SVM112-B View Safety Info February, 2001 TM INVERTEC POWER WAVE 450 For use with machines having Code Numbers: 10105 thru 10610 Return to Master TOC View Safety Info View Safety Info Safety Depends on You Return to Master TOC Return to Master TOC RETURN TO MAIN INDEX Lincoln arc welding and cutting equipment is designed and built with safety in mind. However, your overall safety can be increased by proper installation . . . and thoughtful operation on your part.
Return to Master TOC i i SAFETY WARNING CALIFORNIA PROPOSITION 65 WARNINGS Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm. The Above For Diesel Engines The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm. The Above For Gasoline Engines ARC WELDING CAN BE HAZARDOUS.
Return to Master TOC Return to Master TOC ii ELECTRIC SHOCK can kill. ARC RAYS can burn. 3.a. The electrode and work (or ground) circuits are electrically “hot” when the welder is on. Do not touch these “hot” parts with your bare skin or wet clothing. Wear dry, hole-free gloves to insulate hands. 4.a. Use a shield with the proper filter and cover plates to protect your eyes from sparks and the rays of the arc when welding or observing open arc welding.
Return to Master TOC iii WELDING SPARKS can cause fire or explosion. 6.a. Remove fire hazards from the welding area. If this is not possible, cover them to prevent the welding sparks from starting a fire. Remember that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas. Avoid welding near hydraulic lines. Have a fire extinguisher readily available. 6.b.
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC iv iv SAFETY PRÉCAUTIONS DE SÛRETÉ 6. Eloigner les matériaux inflammables ou les recouvrir afin de prévenir tout risque d’incendie dû aux étincelles. Pour votre propre protection lire et observer toutes les instructions et les précautions de sûreté specifiques qui parraissent dans ce manuel aussi bien que les précautions de sûreté générales suivantes: 7.
v v RETURN TO MAIN INDEX MASTER TABLE OF CONTENTS FOR ALL SECTIONS Page Safety.................................................................................................................................................i-iv Installation .............................................................................................................................Section A Operation.............................................................................................................................
Return to Master TOC Section A-1 TABLE OF CONTENTS - INSTALLATION SECTION - Section A-1 Installation Technical Specifications .............................................................................................................A-2 Safety Precautions......................................................................................................................A-3 Select Suitable Location ........................................................................................................
Return to Master TOC Return to Section TOC A-2 A-2 INSTALLATION TECHNICAL SPECIFICATIONS - POWER WAVE 450 INPUT -THREE PHASE ONLY Input Voltages: 200 230 400 460 575 Input Currents @ 500A/40 VDC @ 450A/38 VDC 87 75 76 65 44 38 38 32 32 28 Return to Master TOC Return to Section TOC RATED OUTPUT Duty Cycle Amps Volts at Rated Amperes 60% Duty Cycle 100% Duty Cycle 500 450 40 VDC 38 VDC Constant Open Circuit Voltage Continuous Current Range Process Current Ranges 75 Volts 5-540 Amp
Return to Master TOC Return to Section TOC A-3 INSTALLATION Read this entire installation section before you start installation. LIFTING SAFETY PRECAUTIONS HIGH FREQUENCY PRECAUTIONS WARNING ELECTRIC SHOCK can kill. • Only qualified personnel should perform this installation. Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC • Turn the input power OFF at the disconnect switch or fuse box before working on this equipment. • Do not touch electrically hot parts.
Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC A-4 A-4 INSTALLATION CAUTION Failure to follow these instructions can cause immediate failure of components within the welder. GROUND CONNECTIONS The frame of the welder must be grounded. A ground terminal marked with the symbol is located inside the reconnect/input access door for this purpose. See your local and national electrical codes for proper grounding methods. See Figure A.
A-5 INSTALLATION Return to Master TOC Return to Section TOC A-5 FIGURE A.3 – FRONTPANEL/BACK PANEL 6 5 (IN) 4 Return to Master TOC Return to Section TOC (OUT) 1 3 2 1 WORK TERMINAL 2 ELECTRODE TERMINAL 3 REMOTE CONTROL AMPHENOL RECEPTACLE 4 WATER COOLING FITTINGS (ON BACK PANEL) 5 WIRE FEEDER CONNECTIONS (ON BACK PANEL) 6 ELECTRODE TERMINAL To operate at 200-208 VAC: OUTPUT CONNECTIONS 1. Open the reconnect/input access door. See Figure A.
Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Section TOC NOTES POWER WAVE 450
Return to Master TOC Section B-1 Section B-1 TABLE OF CONTENTS - OPERATION SECTION Operation...............................................................................................................................Section B Safety Instructions ......................................................................................................................B-2 Quick Start Reference for Process Selection Overlay................................................................
Return to Master TOC Return to Section TOC B-2 OPERATION OPERATING INSTRUCTIONS Read and understand this entire section of operating instructions before operating the machine. SAFETY INSTRUCTIONS WARNING ELECTRIC SHOCK can kill. Return to Master TOC Return to Section TOC • Do not touch electrically live parts or electrodes with your skin or wet clothing. • Insulate yourself from the work and ground. • Always wear dry insulating gloves. FUMES AND GASES can be dangerous. • Keep your head out of fumes.
Return to Master TOC Return to Section TOC B-3 OPERATION QUICK START REFERENCE FOR USING THE PROCESS SELECTION OVERLAY Step 2: Adjust the wire feed to speed “WFS” and voltage “V” or arc length “T” (if necessary). a. Press the DISPLAY RECALL key view additional procedure information. Read and understand the “Controls and Settings” and “Operating Overlays” sections of this manual before using the following Quick Start Reference procedure to operate the Power Wave.
Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC B-4 OPERATION GENERAL DESCRIPTION DESIGN FEATURES AND ADVANTAGES The INVERTEC Power Wave power source is a high performance, digitally controlled inverter welding power source capable of complex, high-speed waveform control. It uses three-phase input power only. The Power Wave is designed to be used as a synergic welding system in conjunction with a wire feeder. • Designed to NEMA Standards.
Return to Master TOC Return to Section TOC B-5 B-5 OPERATION CONTROLS AND SETTINGS CASE FRONT CONTROLS All operator controls and adjustments are located on the case front of the Power Wave. Refer to Figure B.1 and corresponding explanations. Refer to Figure B.1 for the location of the following controls: FIGURE B.1 – CASE FRONT CONTROLS 6 3 1 1. LCD DISPLAY: Provides welding procedure information and parameters such as wire type, gas type, WFS, trim, etc. 2.
Return to Master TOC Return to Section TOC B-6 B-6 OPERATION OPERATING OVERLAYS INSTALLING AN OVERLAY OVERVIEW 1. Open the ACCESS DOOR by grasping the provided indent on the door and pulling the door forward. See Figure B.3 for door location. The Power Wave is controlled by a panel of keys (keypad) located on the front of the machine. The operator can access controls by placing an overlay over the keys. FIGURE B.
Return to Master TOC Return to Section TOC B-7 OPERATION OVERLAY TYPES Four types of overlays can be used with the Power Wave. 1. Process Overlays. These overlays are used to create, save and recall specific welding procedures by selecting and adjusting the various welding settings that have been programmed into the Power Wave at the factory. Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC 2. Weld From Memory Overlays.
Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC B-8 OPERATION PULSE, GMAW, FCAW, AND STICK/TIG PROCESS SELECTION OVERLAY An operator can use this overlay to create a new welding procedure, save a newly created welding procedure, view an existing welding procedure, recall an existing welding procedure, and clear a memory location. See Figure B.4. The steps for performing each of these functions are given below. FIGURE B.
Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC Return to Section TOC B-9 OPERATION 3. ELECTRODE CLASS UP/DOWN: Use the ELECTRODE CLASS UP or DOWN keys to select from the material types available for the selected process. Press the ELECTRODE CLASS UP or DOWN key until the desired material type is displayed. 4.
B-10 Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC The RECALL FROM MEMORY and SAVE TO MEMORY keys can be used to clear a memory location. Return to Section TOC 10. RECALL FROM MEMORY KEY: This key is used to recall an existing procedure from memory. You can recall and use any of the previously created welding procedures that are stored in one of the eight memory locations.
Return to Master TOC Return to Section TOC B-11 B-11 OPERATION WELD FROM MEMORY OVERLAY The Weld From Memory Overlay lets an operator recall and use any welding procedure stored in one of eight memory locations. See Figure B.5. FIGURE B.5 – WELD FROM MEMORY OVERLAY 1 1 2 3 4 5 6 LCD DISPLAY WINDOW MEMORY RECALL KEYS PROGRAM LIST DISPLAY RECALL KEY HIGH TEMPERATURE LIGHT MEMORY LIGHTS 5 6 Return to Master TOC Return to Section TOC 2 3 1.
Return to Master TOC Return to Section TOC B-12 B-12 OPERATION WELD FROM MEMORY, DUAL PROCEDURE OVERLAY The Weld From Memory, Dual Procedure Overlay lets an operator recall and use dual welding procedures stored in memory. The overlay must be used with a separate dual procedure switch or a gun that has a two position trigger. The switch or trigger selects which procedure will be active. See Figure B.6 FIGURE B.
Return to Master TOC Return to Section TOC B-13 OPERATION When a pair of welding procedures are recalled from memory, the display window will show the procedure description, wire feed speed, and the preset voltage or arc length trim of the LAST procedure welded with. With this overlay in place, the wire feed speed and the preset voltage or arc length trim can be changed from the wire feeder. The new values will replace the previous values and become a permanent part of the procedure.
Return to Master TOC Return to Section TOC B-14 The Dual Wire Feeders, Dual Procedures Overlay is used when the Power Wave is equipped with two wire feeders and two guns with two position switches. Any welding procedure stored in memory locations 1, 2, 3, or 4 can be automatically recalled and used. See Figure B.7. FIGURE B.
Return to Master TOC Return to Section TOC B-15 B-15 OPERATION LIMITS OVERLAY (OPTIONAL) The Limits Overlay is used to set the maximum and minimum limits of the wire feed speed and voltage or arc length trim for any welding procedure stored in memory. See Figure B.8. FIGURE B.
Return to Master TOC Return to Section TOC B-16 OPERATION Use the LIMIT UP and LIMIT DOWN keys to change the maximum wire feed speed to the desired value. Press the SET LIMIT key again. The new maximum and old minimum wire feed speeds will be displayed. Use the LIMIT UP and LIMIT DOWN keys to change the minimum wire feed speed to the desired value.
Return to Master TOC Return to Section TOC B-17 B-17 OPERATION SETUP OVERLAY The Setup Overlay is used to control the water cooler operation (on/off and prime the water cooler), and to set up the voltage sensing configuration of the machine and wire feeder(s) connected to the Power Wave. See Figure B.9. FIGURE B.
Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC B-18 OPERATION When the “WATER COOLER PRESSURE” light turns on, release the key. If this key has been pressed for 30 seconds and the ‘WATER COOLER PRESSURE’ light still did not turn on, check the water cooler for adequate fluid level. 5. WIRE FEEDER 1 +/- POLARITY KEY: Press this key to change the present voltage sensing polarity of wire feeder 1.
Return to Master TOC Return to Section TOC B-19 OPERATION Use the ELECTRODE SENSE LEAD KEY to select either the - output terminal or the electrode sense (67) lead for the positive voltage reference. The work sense (21) lead is used only in rare circumstances. For most installations, use the WORK SENSE LEAD KEY to select the - output terminal for negative voltage reference. Consult the factory if use of the work sense (21) lead is desired.
Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC Return to Section TOC B-20 OPERATION OVERVIEW OF WELDING PROCEDURES FLUX CORED ARC WELDING (FCAW) AND GMAW PROCEDURES For each wire feed speed, a corresponding voltage has been preprogrammed into the machine by welding experts. This preprogrammed voltage is the best average voltage for the procedure at the given wire feed speed.
Return to Master TOC Return to Section TOC B-21 OPERATION TABLE B.3 – RELATIONSHIP BETWEEN VOLTAGE TRIM AND PRESET VOLTAGE Voltage Trim Relationship to Preset Voltage 0.6 60% of preset voltage 0.8 80% of preset voltage 1.0 no change to preset voltage 1.2 120% of preset voltage 1.4 140% of preset voltage TABLE B.6 – RELATIONSHIP BETWEEN SELECTED ARC LENGTH TRIM AND PRESET ARC LENGTH AS INDICATED BY ARC LENGTH Arc Length Trim Preset Arc Length 0.6 60% of preset length 0.
Return to Master TOC Return to Section TOC B-22 OPERATION In Pulse processes: The wave control adjustment allows the frequency setting to vary. Increasing the wave control allows the frequency setting to increase, and decreasing the wave control allows the frequency setting to decrease. Varying the wave control setting affects the droplet transfer and allows fine-tuning for different welding positions.
Return to Master TOC OPERATION Return to Master TOC Return to Master TOC B-23 OVERLOAD PROTECTION THERMAL PROTECTION OVER CURRENT PROTECTION The Power Wave has thermostatic protection from excessive duty cycles, overloads, loss of cooling, and high ambient temperatures. When the power source is subjected to any of these conditions or any of the conditions mentioned above, a thermostat will open. The yellow high temperature light on the case front comes on. See Figure B.1 for location.
Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Section TOC NOTES POWER WAVE 450
Return to Master TOC Section C-1 Section C-1 TABLE OF CONTENTS - ACCESSORIES Accessories...........................................................................................................................Section C Options/Accessories...................................................................................................................C-2 Wire Feeder Setup ...............................................................................................................C-2 Guns and Cables .
