E-4
TROUBLESHOOTING
POWER WAVE
®
E500
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
Observe all Safety Guidelines detailed throughout this manual
PROBLEMS
(SYMPTOMS)
POSSIBLE
CAUSE
RECOMMENDED
COURSE OF ACTION
BASIC MACHINE PROBLEMS
Major physical or electrical damage is
evident when the sheet metal covers are
removed.
None
Contact your local Lincoln Authorized Field
Service Facility.
Input fuses keep blowing
1.
Improperly sized input fuses.
1.
Make sure fuses are properly sized.
See installation section of this manual
for recommended sizes.
2.
Improper Weld Procedure requiring
output levels in excess of machine
rating.
2.
Reduce output current, duty cycle, or
both.
3.
Major physical or electrical damage is
evident when the sheet metal covers
are removed.
3.
Contact your local authorized Lincoln
Electric Field Service facility for
technical assistance.
Machine will not power up (no lights)
1.
No Input Power.
1.
Make sure input supply disconnect has
been turned ON. Check input fuses.
Make certain that the Power Switch
(SW1) on the power source is in the
“ON” position.
2.
Fuse F1 (in reconnect area) may have
blown.
2.
Power Down and replace the fuse.
3.
Circuit breaker CB1 (on the control
panel) may have tripped.
3.
Power Down and reset CB1.
4.
Improper input voltage selection
(multiple input voltage machines only).
4.
Power down, check input voltage
reconnect according to diagram on
reconnect cover.
Machine won’t weld, can’t get any output.
This problem will normally be
accompanied by an error code. Error codes
are displayed as a series of red and green
flashes by the status light(s). See “Status
Light” section of this document for
additional information.
1. Input voltage is too low or too high.
1. Make certain that input voltage is
correct, according to the Rating Plate
located on the rear of the machine.
2. Thermal Error.
2. See “Thermal LED is ON” section.
3. Primary current limit has been exceeded.
(the main contactor drops out when
output is initiated – see error 31).
3. Possible short in output circuit. Turn
machine off. Remove all loads from the
output of the machine. Turn back on,
and activate output. If condition
persists, turn power off, and contact an
authorized Lincoln Electric Field
Service facility.
4. Inverter Fault - switch pc board,
contactor problem, etc.
4. Contact your local authorized Lincoln
Electric Field Service facility for
technical assistance.
