Welder User Manual

TROUBLESHOOTING & REPAIR
F-54 F-54
POWER WAVE 455/R
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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.
7. Cut X3 and X5 from the fan motor leads.
Leave enough lead length to splice in the
new transformer leads.
8. Cut the X3 lead that is connected to the
input board. Leave enough lead length to
splice in the new transformer lead.
9. Locate, label, and remove primary lead H1
from circuit breaker CB4.
10. Label and remove primary leads H2, H3,
H4, and H5 from the reconnect terminals
on the reconnect panel. Note lead place-
ment for reassembly.
11. Cut any necessary cable ties and clear the
leads.
12. Using the 3/8” nut driver, remove the two
mounting screws that hold the transformer
to the fan baffle and the machine base.
13. Carefully remove the transformer from the
Power Wave 455/R.
REPLACEMENT PROCEDURE
1. Carefully place the transformer into the
Power Wave 455/R.
2. Install the two mounting screws that hold
the transformer to the fan baffle and the
machine base using the 3/8” nut driver.
3. Install the primary leads H2, H3, H4, and
H5 to the reconnect terminals on the
reconnect panel.
4. Connect primary lead H1 to circuit breaker
CB4.
5. Splice the new transformer lead with the
X3 lead connected to the input board.
6. Splice the new transformer fan leads to
the fan motor leads X3 and X5.
7. Connect lead X4 to the main contactor
coil terminal.
8. Connect leads X1 and X2 to the power
board rectifier bridge.
9. Reposition any wire leads and install
cable ties as necessary.
10. Install the case back using the 3/8” nut
driver.
11. Install the case top, sides, and input
access panel using the 3/8” nut driver.