Power Source Error Interpretation Guide - Lincoln Electric POWER WAVE SVM135-B Service Manual

F-93
FLOWCHART - POWER SOURCE ERROR INTERPRETATION GUIDE
Perform the Switch
Codes 32, 33, 34, Y
Board Test on both
and 35?
sides.
Fail
N
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 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
Check for proper reconnect position.
35?
Look for faulty overvoltage connections from the Switch
N
board(s) to the Control board
(+5VDC = normal, 0VDC = fault).
Machine configured N
for 230V?
Y
Code 32 and
34?
Invalid error combination. Check for
N
faulty overvoltage and undervoltage
connections from the Switch
board(s) to the Control board
(+5VDC = normal, 0VDC = fault).
Code 33 and
N
35?
TROUBLESHOOTING AND REPAIR
Perform the Contactor Test.
Perform Input Board Test.
Pass
Perform the Input Rectifier Test.
Perform the Switch Board
Y Pass
Test on Side "A" (left side
facing the front of
machine)
Fail
Check main capacitor for a short circuit
condition.
Replace the Switch Board
Replacement board(s) must have
Check for faulty overvoltacge and
identical part number (including
undervoltage connections from the Switch
the "dash number").
board(s) to the Control board
(+5VDC = normal, 0VDC = fault).
Perform the Switch Board
Y Pass
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").

Power Source Error Interpretation Guide

Start
If the PS Status light is flashing any combination of red and green,
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.
Y
Code 12?
N
Weld Table Error is present.
Reload known good Weld Software.
Codes 21,
Y
22, or 23?
Check the "All Modes" dipswitch in the UI, typically
SW2-8 (refer to dipswitch settings specified for the
N software version loaded in the UI).
Perform Output
Code 31? Y
Rectifier Test
N
Fail
Replace Output
Rectifier Modules as
Required
Any of the following
codes:
32, 33, 34, or 35?
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
Code 36? Y
Check operation of the cooling fan.
N
Check for excessive dirt build up in heatsink fins etc.
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
(32-35) to test the Input Bd., Switch Bd., and main
N
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.
Y
Other Codes? 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
one head to the another on a multi-head system (i.e. PF10x2). Adding a minimum (0.1
N
seconds) of preflow time to each head or upgrading the operating system shoudl
generally solve the problem.
Finish
(Semi Automatic PW-455, PW455/STT)
(For Codes 10555 and Below)
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
Status light on?
(pins A and B in the control cable, wires 541
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).
The current transformer (CT)
feedback signal to the control
Pass board is too high. Look for a
short in the transformer or
primary side of the machine.
faulty connection
Soft Start failure.
contactor operation.
Key:
PS = Power Source
UI = User Interface (Control
Box)
FH = Feed Head
POWER WAVE 455/POWER FEED 10
F-93
connections in the communication path
and 542 in both the UI and FH).