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC C-2 C-2 ACCESSORIES OPTIONS/ACCESSORIES GUNS AND CABLES • Synergic 7 wire feeder (K632-1) standard speed,or (K632-2) high speed Several MAGNUM guns are recommended for use with the Power Wave as shown in Table C.1.
Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC C-3 ACCESSORIES There are two water connections on the rear of the Power Wave. See Figure C.1. Connect the water lines between these connectors and those on the wire feeder. The water is fed through the feeder into the gun. When a water cooler is used, the water cooler must be enabled by using the Setup Overlay. a. Install the Set-up overlay. b.
Return to Master TOC Return to Section TOC C-4 ACCESSORIES G3503-[ ] COOLER PERIODIC MAINTENANCE 1. Preparation: • Always switch off the Power Wave machine power. • Always disconnect the Power Wave machine from service input power. • Do not remove the pump relief valves' 3/4 in. acorn hex nut or attempt to adjust the relief valve setting. Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC 2.
C-5 C-5 Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC ACCESSORIES g. Install new pump and v-band clamp: • Do not apply any lubricant to pump’s drive coupling. • Pump body is properly oriented with its strainer at the 6:00 position. • Tighten v-clamp with 15 to 30 in-lbs. of torque. h. Attach coolant lines to QD and reservoir. i. Wipe dry all areas wetted by coolant.
Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Section TOC C-6 C-6 NOTES POWER WAVE 450
Return to Master TOC D-1 D-1 TABLE OF CONTENTS -MAINTENANCEMaintenance .........................................................................................................................Section D Safety Precautions......................................................................................................................D-2 Routine and Periodic Maintenance ............................................................................................D-2 Input Filter Capacitor Discharge......
Return to Master TOC Return to Section TOC D-2 MAINTENANCE SAFETY PRECAUTIONS WARNING ELECTRIC SHOCK can kill. • Only Qualified personnel should perform this maintenance. • Turn the input power OFF at the disconnect switch or fuse box before working on this equipment. Return to Master TOC Return to Section TOC • Do not touch electrically hot parts. ROUTINE AND PERIODIC MAINTENANCE Perform the following preventive maintenance at least once every six months.
Return to Master TOC Return to Section TOC D-3 MAINTENANCE FIGURE D.1 – RESISTOR LOCATIONS Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC 5 PAIRS OF RESISTORS CHECK VOLTAGES BETWEEN EACH TERMINAL AND FROM EACH RESISTOR TO CASE GROUND 5. Locate two sets of two resistors on the left side of the machine and three sets of two resistors on the right side of the machine. See Figure D.1. Do not touch the resistors or any other internal machine component.
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC D-4 MAINTENANCE 6. Locate the #9 and #12 terminals, identified by the “Discharge” labels, on each of the four Switch Boards. See Figure D.2. D-4 FIGURE D.3 – RESISTORS WITH LEADS CONNECTED 7.
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC D-5 MAINTENANCE PREVENTIVE MAINTENANCE Perform the following preventive maintenance procedures at least once every six months. It is good practice to keep a preventive maintenance record; a record tag attached to the machine works best. D-5 8. Reconnect the shunt and wire #467 to the negative (-) output terminal.
Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC D-6 D-6 MAINTENANCE FIGURE D.
Return to Master TOC Section E-1 Section E-1 TABLE OF CONTENTS -THEORY OF OPERATIONTheory of Operation .............................................................................................................Section E General Description ....................................................................................................................E-2 Input Voltage ...............................................................................................................................
Return to Master TOC Return to Section TOC E-2 E-2 THEORY OF OPERATION FIGURE E.2 – INPUT VOLTAGE CIRCUIT INPUT CONTACTOR INPUT RECTIFIER AND RECONNECT MAIN TRAMSFORMER OUTPUT RECTIFIER CHOKE POSITIVE LEFT SWITCH BOARD THREE PHASE INPUT POWER FET ASSEMBLY CT AUX.
Return to Master TOC Return to Section TOC E-3 E-3 THEORY OF OPERATION FIGURE E.3 – PRECHARGE CIRCUIT INPUT CONTACTOR INPUT RECTIFIER AND RECONNECT MAIN TRAMSFORMER OUTPUT RECTIFIER CHOKE THREE PHASE INPUT POWER FET ASSEMBLY CT AUX.
Return to Master TOC Return to Section TOC E-4 E-4 THEORY OF OPERATION FIGURE E.4 – SWITCH BOARD CIRCUIT INPUT CONTACTOR INPUT RECTIFIER AND RECONNECT MAIN TRAMSFORMER OUTPUT RECTIFIER CHOKE THREE PHASE INPUT POWER FET ASSEMBLY CT AUX.
Return to Master TOC Return to Section TOC E-5 E-5 THEORY OF OPERATION FIGURE E.5 – MAIN TRANSFORMER INPUT CONTACTOR INPUT RECTIFIER AND RECONNECT MAIN TRAMSFORMER OUTPUT RECTIFIER CHOKE THREE PHASE INPUT POWER FET ASSEMBLY CT AUX.
Return to Master TOC Return to Section TOC E-6 E-6 THEORY OF OPERATION FIGURE E.6 – OUTPUT RECTIFIER AND CHOKE INPUT CONTACTOR INPUT RECTIFIER AND RECONNECT MAIN TRAMSFORMER OUTPUT RECTIFIER CHOKE THREE PHASE INPUT POWER FET ASSEMBLY CT AUX.
Return to Master TOC Return to Section TOC E-7 E-7 THEORY OF OPERATION FIGURE E.7 – CONTROL BOARD INPUT CONTACTOR INPUT RECTIFIER AND RECONNECT MAIN TRAMSFORMER OUTPUT RECTIFIER CHOKE THREE PHASE INPUT POWER FET ASSEMBLY CT AUX.
Return to Master TOC Return to Section TOC E-8 E-8 THEORY OF OPERATION FIGURE E.8 – POWER BOARD INPUT CONTACTOR INPUT RECTIFIER AND RECONNECT MAIN TRAMSFORMER OUTPUT RECTIFIER CHOKE THREE PHASE INPUT POWER FET ASSEMBLY CT AUX.
Return to Master TOC Return to Section TOC E-9 E-9 THEORY OF OPERATION FIGURE E.9 – DISPLAY BOARD INPUT CONTACTOR INPUT RECTIFIER AND RECONNECT MAIN TRAMSFORMER OUTPUT RECTIFIER CHOKE THREE PHASE INPUT POWER FET ASSEMBLY CT AUX.
Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC E-10 THEORY OF OPERATION E-10 THERMAL PROTECTION PROTECTIVE CIRCUITS Two normally closed (NC) thermostats protect the machine from excessive operating temperatures. These thermostats are wired in series and are connected to the Control Board. One of the thermostats is located on the heat sink of a switch board, and the other is located on the main choke.
Return to Master TOC Return to Section TOC E-11 E-11 THEORY OF OPERATION FIELD EFFECT TRANSISTOR (FET) OPERATION FIGURE E.10 – FIELD EFFECT TRANSISTOR OPERATION SOURCE TERMINAL GATE TERMINAL (0 VOLTS) DRAIN TERMINAL DRAIN (N) SOURCE (N) Return to Master TOC Return to Section TOC N CHANNEL SUBSTRATE (P) A. PASSIVE GATE TERMINAL (+ 6 VOLTS) Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC SOURCE (N) DRAIN (N) ELECTRONS B.
Return to Master TOC Return to Section TOC E-12 E-12 THEORY OF OPERATION PULSE WIDTH MODULATION FIGURE E.11 – TYPICAL FET OUTPUTS (+) (–) 48 µsec 50 µsec 1 µsec 1 µsec Return to Master TOC Return to Section TOC MINIMUM OUTPUT (+) (–) 20 µsec 20 µsec 10 µsec 50 µsec The term PULSE WIDTH MODULATION is used to describe how much time is devoted to conduction in the positive and negative portions of the cycle. Changing the pulse width is known as MODULATION.
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Section F-1 Section F-1 TABLE OF CONTENTS -TROUBLESHOOTING & REPAIR SECTIONTroubleshooting & Repair Section.......................................................................................Section F How to Use Troubleshooting Guide............................................................................................F-2 PC Board Troubleshooting Procedures and Replacement.......................................
Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC Return to Section TOC F-2 TROUBLESHOOTING & REPAIR HOW TO USE TROUBLESHOOTING GUIDE WARNING Service and repair should be performed by only Lincoln Electric Factory Trained Personnel. Unauthorized repairs performed on this equipment may result in danger to the technician and machine operator and will invalidate your factory warranty.
Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC F-3 TROUBLESHOOTING & REPAIR PC BOARD TROUBLESHOOTING PROCEDURES AND REPLACEMENT WARNING ELECTRIC SHOCK can kill. Have an electrician install and service this equipment. Turn the machine OFF before working on equipment. Do not touch electrically hot parts. Sometimes machine failures appear to be due to PC board failures. These problems can sometimes be traced to poor electrical connections.
PC BOARD REPLACEMENT CALIBRATION REQUIREMENTS Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Master TOC DISPLAY BOARD REPLACED Return to Section TOC F-4 TROUBLESHOOTING & REPAIR Return to Master TOC Return to Section TOC F-4 SNUBBER BOARD REPLACED SHUNT AMPLIFIER BOARD REPLACED IF POSSIBLE QUICK VOLTAGE CALIBRATION CONTROL BOARD REPLACED CURRENT CALIBRATION FULL VOLTAGE CALIBRATION POWER WAVE 450
Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC F-5 TROUBLESHOOTING & REPAIR TROUBLESHOOTING GUIDE PROBLEMS (SYMPTOMS) F-5 Observe Safety Guidelines detailed in the beginning of this manual. POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION OUTPUT PROBLEMS Major physical or electrical damage is evident when the sheet metal cover(s) are removed. 1. Contact your local authorized Lincoln Electric Field Service Facility for technical assistance.
Return to Master TOC Return to Section TOC F-6 TROUBLESHOOTING & REPAIR TROUBLESHOOTING GUIDE PROBLEMS (SYMPTOMS) Observe Safety Guidelines detailed in the beginning of this manual. POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION OUTPUT PROBLEMS Machine has no output – fans are running – display is on – a “clicking” sound is heard coming from the machine. 1. Turn power OFF immediately. 2. Check for proper input voltage (per machine nameplate). 3.
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC F-7 TROUBLESHOOTING & REPAIR TROUBLESHOOTING GUIDE PROBLEMS (SYMPTOMS) F-7 Observe Safety Guidelines detailed in the beginning of this manual. POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION OUTPUT PROBLEMS Fans run slow or intermittently – display is very dim – no weld output. 1.
Return to Master TOC Return to Section TOC F-8 TROUBLESHOOTING & REPAIR TROUBLESHOOTING GUIDE PROBLEMS (SYMPTOMS) Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC Observe Safety Guidelines detailed in the beginning of this manual. POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION OUTPUT PROBLEMS Machine has no output – no fans – no display. Main input fuses are open indicating excessive input current draw.
Return to Master TOC Return to Section TOC F-9 TROUBLESHOOTING & REPAIR TROUBLESHOOTING GUIDE PROBLEMS (SYMPTOMS) Return to Master TOC Observe Safety Guidelines detailed in the beginning of this manual. POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION OUTPUT PROBLEMS Circuit breaker (5 amp) trips when gun trigger is pulled – fans run. Return to Section TOC F-9 1. Make sure that not more than 5 amps of auxiliary power are being used. 2.
Return to Master TOC Return to Section TOC F-10 TROUBLESHOOTING & REPAIR TROUBLESHOOTING GUIDE PROBLEMS (SYMPTOMS) Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC Observe Safety Guidelines detailed in the beginning of this manual. POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION OUTPUT PROBLEMS Machine has no welding output – fans run – display is on. Return to Section TOC F-10 1.
Return to Master TOC Return to Section TOC F-11 TROUBLESHOOTING & REPAIR TROUBLESHOOTING GUIDE PROBLEMS (SYMPTOMS) Return to Master TOC Return to Section TOC Return to Master TOC Return to Master TOC POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION 1. Welding application may exceed recommended duty cycle. 2. Dirt and dust may have clogged the cooling channels inside the machine. Refer to the Maintenance Section of this manual. 1.
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC F-12 TROUBLESHOOTING & REPAIR TROUBLESHOOTING GUIDE PROBLEMS (SYMPTOMS) F-12 Observe Safety Guidelines detailed in the beginning of this manual. POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION FUNCTION PROBLEMS The voltage and or wire feed speed will not adjust to user satisfaction. 1.
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC F-13 TROUBLESHOOTING & REPAIR TROUBLESHOOTING GUIDE PROBLEMS (SYMPTOMS) F-13 Observe Safety Guidelines detailed in the beginning of this manual. POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION FUNCTION PROBLEMS The display cannot be seen clearly or cannot be seen at all. 1.
Return to Master TOC Return to Section TOC F-14 TROUBLESHOOTING & REPAIR TROUBLESHOOTING GUIDE PROBLEMS (SYMPTOMS) Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC Observe Safety Guidelines detailed in the beginning of this manual. POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION FUNCTION PROBLEMS Machine display reads “Error Invalid Overlay,” or it displays an invalid ID number on power-up. Return to Section TOC F-14 1.
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC F-15 TROUBLESHOOTING & REPAIR TROUBLESHOOTING GUIDE PROBLEMS (SYMPTOMS) F-15 Observe Safety Guidelines detailed in the beginning of this manual. POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION FUNCTION PROBLEMS The Beeper (Piezoelectric Buzzer) cannot be heard – machine operating normally. 1.
