[Cause]
PowerWaveErrorCode No.41 occurred. The secondary current is high (a long-term average), causing an overload. This usually occurs when the external welding circuit of the welding machine is short-circuited. Using the wrong output terminal on a welding machine with the STT function, or losing 1 phase of a 3-phase input, may also cause the error. When this error occurs, the output current is reduced to 100A, possibly resulting in the state called "noodle welding".
[Countermeasure]
First check whether the welding conditions exceed the welding equipment output limit. Check for a short circuit in the welding circuit. Check that the stickout, wire diameter, and gas are correct for the selected welding mode. Check the welding circuit for leakage paths that could cause short circuits or other excessive currents. Check that all 3 input-line branches are connected to the input contactor. Check that when the contactor is closed, all 3 branches are on the output side relative to the rectifier. If the center branch is missing (single-phase operation), the ２nd-side limit may decrease significantly and cause incorrect operation. Welding machines with an STT output terminal use a lower secondary output limit to protect the STT circuit. If the machine has an STT output terminal, consider using the standard output terminal for applications requiring greater output. (Note: The lower limit applies only to current flowing through the STT terminal.) If the problem persists, before performing any other operations (power-off or jogging) after this alarm occurs, use the abnormal-state recording function ("Abnormal State Record" in the auxiliary menu) to obtain an image backup and contact the service center. If that function cannot be used, record the conditions and operating steps up to the alarm, obtain an image backup, and contact the service center.
WARN Secondary over current (%s^1,%s^2)
[Cause]
PowerWaveErrorCode No.46 occurred. The secondary current is high (averaged over a period of time), causing an overload. This usually occurs when the external welding circuit of the welding machine is short-circuited. Using the wrong output terminal on a welding machine with the STT function, or losing 1 phase of a 3-phase input, may also cause the error. A welding mode that attempts to start welding with high current may also cause it.
[Countermeasure]
Check for a short circuit in the welding circuit. Check that the stickout, wire diameter, and gas are correct for the selected welding mode. If the problem persists, before performing any other operations (power-off or jogging) after this alarm occurs, use the abnormal-state recording function ("Abnormal State Record" in the auxiliary menu) to obtain an image backup and contact the service center. If that function cannot be used, record the conditions and operating steps up to the alarm, obtain an image backup, and contact the service center.