Welder User Manual

ManualsBrandsLincoln Electric ManualsWelding SystemPOWER WAVE SVM156-A

SVM156-A

October, 2001

Safety Depends on You

Lincoln arc welding and cutting

equipment is designed and built

with safety in mind. However,

your overall safety can be in-

creased by proper installation . . .

and thoughtful operation on

your part. DO NOT INSTALL,

OPERATE OR REPAIR THIS

EQUIPMENT WITHOUT

READING THIS MANUAL AND

THE SAFETY PRECAUTIONS

CONTAINED THROUGHOUT.

And, most importantly, think

before you act and be careful.

SERVICE MANUAL

For use with machines having Code Numbers: 10675

10676

POWER WAVE 455/R

Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC

View Safety Info View Safety Info View Safety Info View Safety Info

POWERWAVE 455/R

I ON

O OFF

POWERWAVE 455/R

• Sales and Service through Subsidiaries and Distributors Worldwide •

Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com

• World's Leader in Welding and Cutting Products •

IEC 60974-1

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Summary of content (150 pages)

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View Safety Info SVM156-A October, 2001 TM POWER WAVE 455/R For use with machines having Code Numbers: 10675 10676 View Safety Info Safety Depends on You View Safety Info Return to Master TOC Return to Master TOC Return to Master TOC RETURN TO MAIN MENU 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.
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Return to Master TOC i i SAFETY WARNING CALIFORNIA PROPOSITION 65 WARNINGS The engine exhaust from this product contains Diesel engine exhaust and some of its constituents chemicals known to the State of California to cause are known to the State of California to cause cancancer, birth defects, or other reproductive harm. cer, birth defects, and other reproductive harm. The Above For Gasoline Engines The Above For Diesel Engines ARC WELDING can be hazardous.
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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.
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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.
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Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC iv iv SAFETY PRÉCAUTIONS DE SÛRETÉ 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: Sûreté Pour Soudage A L’Arc 1. Protegez-vous contre la secousse électrique: a. Les circuits à l’électrode et à la piéce sont sous tension quand la machine à souder est en marche.
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v - MASTER TABLE OF CONTENTS FOR ALL SECTIONS RETURN TO MAIN MENU Page Safety .................................................................................................................................................i-iv Installation.............................................................................................................................Section A Operation...............................................................................................................................
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Return to Master TOC Section A TABLE OF CONTENTS - INSTALLATION SECTION - Installation.............................................................................................................................Section A Technical Specifications ..............................................................................................................A-2 Safety Precautions ......................................................................................................................
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Return to Master TOC A-2 INSTALLATION TECHNICAL SPECIFICATIONS - POWER WAVE 455/R (K1761-1), (K1761-2) INPUT AT RATED OUTPUT - THREE PHASE ONLY INPUT VOLTS OUTPUT CONDITIONS INPUT CURRENT AMPS (K1761-1) 208/230/460V - 60HZ 450A@38V 100% 570A@43V 60% 70/65/35 87/82/48 200/220/440V - 50HZ 400A@36V 100% 500A@40V 60% 64/58/32 79/74/41 (K1761-2) 208/230/460/575V-60HZ 450@38V 100% 570@43V 60% 58/53/25/22 82/78/37/31 200/220/440V - 50HZ 400@36V 100% 500A@40V 60% 49/45/23 67/61/31 IDLE POWER POWE
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Return to Master TOC Return to Section TOC A-3 A-3 INSTALLATION TECHNICAL SPECIFICATIONS - POWER WAVE 455/R (K1761-1), (K1761-2) (continued) PHYSICAL DIMENSIONS HEIGHT WIDTH DEPTH 26.10 in 663 mm 19.86 in 505 mm 32.88 in 835 mm WEIGHT (K1761-1) 247 lbs. 112 kg. (K1761-2) 254 lbs. 115 kg.
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Return to Master TOC Return to Section TOC A-4 A-4 INSTALLATION SAFETY PRECAUTIONS CAUTION Read this entire installation section before you start installation. WARNING ELECTRIC SHOCK can kill. DO NOT MOUNT OVER COMBUSTIBLE SURFACES. Where there is a combustible surface directly under stationary or fixed electrical equipment, that surface shall be covered with a steel plate at least .06”(1.6mm) thick, which shall extend not less than 5.90”(150mm) beyond the equipment on all sides.
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A-5 INSTALLATION . Disconnect input power before . inspecting or servicing machine. VOLTAGE=200-208V W / L3 V / L2 200-208V CR1 220-230V U / L1 380-415V Do not operate with covers removed. 'A' 440-460V ELECTRIC . Do not touch electrically live parts. SHOCK Only qualified persons should install, CAN KILL use or service this equipment. .
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Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC A-6 A-6 INSTALLATION INPUT VOLTAGE CHANGE OVER (FOR MULTIPLE INPUT VOLTAGE MACHINES ONLY) WELDING WITH MULTIPLE POWER WAVES CAUTION Welders are shipped connected for the highest input voltage listed on the rating plate. To move this connection to a different input voltage, see the diagram located on the inside of the input access door. (Figure A.1.
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Return to Master TOC Return to Section TOC A-7 When these parameters are identical, the pulsing frequency will be the same, helping to stabilize the arcs. Every welding gun requires a separate shielding gas regulator for proper flow rate and shielding gas coverage. Do not attempt to supply shielding gas for two or more guns from only one regulator. If an anti-spatter system is in use, each gun must have its own anti-spatter system. See Figure A.2.
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Return to Master TOC Return to Section TOC A-8 VOLTAGE SENSING The sense leads connect to the Power Wave at the four-pin connector located underneath the output terminal cover. Lead 67 senses electrode voltage. Lead 21 senses work voltage. The best arc performance occurs when the Power Wave has accurate data about the arc conditions. Depending upon the process, inductance within the electrode and work lead cables can influence the voltage apparent at the terminals of the welder.
