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FLEXTEC
®
500X
ERROR CODES
Errors are displayed on the user interface. In addition, there are
status lights on the User Interface PC board and the Switch PC
board that contain error sequences.
Included in this section is information about the status lights and
some basic troubleshooting charts for both machine and weld
performance.
Error Code
6
No CAN messages from Power Source
18
ArcLink Auto-Mapping Failed
Device that controls sequence of the
21
welding operation halted due to an error
31
Primary Overcurrent
36
Thermal Fault
45
Output Voltage Limit Exceeded
213
Communication Fault
711
DC Link Capacitor Over/Under Voltage
Misconnect Protection - UI detected Aux.
713
Trans. Voltage too high
Misconnect Protection - UI detected Aux.
714
Trans. Voltage too low
Switch PC Board Error
719
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your
Lincoln Authorized Service Facility for technical troubleshooting assistance before you proceed.
WWW.LINCOLNELECTRIC.COM/LOCATOR
Description
Communication from the Power Source failed before mapping was
compete.
The machine could not properly configure the devices that are
attached to it. This configuration problem could be caused by the
type of devices that are connected to the machine or a required
device that is not connected.
A component of the system encountered an error during the
welding sequence and caused the system to stop. The component
with the error could be a wire drive, a user interface or some other
part of the system.
Peak current through the transformer primary has exceeded its
threshold.
Machine shutoff output due to elevated internal temperature.
During OCV, the voltage at the studs exceeded the allowable levels.
CAN communication between the User Interface PC board and the
Switch PC board has been interrupted.
The voltage on the main DC link capacitors housed on the
swtichboard has either gone too high or too low.
Occurs upon power up when the supply voltage to the User
Interface PC board exceeds an acceptable level.
Occurs upon power up when the supply voltage to the User
Interface PC board is below an acceptable level.
The Switch PC board experienced an internal error.
If any of these conditions persist contact an authorized Lincoln Field Service Shop.
E-2
The status lights on the User Interface board and the Switch board
are dual-color LED's. Normal operation for each is steady green.
Error conditions are indicated in the following chart.
Check the physical wiring connection of the CAN wires. Verify that the
switch board has input power from the auxiliary transformer.
Refer to the operators manual for proper configuration. Verify all
devices in the system are properly powered.
Read the status LED of the switch board for a detailed fault code. Check
the event logs of the various system components to determine the
cause of the fault.
Check the input power (voltage and frequency). Verify that the PC
boards an input rectifier are in working condition and proper input
power and welding output cable connections. Verify proper
connections of main internal power components. Power must be cycled
to the machine to reset the error.
Check for material blocking intake or exhaust louvers. Blow air in the
rear louvers to clear dirt from the fan. Note: (The Fan As Needed
circuitry automatically shuts off the fan 5 minutes after welding has
stopped). Welding output ratings may have been exceeded. Allow the
machine to cool down and reset. Measure the thermostats at the
Switchboard and replace if defective.
If VRD is enabled, the stud voltage exceeded 35 volts peak. In standard
operation, the stud voltage exceeded 113 volts peak. Verify the voltage
feedback leads are properly connected inside the machine. Verify the
input voltage is within +/- 10% of the nominal value.
Power must be cycled to the machine to reset the error. Visually
inspect the CAN harness to ensure connections and condition. Verify
power supply to the User Interface and Switch PC boards. Replace
defective assemblies as required.
Verify all three phases of the AC input line are connected properly to
the machine and that no fuses or breakers are damaged. Verify all
power connections to the main switch PC board.
Verify the primary reconnect is properly configured for the input
voltage
Power must be cycled to the machine to reset the error.
Verify the primary reconnect is properly configured for the input
voltage
Power must be cycled to the machine to reset the error.
Power must be cycled to the machine to reset the error. Replace the
switchboard if the error persists.
TROUBLE SHOOTING
Corrective Action
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