Lincoln Power Wave Error Codes

36: Thermal error

What it means: The power source has detected over temperature and stops output; the yellow Thermal LED on the front panel is usually lit as well.^{[1][2][3][4][5][6][7][8][9][10][11]}

Also on: Power Wave STT Module (same code and name). i400 on a FANUC robot: LECO (FANUC#) 54.

Device response: output off; fix the cause, then turn power off and on to clear

Likely causes

• Cooling fan not running, running slowly or stalled
• Intake or exhaust louvers blocked, or dirt clogging the cooling channels
• Weld procedure or duty cycle above the machine rating
• Open thermostat circuit: broken wire, loose connection or failed thermostat on the output rectifier, choke or DC bus board
• On S500, S500 CE and R500 units from mid 2014, a defective Rev 2 M22853 fan that stalls (Lincoln service notice 201408004-3)

First checks, in this order

1. Check that the fans run. On S350 and S500 they run slowly at idle and at high speed when output is triggered; on 455M and i400 they should run whenever output is on.
2. Clear anything blocking the intake or exhaust louvers and blow dust out of the cooling channels.
3. Let the machine cool, then reduce the output current, the duty cycle, or both.
4. Check the thermostat circuit for broken wires, open connections or faulty thermostats.
5. On a 455M or i400, a tripped DC bus board thermostat can come from too much load on the 40 V DC feeder supply; check that load.
6. Cycle input power to clear the code once the cause is fixed.

54: Secondary (Output) over current error

What it means: The long term average weld (secondary) current has gone over the machine limit and the machine shuts its output down to protect itself. Limit: 325 A on S350 and R350; 325 A single phase or 575 A three phase on S500 and R500.^{[1][2][3][4][5]}

Device response: output shuts down; cycle power to clear

Likely causes

• Weld procedure asking for more average current than the machine can deliver
• Duty cycle too high for the procedure
• Possible short in the output (weld) circuit

First checks, in this order

1. Adjust the procedure or reduce the load to lower the current drawn from the machine.
2. Check the output circuit, cables and torch for a short.
3. Cycle power to clear. If the error keeps coming back, contact a Lincoln authorized field service facility.

54: Secondary (output) over current

What it means: The long term average weld current has gone over the i400 limit of 450 A, and the machine turns its output off immediately.^[8][14]

Also on: FANUC robot controller: LECO (FANUC#) 84

Device response: output off immediately; cycle power to clear

Likely causes

• Weld procedure demanding more than 450 A average
• Duty cycle too high for the procedure

First checks, in this order

1. Adjust the procedure to reduce output demand.
2. Cycle power to clear the code.

31: Primary overcurrent error

What it means: Too much current on the primary (input) side of the inverter, so the machine will not give output.^{[6][7][9][12]}

Device response: output off; cycle power to clear

Likely causes

• Short in the main transformer or output rectifier (455M, 455M/STT)
• Switch board or output rectifier failure (455/R)
• Short in the output circuit

First checks, in this order

1. Turn the machine off and remove all loads from the output.
2. Turn it back on. If the error comes back, turn power off and contact a Lincoln authorized field service facility.

31: Primary (Input) overcurrent error

What it means: Too much primary (input) current; the main contactor drops out when output is started.^[8][14]

Also on: FANUC robot controller: LECO (FANUC#) 49

Device response: output off; cycle power to clear

Likely causes

• Switch board failure
• Output rectifier failure
• Short in the output circuit

First checks, in this order

1. Turn the machine off and remove all loads from the output.
2. Turn it back on and activate the output.
3. If the error comes back, turn power off and contact a Lincoln authorized field service facility.

41: Secondary overcurrent error

What it means: The weld current limit has been exceeded and the machine phases its output back to about 100 A, which welders call noodle welding. The limit is 570 A on the standard stud and 325 A on single phase input (and on the STT stud of the 455/R).^{[6][7][9][12]}

Device response: output phases back to about 100 A

Likely causes

• Procedure drawing too much current, often a high wire feed speed procedure
• Single phase input (loss of L2), which lowers the limit from 570 A to 325 A

First checks, in this order

1. Adjust the procedure or reduce the load to lower the current drawn.
2. Check that all three input phases are present.
3. If the problem persists, contact a Lincoln authorized field service facility.