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WORK VOLTAGE SENSING CONTROL CABLE SPECIFICATIONS The Power Wave is shipped from the factory with the work sense lead enabled. It is recommended that genuine Lincoln control cables be used at all times. Lincoln cables are specifically designed for the communication and power needs of the Power Wave / Power Feed system. For processes requiring work voltage sensing, connect the (21) work voltage sense lead from the Power Wave to the work.
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Return to Master TOC Return to Section TOC A-10 A-10 INSTALLATION DIP SWITCH SETTINGS AND LOCATIONS CONTROL BOARD DIP SWITCH: DIP switches on the PC boards allow for custom configuration of the Power Wave. Access the DIP switches as follows: switch switch switch switch switch switch switch switch WARNING ELECTRIC SHOCK CAN KILL.
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Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC A-11 INSTALLATION DEVICENET/GATEWAY BOARD DIP SWITCH, BANK (S2): switch 1,2 = configure the baud rate for DeviceNET Prior to S24958-6 software switch 1 switch 2 baud rate off off ------- on off 125K off on 250K on on 500 S24958-6 and later software switch 1 switch 2 baud rate off off 125K off on 250K on off 500K on on 500K Return to Section TOC Return to Master TOC Return to Section TOC
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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 A-12 NOTES POWER WAVE 455/R A-12
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Return to Master TOC Section B-1 TABLE OF CONTENTS - OPERATION SECTION - Section B-1 Operation...............................................................................................................................Section B Safety Precautions ......................................................................................................................B-2 Graphic Symbols.........................................................................................................................
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Return to Master TOC Return to Section TOC B-2 OPERATION SAFETY PRECAUTIONS Read this entire section of operating instructions before operating the machine. WARNING Return to Master TOC Return to Section TOC ELECTRIC SHOCK can kill. • Unless using cold feed feature, when feeding with gun trigger, the electrode and drive mechanism are always electrically energized and could remain energized several seconds after the welding ceases.
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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-3 B-3 OPERATION GRAPHIC SYMBOLS THAT APPEAR ON THIS MACHINE OR IN THIS MANUAL INPUT POWER SMAW ON GMAW OFF FCAW HIGH TEMPERATURE GTAW MACHINE STATUS U0 OPEN CIRCUIT VOLTAGE CIRCUIT BREAKER U1 INPUT VOLTAGE WIRE FEEDER U2 OUTPUT VOLTAGE POSITIVE OUTPUT I1 INPUT CURRENT NEGATIVE OUTPUT I2 OUTPUT CURRENT 3 PHASE INVERTER PROTECTIVE GROUND INPUT POWER
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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 B-4 OPERATION B-4 GENERAL DESCRIPTION DESIGN FEATURES AND ADVANTAGES The Power Wave power source is designed to be a part of a modular, multi-process welding system. Depending on configuration, it can support constant current, constant voltage, Surface Tension Transfer and pulse welding modes.
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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 B-5 OPERATION RECOMMENDED PROCESSES AND EQUIPMENT B-5 REQUIRED EQUIPMENT • PF-10/R Wire Feeder, K1780-1 • Control Cables (22 pin to 22 pin), K1795-10,-25,-50,100 RECOMMENDED PROCESSES The Power Wave 455/R can be set up in a number of configurations, some requiring optional equipment or welding programs.
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Return to Master TOC Return to Section TOC B-6 CASE FRONT CONTROLS 3. HIGH TEMPERATURE LIGHT (thermal overload): A yellow light that comes on when an over temperature situation occurs. Output is disabled until the machine cools down. When cool, the light goes out and output is enabled. All operator controls and adjustments are located on the case front of the Power Wave. (See Figure B.1) 1. POWER SWITCH: Controls input power to the Power Wave. 2.
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Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC B-7 OPERATION WELDING MODE DESCRIPTIONS CONSTANT VOLTAGE WELDING For each wire feed speed, a corresponding voltage is preprogrammed into the machine through special software at the factory. The preprogrammed voltage is the best average voltage for a given wire feed speed.
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Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC B-8 OPERATION PULSE WELDING Pulse welding procedures are set by controlling an overall “arc length” variable. When pulse welding, the arc voltage is highly dependent upon the waveform. The peak current, background current, rise time, fall time and pulse frequency all affect the voltage. The exact voltage for a given wire feed speed can only be predicted when all the pulsing waveform parameters are known.
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Return to Master TOC Return to Section TOC B-9 B-9 OPERATION STT WELDING The pictures illustrate the waveshape of current for the process. They are not drawn to scale, and are intended only for the purpose of showing how the variables affect the waveform. Trim in the STT mode adjusts the tailout and background portion of the waveform. Trim values greater than 1.0 add more energy to the weld and make the weld puddle hotter; trim values less than 1.0 reduce energy to weld. A nominal value of 1.
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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 B-10 NOTES POWER WAVE 455/R B-10
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TABLE OF CONTENTS - ACCESSORIES SECTION - Optional Equipment ....................................................................................................................C-2 Factory Installed ...................................................................................................................C-2 Field Installed .......................................................................................................................
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Return to Master TOC Return to Section TOC C-2 Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC C-2 OPTIONAL EQUIPMENT FACTORY INSTALLED There are no factory installed options available for the Power Wave 455R. The water cooler is designed to cool only one welding gun and should be not used to cool multiple guns or other devices.
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TABLE OF CONTENTS - MAINTENANCE SECTION - Safety Precautions......................................................................................................................D-2 Routine and Periodic Maintenance.............................................................................................D-2 Main Assembly (Exploded View) ...............................................................................................D-3 Return to Master TOC Return to Master TOC Section D-1 Maintenance ..