Return to Master TOC Return to Section TOC F-16 TROUBLESHOOTING & REPAIR TROUBLESHOOTING GUIDE PROBLEMS (SYMPTOMS) Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC Observe Safety Guidelines detailed in the beginning of this manual. POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION FUNCTION PROBLEMS The machine beeps without the keys being pressed.
Return to Master TOC Return to Section TOC F-17 TROUBLESHOOTING & REPAIR TROUBLESHOOTING GUIDE PROBLEMS (SYMPTOMS) F-17 Observe Safety Guidelines detailed in the beginning of this manual. POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION FUNCTION PROBLEMS Foreign characters are shown on the Power Wave display. Contact your local Lincoln Authorized Field Service Facility. 1. Make sure molex plug J19 is plugged into the Display board securely and the pins are secure in the plug body.
Return to Master TOC Return to Section TOC F-18 TROUBLESHOOTING & REPAIR TROUBLESHOOTING GUIDE PROBLEMS (SYMPTOMS) Observe Safety Guidelines detailed in the beginning of this manual. POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION FUNCTION PROBLEMS 1. Make sure that a stick welding procedure is selected on the Power Wave. 1. Perform the (K941-1) Remote Control Kit Test or install a new K941-1. 2.
Return to Master TOC Return to Section TOC F-19 TROUBLESHOOTING & REPAIR TROUBLESHOOTING GUIDE PROBLEMS (SYMPTOMS) Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC Observe Safety Guidelines detailed in the beginning of this manual. POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION WELDING PROBLEMS Machine loses output while welding. Fans and display are functioning properly. Return to Section TOC F-19 1.
Return to Master TOC Return to Section TOC F-20 TROUBLESHOOTING & REPAIR TROUBLESHOOTING GUIDE PROBLEMS (SYMPTOMS) Observe Safety Guidelines detailed in the beginning of this manual. POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION WELDING PROBLEMS Return to Master TOC For no apparent reason the weld characteristics have changed. Return to Section TOC F-20 1. Check for proper wire feed speed setting. In the MIG/MAG and FCAW Modes, check for proper voltage settings.
Return to Master TOC Return to Section TOC F-21 TROUBLESHOOTING & REPAIR TROUBLESHOOTING GUIDE PROBLEMS (SYMPTOMS) Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC Observe Safety Guidelines detailed in the beginning of this manual. POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION WELDING PROBLEMS Machine often “noodle welds” with a particular procedure. Return to Section TOC F-21 1.
CONTROL BD GROUND PLANE PROTECTION BD POWER BD 1 1 16 J20 J30 8 1 1 J21 16 1 16 8 J41 1 J31 1 14 POWER WAVE 450 12 J32 J42 6 1 1 4 6 J23 6 J33 1 1 1 1 J24 J34 1 1 1 10 4 J25 6 1 1 4 1 J39 1 1 4 J26 J27 J28 6 1 4 J44 4 12 J35 J36 J37 J38 14 14 1 Return to Master TOC Return to Section TOC J43 TOP VIEW DISPLAY J22 1 12 Return to Master TOC Return to Master TOC J40 Return to Section TOC Return to Section TOC 4 Return to Master TOC Retu
Return to Master TOC Return to Section TOC F-23 TROUBLESHOOTING & REPAIR CAPACITOR DISCHARGE PROCEDURE WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.
F-24 F-24 Return to Master TOC Return to Section TOC TROUBLESHOOTING & REPAIR CAPACITOR DISCHARGE PROCEDURE (continued) TEST PROCEDURE 1. Remove main input supply power to the machine. 2. With the 3/8" nut driver, remove the screws that hold the handle to the machine. 3. Remove the rubber gasket (cover seal) from the lift bail. Return to Master TOC Return to Section TOC 4. With the 5/16" nut driver, remove the sheet metal screws from the case top. 5.
F-25 F-25 Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC Return to Section TOC TROUBLESHOOTING & REPAIR CAPACITOR DISCHARGE PROCEDURE (continued) FIGURE F.3 – DISCHARGE LABEL D I S C H A R G E D I S C H A R G E D I S C H A R G E D I S C H A R G E WARNING ELECTRIC SHOCK can kill. Proceed with caution. Be careful not to touch any internal machine components during the discharge procedure. Return to Master TOC 9.
F-26 F-26 Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC TROUBLESHOOTING & REPAIR CAPACITOR DISCHARGE PROCEDURE (continued) FIGURE F.4 - RESISTOR WITH LEADS CONNECTED. 11. Check the voltage across terminals #9 and #12 with the DC voltmeter. Terminal #9 has positive polarity and terminal #12 has negative polarity. Voltage should be zero.
Return to Master TOC Return to Section TOC F-27 TROUBLESHOOTING & REPAIR AUXILIARY TRANSFORMER TEST #1 WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.
F-28 F-28 Return to Master TOC Return to Section TOC TROUBLESHOOTING & REPAIR AUXILIARY TRANSFORMER TEST #1 (continued) FIGURE F.5 - TRANSFORMER T1 AND T2 LOCATION 3 4 Return to Master TOC Return to Section TOC 2 1 1. AUXILIARY TRANSFORMER T1, PLUG J5 LOCATED IN BASE 2. PROTECTION BOARD 3. PLUG J30 4. AUXILIARY TRANSFORMER T1 TEST PROCEDURE Return to Master TOC Return to Section TOC 1. Remove main input supply power to the machine. 2.
F-29 F-29 Return to Master TOC Return to Section TOC TROUBLESHOOTING & REPAIR AUXILIARY TRANSFORMER TEST #1 (continued) 11. Remove plugs J32 and J33 from the protection board. 12. Turn the main input supply power to the machine back ON. WARNING Return to Master TOC Return to Section TOC ELECTRIC SHOCK can kill. Proceed with caution. Be careful not to touch any internal machine components during the remainder of the test procedure. 13.
4 POWER WAVE 450 (T3) W (L3) (324) (T2) V (L2) 24VAC CR1 (T1) (326) MAIN CONTACTOR U (L1) G 1 3 POWER SWITCH SWI (L3A) 2 (L1A) (HIB) (321B) F1 321A FUSE BOT.
Return to Master TOC Return to Section TOC F-31 TROUBLESHOOTING & REPAIR AUXILIARY TRANSFORMER TEST #2 WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.
F-32 F-32 Return to Master TOC Return to Section TOC TROUBLESHOOTING & REPAIR AUXILIARY TRANSFORMER TEST #2 (continued) FIGURE F.7 - TRANSFORMER T1 AND T2 LOCATION Return to Master TOC Return to Section TOC 2 3 1 1. AUXILIARY TRANSFORMER T1 WITH PLUG J73 2. PLUG J30 3. PROTECTION BOARD TEST PROCEDURE Return to Master TOC Return to Section TOC 1. Remove main input supply power to the machine. 2. With the 3/8" nut driver, remove the 4 screws that hold the handle to the machine. 3.
F-33 F-33 Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC TROUBLESHOOTING & REPAIR AUXILIARY TRANSFORMER TEST #2 (continued) 11. To conduct this test, you will be measuring the voltage between pin 2 and pin 5 of plug J4. The plug is located in the machine undercarriage and is somewhat difficult to reach. It is probably easiest to disconnect the plug and insert the probes of your voltmeter alongside pins 2 and 5 before turning on input power, which is the next step.
4 POWER WAVE 450 (T3) W (L3) (324) (T2) V (L2) 24VAC CR1 (T1) (326) MAIN CONTACTOR U (L1) G 1 3 POWER SWITCH SWI (L3A) 2 (L1A) (HIB) (321B) F1 321A FUSE BOT.
Return to Master TOC Return to Section TOC F-35 TROUBLESHOOTING & REPAIR AUXILIARY TRANSFORMER PRIMARY WIRING HARNESS TEST WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.
F-36 F-36 Return to Master TOC Return to Section TOC TROUBLESHOOTING & REPAIR AUXILIARY TRANSFORMER PRIMARY WIRING HARNESS TEST (continued) FIGURE F.9 - RECONNECT PANEL/TERMINAL STRIP LOCATION 1 Return to Master TOC Return to Section TOC 2 3 4 1. 2. 3. 4. RECONNECT PANEL (ON LEFT SIDE) TERMINAL STRIP FAN MOTORS AUXILIARY TRANSFORMERS Return to Master TOC Return to Section TOC TEST PROCEDURE 1. Remove main input supply power to the machine. 2.
F-37 F-37 Return to Master TOC Return to Section TOC TROUBLESHOOTING & REPAIR AUXILIARY TRANSFORMER PRIMARY WIRING HARNESS TEST (continued) 10. Check the wires that run from the reconnect panel to the terminal strip. Look for shorts between wires caused by broken or burned insulation. See the Input and Auxiliary Circuit Wiring Diagram, Figure F.10. Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC Return to Section TOC 11.
POWER WAVE 450 (T3) W (L3) (324) (T2) V (L2) 24VAC CR1 (T1) (326) MAIN CONTACTOR U (L1) G 1 3 POWER SWITCH SWI (L3A) 2 (L1A) 4 (HIB) (321B) F1 321A FUSE BOT.
Return to Master TOC Return to Section TOC F-39 TROUBLESHOOTING & REPAIR AUXILIARY TRANSFORMER #1 SECONDARY AND WIRING HARNESS TEST WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.
F-40 F-40 Return to Master TOC Return to Section TOC TROUBLESHOOTING & REPAIR AUXILIARY TRANSFORMER #1 SECONDARY AND WIRING HARNESS TEST (continued) FIGURE F.11 - PLUG AND RECEPTACLE INSPECTION POINTS 1 6 Return to Master TOC Return to Section TOC 5 4 1. 2. 3. 4. 5. 6. 2 3 TEST PROCEDURE Return to Master TOC Return to Section TOC 1. Remove main input supply power to the machine. 2. With the 3/8" nut driver, remove the 4 screws that hold the handle to the machine. 3.
F-41 F-41 Return to Master TOC Return to Section TOC TROUBLESHOOTING & REPAIR AUXILIARY TRANSFORMER #1 SECONDARY AND WIRING HARNESS TEST (continued) 10. Check for shorts at plugs J33, J34, J35, J37, and J38 on the protection board. Inspect the board for evidence of arcing. 11. After the test is completed and the problem successfully repaired, reconnect all plugs disconnected for the test. 12. Install the PC board cover. 13. Install the machine case sides and top.
POWER WAVE 450 336 *336 J33 334 J33 333 J33 5A C.B.
Return to Master TOC Return to Section TOC F-43 TROUBLESHOOTING & REPAIR INPUT POWER AND WIRING HARNESS TEST WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.
F-44 F-44 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC TROUBLESHOOTING & REPAIR INPUT POWER AND WIRING HARNESS TEST FIGURE F.13 - INPUT POWER INSPECTION POINTS 2 3 1 1. POWER SWITCH (S1) 2. MAIN CONTACTOR INPUT LEADS (TOP) 3. PROTECTION BOARD TEST PROCEDURE Return to Master TOC Return to Section TOC 1. Remove main input supply power to the machine. 2. With the 3/8" nut driver, remove the 4 screws that hold the handle to the machine. 3.
F-45 F-45 Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC TROUBLESHOOTING & REPAIR INPUT POWER AND WIRING HARNESS TEST (continued) 9. Check for shorts or fusing at the input (top) leads to the main contactor. 10. Remove plug J30 from the protection board. Check the resistance on the J30 header (the plug mounted on the board) between pin 1 and pin 6. Resistance should be very high. If resistance is low or zero ohms, the protection board is faulty. 11.
POWER WAVE 450 (T3) W (L3) (324) (T2) V (L2) 24VAC CR1 (T1) (326) MAIN CONTACTOR U (L1) G 1 3 POWER SWITCH SWI (L3A) 2 (L1A) 4 (HIB) (321B) F1 321A FUSE BOT.
Return to Master TOC Return to Section TOC F-47 TROUBLESHOOTING & REPAIR INPUT RECTIFIER RESISTANCE TEST WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.
F-48 F-48 Return to Master TOC Return to Section TOC TROUBLESHOOTING & REPAIR INPUT RECTIFIER RESISTANCE TEST (continued) FIGURE F.15 - RECONNECT SWITCH LOCATION 3 1 Return to Master TOC Return to Section TOC 2 Return to Master TOC Return to Section TOC 1. RECONNECT SWITCH 2. INPUT RECTIFIER 3. MAIN CONTACTOR WARNING TEST PROCEDURE 2. With the 3/8" nut driver, remove the 4 screws that hold the handle to the machine. 3. Remove the rubber gasket (cover seal) from the lift bail. 4.
F-49 F-49 Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC TROUBLESHOOTING & REPAIR INPUT RECTIFIER RESISTANCE TEST (continued) 9. Check all leads connected to the input rectifier. Check for looseness or shorted wires. 10. Using an analog type meter, perform the resistance test Steps A through L according to the Table F.1.
Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Section TOC F-50 F-50 NOTES POWER WAVE 450
Return to Master TOC Return to Section TOC F-51 TROUBLESHOOTING & REPAIR OUTPUT SHUNT/WELDING FEEDBACK TEST WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.
F-52 F-52 Return to Master TOC Return to Section TOC TROUBLESHOOTING & REPAIR QUICK SHUNT TEST TEST PROCEDURE 1. Remove main input supply power to the Power Wave 450. 2. Disconnect the Output leads from the machine. Return to Master TOC Return to Section TOC 3. If a wire feeder is connected to the Power Wave 450, release the drive roll tension so the unit will not feed wire when the trigger is activated. 4. Turn on the Power Wave 450 and activate the gun trigger and hold for several seconds.