49: Single phase error

What it means: The machine is running on single phase input power; the weld current limit drops from 570 A to 325 A, so it will not produce full output.^{[6][7][9][12]}

Device response: keeps running with the weld current limit cut to 325 A

Likely causes

• Loss of the middle input leg (L2)
• Blown fuse, open breaker or loose connection on one input line

First checks, in this order

1. Measure the input voltage on all three lines and compare it with the rating plate on the rear of the machine.
2. Check the input fuses or breaker and the L2 connection at the disconnect and at the machine.

58: Primary Fault error

What it means: The main control board reports a fault on the primary (input) side, most likely an over power condition that pulled the primary bus voltage too low. The input control board holds the detailed code.^{[1][2][3][4][5]}

Device response: output off; cycle power to clear

Likely causes

• Over power condition causing undervoltage on the primary bus
• An input control board fault (see the 3xx codes)

First checks, in this order

1. Read the input control board code from its status light or status beeper (on the R350 the light is inside, seen through the left case side louvers).
2. Cycle input power.
3. If the error does not clear, contact the Lincoln Service Department.

336: Thermal Fault

What it means: Input control board code: the thermostat on the primary module has tripped.^{[1][2][3][4][5][13]}

Also on: S350 machine schematic PFC board legend: THERMAL FAULT (NO FIRST STAGE FAN)

Device response: S500 and R500: Temporary, clears by itself when the condition is gone

Likely causes

• Bottom (first stage) fan not working
• Fan malfunction or blocked air vent (S500, R500)

First checks, in this order

1. Check that the bottom fan runs.
2. Clear blocked vents and louvers and let the machine cool.
3. On S500 and R500 this code is Temporary and clears by itself once the condition is removed.

81: Motor Overload

What it means: Wire drive module code: the long term average wire drive motor current limit has been exceeded, which usually means the wire feed system is mechanically overloaded.^[2][4][5][8]

Also on: i400 on a FANUC robot: LECO (FANUC#) 129

Likely causes

• Mechanical overload of the wire feed system
• Conduit to the feeder with bends or twists, or too long
• Gear ratio with too little torque for the wire size

First checks, in this order

1. Check for wire feeding problems along the whole path from reel to torch.
2. Remove bends and twists in the conduit, and use a shorter conduit from the reel if it is long.
3. If the problem continues, use a higher torque gear ratio (lower speed range).

82: Motor Overcurrent

What it means: Wire drive module code: the absolute maximum motor current has been exceeded. This is a short term limit that protects the drive circuitry.^[2][4][5][8]

Also on: i400 on a FANUC robot: LECO (FANUC#) 130

Likely causes

• Wire drive jammed or seized for a moment
• Sudden mechanical load on the feed rolls or motor

First checks, in this order

1. Check the drive rolls, gears and wire path for a jam.
2. Check for feeding problems and conduit bends.
3. Cycle power to clear; if it repeats, contact a Lincoln authorized field service facility.

83: Shutdown #1 Is Open

What it means: Wire drive module code: the Shutdown 1 input on the green I/O connector on the bottom of the controller is open, so the wire drive stops.^[2][5]

Likely causes

• Jumper missing or connector loose on the green I/O connector
• Remote shutdown circuit open (safety device, door switch or cell interlock wired to Shutdown 1)

First checks, in this order

1. If the input is not used externally, check the green I/O connector and its jumper.
2. If a remote circuit uses the input, check that circuit end to end.

84: Shutdown #2 Is Open

What it means: Wire drive module code: the Shutdown 2 input on the green I/O connector on the bottom of the controller is open, so the wire drive stops.^[2][5]

Likely causes

• Jumper missing or connector loose on the green I/O connector
• Remote shutdown circuit open (safety device or cell interlock wired to Shutdown 2)

First checks, in this order

1. If the input is not used externally, check the green I/O connector and its jumper.
2. If a remote circuit uses the input, check that circuit end to end.