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Return to Master TOC Return to Section TOC D-2 MAINTENANCE PERFORM THE FOLLOWING DAILY: SAFETY PRECAUTIONS 1. Check that no combustible materials are in the welding or cutting area or around the machine. WARNING 2. Remove any debris, dust, dirt, or materials that could block the air flow to the machine for cooling. 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.
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D-3 MAINTENANCE Return to Master TOC Return to Section TOC D-3 FIGURE D.1 – MAIN ASSEMBLY (EXPLODED VIEW) 7 7 1 Return to Master TOC Return to Section TOC 7 3 Return to Master TOC Return to Section TOC 4 2 2 6 5 1. CASE FRONT ASSEMBLY 2. TRANSFORMER AND OUTPUT RECTIFIER ASSEMBLY 3. INPUT ASSEMBLY Return to Master TOC Return to Section TOC 4. CONTROL BOX AND VERTICAL DIVIDER ASSEMBLY 2 5. BASE, LIFT BAIL AND FAN ASSEMBLY 6. SWITCH BOARD HEATSINK ASSEMBLY 7.
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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 D-4 NOTES POWER WAVE 455/R D-4
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Return to Master TOC Section E-1 Section E-1 TABLE OF CONTENTS - THEORY OF OPERATION SECTION - Theory of Operation .............................................................................................................Section E General Description ....................................................................................................................E-2 Input Voltage and Precharge ......................................................................................................
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Return to Master TOC Return to Section TOC E-2 FIGURE E.2 – INPUT VOLTAGE AND PRECHARGE IGBT DRIVE FROM CONTROL BOARD POWER WAVE 455/R INPUT RECTIFIER Return to Master TOC +20 VDC FROM POWER BOARD IGBT DRIVE FROM CONTROL CT CURRENT TO CONTROL BOARD BOARD SW1 CURRENT TRANSDUCER STT CHOPPER BOARD STT ELECTRODE TERMINAL + RIGHT SWITCH BOARD CAP.
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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 E-3 THEORY OF OPERATION E-3 INPUT VOLTAGE AND PRECHARGE The Power Wave 455/R can be connected for a variety of three-phase input voltages. Refer to Figure E.2. The initial input power is applied to the Power Wave 455/R through a line switch located on the front of the machine.
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Return to Master TOC Return to Section TOC E-4 FIGURE E.
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Return to Master TOC Return to Section TOC E-5 FIGURE E-4 – DC BUS BOARD, POWER BOARD, FEED HEAD BOARD, GATEWAY BOARD AND VOLTAGE SENSE BOARD IGBT DRIVE FROM CONTROL BOARD POWER WAVE 455/R Return to Master TOC Return to Section TOC + STT DRIVE 67B CONTACTOR AND PRECHARGE CONTROL SIGNALS FROM CONTROL BOARD S6 VOLT SENSE BOARD VOLTAGE SENSE OUTPUT DEVICE NET S5 VOLTAGE SENSE SELECT ARC LINK 2 4 V A C FROM CONTROL BOARD FEED HEAD BOARD 40 VDC 115 VAC FAN RELAY OUTPUT CHOKE GATEWAY BOARD
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FIGURE E.
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Return to Master TOC Return to Section TOC E-7 FIGURE E.6 – CONTROL BOARD IGBT DRIVE FROM CONTROL BOARD POWER WAVE 455/R Return to Master TOC Return to Section TOC + STT DRIVE 67B CONTACTOR AND PRECHARGE CONTROL SIGNALS FROM CONTROL BOARD S6 VOLT SENSE BOARD VOLTAGE SENSE OUTPUT DEVICE NET S5 VOLTAGE SENSE SELECT ARC LINK 2 4 V A C FROM CONTROL BOARD FEED HEAD BOARD 40 VDC 115 VAC FAN RELAY GATEWAY BOARD OUTPUT CHOKE WORK TERMINAL CONNECTION TO ROBOT TO LEFT S.B. TO RIGHT S.B.
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Return to Master TOC Return to Section TOC E-8 FIGURE E.
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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 E-9 THEORY OF OPERATION E-9 THERMAL PROTECTION OVER CURRENT PROTECTION Three normally closed (NC) thermostats protect the machine from excessive operating temperatures. These thermostats are wired in series and are connected to the control board.
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E-10 THEORY OF OPERATION Return to Master TOC Return to Section TOC E-10 FIGURE E.8 – STT WAVEFORMS Wave Control +10.0 Wave Control 0.00 Wave Control -10.0 Return to Master TOC Return to Section TOC Current Time STT Wave control characteristics Return to Master TOC Return to Section TOC Trim 1.50 Current Trim 1.00 Time Trim 0.
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FIGURE E.9 – IGBT OPERATION POSITIVE VOLTAGE APPLIED SOURCE Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC n+ Return to Section TOC E-11 THEORY OF OPERATION Return to Master TOC Return to Section TOC E-11 GATE SOURCE n+ n+ GATE n+ p BODY REGION p BODY REGION n- DRAIN DRIFT REGION n- DRAIN DRIFT REGION n+ BUFFER LAYER n+ BUFFER LAYER p+ INJECTING LAYER p+ INJECTING LAYER DRAIN DRAIN B. ACTIVE A.
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THEORY OF OPERATION Return to Master TOC Return to Section TOC E-12 E-12 FIGURE E.10 – TYPICAL IGBT OUTPUTS 25 sec sec sec 50 sec sec Return to Master TOC Return to Section TOC MINIMUM OUTPUT 24 sec 24 sec 1 sec 1 sec 50 sec MAXIMUM OUTPUT Return to Master TOC Return to Section TOC PULSE WIDTH MODULATION The term PULSE WIDTH MODULATION (PWM) is used to describe how much time is devoted to conduction in the positive and negative portions of the cycle.
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Return to Master TOC Section F-1 TABLE OF CONTENTS - TROUBLESHOOTING & REPAIR SECTION - Troubleshooting & Repair ...................................................................................................Section F How to Use Troubleshooting Guide ...........................................................................................F-2 PC Board Troubleshooting Procedures.......................................................................................F-3 Troubleshooting Guide ...........
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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.
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Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC F-3 TROUBLESHOOTING & REPAIR PC BOARD TROUBLESHOOTING PROCEDURES 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.
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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-4 TROUBLESHOOTING & REPAIR TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginning of this manual. PROBLEMS (SYMPTOMS) F-4 POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION OUTPUT PROBLEMS Major physical or electrical damage is evident when the sheet metal covers are removed.
