Lincoln Electric 455 M 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 list of possible error codes that the Power Wave 455M (CE) can output via the status light (see "Troubleshooting the Power Wave / Power Feed System Using the Status LED." If connected to a PF-10/11 these error codes will generally be accompanied by an "Err 006" or "Err 100" on the user interface display.

 

 

 

Error Code #

Indication

 

11

CAN communication bus off.

Probably due to excessive number of communication errors.

 

12

User Interface time out error.

UI is no longer responding to the Power Source. The most likely

 

 

 

 

 

 

 

 

cause is a fault/bad connection in the communication leads or con-

 

 

 

 

trol cable.

 

 

 

 

 

 

 

 

 

 

 

21

Unprogrammed Weld Mode.

Contact the Service Department for instructions on reloading the

 

 

 

 

Welding Software.

 

 

22

Empty Weld Table.

Contact the Service Department for instructions on reloading the

 

 

 

 

Welding Software.

 

23

Weld Table checksum error.

Contact the Service Department for instructions on reloading the

 

 

 

 

 

Welding Software.

 

31

Primary overcurrent error.

Excessive Primary current present. May be related to a short in the

 

 

 

 

 

 

 

main transformer or output rectifier.

 

32

Capacitor "A" under voltage

Low voltage on the main capacitors. May be caused by improper

 

 

 

(Left side facing machine)

input configuration.

 

33

Capacitor "B" under voltage

When accompanied by an overvoltage error on the same side, it

 

 

 

(Right side facing machine)

indicates no capacitor voltage present on that side, and is usually

 

 

 

 

the result of an open or short in the primary side of the machine.

 

34

Capacitor "A" over voltage

Excess voltage on the main capacitors. May be caused by improp-

 

 

 

 

 

 

 

(Left side facing machine)

er input configuration.

 

 

35

Capacitor "B" over voltage

When accompanied by an under voltage error on the same side, it

 

indicates no capacitor voltage present on that side, and is usually

 

 

 

(Right side facing machine)

 

 

 

the result of an open or short in the primary side of the machine.

 

 

 

 

 

 

 

 

 

 

 

36

Thermal error

Indicates over temperature. Usually accompanied by Thermal LED.

 

Check fan operation. Be sure process does not exceed duty cycle

 

 

 

 

 

 

 

 

limit of the machine.

 

 

 

 

 

 

37

Soft start error

Capacitor precharge failed. Usually accompanied by codes 32-35.

 

41

Secondary overcurrent error

The secondary (weld) current limit has been exceeded. When this

 

occurs the machine output will phase back to 100 amps, typically

 

 

 

 

 

 

 

 

resulting in a condition referred to as "noodle welding"

 

 

 

 

NOTE: The secondary limit is 570 amps for the standard stud, and

 

 

 

 

325 amps.

 

 

 

 

 

 

 

43

Capacitor delta error

The maximum voltage difference between the main capacitors has

 

been exceeded. May be accompanied by errors 32-35.

 

 

 

 

 

 

 

 

 

 

49

Single phase error

Indicates machine is running on single phase input power. Usually

 

 

 

 

caused by the loss of the middle leg (L2).

 

 

Other

 

Error codes that contain three or four digits are defined as fatal

 

 

 

 

 

errors. These codes generally indicate internal errors on the PS

 

 

 

 

Control Board. If cycling the input power on the machine does not

 

 

 

 

clear the error, try reloading the operating system. If this fails,

 

 

 

 

replace the control board.

 

 

 

 

 

 

 

 

 

 

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 455M (CE)

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Contents Power Wave 455 M 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 Thru E-6 Section ESection F-1 Section F-2Technical Specifications Power Wave 455M CE K2202-2 InstallationHigh Frequency Protection Machine GroundingLifting StackingInput Fuse and Supply Wire Considerations Input ConnectionTable A.1 Negative Electrode Polarity Voltage SensingCable INDUCTANCE, and ITS Affect on Pulse Welding System Description Table A.2Electrode Voltage Sensing Single 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 Sensor1OPERATIONB-1 Safety PrecautionsPower Wave 455M CE Definition of Welding Terms OperationRecommended Processes and Equipment General DescriptionRequired Equipment LimitationsFigure B.1 Case Front ControlsFringe Procedures Nominal ProceduresWelding Adjustments Making a WeldWelding Mode Constant Voltage WeldingARC Control Figure A.6 Current Wave Form Pulse Pulse WeldingFactory Installed AccessoriesField Installed Optional EquipmentRoutine Maintenance MaintenanceHOW to USE Troubleshooting Guide TroubleshootingError code before the machine is turned off Using the Status LED to Troubleshoot System ProblemsError Code # Indication Error Codes for the Power WaveContact your local Lincoln Authorized Field Service FacilityPower Feed System Using Status LED section of this text Cabling, etc Verify weld mode is correct for Power Wave 455M CE Wiring Diagram Connection Diagram Semi-automatic Simple System Connection DiagramDimension Print Power Wave 455M DiagramsPrecaucion Warnung