Lincoln Electric 10372 Service Manual page 159

F-95
FLOWCHART - FUNCTIONAL TROUBLESHOOTING GUIDE
See UI Error
Chart for
N N Error 006?
additional error
codes.
Status Light on the PS
N
on?
Communication Fault.
Check Wiring and Solid Condition of
Linc-Net Cables for Red Status light
open circuit
Flashing Green
System is stuck in Remapping loop.
Most likely cause is the loss of the
+5Vcan Supply. Check J27 on PS
Control Board, check Power Board,
Etc.
Check Status Light and harness
Verify all connections to the PS Control Board
5 Green LED's lit on
Y Perform Power Board test to verify correct
the PS Control
voltage levels
Board?
Reload the PS Software. If Problem still
N
exists, replace PS Control Board.
Check/repair harness between:
The Power Board and the Control Board.
Run Power
Pass
- AND/OR -
Board Test
The Power Board and the wire feeder
receptacle (S1), including the output
Fail
circuit breaker (CB1).
Was 60-80 VDC at Power Replace the
Y
Board input connector Power Board.
N
Check/repair harness
Voltage at the Power Y between the Power
Board Capacitor?
Board and the Capacitor.
N
Check for 60 to 80 VDC at the
Output of the rectifier. If present,
Voltage at the input to Y
check harness from rectifier to
the Rectifier?
Capacitor. If not replace rectifier
N
Input power does not appear to be
supplied to aux. transformers
Check input power, check reconnect,
check Breakers, check Line Switch, etc.
TROUBLESHOOTING AND REPAIR
N Error 100?
Y
Y
Main UI Display
Y
Y
Go To PS
Flashing Error
Red and Green Interpretation
Guide.
Can you adjust
WFS and Voltage?
Y
Errors on UI Does Wire feed when
N N
Display? you pull the trigger?
Y
Is there OCV from the
Errors on UI
N brass block to the work stud
Display?
with the trigger pulled
N
Look for open
circuit in the
System is functional. If
PS secondary
performance problems
exist see System
Troubleshooting guide
Be sure the trigger is engaged long enough to overcome any set preflow
delay, or turn the preflow timer off.
Check trigger circuit operation from the gun to the FH Control Board.
Perform the Drive Motor Test to verify motor voltage is present when the
trigger is pulled.
Check the continuity of the Shutdown circuit in the FH (wires
570 & 571). If the path between these wires is interrupted the
FH will not operate and the Status light will flash red while all
other nodes appear normal.
A rapidly flashing red Status light indicates the node needs to be
reprogrammed.
Turn On
UI Status
N Y
panel on? on?
Y
N
Errors on UI
Display?
N
PS Status
N
Select a CV
on?
Mode
Check connections from UI Control Board to
Display panel. If the display and Status light are
Y
N
Check for 12 VDC at J4 pins 1 to 4 , and J4
pins 3 to 8 on the UI Control board. If voltage is
Y
Check For
40VDC at UI
OK
Control Board
Y
Not OK
Check PS breaker (CB1), Linc-Net
cables, wiring in UI and PS.
+40 VDC section of Power Board
may be malfunctioning, Perform
Y
Power Board test
Performance
Verify no Limits are set.
Check Harness for UI Control Board
to the Dislay Panel (specifically the
wires to the Encoder Board.
Run The Dual Encoder PC Board
Test
N
FH Status On?
Y
FH Status
Green Red
Condition?
Flashing
FH Status
Flashing Red Flashing Green
Condition?
Flashing
Red and Green
FH has a motor
overcurrent/overtemperature
error.
Functional Troubleshooting Guide
(Semi Automatic PW-455, PW455/STT)
(For Codes 10555 and Below)
Condition of
Other
Status Light?
At this point, voltage is being supplied to the UI Control
Solid Green
Board, and the on board supply is properly converting it to
12Vdc. This has been verified by the condition of the Status
light and by measurement at the display.
Verify 12 VDC is being Because the Status light indicates a healthy condition, the
supplied to UI Display Y
problem is most likely in the harness from the Display to
PCBD (J1 pin 7 to 8)
the UI Control board or in the Display board itself. Check the
harness, and run the Display Panel Check.
N
There is a remote possibility that the Communications
Hardware on the UI Control board is not functioning
properly.
still not functioning, remove P4 from the UI
Control Board.
not present, replace UI Control Board
At this point, voltage is being supplied to the UI Control
Board, and the on board supply is properly converting it to
12Vdc, which has been verified at the display.
N
The Status light is not functioning, so the most likely
problem is that the UI Control board is "lost".Try reloading
Verify 12 VDC is being
supplied to UI Display Y the UI Software. If problem still exists, Replace the Control
PCBD (J1 pin 7 to 8) board.
There is a remote possibility that a multiple fault exists in
the harness from the Display to the UI Control board, or in
any combination of the following: The harness, the Display
board, and the Status light.
UNHEALTHY STATUS LIGHT WITH BLANK DISPLAY:
Improper system configuration (dipswitch settings) can result in
mapping errors that cause PS to continuously issue a system reset
command. The result is the UI gets stuck in a reset loop, usually
accompanied by a blank display with a green and/or red flashing
status light. Correct the system configuration.
Check the connections on wires 541 & 542, and pins A & B in the
Linc-Net control cable.
UI software may be corrupt. Reload UI soft ware
FH does not appear to have power.
Check +40 VDC connections on
pins "D" & "E" of the Linc Net
receptacle in the FH.
The FH has detected no activity from the
communication network.
Check the connections on wires 541 & 542, and pins
A & B in the Linc-Net control cable.
Check the system configuration.
If the FH is not recognized as part of a valid group, or if
improper dipswitch settings result in a duplicate or invalid
network assignment, a mapping error will be generated.
F-95
Key:
PS = Power Source
UI = User Interface (Control
Box)
FH = Feed Head
POWER WAVE 455/POWER FEED 10