Thermal Arc POWERMASTER 400SP, Service Manual

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POWERMASTER 400SP, 500SP AUTOMATION
7-4 Octobe r 30, 2008
7.04 Error Codes
In case of a malfunction, an e rr o r code is indicated on the digital multifunction display (54) and the co rr e-
sponding e rr o r desc r iption appea r s on the LCD display (50) . As long as an e rr o r code is indicated, welding
ope r ation is not possible.
*1 Check module temperatures in menu Extras, Diagnosis > Module temperatures
*2 Check supply voltages in menu Extras, Diagnosis > Operating voltages
*3 Check the flow rate in menu Extras, Diagnosis > Flow rate cooling system
Code Description Cause Remedy
E01 Thermal overload Thermal sensor of power unit measures a too
high temperature (>176°F) Let machine cool down in standby (*1)
Check temperature sensor (short circuit)
E02 Mains overvoltage Mains voltage too high (24V supply > 36V) Check mains voltage and control
transformer (*2)
E03 Secondary over-current Welding current is too high Notify an accredited Thermal Arc Service
Provider for repair
E04 Air cooling error Temperature sensor of the power unit
detects that the unit heats up too fast Check fans and their wiring
E05 Cooling system error Flowrate of the cooling liquid is too low (< 0,3
l/min)
Pump is not working Check connectors of flow-meter, level of
cooling liquid and flowrate (*3)
Check fuse SI7 (2,5A) on pc-board MV-
MAPRO
E06 Secondary overvoltage Master detects output voltage is too high
(>100V) Notify an accredited Thermal Arc Service
Provider for repair
E07 EEProm checksum error No welding program stored or error during
reading from memory Transfer welding programs to machine
again, exchange MV-MAPRO if error still
persists
E08 Wire feed / tacho Power consumption of wire feed motor too
high
No tacho signal
No CAN-Bus connection between MAPRO
and DMR Blow out torch package with compressed
air
Check wire feed unit
Check wiring of wire feed motor and PC-
board DMR
E09 Error v/a measuring Measuring difference between Master and
Process Check wiring of pc-board LSW, pc-board
DP-EMV and PC-board DP-UFI-BO
E11 Remote-control connection Short circuit between remote control cables Check remote control and wiring of remote
control socket
E12 Communication Process Process is not responding to Master Switch the machine off and on again
Optionally exchange PC-board DP-MAPRO
E13 Temp. sensor error Temp. sensor is defective Notify an accredited Thermal Arc Service
Provider for repair
E14 Op. voltages error Supply voltage is too low (< 17V) Check mains voltage and control
transformer (*2)
E16 Overcurrent protection1 Power consumption of power unti 1 is too
high Notify an accredited Thermal Arc Service
Provider for repair
E17 Op. voltage 18V error 18 V from control transformer missing Check mains supply and control
transformer
E18 overload protection Safety shutdown to protect electrical
components
Temp. sensor is disconnected Let machine cool down in standby
Check temp. sensor
E19 Power module error Chargeup time for capacitors >1 second Check mains input
Check MVPWRUP board and it’s wiring
E20 Overvoltage sec. Process reports a too high output voltage or
no voltage Notify an accredited Thermal Arc Service
Provider for repair
E21 Output voltage/current External current/voltage or measure-
difference between Master and Process Notify an accredited Thermal Arc Service
Provider for repair
E22 Mains undervoltage 1 Power unit 1 reports mains voltage too low Check mains voltage and mains rectifier
E23 Mains overvoltage Power unit reports mains voltage too high Check mains voltage
E24 Overcurrent protection2 Power consumption of power unti 2 is too
high Notify an accredited Thermal Arc Service
Provider for repair
E25 Power module detection DIP-switch on pc-board MVDRV have been
set wrong Notify an accredited Thermal Arc Service
Provider for repair
E26 Error voltage symmetry DC-link voltage difference (>50V) between
power units Notify an accredited Thermal Arc Service
Provider for repair
E27 No program (DSP) Wrong material-wire-gas combination
Welding programs faulty or not available Select other material-wire-gas combination
Transfer welding programs to machine
again
E30 Op. voltage 15V error Supply voltage is too low Check mains voltages
E31 Communication error Master is not responding to Process Switch the machine off and on again
? A “?“ is shown in the display The display board doesn’t get any data from
the MV-MAPRO
Check the flat ribbon cable of the DS20BF
Check interpass hose (only machines with
separate wire feeder) and it’s connectors
Check PC-boards DMR and MV-MAPRO