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TROUBLESHOOTING & REPAIR
STATUS LED ERROR CODE TABLE
NOTE: The error code signal sequence is always preceded by a 2 second green light. If more than one error code is present, a 4 second off signal will separate the individual error code signals. Note that the [2 sec. green] is only displayed at the beginning of the entire code sequence, not between codes if more than one error code is present.
Example: (Code. #11 “one long red” followed by “one short red”) followed by (Code. #21 “two long reds” fol- lowed by “one short red”).
[2 sec. green] [1.2 sec. red] [1.6 sec. off] [0.4 sec. red] [4.0 sec. off] [1.2 sec. red] [0.4 sec. off] [1.2 sec. red] [1.6 sec. off] [0.4 sec. red]
ERROR CODES FOR THE POWER WAVE
The following is a list of possible error codes that the POWER WAVE 355/405 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.
11 | CAN communication bus off. |
| Probably due to excessive number of communication errors. |
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12 | User interface time out error. |
| UI is no longer responding to the Power Source. The most |
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| likely cause is a fault/bad connection in the communication |
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| leads or control cable. |
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21 | Unprogrammed weld mode. |
| Contact the service department for instructions on reloading |
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| the Welding Software. |
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22 | Empty weld table. |
| Contact the service department for instructions on reloading |
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| the Welding Software. |
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23 | Weld table checksum error. |
| Contact the service department for instructions on reloading |
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| the Welding Software. |
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31 | Primary overcurrent error. |
| Excessive Primary current present. May be related to a |
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| short in the main transformer or output rectifier. |
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32 | Capacitor “A” under voltage. |
| Low voltage on the main capacitors. May be caused by |
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| improper input configuration. |
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33 | Capacitor “B” under voltage. |
| When accompanied by an overvoltage error on the same |
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| side, it indicates no capacitor voltage present on that side, |
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| and is usually the result of an open or short in the primary |
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| side of the machine. |
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34 | Capacitor “A” overvoltage. |
| Excessive voltage on the main capacitors. May be caused |
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| by improper input configuration. |
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35 | Capacitor “B” overvoltage. |
| When accompanied by an under voltage error on the same |
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| side, it indicates no capacitor voltage present on that side, |
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| and is usually the result of an open or short in the primary |
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| side of the machine. |
36 | Thermal error. |
| Indicates over temperature. Usually accompanied by ther- |
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| mal LED. Check fan operation. Be sure process does not |
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| exceed duty cycle limit of the machine. |
37 | Softstart error. |
| Capacitor precharge failed. Usually accompanied by codes |
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41 | Secondary overcurrent error |
| The secondary (weld) current limit has been exceeded. |
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| When this occurs the machine output will phase back to |
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| 100 amps, typically resulting in a condition referred to as |
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| “noodle welding” |
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| NOTE: The secondary limit is 570 for the standard stud, and |
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| 325 amps for all single phase operation. |
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| POWER WAVE 355/405 | |
