Lincoln Electric SVM135-B service manual Power Source Error Interpretation Guide

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F-93	TROUBLESHOOTING AND REPAIR	F-93
FLOWCHART - POWER SOURCE ERROR INTERPRETATION GUIDE

	Power Source Error Interpretation Guide
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(Semi Automatic PW-455, PW455/STT)

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					Perform the Contactor Test.
Codes 32, 33, 34,	Y	Perform	the Switch	Pass	Perform Input Board Test.

If the PS Status light is flashing any combination of red and green,

				(For Codes 10555 and Below)
		errors are present in the PW-455.
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 separated by a green light.

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and 35?				Board Test on both
						sides.
										Perform the Input Rectifier Test.
	N						Fail
		Replace as Necessary.
			Replacement board(s) must have
		identical part number (including the
				"dash number").
					Both Switch boards are reporting an undervoltage error.
								Check Input Voltage.
								Perform the Input Board Test.

Code 12?

N

Codes 21, 22, or 23?

N

Y

Weld Table Error is present.

Reload known good Weld Software.

Y

Check the "All Modes" dipswitch in the UI, typically SW2-8 (refer to dipswitch settings specified for the software version loaded in the UI).

				UI previously recognized by the system is no
					longer communicating, but power appears to
						be present at the UI. Check for intermittent
	UI Display and
			Y
							connections in the communication path
Status light on?
					(pins A and B in the control cable, wires 541
							and 542 in both the UI and FH).
		N

UI previously recognized by the system is no longer communicating, and no power appears to be present at the UI. Check for intermittent connections in the +40 VDC path (pins D and E in the control cable, wires 540 and 500 in both the UI and FH).

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Code 32 and		Y			Check for proper reconnect position.
33?
			Look for faulty undervoltage connections from the Switch board(s) to the
				Control board (+5VDC = normal, 0VDC = fault).
	N
			If the symptom is intermittent, Check the operation of the main contactor.

Both Switch boards are reporting an overvoltage error.

							Check the Input Voltage.
Code 34 and		Y
35?				Check for proper reconnect position.
			Look for faulty overvoltage connections from the Switch
	N
						board(s) to the Control board
					(+5VDC = normal, 0VDC = fault).

The current transformer (CT)

feedback signal to the control

Perform Output

Code 31?

Y

Pass

board is too high. Look for a

Rectifier Test

short in the transformer or

primary side of the machine.

N

Fail

Replace Output

Rectifier Modules as

Required

Any of the following

codes:

32, 33, 34, or 35?

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Machine configured

N

for 230V?

Y

Code 32 and

Perform the Switch Board

Y

Test on Side "A" (left side

34?

facing the front of

Invalid error combination. Check for

machine)

N

faulty overvoltage and undervoltage

Fail

connections from the Switch

board(s) to the Control board

(+5VDC = normal, 0VDC = fault).

Replace the Switch Board

Replacement board(s) must have

identical part number (including

the "dash number").

	Code 33 and				Perform the Switch Board
N		Y
	35?				Test on Side "B" (right
					side facing the front of
						machine)
							Fail
						Replace the Switch
					BoardReplacement board(s)
			must have identical part number
				(including the "dash number").

Pass

Check main capacitor for a short circuit

condition.

Check for faulty overvoltacge and

undervoltage connections from the Switch board(s) to the Control board

(+5VDC = normal, 0VDC = fault).

Pass

N

Thermal Error (generally accompanied by a thermal error light):

Check continuity of thermostat circuit. Thermostats are connected

in series, so open circuit reading indicates tripped thermostat or

Y

Code 36?

faulty connection

Check operation of the cooling fan.

N

Check for excessive dirt build up in heatsink fins etc.

Soft Start failure.

Generally accompanied by under and over voltage errors

(32-35), because the system is unable to charge the

main capacitors to an acceptable voltage level.

Code 37?

Y

Follow the branch for under and over voltage errors

N

(32-35) to test the Input Bd., Switch Bd., and main

contactor operation.

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.

Other Codes?

Y

EXCEPTION:

Reoccuring fatal errorscan sometimes be caused by overloading the system. As an

example this could occur in earlier versions of PS software when rapidly changing from

N

one head to the another on a multi-head system (i.e. PF10x2). Adding a minimum (0.1

seconds) of preflow time to each head or upgrading the operating system shoudl

generally solve the problem.

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	Key:
		PS = Power Source
		UI = User Interface (Control
		Box)
Finish
	FH = Feed Head

POWER WAVE 455/POWER FEED 10