F-53 F-53 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC TROUBLESHOOTING & REPAIR OUTPUT SHUNT/WELDING FEEDBACK TEST (continued) FIGURE F.16 - SHUNT AMPLIFIER BOARD LOCATION 1 Return to Master TOC Return to Section TOC 1. SHUNT AMPLIFIER BOARD TEST PROCEDURE 3. Remove the rubber gasket (cover seal) from the lift bail. 4. With the 5/16" nut driver, remove the sheet metal screws from the case top.
F-54 F-54 Return to Master TOC Return to Section TOC TROUBLESHOOTING & REPAIR OUTPUT SHUNT/WELDING FEEDBACK TEST (continued) WARNING ELECTRIC SHOCK can kill. Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC Return to Section TOC Proceed with caution. Be careful not to touch any internal machine components during the remainder of the test procedure. 9. Check for +15 VDC between plug J50 pin 3+ and J50 - pin 1-. 10.
Return to Master TOC Return to Section TOC F-55 TROUBLESHOOTING & REPAIR PIEZO-ELECTRIC ALARM BUZZER TEST WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.
F-56 F-56 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC TROUBLESHOOTING & REPAIR PIEZO-ELECTRIC ALARM BUZZER TEST FIGURE F.17 - ALARM BUZZER LOCATION 2 1. LEADS 300, 301 TO PLUG J15 ON DISPLAY BOARD 2. PIEZO-ELECTRIC ALARM BUZZER 1 TEST PROCEDURE Return to Master TOC Return to Section TOC 1. Remove main input supply power to the machine. 2. With the 3/8" nut driver, remove the 4 screws that hold the handle to the machine. 3.
Return to Master TOC Return to Section TOC F-57 TROUBLESHOOTING & REPAIR OUTPUT RECTIFIER DIODES TEST WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.
F-58 F-58 Return to Master TOC Return to Section TOC TROUBLESHOOTING & REPAIR OUTPUT RECTIFIER DIODES TEST FIGURE F.18 - SNUBBER BOARD, OUTPUT TERMINAL LOCATION Return to Master TOC Return to Section TOC 1 2 1. 2. 3. 4. PC BOARD FRONT/BOTTOM COVER SNUBBER PC BOARD NEGATIVE OUTPUT TERMINAL POSITIVE OUTPUT TERMINAL 3 TEST PROCEDURE Return to Master TOC Return to Section TOC 1. Remove main input supply power to the machine. 2.
Return to Master TOC Return to Section TOC F-59 TROUBLESHOOTING & REPAIR FIELD EFFECT TRANSISTOR/SWITCH BOARD TEST OR IGBT/SWITCH BOARD TEST WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty.
F-60 F-60 Return to Master TOC FIELD EFFECT TRANSISTOR/SWITCH BOARD TEST FIGURE F.19 – F.E.T. SWITCH BOARD LOCATION 1 Return to Master TOC Return to Section TOC Return to Section TOC TROUBLESHOOTING & REPAIR 1. FET OR IGBT SWITCH BOARD ASSEMBLY Return to Master TOC Return to Section TOC TEST PROCEDURE Return to Master TOC Before continuing with the test procedure, perform the following capacitor discharge procedure to avoid electric shock. 2.
F-61 F-61 Return to Master TOC FIELD EFFECT TRANSISTOR/SWITCH BOARD TEST (continued) FIGURE F.20 - RESISTOR LOCATIONS 5 PAIRS OF RESISTORS CHECK VOLTAGES BETWEEN EACH TERMINAL AND FROM EACH RESISTOR TO CASE GROUND Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC Return to Section TOC TROUBLESHOOTING & REPAIR 7. Locate the two sets of two resistors on the left side of the machine and three sets of two resistors on the right side of the machine. See Figure F.20.
F-62 F-62 Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC TROUBLESHOOTING & REPAIR FIELD EFFECT TRANSISTOR/SWITCH BOARD TEST (continued) FIGURE F.21 - DISCHARGE LABEL D I S C H A R G E D I S C H A R G E D I S C H A R G E D I S C H A R G E FIGURE F.22 RESISTOR WITH LEADS CONNECTED D I S C H A R G E 9.
F-63 F-63 FIELD EFFECT TRANSISTOR/SWITCH BOARD TEST (continued) FIGURE F.
F-64 F-64 Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC TROUBLESHOOTING & REPAIR FIELD EFFECT TRANSISTOR/SWITCH BOARD TEST (continued) Switch Board Test 1: (For Switch Board Marked CAP 1 on the Switch Board Assembly Connection Decal - See Figure F.23.) A. Disconnect all wiring harness leads from switch board 1. Fold the leads up so that they do not interfere with the exposed PC board terminals. B.
F-65 F-65 Return to Master TOC Return to Section TOC TROUBLESHOOTING & REPAIR FIELD EFFECT TRANSISTOR/SWITCH BOARD TEST (continued) TABLE F.
F-66 F-66 Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC TROUBLESHOOTING & REPAIR FIELD EFFECT TRANSISTOR/SWITCH BOARD TEST (continued) TABLE F.
F-67 F-67 Return to Master TOC Return to Section TOC TROUBLESHOOTING & REPAIR FIELD EFFECT TRANSISTOR/SWITCH BOARD TEST (continued) TABLE F.
F-68 F-68 Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC TROUBLESHOOTING & REPAIR FIELD EFFECT TRANSISTOR/SWITCH BOARD TEST (continued) TABLE F.
F-69 F-69 Return to Master TOC Return to Section TOC TROUBLESHOOTING & REPAIR FIELD EFFECT TRANSISTOR/SWITCH BOARD TEST (continued) TABLE F.
F-70 F-70 Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC TROUBLESHOOTING & REPAIR FIELD EFFECT TRANSISTOR/SWITCH BOARD TEST (continued) TABLE F.
F-71 F-71 Return to Master TOC Return to Section TOC TROUBLESHOOTING & REPAIR FIELD EFFECT TRANSISTOR/SWITCH BOARD TEST (continued) TABLE F.
F-72 F-72 Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC TROUBLESHOOTING & REPAIR FIELD EFFECT TRANSISTOR/SWITCH BOARD TEST (continued) TABLE F.
F-73 F-73 Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC TROUBLESHOOTING & REPAIR IGBT/SWITCH BOARD TEST (G3165-1) TABLE F.6 – NOTE: This test will NOT determine if an individual IGBT device is open.
F-74 F-74 Return to Master TOC Return to Section TOC TROUBLESHOOTING & REPAIR IGBT/SWITCH BOARD TEST (Continued) TABLE F.
Return to Master TOC Return to Section TOC F-75 TROUBLESHOOTING & REPAIR SNUBBER AND BLEEDER RESISTOR TEST WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.
F-76 F-76 SNUBBER AND BLEEDER RESISTOR TEST FIGURE F.
F-77 F-77 Return to Master TOC Return to Section TOC TROUBLESHOOTING & REPAIR SNUBBER AND BLEEDER RESISTOR TEST (continued) TEST PROCEDURE 1. Remove main input supply power to the machine. 2. With the 3/8" nut driver, remove the 4 screws that hold the handle to the machine. 3. Remove the rubber gasket (cover seal) from the lift bail. Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC Return to Section TOC 4.
F-78 F-78 Return to Master TOC Return to Section TOC TROUBLESHOOTING & REPAIR SNUBBER AND BLEEDER RESISTOR TEST (continued) C. With the volt/ohmmeter, check for 25 ohms resistance between lead #404 and #9F. If the measurement reads between 20 and 30 ohms, resistor R4 and leads #404 and #9F are okay. Go to step D. Return to Master TOC Return to Section TOC If the measurement does not read between 20 and 30 ohms, check for continuity in leads #404 and #9F.
Return to Master TOC Return to Section TOC F-79 FIGURE F.25 – SNUBBER AND BLEEDER RESISTOR WIRING DIAGRAM (401) SWITCH BOARD #1 401 12A Return to Master TOC Return to Section TOC 402 9A 403 12B Return to Master TOC (12L) TO RECONNECT SWITCH R9 R2 (9E) (9A) 25Ω ( 25W ) ( 7.
Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Section TOC F-80 F-80 NOTES POWER WAVE 450
Return to Master TOC Return to Section TOC F-81 TROUBLESHOOTING & REPAIR RECONNECT SWITCH TEST 1 WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.
F-82 F-82 Return to Master TOC Return to Section TOC TROUBLESHOOTING & REPAIR RECONNECT SWITCH TEST 1 FIGURE F.26 - RECONNECT SWITCH 1 Return to Master TOC Return to Section TOC 1. RECONNECT PANEL 2. RECONNECT SWITCH 3. LEAD CONNECTIONS 3 2 Return to Master TOC Return to Section TOC TEST PROCEDURE WARNING 1. Remove main input supply power to the machine. 2. With the 3/8" nut driver, remove the 4 screws that hold the handle to the machine. 3.
F-83 F-83 Return to Master TOC Return to Section TOC TROUBLESHOOTING & REPAIR RECONNECT SWITCH TEST 1 (continued) For 380 or 460 VAC: A. Check that the following leads are connected together at the reconnect switch: #9A, #9B, #9K, and POS. B. Check that the following leads are connected together at the reconnect switch: #9C, #9D, #9J, #12A, #12B, and #12J. Return to Master TOC Return to Section TOC C.
G U V W (324) CR1 (326) L1 L2 L3 POWER WAVE 450 12B SWITCH BOARD #2 9B SWITCH BOARD #1 12A - NEG + POS C3 12C SWITCH BOARD #3 9C R10 ON OFF OFF ON 380V 230V 460V ON OFF TO WATER COOLER F1 C2 R9 AC1 AC2 AC3 LOAD 1 (H1) (321B) C1 9A T1 T2 T3 (L1A) 4 LINE (L3A) 2 3 BOT.
Return to Master TOC Return to Section TOC F-85 TROUBLESHOOTING & REPAIR RECONNECT SWITCH TEST 2 WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.
F-86 F-86 Return to Section TOC Return to Master TOC Return to Master TOC RECONNECT SWITCH TEST 2 (continued) FIGURE F.28 - RECONNECT SWITCH 1 1. RECONNECT PANEL 2. RECONNECT SWITCH 3. LEAD CONNECTIONS 3 2 Return to Master TOC Return to Section TOC Return to Section TOC TROUBLESHOOTING & REPAIR TEST PROCEDURE WARNING 1. Remove main input supply power to the machine. 3. Remove the rubber gasket (cover seal) from the lift bail. 4.
F-87 F-87 Return to Master TOC Return to Section TOC TROUBLESHOOTING & REPAIR RECONNECT SWITCH TEST 2 (continued) • Lead #9A between the reconnect switch and switch board #1. • Lead #9B between the reconnect switch and switch board #2. • Lead #9C between the reconnect switch and switch board #3. • Lead #9D between the reconnect switch and switch board #4. Return to Master TOC Return to Section TOC • Lead #9J between the reconnect switch and plug J31 - pin 10 of the protection board.
G U V W (324) CR1 (326) L1 L2 L3 POWER WAVE 450 12B SWITCH BOARD #2 9B SWITCH BOARD #1 12A - NEG + POS C3 12C SWITCH BOARD #3 9C R10 ON OFF OFF ON 380V 230V 460V ON OFF TO WATER COOLER F1 C2 R9 AC1 AC2 AC3 LOAD 1 (H1) (321B) C1 9A T1 T2 T3 (L1A) 4 LINE (L3A) 2 3 BOT.
Return to Master TOC Return to Section TOC F-89 TROUBLESHOOTING & REPAIR STATIC CAPACITOR BALANCE TEST WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.
F-90 F-90 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC TROUBLESHOOTING & REPAIR STATIC CAPACITOR BALANCE TEST (continued) FIGURE F.30 - BLEEDER RESISTORS R9 AND R10 LOCATION 1 Return to Master TOC Return to Section TOC 1. RESISTORS R9 AND R10 (BLEEDER RESISTORS) TEST PROCEDURE WARNING 1. Remove main input supply power to the machine. 2. With the 3/8" nut driver, remove the 4 screws that hold the handle to the machine. 3.
F-91 F-91 Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC TROUBLESHOOTING & REPAIR STATIC CAPACITOR BALANCE TEST (continued) For 380 VAC Input Voltage or Higher: WARNING ELECTRIC SHOCK can kill. With input supply power ON, there are high voltages inside the machine. Do not reach into the machine or touch any internal part of the machine, including resistors R9 and R10.
Return to Master TOC Return to Section TOC F-92 Figure F.31 – SNUBBER AND BLEEDER RESISTOR WIRING DIAGRAM SNUBBER AND BLEEDER RESISTOR WIRING DIAGRAM (401) SWITCH BOARD #1 401 12A Return to Master TOC Return to Section TOC 402 9A 403 12B Return to Master TOC (12L) TO RECONNECT SWITCH R9 R2 (9E) (9A) 25Ω ( 25W ) ( 7.
Return to Master TOC Return to Section TOC F-93 TROUBLESHOOTING & REPAIR DYNAMIC CAPACITOR BALANCE TEST WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.
F-94 F-94 Return to Master TOC Return to Section TOC TROUBLESHOOTING & REPAIR DYNAMIC CAPACITOR BALANCE TEST (continued) FIGURE F.
F-95 F-95 Return to Master TOC Return to Section TOC TROUBLESHOOTING & REPAIR DYNAMIC CAPACITOR BALANCE TEST (continued) WARNING ELECTRIC SHOCK can kill. Return to Master TOC Return to Section TOC With input power ON, there are high voltages inside the machine, including the protection board. Do not reach into the machine or touch any internal part of the machine while power is ON. 10. Turn input power ON. must be OFF. Machine output 11.
