E-6
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
WELD AND ARC QUALITY PROBLEMS
General degradation of weld performance.
1. Wire feed problem.
1. Check for feeding problems. Check
actual WFS vs. preset. Verify proper wire
drive and gear ratio has been selected.
2. Cabling problems.
2. Check for bad connections, excessive
loops in cable, etc.
NOTE: The presence of heat in the
external welding circuit indicates poor
connections or undersized cables.
3. Loss of, or improper Shielding Gas.
3. Verify gas flow and type are correct.
4. Verify weld mode is correct for process.
4. Select the correct weld mode for the
application.
5. Machine calibration.
5. Verify the calibration of the output
current and voltage.
6. Secondary current limit has been
reached.
6. Adjust procedure to reduce output
demand.
Wire burns back to tip when the arc is
initiated.
1. Voltage sense lead problem.
1. Check sense lead connections. Check
the sense lead configuration and arc
polarity. Make sure Electrode and Work
connections are not reversed.
2. Wire feed problem.
2. Check for feeding problems. Verify
proper wire drive and gear ratio has
been selected.
Wire burns back to tip at the end of the
weld.
1. Burnback Time.
1. Reduce burnback time and/or workpoint.
Machine output shuts down during a weld. 1.Inverter or System Fault
1. A non-recoverable inverter fault will
interrupt welding, and open the main
contactor. This condition will also result
in an alternating red and green status
light on the control panel. See the Status
Light section for more information.
Machine won’t produce full output.
1. Input voltage may be too low, limiting
output capability of the power source.
1. Make certain that the input voltage is
proper, according to the Rating Plate
located on the rear of the machine.
2. Machine calibration.
2. Calibrate secondary current and voltage.