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Return to Master TOC Return to Section TOC F-5 TROUBLESHOOTING GUIDE PROBLEMS (SYMPTOMS) Observe Safety Guidelines detailed in the beginning of this manual. POSSIBLE AREAS OF MISADJUSTMENT(S) 1. Make certain the input power switch SW1 is in the ON position. 2. Check the main input fuses (or breakers). If open, replace or reset. Return to Master TOC RECOMMENDED COURSE OF ACTION OUTPUT PROBLEMS The machine is dead—no lights— no output—the machine appears to be off.
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Return to Master TOC Return to Section TOC F-6 Return to Master TOC Return to Section TOC TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginning of this manual. PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF MISADJUSTMENT(S) 1. Turn the input power off and make certain the reconnect panel is configured correctly for the applied input voltage. 2. If the Thermal light is lit, the unit may be overheated.
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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 F-7 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 The machine often "noodle welds" when running a particular process.
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Return to Master TOC Return to Section TOC F-8 Observe Safety Guidelines detailed in the beginning of this manual. TROUBLESHOOTING GUIDE PROBLEMS (SYMPTOMS) RECOMMENDED COURSE OF ACTION POSSIBLE AREAS OF MISADJUSTMENT(S) FUNCTION PROBLEMS The Auxiliary Receptacle is "dead." The 120VAC is not present at the receptacle. 1. Check the 10 amp circuit breaker (CB2) located on the case front. Reset if necessary. Return to Master TOC Return to Section TOC 2.
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Return to Master TOC Return to Section TOC F-9 TROUBLESHOOTING & REPAIR INPUT FILTER 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.
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Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC F-10 TROUBLESHOOTING & REPAIR F-10 INPUT FILTER CAPACITOR DISCHARGE PROCEDURE (CONTINUED) FIGURE F.1 – CAPACITOR DISCHARGE PROCEDURE SWITCH BOARD Return to Master TOC Return to Section TOC CAPACITOR TERMINALS TEST PROCEDURE 1. Remove input power to the Power Wave 455/R. 2. Using the 3/8” nut driver, remove the left and right case sides. 3.
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Return to Master TOC Return to Section TOC F-11 TROUBLESHOOTING & REPAIR 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. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.
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Return to Master TOC Return to Section TOC F-12 F-12 TROUBLESHOOTING & REPAIR SWITCH BOARD TEST (CONTINUED) FIGURE F.2 – RECONNECT SWITCHES 19C 19D Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC RECONNECT SWITCHES TEST PROCEDURE 1. Remove input power to the Power Wave 455/R. 2. Using the 3/8” nut driver, remove the case top and sides. Return to Master TOC Return to Section TOC 3. Perform the Procedure. Capacitor Discharge 4.
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Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC F-13 SWITCH BOARD TEST (CONTINUED) FIGURE F.3 – SWITCH BOARD TEST POINTS 13/14 OR 17/18 Return to Master TOC SWITCH BOARD Return to Section TOC F-13 TROUBLESHOOTING & REPAIR -20 +19 11/12 OR 15/16 8. Reconnect leads 19C and 19D to the reconnect switches. Ensure that the leads are installed in the same location they were removed from. 9. Install the right and left case sides and top using the 3/8” nut driver.
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Return to Master TOC Return to Section TOC F-14 TROUBLESHOOTING & REPAIR INPUT RECTIFIER 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.
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Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC F-15 INPUT RECTIFIER TEST (CONTINUED) FIGURE F.4 – INPUT RECTIFIER TEST INPUT RECTIFIER B NEG (-) POS (+) TEST PROCEDURE 1. Remove input power to the Power Wave 455/R. 3. Perform the Procedure. Return to Master TOC C A 2. Using the 3/8” nut driver, remove the case top.
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Return to Master TOC Return to Section TOC F-16 INPUT RECTIFIER TEST (CONTINUED) 6. Use the analog ohmmeter to perform the tests detailed in Table F.2. 7. If the input rectifier does not meet the acceptable readings outlined in the table, the component may be faulty. Replace. Return to Master TOC Return to Section TOC NOTE: Before replacing the input rectifier, perform the Switch Board Test and the Input Contactor Test. 9.
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Return to Master TOC Return to Section TOC F-17 TROUBLESHOOTING & REPAIR INPUT 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.
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Return to Master TOC Return to Section TOC F-18 F-18 TROUBLESHOOTING & REPAIR INPUT CONTACTOR TEST (CONTINUED) FIGURE F.5 – INPUT CONTACTOR COIL INPUT CONTACTOR 601 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC X4 TEST PROCEDURE 1. Remove input power to the Power Wave 455/R. 2. Using the 3/8” nut driver, remove the input access panel and case top. 4. Using the external 24 VAC supply, apply 24 VAC to the terminals of the input contactor coil.
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Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC F-19 TROUBLESHOOTING & REPAIR INPUT CONTACTOR TEST (CONTINUED) FIGURE F.6 – INPUT CONTACTOR TEST POINTS L3 T3 L2 T2 L1 T1 5. With the input contactor activated, check the continuity across the three sets of contacts. (Zero ohms or very low resistance is normal.) Refer to Figure F.6. If the resistance is high, the input contactor is faulty. Replace the input contactor. 7.
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Return to Master TOC Return to Section TOC F-20 TROUBLESHOOTING & REPAIR DC BUS POWER SUPPLY PC 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. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.
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Return to Master TOC Return to Section TOC F-21 TROUBLESHOOTING & REPAIR F-21 DC BUS POWER SUPPLY PC BOARD TEST (CONTINUED) FIGURE F.7 – DC BUS POWER SUPPLY POWER SUPPLY PC BOARD LED Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC DC BUS POWER SUPPLY PC BOARD J47 J46 CAPACITOR C3 CAUTION! J46 J47 1 2 1 2 3 4 3 4 5 6 7 8 TEST PROCEDURE WARNING 1. Remove input power to the machine. ELECTRIC SHOCK can kill. 2.
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Return to Master TOC Return to Section TOC F-22 DC BUS POWER SUPPLY PC BOARD TEST(CONTINUED) 6. Check the DC Bus Power Supply PC Board input and output voltages according to Table F.3. See Figure F.7 and the Wiring Diagram. 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 High voltage is present at the terminals of Capacitor C3 near where testing is to be done.