83: Shutdown #1

What it means: Wire drive module code. The shutdown inputs are disabled on these models, so this code means the feed head control board may have the wrong operating software.^[4][8][14]

Also on: i400 on a FANUC robot: LECO (FANUC#) 131

Likely causes

• Wrong operating software on the feed head control PC board

First checks, in this order

1. Note the code and have the feed head control board software checked and reloaded by Lincoln service.

84: Shutdown #2

What it means: Wire drive module code. The shutdown inputs are disabled on these models, so this code means the feed head control board may have the wrong operating software.^[4][8][14]

Also on: i400 on a FANUC robot: LECO (FANUC#) 132

Likely causes

• Wrong operating software on the feed head control PC board

First checks, in this order

1. Note the code and have the feed head control board software checked and reloaded by Lincoln service.

32: Capacitor "A" under voltage (Left side facing machine)

What it means: Low voltage on main capacitor bank A, the left one when you face the machine.^{[6][7][9][12]}

Device response: output off; cycle power to clear

Likely causes

• Wrong input voltage configuration (reconnect)
• With an overvoltage code on the same side (34): zero voltage on that side's capacitors, usually from an open or short in the primary side

First checks, in this order

1. Power down and check the input voltage reconnect against the diagram on the reconnect cover.
2. Check that the input voltage matches the rating plate.
3. If 32 and 34 appear together, contact a Lincoln authorized field service facility for the primary side repair.

33: Capacitor "B" under voltage (Right side facing machine)

What it means: Low voltage on main capacitor bank B, the right one when you face the machine. Together with an overvoltage code on the same side (35) it means zero voltage on that side's capacitors.^{[6][7][9][12]}

Device response: output off; cycle power to clear

Likely causes

• Wrong input voltage configuration (reconnect)
• Open or short in the primary side of the machine

First checks, in this order

1. Power down and check the input voltage reconnect against the diagram on the reconnect cover.
2. Check that the input voltage matches the rating plate.
3. If 33 and 35 appear together, contact a Lincoln authorized field service facility for the primary side repair.

34: Capacitor "A" over voltage (Left side facing machine)

What it means: Too much voltage on main capacitor bank A, the left one when you face the machine.^{[6][7][9][12]}

Device response: output off; cycle power to clear

Likely causes

• Wrong input voltage configuration (reconnect)
• With an undervoltage code on the same side (32): zero voltage on that side's capacitors, usually from an open or short in the primary side

First checks, in this order

1. Power down and check the input voltage reconnect against the diagram on the reconnect cover.
2. Check that the line voltage matches the rating plate.
3. If 34 and 32 appear together, contact a Lincoln authorized field service facility.

35: Capacitor "B" over voltage (Right side facing machine)

What it means: Too much voltage on main capacitor bank B, the right one when you face the machine. Together with an undervoltage code on the same side (33) it means zero voltage on that side's capacitors.^{[6][7][9][12]}

Device response: output off; cycle power to clear

Likely causes

• Wrong input voltage configuration (reconnect)
• Open or short in the primary side of the machine

First checks, in this order

1. Power down and check the input voltage reconnect against the diagram on the reconnect cover.
2. Check that the line voltage matches the rating plate.
3. If 35 and 33 appear together, contact a Lincoln authorized field service facility.

37: Soft start error

What it means: The main capacitor precharge failed at power up; it usually comes with codes 32 to 35.^{[6][7][9][12]}

Device response: output off; cycle power to clear

Likely causes

• Capacitor precharge circuit failure
• Input configuration or primary side problem behind the 32 to 35 codes that come with it

First checks, in this order

1. Read all codes on the status light; work on the 32 to 35 codes first.
2. Check the input voltage reconnect and the line voltage.
3. Cycle power; if 37 returns, contact a Lincoln authorized field service facility.

