Lincoln Electric IM986 manual Error Codes for the Power Wave, Error Code #, Indication

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E-3	TROUBLESHOOTING	E-3
	Observe all Safety Guidelines detailed throughout this manual

ERROR CODES FOR THE POWER WAVE®

The following is a partial list of possible error codes for the POWER WAVE® i400. For a complete listing consult the Service Manual for this machine.

POWER SOURCE–––WELD CONTROLLER

	Error Code #	LECO	Indication
		(FANUC#)
31	Primary (Input) overcurrent error.	49	Excessive Primary current present. May be related to a
			switch board or output rectifier failure.
32	Capacitor “A” under voltage	50	Low voltage on the main capacitors. May be caused by
	(right side facing the Switch PC Board)		improper input configuration, or an open/short circuit in the
33	Capacitor bank "B" under voltage	51	primary side of the machine.
	(left side facing the Switch PC Board)	51
	(left side facing the Switch PC Board)
34	Capacitor "A" over voltage	52	Excess voltage on the main capacitors. May be caused by
	(right side facing the Switch PC Board)	52	improper input configuration, excessive line voltage, or
	(right side facing the Switch PC Board)		improper input configuration, excessive line voltage, or
35	Capacitor "B" over voltage	53	improper capacitor balance (see Error 43)
	(left side facing the Switch PC Board)	53
36	Thermal error	54	Indicates over temperature. Usually accompanied by
		54	Thermal LED. Check fan operation. Be sure process does
			not exceed duty cycle limit of the machine.
37	Softstart (pre-charge) error	55	Capacitor precharge failed. Usually accompanied by
			codes 32 and 33.
39	Misc. hardware fault	57	Unknown glitch has occurred on the fault interrupt circuit-
			ry. Sometimes caused by primary over current fault, or
			intermittent connections in the thermostat circuit.
43	Capacitor delta error	67	The maximum voltage difference between the main capac-
			itors has been exceeded. May be accompanied by errors
			32-35. May be caused by an open or short in the primary
			or secondary circuit(s).
54	Secondary (output) over current	84	The long term average secondary (weld) current limit has
			been exceeded. This error will immediately turn off the
			machine output.
			NOTE: The long term average secondary current limit is
			450 amps.

			A complete list of error codes is available in the
			Diagnostics Utility (included on the POWER WAVE®
		see com-	Utilities and Service Navigator CDʼs or available at
Other		see com-	www.powerwavesoftware.com).
Other		plete
		listing	Error codes that contain three or four digits are defined as
			fatal errors. These codes generally indicate internal errors
			on the Power Source Control Board. If cycling the input
			power on the machine does not clear the error, contact the
			Service Department

CAUTION

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.

POWER WAVE® i400

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Contents Power Wave Safety Depends on YouSafety Mar ʻ95Electric Shock can kill AUGIii JanPrécautions DE Sûreté Mar. ʻ93Electromagnetic Compatibility EMC Safety Thank You ViiTable of Contents Phase Input Height Width Depth WeightOperating Temperature Range Storage Temperature RangeEnclosure ClassClass F K2673-23 155CInstallation Safety PrecautionsInput Fuse and Supply Wire Considerations Power Supply Connection for the Fanuc R30iA ControllerInput and Grounding Connections Input ConnectionsConnection Diagrams and System Optional EquipmentPower Wave Utilities Fanuc R30iA Controller Mounting Typical Single ARM Typical Master / Slave System Dual ARM Typical I400Electrode and Work Connections General Guidelines Table A.1Percent DutyCable INDUCTANCE, and ITS Effects on Welding Remote Sense Lead ConnectionsVoltage Sensing Overview Table A.2Work Voltage Sensing Voltage Sensing Considerations for Multiple Arc SystemsIf Sense Leads are not Used See Figure A.3Power Regarding cable placement, best results will be Control Cable ConnectionsCommon Equipment Connections General GuidelinesOther SET-UP Issues Operation Electric Shock can killInput Power Three Phase Direct CurrentProduct Description Recommended Processes and EquipmentCase Front Case Front Control DescriptionCase Back Case Back Components DescriptionPin Leads Function 115V / 15A Duplex ReceptaclePOWER-UP Sequence Common Welding ProceduresInternal Controls Internal Controls DescriptionBasic Welding Controls Constant Voltage WeldingPulse Welding Non Synergic CVAccessories Factory InstalledField Installed Optional EquipmentMaintenance Routine MaintenancePeriodic Maintenance Calibration SpecificationCapacitor Discharge Procedure Figure D.1aTroubleshooting HOW to USE Troubleshooting GuideUsing the Status LED to Troubleshoot System Problems Table E.1Error Code # Error Codes for the Power WaveIndication Wire Drive Module Recommended Symptoms ProblemsCourse of Action Observe Safety Guidelines LEDRecommended Weld and ARC Quality Problems DeviceNet PLC Controlled System Power Supply Under the Produced Assembly thatTouch Sense command From the DeviceNet tab Passive ModeBad Weld Starting Wire Feed problem Through the wire conduit. VerifyStrike Wire Feed Speed Ly connected and configured asRespond quickly Analog In Active Selections From the DeviceNet tabNeeds to be changed, select ModificationBad Weld Ending Burnback Disabled From the DeviceNet tab Other than Analog Scans Between UpdatesBurnback is present Burnback Time That Burnback is present for all Analogs Welding set pointsProblems Possible Recommended Symptoms Diagrams Enhanced DiagamDimension Print Power Wave Aviso DE Use ventilation or exhaust to Guards off