Lincoln Electric 11226, 11124 Power SOURCE- Weld Controller, Error Codes, Error Code # Indication

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E-13

TROUBLESHOOTING

E-13

 

 

 

 

Observe all Safety Guidelines detailed throughout this manual

 

ERROR CODES

The following is a partial list of possible error codes for the Power Wave AC/DC 1000. For a complete listing con- sult the Service Manual for this machine.

POWER SOURCE- WELD CONTROLLER

 

 

Error Code #

Indication

 

 

 

 

31

Primary (Input) overcurrent error.

Excessive Primary current present. May be related to a switch board or output

 

 

 

rectifier failure.

 

 

 

 

32

Capacitor "A" under voltage (Left

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

 

 

side facing machine)

ration, or an open/short circuit in the primary side of the machine.

33Capacitor "B" under voltage (Right side facing machine)

34

Capacitor "A" over voltage

(Left

Excess voltage on the main capacitors. May be caused by improper input con-

 

side facing machine)

 

figuration, , excessive line voltage, or improper capacitor balance (see Error

 

 

 

43)

 

35

Capacitor "B" over voltage

(Right

 

 

 

 

side facing 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 pre-charge failed. Usually accompanied by codes 32-35.

 

 

 

41 Secondary (Output) overcurrent error

The long term average secondary (weld) current limit has been exceeded.

 

 

 

This error will cause the machine output to phase back to 100 amps, typi-

 

 

 

cally resulting in a condition referred to as “noodle welding”.

 

 

 

NOTE: The long term average secondary current limit is 1050 amps.

 

 

 

 

 

43

Capacitor delta error

 

The maximum voltage difference between the main capacitors 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).

 

 

 

46 Secondary (Output) overcurrent error

Absolute maximum output level has been exceeded. Usually associated with

 

 

 

excessive short circuit currents and/or specific weld mode issues. This is a

 

 

 

short term average designed to protect the inverter switching circuitry.

 

 

 

 

 

49

Single phase error

 

Indicates machine is running on single phase input power. Usually caused by

 

 

 

the loss of the middle leg of the input power (L2).

54Secondary (Output) overcurrent error The long term average secondary (weld) current limit has been exceeded.

This error will immediately turn off the machine output.

Other

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® AC/DC 1000

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Page 63 Page 65
Contents Power Wave AC/DC Safety Mar ‘95Electric Shock can kill Welding and Cutting Sparks can Cause fire or explosion IiiPrécautions DE Sûreté Sûreté Pour Soudage a L’ArcSafety Safety Thank You Table of Contents Table of Contents Specifications Installation Input Fuse and Supply Wire Considerations Input and Ground ConnectionsInput Connection Input Voltage SelectionSystem Connection System OverviewRecommended Equipment System Description Single Arc Tandem Arc Triple Arc 3,4Optional Equipment System Identifier DescriptionElectrode Studs Work Studs Arclink 5 Pin Step by Step Installation Checklist Wire Reel Mountings Step by Step Installation Checklist System DeviceNet PLC Controller Installation Connection Diagram- Parallel Machines PF-10A Controlled Systems PF-10S ConnectionsDeviceNet PLC Controlled Systems Electrode and Work ConnectionsRemove the front cover from the power source Cable INDUCTANCE, and ITS Effects on WeldingRemote Sense Lead Connections Voltage Sensing OverviewVoltage Sensing for Slave machines Voltage Sensing Considerations for Multiple ARC SystemsPower Control Cable Connections Common Equipment ConnectionsInstallation External I/O Connector Receptacle SpecificationTable A.4 RS232 Connector S3 DB-25 style Table A.5 DeviceNet Connector S5 5 pin mini styleTable A.7 External I/O S7 12 pin terminal block Transmit +Transmit Receive +Wire Drive Gear Ratio Setting Ethernet ConfigurationInternal Controls Devicenet ConfigurationInternal Controls Description Feed Head Board DIP Switch S1 Control Board DIP Switch S1Ethernet Board DIP Switches S1, S2 Off 0default Object InstanceTable A.14 Table A.15Devicenet MAC ID Table A.16 Master / Slave Config MasterSlave Bank S4 Bank S3Definitions of Welding Modes OperationCommon Welding Abbreviations Positive Output Negative Output Phase Inverter Input Power Three PhaseProtective GroundProduct Summary Recommended ProcessesProcess Limitations Equipment LimitationsCase Front Control Descriptions See Figure B.4Figure B.5 Power Wave AC/DC POWER-UP Sequence Case Rear ComponentsCommon Welding Procedures Duty CycleOverview of the AC/DC Submerged ARC Process Making a WeldMultiple ARC System Considerations Basic Modes of OperationConstant Current CC Constant Voltage CVRE-STRIKE Timer Weld SequenceStart Options END OptionsWeld Process Adjustments DC Offset AC AdjustmentsWave Balance FrequencyPhase RecommendationsAccessories KITS, Options and AccessoriesOptional Kits and Accessories Software ToolsPeriodic Maintenance MaintenanceCalibration Specification Troubleshooting HOW to USE Troubleshooting GuideSymptoms RecommendedCourse of Action Qualified person should Perform this operationRecommended Symptoms ARC Quality Problems Weld Tab of the Diagnostics Utility Diagnostics Utility, select Monitor Diagnostics Utility displaysDiagnostics Utility, select Power Wave’s passive mode Changed, select Configure,Produced Assembly that Gas Analog In Active Selections From the DeviceNet tabBad Weld Ending Burnback Disabled Scans Between Updates and I/OBetween Updates is 1/4 of I/O Bad Welding Analog Scans Between UpdatesManager utility Present. Read the error codes before the machine Utility included on the Power Wave Submerged ArcUtilities and Service Navigator CD’s. This is the pre Is turned offPower SOURCE- Weld Controller Error CodesError Code # Indication This error will immediately turn off the machine outputWire Drive Module Diagrams 1000Diagrams AC Switch Wiring Diagram AC Switch Wiring Diagram Dimension Print Power Wave AC/DC Precaucion Warnung
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