43: Capacitor delta error

What it means: The voltage difference between the two main capacitor banks is larger than allowed; it may come with codes 32 to 35.^{[6][7][9][12]}

Device response: output off; cycle power to clear

Likely causes

• Capacitor banks out of balance
• Primary side problem behind the 32 to 35 codes that come with it

First checks, in this order

1. Read all codes on the status light and handle the 32 to 35 codes as well.
2. Check the input voltage reconnect and the line voltage.
3. If the error stays after a power cycle, contact a Lincoln authorized field service facility.

56: Chopper communication error

What it means: The communication link between the main control board and the chopper has errors.^{[1][2][3][4][5]}

Device response: output off; cycle power to clear

Likely causes

• Communication errors on the internal link between the main control board and the chopper

First checks, in this order

1. Cycle input power to the machine.
2. If the error does not clear, contact the Lincoln Service Department.

71: Secondary (Output) over power error

What it means: The long term weld (secondary) power limit has been exceeded: 25 kW on three phase input, 14 kW on single phase input.^[2][3][5]

Device response: output off; cycle power to clear

Likely causes

• Procedure running high current and voltage for long periods
• Machine on single phase input, which lowers the limit to 14 kW

First checks, in this order

1. Reduce the output demand of the procedure or the duty cycle.
2. Confirm all three input phases are present if the machine should be on three phase.
3. Cycle power to clear.

331: Peak input current limit

What it means: Input control board code: the input current limit has been exceeded, typically a short term power overload.^[1][4][13]

Also on: S350 machine schematic PFC board legend: PEAK INPUT CURRENT LIMIT

Likely causes

• Short term power overload from the weld procedure
• Input supply problem

First checks, in this order

1. Reduce the output demand and cycle power.
2. If the problem persists, contact the Lincoln Service Department.

331: Instantaneous Input Current Limit

What it means: Input control board code: the instantaneous input current limit has been exceeded, typically a short term power overload.^[2][3][5]

Device response: Persistent: cycle power to clear

Likely causes

• Short term power overload from the weld procedure

First checks, in this order

1. Cycle power to clear (Persistent code).
2. If the problem persists, contact the Lincoln Service Department.

337: Pre-charge timeout

What it means: Input control board code: the start-up sequence failed because the DC bus did not charge to the required level by the end of precharge.^{[1][2][3][4][5]}

Also on: S500 and R500 manuals write it as Precharge Timeout

Device response: S500 and R500: Persistent, cycle power to clear

Likely causes

• Problem in the start-up (precharge) sequence
• Low or unstable input voltage at power up

First checks, in this order

1. Check the input voltage, then cycle power (Persistent code on S500 and R500).
2. If the problem persists, contact the Lincoln Service Department.

346: Transformer primary over current

What it means: Input control board code: the transformer primary current is too high, typically a short term power overload.^{[1][2][3][4][5]}

Device response: S500 and R500: Persistent, cycle power to clear

Likely causes

• Short term power overload from the weld procedure

First checks, in this order

1. Reduce the output demand and cycle power (Persistent code on S500 and R500).
2. If the problem persists, contact the Lincoln Service Department.

333: Under-voltage lockout

What it means: Input control board code: the +15 V DC supply on the input control board is too low.^[1][4]

Likely causes

• Input voltage outside the acceptable range
• Input control board supply problem

First checks, in this order

1. Verify the input voltage is within the acceptable range on the rating plate.
2. If the problem persists, contact the Lincoln Service Department.

334: Startup Current Check Failure

What it means: Input control board code: the input current limit was exceeded while the machine was powering up.^{[2][3][5][13]}

Also on: S350 machine schematic PFC board legend: START UP CURRENT CHECK FAILURE

Device response: Persistent: cycle power to clear

Likely causes

• Input current too high during power up

First checks, in this order

1. Cycle power to clear (Persistent code).
2. If the problem persists, contact the Lincoln Service Department.

335: Startup Voltage Check Failure

What it means: Input control board code: the input voltage was too high or too low while the machine was powering up.^{[2][3][5][13]}

Also on: S350 machine schematic PFC board legend: START UP VOLTAGE CHECK FAILURE

Device response: Temporary: clears by itself when the condition is gone

Likely causes

• Input voltage outside 200 V to 650 V at power up

First checks, in this order

1. Verify that the input voltage is between 200 V and 650 V.
2. This code is Temporary and clears by itself once the voltage is back in range.

