Lincoln Electric Expert Troubleshooting for Powerwave 455M Welding System

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TROUBLESHOOTING

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USING THE STATUS LED TO TROUBLESHOOT SYSTEM PROBLEMS

The Power Wave / Power Feed are best diagnosed as a system. Each component (power source, user inter- face, and feed head) has a status light, and when a problem occurs it is important to note the condition of each. In addition, errors displayed on the user interface in most cases indicate only that a problem exists in the power source, not what the problem may be.

Therefore, prior to cycling power to the system, check the power source status light for error sequences as noted below. This is especially important if the user interface displays "Err 006" or "Err 100" .

charts for both machine and weld performance.

The STATUS LIGHT is a two color light that indicates system errors. Normal operation is a steady green light. Error conditions are indicated in the following chart.

NOTE: The POWER WAVE 455M/STT (CE) status light will flash green, and sometimes red and green, for up to one minute when the machine is first turned on. This is a normal situation as the machine goes through a self test at power up.

Included in this section is information about the power source Status LED, and some basic troubleshooting

LIGHT CONDITION

MEANING

Status LED is solid green (no blinking).

1. System OK. Power source communicating normally

 

with wire feeder and its components.

 

 

Status LED is blinking green.

2. Occurs during a reset, and indicates the POWER

 

WAVE 455M/STT (CE) is mapping (identifying) each

 

component in the system. Normal for first 1-10 sec-

 

onds after power is turned on, or if the system con-

 

figuration is changed during operation.

 

 

Status LED is blinking red and green.

3. Non-recoverable system fault. If the PS Status light

 

is flashing any combination of red and green, errors

 

are present in the POWER WAVE 455M/STT (CE).

 

Read the error code before the machine is turned off.

 

Error Code interpretation through the Status light is

 

detailed in the Service Manual. Individual code digits

 

are flashed in red with a long pause between digits. If

 

more than one code is present, the codes will be sep-

 

arated by a green light.

 

To clear the error, turn power source off, and back on

 

to reset.

 

 

Status LED is solid red (no blinking).

Non recoverable hardware fault. Generally indicates

 

nothing is connected to the POWER WAVE 455M/STT

 

(CE) wire feeder receptacle. See Trouble Shooting

 

Section.

Status LED is blinking red.

Not applicable.

 

 

POWER WAVE 455M/STT (CE)

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Contents Power Wave 455M/STT California Proposition 65 Warnings SafetyElectric Shock can kill Iii Welding Sparks can cause fire or explosionSûreté Pour Soudage a L’Arc Précautions DE SûretéSafety Safety Thank You Table of Contents Table of Contents Technical Specifications Power Wave 455M/STT CE K2203-2 InstallationHigh Frequency Protection Machine GroundingLifting StackingInput Connection Input Fuse and Supply Wire ConsiderationsElectrode and Work Cable Connections Table A.1Negative Electrode Polarity Voltage SensingCable INDUCTANCE, and ITS Effects on Pulse Welding Table A.2 System DescriptionWork Voltage Sensing Electrode Voltage SensingSingle Head Feeder Configuring the SystemSingle Head Boom Feeder UP to 4 Feeders AllowedDual Head Boom Feeder using two single heads Control Cable Specifications Welding with Multiple Power WavesInstallation DIP Switch Settings and Locations Receptacle SpecificationsControl Board DIP Switch Water Flow SensorOperation Safety PrecautionsPower Wave 455M/STT CE Definition of Welding Terms Recommended Processes and Equipment General DescriptionRecommended Equipment Required EquipmentPower Wave 455M/STT CE Case Front ControlsCase Front Layout Fringe Procedures Nominal ProceduresWelding Adjustments Making a WeldWelding Mode Constant Voltage WeldingARC Control Figure A.6 Current Wave Form Pulse Pulse WeldingFigure A.7 STT WeldingFactory Installed AccessoriesField Installed Optional EquipmentRoutine Maintenance MaintenanceHOW to USE Troubleshooting Guide TroubleshootingUsing the Status LED to Troubleshoot System Problems Error Code # Description Indication Error Codes for the PowerwaveContact your local Lincoln Authorized Field Service FacilityIf the Thermal LED is also lit, see Exceeding the 325 amp limit on STT output terminal WFS 455M/STT Power Wave 455M/STT CE Wiring DiagramConnection Diagram Semi-automatic Simple System Connection DiagramPower Wave 455/STT Wire Feeder Work SenseDimension Print Power Wave 455M DiagramsPage Precaucion Aviso DE