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Return to Master TOC Return to Section TOC F-23 TROUBLESHOOTING & REPAIR POWER 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. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.
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TROUBLESHOOTING & REPAIR Return to Master TOC Return to Section TOC F-24 POWER BOARD TEST (CONTINUED) FIGURE F.8 – POWER BOARD TEST J41 Return to Master TOC 1 Return to Master TOC 4 Return to Master TOC Return to Section TOC Return to Section TOC J42 Return to Section TOC F-24 2 3 5 6 J42 1 J43 2 1 2 3 4 3 4 J41 7 8 9 10 11 12 J43 5 6 TEST PROCEDURE 1. Remove input power to the Power Wave 455/R. 2. Using the 3/8” nut driver, remove the case top. 6.
PAGE 71
Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC F-25 F-25 TROUBLESHOOTING & REPAIR POWER BOARD TEST (CONTINUED) TABLE F.4 – POWER BOARD VOLTAGE CHECKS CHECK POINT LOCATION TEST DESCRIPTION CONNECTOR PLUG PIN NO. LEAD NO.
PAGE 72
Return to Master TOC Return to Section TOC F-26 TROUBLESHOOTING & REPAIR INPUT 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. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.
PAGE 73
INPUT BOARD TEST (CONTINUED) FIGURE F.9 – INPUT CONTACTOR CR1 Return to Master TOC Return to Section TOC J60 Return to Master TOC Return to Section TOC J61 601 1 2 3 4 1 2 3 4 5 X4 INPUT CONTACTOR 5 6 7 J60 8 6 7 8 9 10 J61 TEST PROCEDURE WARNING 1. Remove input power to the Power Wave 455/R. ELECTRIC SHOCK can kill. 2. Using the 3/8” nut driver, remove the case top. High voltage is present when input power is applied to the machine. Return to Master TOC 3.
PAGE 74
Return to Master TOC Return to Section TOC F-28 TROUBLESHOOTING & REPAIR INPUT BOARD TEST(CONTINUED) 6. Remove input power to the Power Wave 455/R. If any of the voltages are low or not present, perform the Input Contactor Test. If that checks out, the Input Board may by faulty. 9. Turn on the Power Wave 455/R. Check for the presence of 24 VAC from lead X4 to lead 601. See Figure F. 9. If the voltage is not present, perform the Auxiliary Transformer #1 Test. 7.
PAGE 75
Return to Master TOC Return to Section TOC F-29 F-29 TROUBLESHOOTING & REPAIR INPUT BOARD TEST(CONTINUED) TABLE F.5 – INPUT BOARD VOLTAGE CHECKS TEST POINTS LEAD NUMBERS EXPECTED VOLTAGE READINGS J61 SAME AS INPUT VOLTAGE PLUG J61 PIN 8 (H1D) TO PLUG J61 PIN 2 (612) COMMENTS Present when Input Switch SW1 is closed.
PAGE 76
Return to Master TOC Return to Section TOC F-30 TROUBLESHOOTING & REPAIR STT CHOPPER 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. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.
PAGE 77
F-31 TROUBLESHOOTING & REPAIR Return to Master TOC Return to Section TOC F-31 STT CHOPPER BOARD TEST (CONTINUED) FIGURE F.10 – STT CHOPPER BOARD TEST DETAILS CONTROL PC BOARD POWER PC BOARD J43 J43 J7 Return to Master TOC Return to Section TOC J7 1 2 3 4 5 6 7 8 346 9 10 11 12 13 14 15 16 4W 4R 1 2 3 4 5 6 7 8 9 10 11 12 345 Return to Master TOC Return to Section TOC STT OUTPUT TERMINAL POWER WAVE + OUTPUT TERMINAL TEST PROCEDURE 1.
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Return to Master TOC Return to Section TOC F-32 TROUBLESHOOTING & REPAIR STT CHOPPER BOARD TEST (CONTINUED) 4. Carefully apply input power to the Power Wave 455/R. 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 High voltage is present when input power is applied to the machine. Return to Section TOC F-32 For steps 5 and 6, see Figure F.10. 6.
PAGE 79
Return to Master TOC Return to Section TOC F-33 TROUBLESHOOTING & REPAIR POWER WAVE CURRENT TRANSDUCER 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.
PAGE 80
Return to Master TOC Return to Section TOC F-34 TROUBLESHOOTING & REPAIR F-34 POWER WAVE CURRENT TRANSDUCER TEST (CONTINUED) FIGURE F.11 – POWER WAVE CURRENT TRANSDUCER TEST CONTROL BOARD Return to Master TOC Return to Section TOC J8 J8 211 212 213 1 2 3 4 5 6 7 8 216 CURRENT TRANSDUCER Return to Master TOC Return to Section TOC 1234 P91 TEST PROCEDURE WARNING 1. Remove input power to the Power Wave 455/R. 2. Using the 3/8” nut driver, remove the case top and the control box cover.
PAGE 81
Return to Master TOC Return to Section TOC F-35 POWER WAVE CURRENT TRANSDUCER TEST (CONTINUED) FIGURE F.12 – RECEPTACLE S7 TRIGGERED RECEPTACLE S7 POWER WAVE Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Master TOC STT Return to Section TOC F-35 TROUBLESHOOTING & REPAIR 5. Turn on the Power Wave 455/R. Check for the correct DC supply voltage to the current transducer at plug J8. See Figure F.11.
PAGE 82
Return to Master TOC Return to Section TOC F-36 TROUBLESHOOTING & REPAIR POWER WAVE CURRENT TRANSDUCER TEST (CONTINUED) 8. If for any reason the machine cannot be loaded to 250 amps, Table F.6 shows what feedback voltage is produced at various current loads. Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC 9.
PAGE 83
Return to Master TOC Return to Section TOC F-37 TROUBLESHOOTING & REPAIR STT CURRENT TRANSDUCER 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.
PAGE 84
Return to Master TOC Return to Section TOC F-38 F-38 TROUBLESHOOTING & REPAIR STT CURRENT TRANSDUCER TEST (CONTINUED) FIGURE F.13 – STT CURRENT TRANSDUCER TEST CONTROL BOARD Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC J8 813 1 2 3 4 5 6 7 8 811 816 812 J8 1234 P90 CURRENT TRANSDUCER TEST PROCEDURE WARNING 1. Remove input power to the Power Wave 455/R. Return to Master TOC Return to Section TOC 2.
PAGE 85
Return to Master TOC Return to Section TOC F-39 STT CURRENT TRANSDUCER TEST (CONTINUED) FIGURE F.14 – RECEPTACLE S7 TRIGGERED POWER WAVE RECEPTACLE S7 Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC STT 5. Turn on the Power Wave 455/R. Check for the correct DC supply voltage to the current transducer at plug J8. NOTE: The machine can be triggered by jumpering pin 1 to pin 2 at receptacle S7. See Figure F. 14. A.
PAGE 86
Return to Master TOC TROUBLESHOOTING & REPAIR Return to Master TOC Return to Master TOC F-40 STT CURRENT TRANSDUCER TEST (CONTINUED) 8. If for any reason the machine cannot be loaded to 50 amps, Table F.6 shows what feedback voltage is produced at various current loads. faulty. Also make certain that lead 811 (plug J8 pin 5) has continuity (zero ohms) between the current transducer and the control board. See the Wiring Diagram. 9.
PAGE 87
Return to Master TOC Return to Section TOC F-41 TROUBLESHOOTING & REPAIR OUTPUT RECTIFIER 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.
PAGE 88
Return to Master TOC Return to Section TOC F-42 TROUBLESHOOTING & REPAIR F-42 OUTPUT RECTIFIER TEST (CONTINUED) FIGURE F.15 – OUTPUT RECTIFIER TEST I ON Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC POWERWAVE 455/R NEGATIVE (-) OUTPUT TERMINAL STT OUTPUT TERMINAL POSITIVE (+) OUTPUT TERMINAL TEST PROCEDURE 1. Remove main input supply power to the Power Wave 455/R. 2.
PAGE 89
Return to Master TOC Return to Section TOC F-43 TROUBLESHOOTING & REPAIR AUXILIARY TRANSFORMER NO. 1 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.
PAGE 90