338: Input Power Limit

What it means: Input control board code: the input power drawn by the machine went above a safe level.^[2][3][5]

Device response: Persistent: cycle power to clear

Likely causes

• Weld procedure drawing too much input power

First checks, in this order

1. Reduce the output demand and cycle power (Persistent code).
2. If the problem persists, contact the Lincoln Service Department.

341: Input Voltage Dropout

What it means: Input control board code: the input voltage dropped out for a moment.^[2][3][5]

Device response: Temporary: clears by itself when the condition is gone

Likely causes

• Loose input connection
• Poor quality or sagging input power

First checks, in this order

1. Check the input connections.
2. Verify the quality of the input power.
3. This code is Temporary and clears by itself once the voltage is stable.

347: Average Input Current Limit

What it means: Input control board code: the average input current limit has been exceeded, typically a short term power overload.^[2][3][5]

Device response: Persistent: cycle power to clear

Likely causes

• Short term power overload from the weld procedure

First checks, in this order

1. Reduce the output demand and cycle power (Persistent code).
2. If the problem persists, contact the Lincoln Service Department.

349: Bus Undervoltage

What it means: Input control board code: the DC bus voltage dropped below the allowed limit.^[2][3][5]

Device response: Temporary: clears by itself when the condition is gone

Likely causes

• Low or sagging input voltage
• Input power problem during heavy output

First checks, in this order

1. Check the input voltage and connections.
2. This code is Temporary and clears by itself once the condition is gone.
3. If the problem persists, contact the Lincoln Service Department.

11: CAN communication bus off

What it means: The CAN communication bus between the power source and the feeder or user interface has shut down, probably after too many communication errors.^{[6][7][9][12]}

Device response: output off; cycle power to clear

Likely causes

• Excessive number of communication errors on the bus
• Damaged or loose control cable or communication leads

First checks, in this order

1. Note the code before switching off.
2. Check the control cable and its connectors between the power source and the wire feeder.
3. Cycle power to reset.

12: User Interface time out error

What it means: The user interface has stopped responding to the power source.^{[6][7][9][12]}

Device response: output off; cycle power to clear

Likely causes

• Fault or bad connection in the communication leads
• Damaged control cable

First checks, in this order

1. Check the communication leads and control cable from the power source to the user interface.
2. Cycle power to reset.

21: Unprogrammed Weld Mode

What it means: The selected weld mode is not programmed in the power source welding software.^{[6][7][9][12]}

Likely causes

• Weld mode selected that is missing from the loaded welding software

First checks, in this order

1. Check the weld mode selected on the feeder or robot.
2. Contact the Lincoln Service Department for instructions on reloading the welding software.

22: Empty Weld Table

What it means: The weld table in the power source is empty, so it cannot run a weld mode.^{[6][7][9][12]}

Likely causes

• Welding software (weld table) missing or not loaded

First checks, in this order

1. Contact the Lincoln Service Department for instructions on reloading the welding software.

23: Weld Table checksum error

What it means: The weld table failed its checksum test, so the welding software is corrupt.^{[6][7][9][12]}

Likely causes

• Corrupted welding software

First checks, in this order

1. Contact the Lincoln Service Department for instructions on reloading the welding software.

32: Capacitor "A" under voltage (right side facing the Switch PC Board)

What it means: Low voltage on main capacitor A, the right one when you face the switch PC board.^[8][14]

Also on: FANUC robot controller: LECO (FANUC#) 50

Device response: output off; cycle power to clear

Likely causes

• Wrong input voltage configuration (reconnect)
• Open or short circuit in the primary side of the machine

First checks, in this order

1. Power down and check the input voltage reconnect against the diagram on the reconnect cover.
2. Check that the input voltage matches the rating plate.
3. If the code returns, contact a Lincoln authorized field service facility.

