

1. Defective SCR firing
output at all
board.
settings.
2. Check harnesses and repair/replace as
2. Defective harness.
necessary.
3. Adjust per instructions above
3. Wrong voltage range
on current controls
4. Contact Authorized Magnaflux Service
Center
4. Shorted SCR.

Current assurance Defective Ammeter Replace Ammeter

light defective.

Demag does not 1. SCR is not properly 1. Call Authorized Service Center
work or does not balanced.
completely demag. 2. Change 1 cap.
2. Defective 1 Cap.

Contacts push- 1. Lamp burned out. 1. Replace lamp.

button does not
light at all. 2. Defective PB switch 2. Replace Switch

Coil push-button 1. Lamp burned out. 1. Replace lamp.

does not light at all.
2. Defective PB switch. 2. Replace Switch

No push-buttons 1. Fuse 4FU blown. 1. Replace fuse 4FU. Check for shorts if fuse
light. continues to blow.
2. No 115v control
supply. 2. Check 115Vac voltage between 1 and 2.

White light does not 1. Bulb burned out. 1. Replace bulb.

work
2. Fuse 7FU blown. 2. Replace fuse 7FU. Check for shorts if fuse
continues to blow.
3. Defective switch.
3. Check white light switch and replace if
4. Defective relay 3CR defective.

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 Table 5-1. TROUBLESHOOTING GUIDE

Trouble Probable Cause Remedy

4. Replace 3CR

Meter does not 1. Meter not responding. 1. Connect oscilloscope to terminal 5 & 6 on
work. meter, (AT 50MV/ DIV) At 2,000 amps,
wave form should be approximately 2
2. Meter got wet
divisions (0 to peak). If wave form is not
there, check harness.
2. Replace Meter

Meter does not 1. Fuse 4FU blown. 1. Replace fuse 4FU. Check for shorts if fuse
light. continues to blow.
2. Defective harness.
2. Check harnesses and replace or fix as
3. Meter failure from necessary.
surge.
3. Check cables for worn indication. Replace
meter if necessary.

MOD AC not firing Inhibit lamp on AC firing

board not OFF during mag AC relay not energizing. AC switch not ON. AC
shot. firing board bad.

Revised July 2014

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