F-44 TROUBLESHOOTING & REPAIR Return to Master TOC Return to Section TOC F-44 AUXILIARY TRANSFORMER NO. 1 TEST (CONTINUED) FIGURE F.16 – AUXILIARY TRANSFORMER NO. 1 TEST X3 X5 INPUT CONTACTOR X1 + 601 FAN MOTOR LEADS Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC X4 - X2 POWER BOARD RECTIFIER BRIDGE TEST PROCEDURE 1. Remove the main input power to the Power Wave 455/R machine. 5. Locate secondary leads X3 and X5 (fan motor leads). 2.
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Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC F-45 TROUBLESHOOTING & REPAIR AUXILIARY TRANSFORMER NO. 1 TEST (CONTINUED) TABLE F.7 – SECONDARY VOLTAGES LEAD IDENTIFICATION NORMAL EXPECTED VOLTAGE X1 to X2 X3 to X5 X3 to X4 52 VAC 115 VAC 24 VAC 7. Carefully apply the correct input voltage to the Power Wave 455/R. WARNING ELECTRIC SHOCK can kill. High voltage is present at primary of the Auxiliary Transformer.
PAGE 92
Return to Master TOC Return to Section TOC F-46 TROUBLESHOOTING & REPAIR AUXILIARY TRANSFORMER NO. 2 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.
PAGE 93
Return to Master TOC Return to Section TOC F-47 F-47 TROUBLESHOOTING & REPAIR AUXILIARY TRANSFORMER NO. 2 TEST (CONTINUED) FIGURE F.17 – AUXILIARY TRANSFORMER NO. 2 TEST H4 H3 H1 1 2 3 VIEWED FROM TRANSFORMER LEAD SIDE 5 6 H5 H6 H2 P50 Return to Master TOC Return to Section TOC 4 350 352 1 2 VIEWED FROM TRANSFORMER LEAD END 3 4 33A P52 Return to Master TOC Return to Section TOC TEST PROCEDURE 1. Remove the main input power to the Power Wave 455/R machine. 2.
PAGE 94
Return to Master TOC Return to Section TOC F-48 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.
PAGE 95
Return to Master TOC Return to Section TOC F-49 F-49 TROUBLESHOOTING & REPAIR INPUT RECTIFIER REMOVAL AND REPLACEMENT (CONTINUED) FIGURE F.18 – INPUT RECTIFIER REMOVAL AND REPLACEMENT INPUT RECTIFIER C B A NEG (-) Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC POS (+) REMOVAL PROCEDURE REPLACEMENT PROCEDURE 1. Remove input power to the Power Wave 455/R. 1. Clean heat sink surfaces. 2.
PAGE 96
Return to Master TOC Return to Section TOC F-50 TROUBLESHOOTING & REPAIR INPUT CONTACTOR 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.
PAGE 97
Return to Master TOC Return to Section TOC F-51 F-51 TROUBLESHOOTING & REPAIR INPUT CONTACTOR REMOVAL AND REPLACEMENT (CONTINUED) FIGURE F.19 – INPUT CONTACTOR REMOVAL AND REPLACEMENT INPUT CONTACTOR 601 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC X4 REMOVAL PROCEDURE REPLACEMENT PROCEDURE 1. Remove input power to the Power Wave 455/R. 1. Mount the contactor and tighten the mounting screws. 2.
PAGE 98
Return to Master TOC Return to Section TOC F-52 TROUBLESHOOTING & REPAIR AUXILIARY TRANSFORMER NO. 1 REMOVAL AND REPLACEMENT 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.
PAGE 99
AUXILIARY TRANSFORMER NO. 1 REMOVAL AND REPLACEMENT PROCEDURE (CONTINUED) FIGURE F.20 – AUXILIARY TRANSFORMER NO.
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Return to Master TOC Return to Section TOC F-54 TROUBLESHOOTING & REPAIR AUXILIARY TRANSFORMER NO. 1 REMOVAL AND REPLACEMENT PROCEDURE (CONTINUED) 6. Remove leads X1 and X2 from the power board rectifier bridge. Refer to Figure F.20. 8. Cut the X3 lead that is connected to the input board. Leave enough lead length to splice in the new transformer lead. Return to Master TOC Return to Section TOC 7. Cut X3 and X5 from the fan motor leads. Leave enough lead length to splice in the new transformer leads.
PAGE 101
Return to Master TOC Return to Section TOC F-55 TROUBLESHOOTING & REPAIR AUXILIARY TRANSFORMER NO. 2 REMOVAL AND REPLACEMENT 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.
PAGE 102
Return to Master TOC Return to Section TOC F-56 F-56 TROUBLESHOOTING & REPAIR AUXILIARY TRANSFORMER NO. 2 REMOVAL AND REPLACEMENT PROCEDURE (CONTINUED) FIGURE F.21 – AUXILIARY TRANSFORMER NO. 2 REMOVAL AND REPLACEMENT INPUT CONTACTOR 601 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC X4 P52 P50 CB4 CIRCUIT BREAKER & 115V RECEPTACLE LEADS 33/32 REMOVAL PROCEDURE Return to Master TOC Return to Section TOC 1. Remove input power to the Power Wave 455/R. 2.
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Return to Master TOC Return to Section TOC F-57 TROUBLESHOOTING & REPAIR AUXILIARY TRANSFORMER NO. 2 REMOVAL AND REPLACEMENT PROCEDURE (CONTINUED) REPLACEMENT PROCEDURE 1. Carefully place the transformer into the Power Wave 455/R. Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC Return to Section TOC 2. Install the two mounting screws that hold the transformer to the machine base using the 3/8” nut driver. 3.
PAGE 104
Return to Master TOC Return to Section TOC F-58 TROUBLESHOOTING & REPAIR CONTROL, FEED HEAD, OR VOLTAGE SENSE PC BOARD REMOVAL AND REPLACEMENT WARNING Return to Master TOC Return to Section TOC 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.
PAGE 105
Return to Master TOC Return to Section TOC F-59 TROUBLESHOOTING & REPAIR F-59 CONTROL, FEED HEAD, OR VOLTAGE SENSE PC BOARD REMOVAL AND REPLACEMENT (CONTINUED) FIGURE F.22 – CONTROL OR FEED HEAD BOARD REMOVAL AND REPLACEMENT COMPARTMENT COVER Return to Master TOC Return to Section TOC CONTROL BOARD Return to Master TOC Return to Section TOC POWER BOARD REMOVAL PROCEDURE 1. Remove input power to the Power Wave 455/R. Return to Master TOC Return to Section TOC 2.
PAGE 106
Return to Master TOC Return to Section TOC F-60 F-60 TROUBLESHOOTING & REPAIR CONTROL, FEED HEAD, OR VOLTAGE SENSE PC BOARD REMOVAL AND REPLACEMENT (CONTINUED) FIGURE F.23 – VOLTAGE SENSE BOARD REMOVAL AND REPLACEMENT COMPARTMENT COVER Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC Return to Section TOC CONTROL BOARD VOLTAGE SENSE BOARD POWER BOARD 9. Tilt back the rear of the control box to access the PC board mounting nuts.
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Return to Master TOC Return to Section TOC F-61 TROUBLESHOOTING & REPAIR CONTROL, FEED HEAD, OR VOLTAGE SENSE PC BOARD REMOVAL AND REPLACEMENT (CONTINUED) 3. Secure the rear of the control box in place using two screws and the 3/8” nut driver. 4. Press the Voltage Sense Board onto its standoffs. Make sure the board snaps into place on all three standoffs. 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.
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Return to Master TOC Return to Section TOC F-62 TROUBLESHOOTING & REPAIR GATEWAY PC BOARD REMOVAL AND REPLACEMENT WARNING Return to Master TOC Return to Section TOC 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.
PAGE 109
Return to Master TOC Return to Section TOC F-63 TROUBLESHOOTING & REPAIR F-63 GATEWAY PC BOARD REMOVAL AND REPLACEMENT (CONTINUED) FIGURE F.24 – GATEWAY BOARD REMOVAL AND REPLACEMENT Return to Master TOC Return to Section TOC DEVICENET/ GATEWAY BOARD (LOCATED BEHIND FRONT COVER) Return to Master TOC Return to Section TOC PHILLIPS SCREW REMOVAL PROCEDURE REPLACEMENT PROCEDURE 1. Remove input power to the Power Wave 455/R. 1.
PAGE 110
Return to Master TOC Return to Section TOC F-64 TROUBLESHOOTING & REPAIR STT CURRENT TRANSDUCER 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.