33: Capacitor bank "B" under voltage (left side facing the Switch PC Board)

What it means: Low voltage on main capacitor bank B, the left one when you face the switch PC board.^[8][14]

Also on: FANUC robot controller: LECO (FANUC#) 51

Device response: output off; cycle power to clear

Likely causes

• Wrong input voltage configuration (reconnect)
• Open or short circuit in the primary side of the machine

First checks, in this order

1. Power down and check the input voltage reconnect against the diagram on the reconnect cover.
2. Check that the input voltage matches the rating plate.
3. If the code returns, contact a Lincoln authorized field service facility.

34: Capacitor "A" over voltage (right side facing the Switch PC Board)

What it means: Too much voltage on main capacitor A, the right one when you face the switch PC board.^[8][14]

Also on: FANUC robot controller: LECO (FANUC#) 52

Device response: output off; cycle power to clear

Likely causes

• Wrong input voltage configuration (reconnect)
• Line voltage too high
• Capacitors out of balance (see code 43)

First checks, in this order

1. Power down and check the input voltage reconnect.
2. Measure the line voltage against the rating plate.
3. Check for code 43 alongside it.

35: Capacitor "B" over voltage (left side facing the Switch PC Board)

What it means: Too much voltage on main capacitor B, the left one when you face the switch PC board.^[8][14]

Also on: FANUC robot controller: LECO (FANUC#) 53

Device response: output off; cycle power to clear

Likely causes

• Wrong input voltage configuration (reconnect)
• Line voltage too high
• Capacitors out of balance (see code 43)

First checks, in this order

1. Power down and check the input voltage reconnect.
2. Measure the line voltage against the rating plate.
3. Check for code 43 alongside it.

37: Softstart (pre-charge) error

What it means: The main capacitor precharge failed at power up; it usually comes with codes 32 and 33.^[8][14]

Also on: FANUC robot controller: LECO (FANUC#) 55

Device response: output off; cycle power to clear

Likely causes

• Capacitor precharge circuit failure
• Input configuration or primary side problem behind codes 32 and 33

First checks, in this order

1. Read all codes on the status light and work on 32 and 33 first.
2. Check the input voltage reconnect and the line voltage.
3. If 37 returns after a power cycle, contact a Lincoln authorized field service facility.

39: Misc. hardware fault

What it means: An unknown glitch has occurred on the fault interrupt circuitry.^[8][10][14]

Also on: Power Wave STT Module (same code and name). i400 on a FANUC robot: LECO (FANUC#) 57.

Device response: output off; cycle power to clear

Likely causes

• Primary overcurrent event (i400)
• Intermittent connections in the thermostat circuit

First checks, in this order

1. Check the thermostat circuit wiring and connectors for loose or intermittent contacts.
2. Check for a primary overcurrent (code 31) alongside it.
3. Cycle power; if it repeats, contact a Lincoln authorized field service facility.

43: Capacitor delta error

What it means: The voltage difference between the main capacitors is larger than allowed; it may come with codes 32 to 35.^[8][14]

Also on: FANUC robot controller: LECO (FANUC#) 67

Device response: output off; cycle power to clear

Likely causes

• Open or short in the primary circuit
• Open or short in the secondary circuit

First checks, in this order

1. Read all codes on the status light and handle the 32 to 35 codes as well.
2. Check the input voltage reconnect and the line voltage.
3. If the error stays after a power cycle, contact a Lincoln authorized field service facility.

99: STT Status error

What it means: The STT switch PC board in the Power Wave STT Module reports a status failure.^[10]

Device response: output off; cycle power to clear

Likely causes

• Weld leads connected wrongly (reverse polarity)
• Loss of input voltage to the STT switch board
• STT switch board failure

First checks, in this order

1. Check the weld cable connections and polarity.
2. Look at the diagnostic LEDs on the STT switch PC board: gate and status LEDs off while triggered usually means reversed weld cables; status LED off all the time points to the board's power supply undervoltage lockout, so verify the input voltage to the board.
3. Cycle power to clear.