G U V W (324) CR1 (326) L1 L2 L3 POWER WAVE 450 12B SWITCH BOARD #2 9B SWITCH BOARD #1 12A - NEG + POS C3 R10 12C SWITCH BOARD #3 9C ON OFF OFF ON 380V 230V 460V ON OFF TO WATER COOLER F1 C2 R9 AC1 AC2 AC3 (321B) LOAD 1 (H1) 3 C1 9A T1 T2 T3 (L1A) 4 LINE (L3A) 2 BOT.
Return to Master TOC Return to Section TOC F-97 TROUBLESHOOTING & REPAIR INTERNAL AND AUXILIARY SUPPLY VOLTAGE TEST WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.
F-98 F-98 Return to Master TOC Return to Section TOC TROUBLESHOOTING & REPAIR INTERNAL AND AUXILIARY SUPPLY VOLTAGE TEST (continued) TEST PROCEDURE WARNING 1. Remove main input supply power to the machine. 2. With the 3/8" nut driver, remove the 4 screws that hold the handle to the machine. 3. Remove the rubber gasket (cover seal) from the lift bail. Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC 4.
F-99 F-99 Return to Master TOC Return to Section TOC TROUBLESHOOTING & REPAIR INTERNAL AND AUXILIARY SUPPLY VOLTAGE TEST (continued) C.
F-100 F-100 Return to Master TOC Return to Section TOC TROUBLESHOOTING & REPAIR INTERNAL AND AUXILIARY SUPPLY VOLTAGE TEST (continued) 13. With the Volt/ohmmeter, check the following leads for continuity: A.
6 3 5 2 (115V) (24V) (42V) 336 334 333 5A C.B.
Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Section TOC F-102 F-102 NOTES POWER WAVE 450
Return to Master TOC Return to Section TOC F-103 TROUBLESHOOTING & REPAIR MAIN CONTACTOR TEST WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.
F-104 F-104 Return to Master TOC MAIN CONTACTOR TEST (continued) L3 L1 L1 L2 T1 T2 T3 L3 CR1 TEST PROCEDURE WARNING 1. Remove main input supply power to the machine. 3. Remove the rubber gasket (cover seal) from the lift bail. 5. With the 5/16" nut driver, remove the screws holding the right and left case sides. Remove the case sides by lifting up and out. Return to Master TOC Before continuing with the test procedure, perform the capacitor discharge procedure to avoid electric shock. 2.
F-105 F-105 Return to Master TOC MAIN CONTACTOR TEST (continued) A. With the power switch SW1 OFF, check to see if leads L1A and L3A are shorted together. If they are shorted, visually inspect the leads. If the leads are okay, then power switch SW1 is faulty and must be replaced. Return to Master TOC Return to Master TOC B. Remove leads L1, L2, and L3 from the main contactor. Check if the terminals of the main contactor are still shorted. If they are, the main contactor is faulty and must be replaced.
G U V W (324) CR1 (326) L1 L2 L3 POWER WAVE 450 12B SWITCH BOARD #2 9B SWITCH BOARD #1 12A - NEG + POS BOT.
Return to Master TOC Return to Section TOC F-107 TROUBLESHOOTING & REPAIR SERIAL LOOP WIRING HARNESS TEST WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.
F-108 F-108 Return to Master TOC Return to Section TOC TROUBLESHOOTING & REPAIR SERIAL LOOP WIRING HARNESS TEST (continued) FIGURE F.37 - WIRE FEEDER AMPHENOL LOCATIONS Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC 1 1. WIRE FEEDER CONNECTIONS (ON BACK PANEL) TEST PROCEDURE 3. Remove the rubber gasket (cover seal) from the lift bail. 4. With the 5/16" nut driver, remove the sheet metal screws from the case top.
F-109 F-109 Return to Master TOC Return to Section TOC TROUBLESHOOTING & REPAIR SERIAL LOOP WIRING HARNESS TEST (continued) B. Check for loose or broken leads between the following pins: A.
FIGURE F.38 – SERIAL LOOP WIRING DIAGRAM J22 (5R) J44 5 40mA current supply 5 Return to Master TOC Return to Section TOC Serial Loop Master Transmit & Receive Lines TxD DISPLAY BOARD RxD DK+ J26 3 Return to Master TOC Return to Master TOC Return to Section TOC (263) POWER BOARD J14 6 TRN Display Board Port Switch Open: DK Board S.L. Comunication enabled Closed: DK Board S.L.
Return to Master TOC Return to Section TOC F-111 TROUBLESHOOTING & REPAIR WIRE FEEDER 1 TRIGGER CIRCUIT TEST WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.
F-112 F-112 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC TROUBLESHOOTING & REPAIR WIRE FEEDER 1 TRIGGER CIRCUIT TEST (continued) FIGURE F.39 - DISPLAY BOARD PLUG LOCATIONS J17 J16 J15 J14 J13 J12 J11 Return to Master TOC Return to Section TOC TEST PROCEDURE Return to Master TOC Before continuing with the test procedure, perform the capacitor discharge procedure to avoid electric shock. 2.
F-113 F-113 Return to Master TOC Return to Section TOC TROUBLESHOOTING & REPAIR WIRE FEEDER 1 TRIGGER CIRCUIT TEST (continued) 11. Remove plug J30 from the protection board. See Figure F.1 for location of the board and plug J30. ELECTRIC SHOCK can kill. WARNING Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC ELECTRIC SHOCK can kill. Return to Master TOC With the input power ON, there are high voltages inside the machine, including the protection board.
FEEDER 1 FEEDER 2 POWER WAVE 450 (77) A B C D EXTERNAL AUXILIARY EQUIPMENT P1 P83 (175A) (176A) (177A) (105B) (102C) (106A) (102D) "Amphenol 2" 4 3 2 7 5 2 1 9 3 J92 6 POWER WAVE SQUARE WAVE TIG PROTECTION BD J93 (105A) (102B) "Amphenol 1" INTERNAL 6-pin Amphenols A C B D E F F E D C D C P82 14-pin Amphenols D C D C Remote Control Kit K941-1 R (76) (4) (75) (2) (4) (2) (4) (2) 8-pin Amphenols J38 J38 J34 J34 J34 J34 14 2 3 P70 (334) 11 7 4
Return to Master TOC Return to Section TOC F-115 TROUBLESHOOTING & REPAIR WIRE FEEDER 2 TRIGGER CIRCUIT TEST WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.
F-116 F-116 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC TROUBLESHOOTING & REPAIR WIRE FEEDER 2 TRIGGER CIRCUIT TEST (continued) FIGURE F.41 - DISPLAY BOARD PLUG LOCATIONS J17 J16 J15 J14 J13 J12 J11 Return to Master TOC Return to Section TOC TEST PROCEDURE Return to Master TOC Before continuing with the test procedure, perform the capacitor discharge procedure to avoid electric shock. 2.
F-117 F-117 Return to Master TOC Return to Section TOC TROUBLESHOOTING & REPAIR WIRE FEEDER 2 TRIGGER CIRCUIT TEST (continued) 11. Remove plug J30 from the protection board. See Figure F.1 for location of the board and plug J30. ELECTRIC SHOCK can kill. WARNING ELECTRIC SHOCK can kill. Return to Master TOC Return to Section TOC With the input power ON, there are high voltages inside the machine. Do not reach into the machine or touch any internal parts. 12. Turn input power ON. 13.
FEEDER 1 FEEDER 2 POWER WAVE 450 (77) (76) A B C D EXTERNAL AUXILIARY EQUIPMENT P1 P83 (175A) (176A) (177A) (105B) (102C) (106A) (102D) "Amphenol 2" 4 3 2 7 5 2 1 9 3 J92 6 POWER WAVE SQUARE WAVE TIG PROTECTION BD J93 (105A) (102B) "Amphenol 1" INTERNAL 6-pin Amphenols A C B D E F F E D C D C P82 14-pin Amphenols D C D C Remote Control Kit K941-1 R (4) (75) (2) (4) (2) (4) (2) 8-pin Amphenols J38 J38 J34 J34 J34 J34 14 2 3 P70 (334) 11 7 4
Return to Master TOC Return to Section TOC F-119 TROUBLESHOOTING & REPAIR TRIGGER CIRCUIT AND WIRING HARNESS TEST WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.
F-120 F-120 Return to Master TOC Return to Section TOC TROUBLESHOOTING & REPAIR TRIGGER CIRCUIT AND WIRING HARNESS TEST (continued) FIGURE F.43 - PROTECTION BOARD PLUG/HEADER LOCATIONS PROTECTION BD 1 1 1 16 J30 J31 Return to Master TOC 2. With the 3/8" nut driver, remove the 4 screws that hold the handle to the machine. Return to Section TOC 3. Remove the rubber gasket (cover seal) from the lift bail. 4. With the 5/16" nut driver, remove the sheet metal screws from the case top. 5.
POWER WAVE 450 J33 334 J33 333 J33 336 *336 AUXILIARY TRANSFORMER 1 W 2 COMMON U 5 42V N 3 24V R 6 115V 5A C.B.
Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Section TOC F-122 F-122 NOTES POWER WAVE 450
Return to Master TOC Return to Section TOC F-123 TROUBLESHOOTING & REPAIR INTERNAL REMOTE CONTROL TEST WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.
F-124 F-124 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC TROUBLESHOOTING & REPAIR INTERNAL REMOTE CONTROL TEST (continued) FIGURE F.45 - DISPLAY BOARD PLUG LOCATIONS Return to Master TOC Return to Section TOC J17 J16 J15 J14 J13 J12 J11 TEST PROCEDURE Return to Master TOC Before continuing with the test procedure, perform the capacitor discharge procedure to avoid electric shock. 2.
Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC F-125 TROUBLESHOOTING & REPAIR INTERNAL REMOTE CONTROL TEST (continued) WARNING ELECTRIC SHOCK can kill. With input power ON, there are high voltages inside the machine, including the protection board. Do not reach into the machine or touch any internal part.
FEEDER 1 FEEDER 2 POWER WAVE 450 (77) A B C D EXTERNAL AUXILIARY EQUIPMENT P1 P83 (175A) (176A) (177A) (105B) (102C) (106A) (102D) "Amphenol 2" 4 3 2 7 5 2 1 9 3 J92 6 POWER WAVE SQUARE WAVE TIG PROTECTION BD J93 (105A) (102B) "Amphenol 1" INTERNAL 6-pin Amphenols A C B D E F F E D C D C P82 14-pin Amphenols D C D C Remote Control Kit K941-1 R (76) (4) (75) (2) (4) (2) (4) (2) 8-pin Amphenols J38 J38 J34 J34 J34 J34 14 2 3 P70 (334) 11 7 4
Return to Master TOC Return to Section TOC F-127 TROUBLESHOOTING & REPAIR K941-1 REMOTE CONTROL KIT TEST WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.
F-128 F-128 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC TROUBLESHOOTING & REPAIR K941-1 REMOTE CONTROL KIT TEST (continued) FIGURE F.47 - 6-PIN AMPHENOL LOCATION 1 1. MACHINE FRONT PANEL 2. REMOTE CONTROL AMPHENOL RECEPTACLE (6-PIN) TEST PROCEDURE Return to Master TOC Return to Section TOC 2 1. Remove the Remote Control Kit from the power source. 2. Perform the following tests. If any test fails, the Remote Control Kit is faulty and should be replaced. A.
FEEDER 1 FEEDER 2 POWER WAVE 450 (77) (76) A B C D EXTERNAL AUXILIARY EQUIPMENT P1 P83 (175A) (176A) (177A) (105B) (102C) (106A) (102D) "Amphenol 2" 4 3 2 7 5 2 1 9 3 J92 6 POWER WAVE SQUARE WAVE TIG PROTECTION BD J93 (105A) (102B) "Amphenol 1" INTERNAL 6-pin Amphenols A C B D E F F E D C D C P82 14-pin Amphenols D C D C Remote Control Kit K941-1 R (4) (75) (2) (4) (2) (4) (2) 8-pin Amphenols J38 J38 J34 J34 J34 J34 14 2 3 P70 (334) 11 7 4
Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Section TOC F-130 F-130 NOTES POWER WAVE 450
Return to Master TOC Return to Section TOC F-131 TROUBLESHOOTING & REPAIR K941-1 REMOTE CONTROL KIT TRIGGER CIRCUIT TEST WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.
F-132 F-132 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC TROUBLESHOOTING & REPAIR K941-1 REMOTE CONTROL KIT TRIGGER CIRCUIT TEST (continued) FIGURE F.49 - DISPLAY BOARD PLUG LOCATIONS J17 J16 J15 J14 J13 J12 J11 Return to Master TOC Return to Section TOC TEST PROCEDURE WARNING NOTE: Before troubleshooting the remote control trigger circuit, troubleshoot the remote control kit itself.
Return to Master TOC Return to Section TOC F-133 TROUBLESHOOTING & REPAIR K941-1 REMOTE CONTROL KIT TRIGGER CIRCUIT TEST (continued) 11. Remove plug J30 from the protection board. See Figure F.1 for location of the board and plug J30. WARNING 15. Remove plug J26 from the protection board. Attach a 150 ohm resistor between plug J26 - pin 1 and J26 - pin 2 (the J26 plug, not the header on the control board). 16. Replace plug J12 into the display board, ELECTRIC SHOCK can kill.