PAGE 111
Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC F-65 TROUBLESHOOTING & REPAIR F-65 STT CURRENT TRANSDUCER REMOVAL AND PLACEMENT (CONTINUED) FIGURE F.25 – STT CURRENT TRANSDUCER REMOVAL AND REPLACEMENT PROCEDURE RESISTOR ASSEMBLY 1234 P90 Return to Master TOC Return to Section TOC STT OUTPUT TERMINAL (TOP RIGHT) CURRENT TRANSDUCER REMOVAL PROCEDURE 1. Remove input power to the Power Wave 455/R. 2.
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Return to Master TOC Return to Section TOC F-66 TROUBLESHOOTING & REPAIR STT CURRENT TRANSDUCER REMOVAL AND REPLACEMENT (CONTINUED) 6. With the 5/16” open end wrench, remove the small screw from the STT output terminal. Label and remove the small leads. See the Wiring Diagram. Return to Master TOC Return to Section TOC 7. Using the 3/4” wrench, remove the bolt, lock washer and flat washer from the STT output terminal. Remove the double heavy output leads. Cut any necessary cable ties. 8.
PAGE 113
Return to Master TOC Return to Section TOC F-67 TROUBLESHOOTING & REPAIR POWER WAVE CURRENT TRANSDUCER 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.
PAGE 114
Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC F-68 TROUBLESHOOTING & REPAIR POWER WAVE CURRENT TRANSDUCER REMOVAL AND REPLACEMENT (CONTINUED) FIGURE F.26 – POWER WAVE CURRENT TRANSDUCER REMOVAL AND REPLACEMENT PROCEDURE CURRENT TRANSDUCER HEAVY LEAD BOLTED CONNECTION (BEHIND CASE FRONT) REMOVAL PROCEDURE 1. Remove input power to the Power Wave 455/R. 2.
PAGE 115
Return to Master TOC Return to Section TOC F-69 TROUBLESHOOTING & REPAIR POWER WAVE CURRENT TRANSDUCER REMOVAL AND REPLACEMENT (CONTINUED) 9. Using the phillips head screw driver, remove the screws and lock washers that hold the transducer to the front panel. 10. Remove the Power Wave current transducer. Return to Master TOC Return to Section TOC 11. Remove the standoffs from the transducer and save them for reassembly with the new transducer. 4.
PAGE 116
Return to Master TOC Return to Section TOC F-70 TROUBLESHOOTING & REPAIR OUTPUT RECTIFIER, STT CHOPPER BOARD AND RECTIFIER 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.
PAGE 117
Return to Master TOC F-71 TROUBLESHOOTING & REPAIR OUTPUT RECTIFIER, STT CHOPPER BOARD AND RECTIFIER MODULE REMOVAL AND REPLACEMENT (CONTINUED) FIGURE F.
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Return to Master TOC Return to Section TOC F-72 TROUBLESHOOTING & REPAIR OUTPUT RECTIFIER, STT CHOPPER BOARD AND RECTIFIER MODULE REMOVAL AND REPLACEMENT (CONTINUED) 7. Using the needle-nose pliers, remove leads #292 and #291 from the rectifier thermostat. 4. Using the 3/16” allen wrench, remove the four screws and lock washers holding the board to the heat sink. 8. Disconnect plug J10 from the STT Chopper Board. 5. Carefully remove the STT Chopper Board. 9.
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Return to Master TOC Return to Section TOC F-73 TROUBLESHOOTING & REPAIR OUTPUT RECTIFIER, STT CHOPPER BOARD AND RECTIFIER MODULE REMOVAL AND REPLACEMENT (CONTINUED) RECTIFIER MODULE REMOVAL AND REPLACEMENT PROCEDURE RECTIFIER ASSEMBLY REPLACEMENT PROCEDURE 1. Using the 9/64” allen wrench, remove the cap screw from the center of the rectifier module that is to be replaced. 1. Position the assembly in place with the mounting bolts. Return to Master TOC Return to Section TOC 2.
PAGE 120
Return to Master TOC Return to Section TOC F-74 TROUBLESHOOTING & REPAIR SWITCH BOARD AND FILTER CAPACITOR 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.
PAGE 121
Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC F-75 F-75 TROUBLESHOOTING & REPAIR SWITCH BOARD AND FILTER CAPACITOR REMOVAL AND REPLACEMENT (CONTINUED) FIGURE F.28 – SWITCH BOARD AND FILTER CAPACITOR REMOVAL AND REPLACEMENT MOLEX PLUG MOUNTING SCREW (4X) 13/14 OR 17/18 SWITCH BOARD 19+ Return to Master TOC Return to Section TOC 20- 11/12 OR 15/16 REMOVAL PROCEDURE NOTE: Observe all static electricity precautions.
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Return to Master TOC Return to Section TOC F-76 TROUBLESHOOTING & REPAIR SWITCH BOARD AND FILTER CAPACITOR REMOVAL AND REPLACEMENT (CONTINUED) 7. Using the 7/16” wrench, remove leads 13/14 or 17/18 from the switch board. 8. Using the 7/16” wrench, remove leads 11/12 or 15/16 from the switch board. 5. Mount the new switch board and tighten the four cap head screws in the following manner. Tighten all until snug. Tighten all from 24 to 28 in-lbs. Return to Master TOC Return to Section TOC 9.
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Return to Master TOC Return to Section TOC F-77 F-77 TROUBLESHOOTING & REPAIR RETEST AFTER REPAIR Retest a machine: If it is rejected under test for any reason that requires you to remove any part which could affect the machine’s electrical characteristics. OR Return to Master TOC Return to Section TOC If you repair or replace any electrical components. INPUT IDLE AMPS AND WATTS Input Volts/Hertz Maximum Idle Amps Maximum Idle KW 208/60 230/60 400/60 460/60 575/60 4.0 3.3 2.1 2.0 1.8 0.45 0.
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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-78 NOTES POWER WAVE 455/R F-78
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Return to Master TOC Section G-1 TABLE OF CONTENTS - ELECTRICAL DIAGRAMS SECTION - Section G-1 Electrical Diagrams ..............................................................................................................Section G Wiring Diagram (Code 10675)....................................................................................................G-2 Wiring Diagram (Code 10676)....................................................................................................
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POWER WAVE LEFT SIDE OF MACHINE C1 .
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POWER WAVE LEFT SIDE OF MACHINE C1 .
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SCHEMATIC - COMPLETE MACHINE 10675 N.A. S 13 .022u 800V A 19C POS NEG T2 414 + 20C 418 521 3J83 SOLENOID +40VDC 522 4J83 SOLENOID INPUT 539 1J83 MOTOR "+" 541 2J83 MOTOR "-" 841 1J84 4J40 V/F (+) 405 5J40 V/F (-) L1A L3A INPUT BOARD ON 1J60 SW1 POWER +13V 232 5J60 OFF D6 2J61 4J84 844 T1 +13V AUX.
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SCHEMATIC-COMPLETE MACHINE CODE 10676 N.A. .022u 800V INPUT RECTIFIER CR1 380-460V 208-230V AC3 T1 POS U AC2 L2 HARMONIC FILTER POS NEG T2 V 20C 1J40 418 NEG 2.7 10W 206A OUTPUT DIODES D1-D4 C2 .05uF 600V R1 50 2.7 10W 1J9 TP3 150V 80J CURRENT TRANSDUCER 3J83 521 X4 P91 N.A. L1A L3A 601 INPUT BOARD ON 1J60 SW1 POWER 4J83 SOLENOID INPUT 539 1J83 MOTOR "+" 541 2J83 MOTOR "-" 232 5J60 841 1J84 6J61 2J61 4J84 844 T1 +13V AUX.
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L 11340 Return to Master TOC Return to Section TOC INPUT 6 PWM .0047 C11 1 2 5 OCI1 50V CNY17-3 6 4 C22 5 R4 1 3.32K 2 X3 3 C12 C13 12 820p 100p 50V 100V X3 11 B 4 A X1 +15 11 B 12 A T1 15 3.32K J10 13 5 /Q T1 1 T2 2 Q X1 6 /Q T2 Q 14 10 X3 4 332 RST 3 1 7 2 3 4 6 R27 8 3.32K X3 10 VS IN C14 .0047 X2 VS OUT NC OUT GND GND 8 D5 C15 C16 C17 100p 100p 475 820p 100V 100V 50V 1.0A 7 30V DZ1 D6 15V 1.0A 1W 30V 301 5 6 50V C23 4.
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PC BOARD ASSEMBLY -CHOPPER 5.50 ±.04 B48 B49 C10 D6 C6 DZ1 D5 R14 R26 X2 C9 X1 C8 R13 C3 X3 R12 C13 R27 C15 C1 R11 R3 R4 C12 R19 R6 C14 R18 C16 R20 D7 C23 C17 C20 A2 xxx x xx x x x x x x x x x x x x x x C19 x x x x x x x x x x x xxx x x x x x x xx C21 R5 R17 C7 C2 xx x x x x x x xx x x x x x x x x x x x C18 x x x x x x x x x x xx x x x x x x x xx ITEM C1 C2 C3,C7,C9,10,C21 C6,C8,C20 C11,C14 C12,C17 C13,C15,C16 C18,C19 C22 C23 REQ'D 1 1 5 3 2 2 3 2 1 1 PART NO.
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Return to Master TOC ELECTRICAL DIAGRAMS G-8 SCHEMATIC-DEVICENET/GATEWAY PC BOARD 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-8 NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
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Return to Master TOC G-9 ELECTRICAL DIAGRAMS PC BOARD ASSEMBLY-DEVICENET/GATEWAY ITEM PART NO. QTY PC BOARD REFERENCE DESCRIPTION DESIGNATORS 1 G3820-D 1 GATEW AY PC BOARD BLANK 2 S24671 1 PLUG, KEYING PLUG 3 M19436-5 1 POTTING TRAY 4 S8025-80 2 SELF TAPPING SCREW 5 E2527 195g. (6.87OZ) EPOXY ENCAPSULATING RESIN 6 E3539 AS REQ.
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D32 1SMB5931 1.5W 18V 100pF /RES 3 9 (3) 2 BAV99 D78 3 R84 CAPA_OV CAPAUV R135 CAPA_UV D7 MMSZ5231 1/2W 5.1V 820pF 1 (2) (1) (4) (4) D6 MMSZ5231 1/2W 5.1V D8 MMSZ5231 1/2W 5.1V 820pF D C69 4700pF (3) 820pF +15V D R32 10 D17 10.0K 3 2 R99 MMSZ5231 1/2W 5.1V 1 R33 10.0K C46 R100 475K 1uF 35V R2 2 J5 J5 1 J5 3 47.
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51 52 53 54 29 30 31 32 33 FOR ITEMS LISTED BELOW REFER TO ELECTRICAL DATABASE FOR COMPONENT SPECIFICATIONS C138 C134 C133 C125 C55 C96 C98 C100 C28 C82 C14 C11 C83 C103 C121 C101 C117 C115 C111 C113 C85 C90 C48 C93 C109 C120 C127 C106 C95 C105 C73 C68 C8 C114 C108 C99 S25020-3SMT 68 SCAP,0.
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G-12 ELECTRICAL DIAGRAMS SCHEMATIC - DIGITIAL POWER SUPPLY PC BOARD 2 R50 10 11 OUT 6 Vref 1 D3 1A 600V 8 VREF VFB 2 4 RT/CT COMP 1 5 GND CS J41 S 10.0 X5 R5 100K 100K IN 3A 600V X8 4 D21 1.0A 30V OV1 C11 22 35V T1 475 C14 0.1 50V C47 1.0 35V 1.21K .33W Vfb1 R52 1.82K 221K 4 6 C7 0.1 50V C6 4.7 35V C8 820p 50V R39 R12 56.2K 5.62K C45 150p 100V 3W 0.05 C32 10p 100V J41 3 R11 Return to Master TOC C42 R13 2700p 50V 10.0K 1 5 8 DZ1 24V 3W R36 30.
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Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC Return to Section TOC G-13 PC BOARD ASSEMBLY-DIGITAL POWER SUPPLY ITEM 1 2 3 4 5 ITEM 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 (3.64) CR Return to Master TOC (6.
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Return to Master TOC G-14 ELECTRICAL DIAGRAMS SCHEMATIC - FEEDHEAD PC BOARD #1 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-14 XA 11-3-2000A 1 OF 3 LRW COMMON DIGITAL CONTROLS FEEDHEAD PC BOARD SCHEMATIC 07/17/2000 3823-1C1/1 NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
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Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC G-15 G-15 ELECTRICAL DIAGRAMS SCHEMATIC- FEEDHEAD PC BOARD #2 TPD Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC TPE COMMON DIGITAL CONTROLS XA 11-3-2000A 2 OF 3 LRW FEEDHEAD PC BOARD SCHEMATIC 07/17/2000 3823-1C1/2 NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
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Return to Master TOC G-16 ELECTRICAL DIAGRAMS SCHEMATIC- FEEDHEAD PC BOARD #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 Return to Section TOC G-16 XA 11-3-2000A 3 OF 3 LRW COMMON DIGITAL CONTROLS FEEDHEAD PC BOARD SCHEMATIC 07/17/2000 3823-1C1/3 NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
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PC BOARD ASSEMBLY-FEEDHEAD Return to Master TOC Return to Master TOC G-17 ELECTRICAL DIAGRAMS 74 75 76 S25001-3320SMT S25005-1SMT S25001-4751SMT 6 2 4 77 S25000-4751SMT 14 78 79 80 S25001-1503SMT S25000-1211SMT S25000-2002SMT 1 1 3 81 S25000-1002SMT 24 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 100 101 102 103 104 105 106 107 S19869-8 S20375-8 S25068-7SMT M15101-14SMT S25069-2SMT S20353-1SMT S25070-6SMT S17900-24SMT S25069-3SMT S25066-2SMT S25057-3SMT M15105-9SMT S15128-21SMT S15
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Return to Master TOC G-18 ELECTRICAL DIAGRAMS SCHEMATIC - INPUT PC BOARD M 19528 Return to Section TOC G-18 PRE-CHARGE CONNECTIONS CONTACTOR OUTPUT 2 10 2 J60 4 CONTACTOR 3 J61 J61 J61 COIL CONNECT CR1 4 TP1 TP3 1 660V 660V 250J 100 10W 10W R2 R1 100 100 10W 10W 3 660V CR2 5 4 CR2 R22 660V 250J R11 D2 3.01K R12 3.01K R13 3.01K R14 3.01K R15 3.01K R16 3.01K R17 3.01K R18 3.01K R19 3.01K R5 +13V R20 10W PRE-CHARGE CONTROL J60 3.
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Return to Master TOC Return to Section TOC G-19 G-19 ELECTRICAL DIAGRAMS PC BOARD ASSEMBLY-INPUT ITEM REQ’D PART NO. IDENTIFICATION 2.80 RESISTORS = OHMS/WATTS CAPACITORS = MFD/VOLTS Return to Master TOC 4.50 xxxxx 4.25 xxxxx INVERTEC 455-655 INPUT J61 J60 D1 R24 R25 R23 TP2 R21 R20 x x x x x R9 x x x x x x xxx x x Return to Master TOC Return to Section TOC xxx TP1 .25 R19 R18 R7 R6 R8 R3 R10 R5 D2 TP3 D3 TP4 R4 R22 C1 Return to Section TOC ~.
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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 G-20 ELECTRICAL DIAGRAMS SCHEMATIC -SWITCH PC BOARD NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
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Return to Master TOC G-21 ELECTRICAL DIAGRAMS PC BOARD ASSEMBLY-SWITCH ITEM 6.00 ±.
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Return to Master TOC ELECTRICAL DIAGRAMS G-22 SCHEMATIC - VOLTAGE SENSE PC BOARD 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-22 NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
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Return to Master TOC Return to Section TOC G-23 G-23 ELECTRICAL DIAGRAMS PC BOARD ASSEMBLY-VOLTAGE SENSE .20 . . 1.80 M19540-1 .20 0 Return to Master TOC Return to Section TOC 0 D1 L1 R1 R2 R3 1 T12199-1 J1 J2 L1 1 1 1 S24020-6 S24020-2G T12218-7 OCI1,OCI2 R1,R2 R3 TP1,TP2 2 2 1 2 S15000-20 S19400-4750 S18380-1 T13640-18 PART NO.
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Return to Master TOC ELECTRICAL DIAGRAMS G-24 SCHEMATIC - 40 VDC BUS PC BOARD 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 NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
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Return to Master TOC Return to Section TOC G-25 PC BOARD ASSEMBLY-40 VDC BUS ITEM X1 1 PART NO M15458-4 IDENTIFICATION IC,PWM-CONTROLLER,IMODE,2842A C2,C3,C5 3 S13490-25 CAPACITOR,TAEL,4.7,35V 10% C16 1 S13490-42 CAPACITOR,TAEL,1.
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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.