FEEDER 1 FEEDER 2 POWER WAVE 450 (77) A B C D EXTERNAL AUXILIARY EQUIPMENT P1 P83 (175A) (176A) (177A) (105B) (102C) (106A) (102D) "Amphenol 2" 4 3 2 7 5 2 1 9 3 J92 6 POWER WAVE SQUARE WAVE TIG PROTECTION BD J93 (105A) (102B) "Amphenol 1" INTERNAL 6-pin Amphenols A C B D E F F E D C D C P82 14-pin Amphenols D C D C Remote Control Kit K941-1 R (76) (4) (75) (2) (4) (2) (4) (2) 8-pin Amphenols J38 J38 J34 J34 J34 J34 14 2 3 P70 (334) 11 7 4
Return to Master TOC Return to Section TOC F-135 TROUBLESHOOTING & REPAIR LCD DISPLAY TEST WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.
F-136 F-136 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC TROUBLESHOOTING & REPAIR LCD DISPLAY TEST (continued) FIGURE F.51 - DISPLAY BOARD PLUG LOCATIONS J17 J16 J15 J14 J13 J12 J11 Return to Master TOC Return to Section TOC TEST PROCEDURE WARNING 1. Remove main input supply power to the machine. Return to Master TOC Before continuing with the test procedure, perform the capacitor discharge procedure to avoid electric shock. 2.
F-137 F-137 Return to Master TOC Return to Section TOC TROUBLESHOOTING & REPAIR LCD DISPLAY TEST (continued) WARNING ELECTRIC SHOCK can kill. With input power ON, there are high voltages inside the machine. Do not reach into the machine or touch any internal part. 13. Perform the following tests to locate the problem: Auxiliary Transformer 1 Test and Internal and Auxiliary Voltage Supply Test. If these tests show no component failures, go to step 14. 14.
POWER WAVE 450 6 3 5 2 (115V) (24V) (42V) 336 334 333 5A C.B.
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC F-139 TROUBLESHOOTING & REPAIR CALIBRATION PROCEDURES POWER WAVE PC BOARD REPLACEMENT CALIBRATION PROCEDURES If the display board is replaced, the display sensor calibration and a voltage calibration must be performed for optimum performance. If the calibration is not done the voltage may be accurate only to within 3 volts.
Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Section TOC F-140 F-140 NOTES POWER WAVE 450
Return to Master TOC Return to Section TOC F-141 TROUBLESHOOTING & REPAIR SENSOR CALIBRATION TEST (FOR DISPLAY BOARD) WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.
F-142 F-142 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC TROUBLESHOOTING & REPAIR SENSOR CALIBRATION TEST (FOR DISPLAY BOARD) (continued) FIGURE F.53 - SENSOR LOCATION BEHIND OVERLAY 1. LEADS 300, 301 TO PLUG J15 ON DISPLAY BOARD 2. PIEZO-ELECTRIC ALARM BUZZER PROCEDURE 1. Turn the machine ON with no overlay in place. The overlay ID number displayed should be 255. Return to Master TOC Return to Section TOC 2.
Return to Master TOC Return to Section TOC F-143 TROUBLESHOOTING & REPAIR QUICK VOLTAGE CALIBRATION WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.
F-144 F-144 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC TROUBLESHOOTING & REPAIR QUICK VOLTAGE CALIBRATION (continued) FIGURE F.54 - TEST AND CALIBRATION OVERLAY PROCEDURE 1. Before changing or disturbing the display board, power up the machine with the L9660-255 Test and Calibration overlay in place. See Figure F.54. 2. Press the Voltage Calibration function (32). The machine should display the following: 5.
Return to Master TOC Return to Section TOC F-145 TROUBLESHOOTING & REPAIR FULL VOLTAGE CALIBRATION WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.
F-146 F-146 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC TROUBLESHOOTING & REPAIR FULL VOLTAGE CALIBRATION(continued) FIGURE F.55 - TEST AND CALIBRATION OVERLAY PROCEDURE 1. The voltage calibration numbers are stored in the display board. They are programmable from the front panel using the Test and Calibration Overlay. Return to Master TOC Return to Section TOC 2. Change the PC board in question. 3.
Return to Master TOC Return to Section TOC F-147 TROUBLESHOOTING & REPAIR FULL VOLTAGE CALIBRATION USING A WELDING ARC WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.
F-148 F-148 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC TROUBLESHOOTING & REPAIR FULL VOLTAGE CALIBRATION(continued) FIGURE F.55a - TEST AND CALIBRATION OVERLAY PROCEDURE 1. The voltage calibration numbers are stored in the display board. They are programmable from the front panel using the Test and Calibration Overlay. Return to Master TOC Return to Section TOC 2. Change the display board in question. 3.
F-149 F-149 Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC TROUBLESHOOTING & REPAIR FULL VOLTAGE CALIBRATION(continued) – POLARITY (+21A) + POLARITY – POLARITY NOTE: Do not attempt to weld for –Polarity (+21A). Set the number to the same as recorded for +Polarity (+67A). Also for +Polarity and –Polarity, move the voltmeter sense lead from the conductor block of the wire feeder to the positive output terminal on the front of the machine. 9. Turn the machine off.
Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Section TOC F-150 F-150 NOTES POWER WAVE 450
Return to Master TOC Return to Section TOC F-151 TROUBLESHOOTING & REPAIR CURRENT CALIBRATION WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.
F-152 F-152 Return to Master TOC CURRENT CALIBRATION (continued) 2. Locate the 10 turn trimmer potentiometer located on the control board. It is the only trimmer on the board. If the trimmer is not accessible with the control board installed, then the board must be removed and laid on the top of the PC board compartment. Be sure the control board is insulated from the other boards and the case parts. All wiring plugs must be connected to the control board. See Figure F.56.
F-153 F-153 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC TROUBLESHOOTING & REPAIR CURRENT CALIBRATION (continued) FIGURE F.58 – TEST AND CALIBRATION OVERLAY PROCEDURE WARNING Return to Master TOC Return to Section TOC 1. Install the Test and Calibration Overlay and apply power to the machine. See Figure F.58. 2. Press the Manual Procedure Entry Key (64). The machine should display the following: PROCESS 1 SETUP 1-0 3.
Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Section TOC F-154 F-154 NOTES POWER WAVE 450
Return to Master TOC Return to Section TOC F-155 TROUBLESHOOTING & REPAIR T1 AUXILIARY TRANSFORMER REMOVAL AND REPLACEMENT WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.
F-156 F-156 Return to Master TOC Return to Section TOC TROUBLESHOOTING & REPAIR T1 AUXILIARY TRANSFORMER REMOVAL AND REPLACEMENT (continued) FIGURE F.59 - T1 AUXILIARY TRANSFORMER LOCATION 1. AUXILIARY TRANSFORMER T1 2. MOUNTING SCREW (2) Return to Master TOC Return to Section TOC 2 1 PROCEDURE Return to Master TOC Return to Section TOC 1. Remove main input supply power to the machine. 2. With the 3/8" nut driver, remove the 4 screws that hold the handle to the machine. 3.
Return to Master TOC Return to Section TOC F-157 TROUBLESHOOTING & REPAIR WATER COOLER REMOVAL AND REPLACEMENT For later model coolers (Inlet & Outlet on lower left of machine back) Refer to IM645-A WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty.
F-158 F-158 Return to Master TOC WATER COOLER REMOVAL AND REPLACEMENT (continued) FIGURE F.60 - WATER COOLER LOCATION 2 Return to Master TOC Return to Section TOC Return to Section TOC TROUBLESHOOTING & REPAIR 1 3 1. WATER COOLER ACCESS DOOR (ON BACK PANEL) 2. WATER COOLING FITTINGS 3. CIRCUIT BREAKER Return to Master TOC Return to Section TOC PROCEDURE WARNING NOTE: These instructions may vary slightly with later model coolers. See instructions included with cooler kit. 1.
Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC F-159 TROUBLESHOOTING & REPAIR WATER COOLER REMOVAL AND REPLACEMENT (continued) 10. With the 9/16" open end wrench, remove the circuit breaker. 11. Locate and disconnect plug J4, behind the water cooler. Plug J 4, a large molex plug, has two leads (H1A and H3A). Double-check that these are the leads feeding the plug; there is another large molex plug in the same area that is not connected to the water cooler. 12.
Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Section TOC F-160 F-160 NOTES POWER WAVE 450
Return to Master TOC Return to Section TOC F-161 TROUBLESHOOTING & REPAIR WATER COOLER DISASSEMBLY WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.
F-162 F-162 Return to Master TOC Return to Section TOC TROUBLESHOOTING & REPAIR WATER COOLER DISASSEMBLY (continued) FIGURE F.61 - WATER COOLER DISASSEMBLY (EARLY MODEL) 1 Return to Master TOC Return to Section TOC 2 PROCEDURE Return to Master TOC Return to Section TOC 3 WARNING 1. Remove main input supply power to the machine. 2. With the 3/8" nut driver, remove the 4 screws that hold the handle to the machine. 3. Remove the rubber gasket (cover seal) from the lift bail. 4.
Return to Master TOC Return to Section TOC F-163 TROUBLESHOOTING & REPAIR WATER COOLER DISASSEMBLY (continued) Reservoir Removal Motor/Pump/Fan Assembly Removal A. After you have completed the capacitor discharge procedure for all four switch boards, remove the water cooler assembly. Refer to the Water Cooler Removal and Replacement Procedure in this section of the manual. A. Perform the Reservoir Removal procedure.
Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Section TOC F-164 F-164 NOTES POWER WAVE 450
Return to Master TOC Return to Section TOC F-165 TROUBLESHOOTING & REPAIR T2 AUXILIARY TRANSFORMER REMOVAL AND REPLACEMENT WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.
F-166 F-166 Return to Master TOC Return to Section TOC TROUBLESHOOTING & REPAIR T2 AUXILIARY TRANSFORMER REMOVAL AND REPLACEMENT (continued) FIGURE F.62 - T2 AUXILIARY TRANSFORMER LOCATION 1. BASE 2. AUXILIARY TRANSFORMER T2 3. MOUNTING SCREW (2) 3 Return to Master TOC Return to Section TOC 2 1 Return to Master TOC 1. Remove main input supply power to the machine. Return to Master TOC Return to Section TOC Return to Section TOC PROCEDURE 2.
Return to Master TOC Return to Section TOC F-167 TROUBLESHOOTING & REPAIR FAN MOTOR REMOVAL AND REPLACEMENT WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.
F-168 F-168 Return to Master TOC Return to Section TOC TROUBLESHOOTING & REPAIR FAN MOTOR REMOVAL AND REPLACEMENT (continued) FIGURE F.63 - FAN MOTOR LOCATION Return to Master TOC Return to Section TOC 1 2 3 Return to Master TOC Return to Section TOC 1. MACHINE BACK 2. TERMINAL STRIP 3. FAN MOTOR AND MOUNTING BRACKET PROCEDURE WARNING 1. Remove main input supply power to the machine. 2. With the 3/8" nut driver, remove the 4 screws that hold the handle to the machine. 3.
F-169 F-169 Return to Master TOC Return to Section TOC TROUBLESHOOTING & REPAIR FAN MOTOR REMOVAL AND REPLACEMENT (continued) FIGURE F.64 - MACHINE BACK SECURED TO LIFT BAIL. Return to Master TOC Return to Section TOC 2 1 11. With the 3/4" wrench, remove the lead connected to the rear positive (+) output terminal. Return to Master TOC Return to Section TOC 1. MACHINE BACK 2. LIFT BAIL 12. Swing the back panel up and secure it to the lift bail. See Figure F.64. Use heavy string or wire.
Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Section TOC F-170 F-170 NOTES POWER WAVE 450
Return to Master TOC Return to Section TOC F-171 TROUBLESHOOTING & REPAIR INPUT RECTIFIER REMOVAL AND REPLACEMENT WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.
F-172 F-172 Return to Master TOC Return to Section TOC TROUBLESHOOTING & REPAIR INPUT RECTIFIER REMOVAL AND REPLACEMENT (continued) FIGURE F.65 - INPUT RECTIFIER LOCATION 1 Return to Master TOC Return to Section TOC CR1 2 3 4 5 6 Return to Master TOC PROCEDURE Return to Master TOC Return to Section TOC Return to Section TOC 1. 2. 3. 4. 5. 6. MAIN CONTACTOR M.O.V. ASSEMBLY SILICONE SEALANT INPUT RECTIFIER 5MM ALLEN SCREW HEAT SINK PANEL WARNING 1.
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC F-173 TROUBLESHOOTING & REPAIR INPUT RECTIFIER REMOVAL AND REPLACEMENT (continued) 10. With the 5 mm Allen wrench and the 10 mm open end wrench, remove the two screws mounting the input rectifier to the heat sink panel. 11.
Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Section TOC F-174 F-174 NOTES POWER WAVE 450
Return to Master TOC Return to Section TOC F-175 TROUBLESHOOTING & REPAIR PRINTED CIRCUIT BOARD REMOVAL AND REPLACEMENT (CONTROL BOARD, POWER BOARD, AND PROTECTION BOARD) WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty.
F-176 F-176 Return to Master TOC Return to Section TOC TROUBLESHOOTING & REPAIR PRINTED CIRCUIT BOARD REMOVAL AND REPLACEMENT (CONTROL BOARD, POWER BOARD, AND PROTECTION BOARD) (continued) FIGURE F.66 - PC BOARD REMOVAL Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC 1 2 1. PC BOARD COVER 2. PC BOARD ASSEMBLY 3. RETAINER CLIPS 3 PROCEDURE WARNING 1. Remove main input supply power to the machine.
Return to Master TOC Return to Section TOC F-177 PRINTED CIRCUIT BOARD REMOVAL AND REPLACEMENT (CONTROL BOARD, POWER BOARD, AND PROTECTION BOARD) (continued) CAUTION Be sure to follow the recommended static-free methods for handling printed circuit boards. Failure to do so can result in permanent damage to the equipment. Return to Master TOC 8. Remove the molex plugs from the PC board you are removing.
Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Section TOC F-178 F-178 NOTES POWER WAVE 450
Return to Master TOC Return to Section TOC F-179 TROUBLESHOOTING & REPAIR DISPLAY BOARD REMOVAL AND REPLACEMENT WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.
F-180 F-180 Return to Master TOC Return to Section TOC TROUBLESHOOTING & REPAIR DISPLAY BOARD REMOVAL AND REPLACEMENT (continued) FIGURE F.68 - DISPLAY BOARD REMOVAL 3 Return to Master TOC Return to Section TOC 2 4 1 5 1. 2. 3. 4. 5. MOLEX PLUG HEADERS (8) KEY PAD RIBBON CONNECTOR LCD DISPLAY WINDOW LCD CONNECTOR MOUNTING PIN HOLE Return to Master TOC Return to Section TOC NOTE: Before changing or disturbing the dis- 1. Remove main input supply power to the machine. 2.
Return to Master TOC Return to Section TOC F-181 TROUBLESHOOTING & REPAIR DISPLAY BOARD REMOVAL AND REPLACEMENT (continued) 8. Carefully remove the key pad ribbon connector from the right side of the display board. 9. Carefully remove the connector to the LCD display.
Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Section TOC F-182 F-182 NOTES POWER WAVE 450
Return to Master TOC Return to Section TOC F-183 TROUBLESHOOTING & REPAIR MAIN INPUT CONTACTOR (CR1) REMOVAL AND REPLACEMENT WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.
F-184 F-184 MAIN INPUT CONTACTOR (CR1) REMOVAL AND REPLACEMENT (continued) L3 T2 T3 T1 Return to Master TOC L3 CR1 324 326 PROCEDURE Return to Master TOC Return to Section TOC Return to Section TOC T1 L2 T3 L1 WARNING 1. Remove main input supply power to the machine. Return to Master TOC Before continuing with the test procedure, perform the capacitor discharge procedure to avoid electric shock. 2. With the 3/8" nut driver, remove the 4 screws that hold the handle to the machine. 3.
Return to Master TOC Return to Section TOC F-185 TROUBLESHOOTING & REPAIR MAIN INPUT CONTACTOR (CR1) REMOVAL AND REPLACEMENT (continued) 9. With the slot head screw driver, remove the two small leads (T1 and T3) from the output side of the contactor. 13. For replacement, mount the contactor to the vertical mounting panel with the two 3/8" mounting screws and nuts. 10. With the slot head screw driver, remove the two contactor coil leads (#324 and #326) from the contactor. 14.
Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Section TOC F-186 F-186 NOTES POWER WAVE 450
Return to Master TOC Return to Section TOC F-187 TROUBLESHOOTING & REPAIR OUTPUT RECTIFIER BRIDGE REMOVAL AND REPLACEMENT WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.
F-188 F-188 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC TROUBLESHOOTING & REPAIR OUTPUT RECTIFIER BRIDGE REMOVAL AND REPLACEMENT (continued) FIGURE F.70 - OUTPUT RECTIFIER BRIDGE LOCATION 1 Return to Master TOC Return to Section TOC 1. OUTPUT RECTIFIER BRIDGE PROCEDURE WARNING 1. Remove main input supply power to the machine. Before continuing with the test procedure, perform the capacitor discharge procedure to avoid electric shock. 2.
Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC F-189 F-189 TROUBLESHOOTING & REPAIR OUTPUT RECTIFIER BRIDGE REMOVAL AND REPLACEMENT (continued) 9. Cut all necessary cable ties on the right side of the machine and disconnect all necessary leads (two heavy and two small leads) from the right side of the output rectifier bridge. Place the fastener hardware back together onto the lead ends to avoid loss. 10.
Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC F-190 TROUBLESHOOTING & REPAIR OUTPUT RECTIFIER BRIDGE REMOVAL AND REPLACEMENT (continued) FIGURE F.72 – CABLE TIE LOCATIONS SECONDARY HARNESS ASSEMBLY (WHITE) Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC PRIMARY HARNESS ASSEMBLY (BLACK) 13. For reassembly, attach the glastic insulated angle mounting pieces to the heat sink first.
Return to Master TOC Return to Section TOC F-191 TROUBLESHOOTING & REPAIR FET MODULE REMOVAL AND REPLACEMENT WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.
Return to Master TOC Return to Section TOC F-192 TROUBLESHOOTING & REPAIR FET MODULE REMOVAL AND REPLACEMENT (continued) FIGURE F.73 - FET MODULE LOCATION 4 Return to Master TOC Return to Section TOC 3 1 1. 2. 3. 4. FET MODULE PIEZO ALARM BUZZER FET MODULE LOCKING BAR RESISTORS 2 Return to Master TOC Return to Section TOC PROCEDURE WARNING 1. Remove main input supply power to the machine. 3. Remove the rubber gasket (cover seal) from the lift bail. 4.
Return to Master TOC Return to Section TOC F-193 F-193 TROUBLESHOOTING & REPAIR FET MODULE REMOVAL AND REPLACEMENT (continued) FIGURE F.74 - LIFT BAFFLE/BAIL REMOVAL 1 Return to Master TOC Return to Section TOC 2 1. LIFT BAIL 2. LIFT BAIL BAFFLE 3. SUBFRAME STAND 3 Return to Master TOC Return to Section TOC 9. With the wire cutters, cut all necessary cable ties. 10. Disconnect the leads to the output rectifier bridge. Cut all necessary cable ties. 11.
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC F-194 TROUBLESHOOTING & REPAIR FET MODULE REMOVAL AND REPLACEMENT (continued) 21. Remove the water cooler assembly in order to access the retainer clips that hold the bottom of the FET module assembly in place. (Complete removal of the unit should not be necessary.
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC F-195 TROUBLESHOOTING & REPAIR FET MODULE REMOVAL AND REPLACEMENT (continued) 30. Install the water cooler assembly. Refer to the Water Cooler Removal and Replacement Procedure in this section of the module. 31.
Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Section TOC F-196 F-196 NOTES POWER WAVE 450
Return to Master TOC Return to Section TOC F-197 TROUBLESHOOTING & REPAIR MAIN TRANSFORMER REMOVAL AND REPLACEMENT WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.
F-198 F-198 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC TROUBLESHOOTING & REPAIR MAIN TRANSFORMER/CHOKE REMOVAL AND REPLACEMENT (continued) FIGURE F.75 - MAIN TRANSFORMER LOCATION 1. MAIN TRANSFORMER 1 Return to Master TOC Return to Section TOC PROCEDURE 1. Remove main input supply power to the machine. 2. With the 3/8" nut driver, remove the 4 screws that hold the handle to the machine. 3. Remove the rubber gasket (cover seal) from the lift bail. 4.
Return to Master TOC Return to Section TOC F-199 TROUBLESHOOTING & REPAIR PRE-POWERUP SWITCH BOARD TEST PROCEDURE FOR REPLACEMENT OF SWITCH ASSEMBLY G2402-2 WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty.
Return to Master TOC Return to Section TOC F-200 TROUBLESHOOTING & REPAIR F-200 PRE-POWERUP SWITCH BOARD TEST PROCEDURE FOR REPLACEMENT OF SWITCH ASSEMBLY G2402-2 (continued) across one of the 7.5K ohm bleeder resistors (R9 or R10). See wiring diagram. FILTER CAPACITOR POLARITY TEST 1. Perform this procedure with the input power removed. Perform the CAPACITOR DISCHARGE Procedure to remove any charge from the input filter capacitors. 2. Configure the machine for 230VAC operation. 4.
Return to Master TOC Return to Section TOC F-201 TROUBLESHOOTING & REPAIR PRE-POWERUP SWITCH BOARD TEST PROCEDURE FOR REPLACEMENT OF SWITCH ASSEMBLY G2402-2 (continued) FIGURE F.77 - FILTER CAPACITOR VOLTAGE + 9L Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC 400 VDC VOLTMETER + 9M 400 VDC VOLTMETER R 10 12M WARNING WARNING MAKE SURE FILTER CAPACITORS ARE DISCHARGED ALL AC SUPPLIES MUST BE ELECTRICALLY ISOLATED (isolation transformers).
Return to Master TOC Return to Section TOC F-202 F-202 TROUBLESHOOTING & REPAIR PRE-POWERUP SWITCH BOARD TEST PROCEDURE FOR REPLACEMENT OF SWITCH ASSEMBLY G2402-2 (continued) FIGURE F.78 - PRETEST POWER SUPPLY PRETEST POWER SWITCH 5A FUSE Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC Return to Section TOC ISOLATED 115 VAC P70 P70 2 2 3 3 5 5 6 6 Connect the pretest power supply to plug P70 as per Figure F.78.
Return to Master TOC Return to Section TOC F-203 F-203 TROUBLESHOOTING & REPAIR PRE-POWERUP SWITCH BOARD TEST PROCEDURE FOR REPLACEMENT OF SWITCH ASSEMBLY G2402-2 (continued) ARC START FOR PW450 ROBOTIC 1. Construct and connect an arc start circuit as per Figure F.79. 3. Leave plug J103 connected to the interface board. 2. Install leads and an arc start switch into plug J103 pin 10 to pin 11 on the interface PC board.
Return to Master TOC Return to Section TOC F-204 TROUBLESHOOTING & REPAIR F-204 PRE-POWERUP SWITCH BOARD TEST PROCEDURE FOR REPLACEMENT OF SWITCH ASSEMBLY G2402-2 (continued) FIGURE F.80 - PC BOARD RECEPTACLE P 23 2 3 Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC Return to Section TOC 5 6 1. Unplug P23 and insert jumper plug into PC board receptacle. See Figure F.80. 5. Turn ON the arc start switch.
Return to Master TOC Return to Section TOC F-205 TROUBLESHOOTING & REPAIR F-205 PRE-POWERUP SWITCH BOARD TEST PROCEDURE FOR REPLACEMENT OF SWITCH ASSEMBLY G2402-2 (continued) FIGURE F.81 - FET DRIVE SIGNAL Return to Master TOC Return to Section TOC 0V 20uS/Div 20V/Div SNUBBER SIGNAL TEST 1. Adjust the grid for a “light” load. 2. Turn ON the variable AC supply applied to the primary circuit. See Figure F.76. 6. Attach the oscilloscope to each of the following eight test points.
Return to Master TOC Return to Section TOC F-206 TROUBLESHOOTING & REPAIR F-206 PRE-POWERUP SWITCH BOARD TEST PROCEDURE FOR REPLACEMENT OF SWITCH ASSEMBLY G2402-2 (continued) FIGURE F.82 - SNUBBER SIGNAL Return to Master TOC Return to Section TOC 0V 20uS/Div 5V/Div 460VAC RECONNECT 1. Reconfigure the machine for 460VAC operation. 2. Turn ON the variable AC supply applied to the primary circuit. See Figure F.76. Return to Master TOC Return to Section TOC 3. Turn on the arc start switch.
Return to Master TOC Return to Section TOC F-207 F-207 TROUBLESHOOTING & REPAIR PRE-POWERUP SWITCH BOARD TEST PROCEDURE FOR REPLACEMENT OF SWITCH ASSEMBLY G2402-2 (continued) FIGURE F.83 - OUTPUT SIGNAL Return to Master TOC Return to Section TOC 0V 10uS/Div 5V/Div 8. Turn the variable AC primary supply to zero volts and then turn it OFF. See Figure F.76. Return to Master TOC Return to Section TOC 9. Once the filter capacitor voltage drops to zero, turn the arc start switch OFF.
Return to Master TOC Return to Section TOC F-208 F-208 TROUBLESHOOTING & REPAIR PRE-POWERUP SWITCH BOARD TEST PROCEDURE FOR REPLACEMENT OF SWITCH ASSEMBLY G2402-2 (continued) FIGURE F.84 - PRIMARY CURRENT SIGNAL Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC 0V 10uS/Div 10V/Div 5. Press the MANUAL PROCEDURE ENTRY Key on the Calibration and Test Overlay and change the Power Wave to “Process 1 Setup 1 -8” mode. PREPARE MACHINE FOR NORMAL OPERATION. 1.
Return to Master TOC G-1 TABLE OF CONTENTS ELECTRICAL DIAGRAMS Electrical Diagrams Section................................................................................................Section G Wiring Diagram ...........................................................................................................................G-2 Schematic Complete Machine ..................................................................................................G-3 Control PC Board Schematic (1 of 4).......
LEFT SIDE OF MACHINE 204 5 76 5 205 TO 6 206 6 7 207 7 8 208 6 291 7 292 8 276 P82 9 275 10 294 P83 J92 11 12 321A 13 TO J30 14 1 3 4 L3A 7 455 8 456 J22 4 5W 5 5R 4 6 226 7 227 TO 10 223 J37 11 224 12 225 372 TO 2 232 3 LCD DISPLAY 233 J14 4 373 1 261 2 262 3 264 4 266 5 265 6 263 J37 J23 15 15 J15 1 300 2 301 PIEZO 1 448 443 3 442 J16 7 449 J44 8 445 9 446 10 447 J32 234 RECT.
SCHEMATIC - COMPLETE MACHINE TRIGGER 24V, 42V, & 115V FROM PROTECTION BD. TX 303 4J17 2J17 203 3J40 3R 202 11J40 3R 206 +5 Vb 2J14 262 2J26 5J14 265 5J26 24V TRIGGER CIRCUIT 24V GD SERIAL COMM. 6J14 263 3J26 3J14 264 4J26 40mA 223 10J42 +15 Va -15 Va 6J22 226 6J42 -15 Va 11J22 224 11J42 +5 Va 12J22 225 12J42 +5 Va 373 4J13 0V 372 2J13 24V 9D 208-230V 1J31 CAP.
SCHEMATIC - CONTROL PC BOARD #1 2241-1 Return to Master TOC G-4 ELECTRICAL DIAGRAMS G Return to Section TOC G-4 +5V +15V +15V J22 10 1 C13 DZ4 4.7 32 18V 35V 1W C21 J22 12 4.7 35V 0.1 X20 50V 50V 34 74HC573 GND 10 24 C18 X5 0.1 74HC573 50V 14 C28 X16 C29 0.1 PSD301 GND 12 20 C27 X13 0.1 1 20 50V 10 50V 50V 12 DZ2 6.2V 1W 54HC08 7 12 C10 C11 4.7 0.1 35V 50V C19 C45 0.1 0.
SCHEMATIC - CONTROL PC BOARD #2 R339 R338 4.75K 4.75K R337 R345 4.75K 4.
+15V +5V +5V 2E: CURRENT MODE CONTROL R274 267 C132 20 14 0.1 0.1 50V 50V X63 C98 54HC4066 50V O7 12 /OE O6 13 O/D(10) 4 D2 O2 17 O/D(11) 5 D3 O3 16 6 D4 O4 15 7 D5 O5 14 8 D6 01 18 D7 00 19 LE 11 Vcc X90 GND C152 4 4 X71 C153 DGND 50V A A A 20 X61 0.1 20 20 C83 C148 0.1 C87 0.
SCHEMATIC - CONTROL PC BOARD #4 50V SER_LOOP C121 +15V 2700p J26 681 820p 600mA ON / OFF 40V SWITCH +5V C120 300V +5V 50V TP3 +15V 1 SWITCH1 (TO HC11) 5 1 OCI4 D22 6 SWITCH2 (TO HC11) 5 2 6 R256 150 THERMAL (TO HC11) 0.1 Return to Master TOC D 6 R232 C122 4 .0047 D27 400V D26 56.
PC BOARD ASSEMBLY-CONTROL ±.04 11.
SCHEMATIC - DISPLAY PC BOARD (SHEET 1) +5V +15V 9 Vdd C57 0.1 50V X7 MC68HC11 Vss 44 Vcc 26 20 C48 0.1 50V X8 DZ5 5.1V 1W PSD301 GND 1 12 DZ4 5.1V 1W C50 X4 20 C49 X9 0.1 50V 74HC573 GND 34 20 10 C56 X3 0.1 50V 74HC573 14 0.1 50V 74HC573 10 14 C20 X11 10 C12 X5 0.1 50V 74HC04 12 7 C52 X16 0.1 50V 54HC08 16 0.1 50V MC6850CS 7 X12 74HC4040 1 Vdd 16 C55 X14 C54 0.1 50V 74HC151 0.1 50V 8 3 C25 X10 4 Vss 8 Vss 14 0.
SCHEMATIC - DISPLAY PC BOARD (SHEET 2) R194 +15V 100 R195 4 R199 C98 330p 100V GA R200 681 3 1 INFRA4 6.81K GA 75.0 2 4 Q22 600mA 40V R176 22.1K 3 1 4 2 2 Q23 600mA 40V R182 6.81K 22.1K C88 3 1 4 2 OCI10 OPTEK OPB706 Q24 600mA 40V R177 INFRA6 6.81K 22.1K C89 150 3 1 4 2 OCI12 OPTEK OPB706 SENSE SENSE INFRA5 150 R110 150 OCI18 OPTEK OPB706 SENSE DZ25 15V 1W R175 R198 GD 22.1K 10.
Return to Master TOC G-11 ELECTRICAL DIAGRAMS PC BOARD ASSEMBLY-DISPLAY G 2862-1 Return to Section TOC G-11 ITEM R50,R59,R60,R63,R64,R65 REQ’D PART NO. S19400-1500 150 1/4W 16 S19400-2212 22.1K 1/4W R67,R88,R104,R105,R110 DESCRIPTION .1/50 C56,C57,C59,C60,C65,C67 C76,C80,C81,C82,C83,C84 R184,R191,R199 11.75 PART NO. S16668-11 C48,C49,C50,C52,C54,C55 R175,R178,R180,R181 12.00 45 C35,C36,C38,C39,C40,C41 R134,R135,R140,R174 ±.
2240 INVERTER POWER SUPPLIES PRIMARY SWITCHING CIRCUIT +5Vref 10K 14 R6 R2 R57 C2 3 COMP IN E1 16 GND X1 TL494 12 100 X2 R26 13 200 200 200 RES 7 1 D11 CR1 CR2 12Vdc 12Vdc R25 R70 R69 R68 R67 D29 1N4936 +5Vref 10K C12 .022 50V .5 5W R33 100K 100K SWITCH_GND C32 0.1 50V GND 1mH 35V 1000 8 D35 9t DZ17 6.2V 1W R190 C178 1N4936 D34 L11 C37 0.1 50V D60 GND CR2 4 IN 8 1mH b OUT X9 -5Vb 15mA N.D. J42 IN +5Va OUT X5 C140 0.1 50V 2.21K 2.
ITEM 8.00 7.80 G2163-1 J44 J42 D9 TP1 R35 TP2 C39 R55 C42 OCI1 R180 C41 J43 R76 R130 23 S16668-11 C8 1 S16668-6 C9,C10 2 S13490-76 C11,C14 2 S13490-42 1.0/35 C12,C176,C177,C178,C189 5 S16668-5 .022/50 C17 1 S13490-40 2.7/50 C18,C102 2 S13490-68 2/150 C33 1 S13490-121 C40,C41,C42 3 T11577-58 .0047/3000V C190 1 T11577-26 .1/100 CR1,CR2 2 S13929-8 D1,D2,D3,D4 4 S18395-22 DIODE HS ASBLY 23 T12705-34 1N4936 D5,D6,D7,D8,D17,D18,D19 .
SCHEMATIC - PROTECTION PRINTED CIRCUIT BOARD D15 DISPLAY BD AMPTROL 2 3 4 5 6 1 2 3 4 5 6 8 9 10 11 12 13 1 14 2 3 4 5 6 1 2 3 4 1 2 3 24VAC +24V 150 R2 J38 J38 J38 J38 J37 J37 J37 J37 J35 J35 J35 J35 J35 J35 J34 J34 J34 J34 J34 J34 7 J34 J34 J34 J34 J34 J34 J34 J34 J33 J33 J33 J33 J33 J33 R1 1 L1 R3 150 R4 D1 C1 D3 24V 42V 150 J36 D11 D13 J32 J32 C12 6.81K .39mH +t 4.7 35V C11 .
Return to Master TOC G-15 ELECTRICAL DIAGRAMS PC BOARD ASSEMBLY-PROTECTION G 3196-1 Return to Section TOC G-15 ITEM .20 11.05 5.63 ±.04 7.80 PROTECTION Q9 R60 R72 R61 G3196-1 R44 R73 C22 R84 R79 R152 R153 C15 R81 C28 C27 R96 R90 C17 R91 C21 3300 / 50 1 S13490-92 11 S16668-5 C12,C30 2 S13490-25 .
Return to Master TOC G-16 ELECTRICAL DIAGRAMS SCHEMATIC -SQUARE WAVE PROTECTION PRINTED CIRCUIT BOARD M 16115 Return to Section TOC G-16 L4 1 J23 J22 .39mH 5 C4 .0047 3000V L5 J23 J22 .39mH 4 C5 Return to Master TOC .0047 3000V L1 3 J23 J22 .39mH 1 C1 .0047 3000V L2 4 J23 J22 .39mH FRANCE Return to Section TOC 2 2 C2 .0047 3000V L6 J23 J22 .39mH 6 C6 .0047 3000V L3 7 AUSTRALIA Return to Master TOC Return to Section TOC CANADA 5 8 J23 J22 .39mH 3 C3 J23 .
Return to Master TOC G-17 ELECTRICAL DIAGRAMS PC BOARD ASSEMBLY-SQUARE WAVE PROTECTION M 16062-1 Return to Section TOC G-17 AICF Return to Master TOC IDENTIFICATION C1, C2, C3, C4, C5, C6 6 T11577-58 .0047/3000 V L1, L2, L3, L4, L5, L6 6 T12218-9F .39 mH J22 1 S18248-6 HEADER J23 1 S18248-8 HEADER -.02 SQUARE WAVE PROTECTION 3.40 Return to Section TOC PART NO. CAPACITORS = MFD/VOLTS +.05 3.60 REQ’D ITEM 3.10 ±.
R10 7 VOLTAGE TO CURRENT 4 R11 J50 R2 511 4.75K 2 INPUT - V CC 3 INPUT + OUT 6 VEE NC 5 C1 4 2 R3 R4 511 4.75K NULL X1 NULL 100 8 562 500 Return to Master TOC G Iout = -Vin * 74.51 (R7 + 392) MAY CHANGE THIS DIAGRAM MAY NOT OR CIRCUITRY OF A PRINTED WITHOUT AFFECTING OF A COMPLETE BOARD. SHOW THE EXACT COMPONENTS CONTROLS HAVING A COMMON CODE NUMBER. Ch’ge.Sht.No. 1-6-95 11-21-97G MFD ( .
Return to Master TOC G-19 ELECTRICAL DIAGRAMS PC BOARD ASSEMBLY- SHUNT M 17150-2 Return to Section TOC G-19 .13 AMPLIFIER Return to Master TOC PA R T N O DESCRIPTION C1 1 S16668-5 .022/50 C2,C3 2 S16668-11 .1/50 DZ1,DZ2 2 T12702-29 1N4744A J50 1 S18248-6 HEADER R1,R3 2 S19400-5110 511 1/4W R2,R4 2 S19400-4751 4.75K R5,R8 2 S19400-3923 392K 1/4W R6 1 S19400-5620 562 1/4W R7 1 S16296-3 500 1/2W TRIMMER R9 1 S19400-1301 1.
11 +OUTPUT (499) J60 100K .5W +15V R11 R12 100K .5W 100K .5W 10.0K 10 R8 100K .5W 100K .5W R17 R9 100K .5W 100K .5W R6 R4 R21 5 +15V 6 X1 10.0K 3 +15V 2 D1 6 DZ3 5.1V 1W 10K R23 5 100K .5W DZ5 5.1V 1W 10K C6 820p 50V DZ4 5.1V 1W L3 (461) 5 6 7 10 12 14 16 1 C7 820p 50V DZ7 5.1V 1W 10K DZ6 5.1V 1W DZ9 5.1V 1W 10K C8 820p 50V 6 DZ8 5.1V 1W X2 TP1 320V 160J J60 J60 -OUTPUT (467) 7 J60 J60 BACKGND (468) 8 5 3 C3 .0047 400V TP2 320V 160J C2 .
PC BOARD ASSEMBLY- SNUBBER IDENTIFICATION 820pF/50 C10,C11,C12,C13 4 S16668-11 D1,D2,D3,D4,D5 5 T12199-1 1N4004 DZ1,DZ2,DZ3,DZ4,DZ5,DZ6 10 T12702-52 1N4733A 2 T12702-29 1N4744A . 1/50 HEADER S18248-10 HEADER J62 1 S18248-8 CONNECTOR R1,R7,R13,R15,R16,R20,R21 10 S19400-1002 10K 1/4W R2,R5 2 T14649-7 2.
C1 10.0 402 --404 R9 10.0 R33 D1 1N4936 W R22 R41 R40 39.2K 39.2K A1 M16100-26 A2 D10 1N4936 2 4 1A 100V 10V 1W IRFD110 DZ10 10V 1W 10.0 R26 10.0 C8 2700p 50V R25 10.0 475 475 C1 C2 G2 G3 G4 C3 C4 C5 C4 .047 1200V A1 401 --403 M16100-26 E1 E2 E3 405 --407 10.0 L 10611 SHT. NO. SUP’S’D’G. DRS INVERTER WELDERS SWITCH P.C. BOARD SCHEMATIC NONE 10-28-96 A1 SNUBBER RESISTOR A1 10.0 R34 SUBJECT E4 E5 R27 100 R24 G1 G5 15.
Return to Master TOC G-23 ELECTRICAL DIAGRAMS PC BOARD ASSEMBLY-SWITCH G 2390-1 Return to Section TOC G-23 ITEM REQ’D A1 1 21B 11B 01B 9B 7B 3B 6B 5B 2B 1B 6.50 A2 1 M16100-7 ELECTRONIC MODULE (SS) B1,B2,B3,B5,B6,B7,B9,B10 10 T13157-6 TAB TERMINAL C1,C5,C6,C7 4 S16668-5 .022/50 C2,C8 2 S16668-4 2700pF/50 C3,C4 { 2 S13490-112 .
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC G-24 G-24 ELECTRICAL DIAGRAMS POWER WAVE RS 232 CONNECTIONS 9 PIN FROM PC NULL MODEM CABLE RS 232 CONNECTOR DCD 1 RD 2 2 TD TD 3 3 RD POWER WAVE INTERNAL WIRING 1 #302 J17 MOLEX DISPLAY BOARD 1 2 3 #303 DTR 4 4 RTS GND 5 5 CTS 5 DSR 6 6 DSR 6 RTS 7 7 GND #306 7 CTS 8 8 DCD #307 8 RI 9 4 9 2
Return to Master TOC We need to know if there are errors in our manuals. We also value any suggestions as to additional tests or procedures that would make this SVM a better tool for you. If you discover new or different “Problems or Symptoms” that are not covered in the three column troubleshooting chart, please share this information with us. Please include the machine’s code number and how the problem was resolved. Thank You, Technical Services Group Lincoln Electric Co. 22801 ST. Clair Ave.