Lincoln Electric 11141 Service Manual
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Lincoln Electric 11141 Service Manual

Lincoln Electric 11141 Service Manual

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POWER WAVE
®
For use with machines having Code Numbers:
11141, 11489,11142, 11490
SERVICE MANUAL
W A
R N
IN
G
R E
M O
TE
P O
W
E R
O N
O FF
SVM181-B
| Issue D ate 17-Aug
© Lincoln Global, Inc. All Rights Reserved.
355M/405M
Need Help? Call 1.888.935.3877
to talk to a Service Representative
Hours of Operation:
8:00 AM to 6:00 PM (ET) Mon. thru Fri.
After hours?
Use "Ask the Experts" at lincolnelectric.com
A Lincoln Service Representative will contact you
no later than the following business day.
For Service outside the USA:
Email: globalservice@lincolnelectric.com

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  • Page 1 POWER WAVE 355M/405M ® For use with machines having Code Numbers: 11141, 11489,11142, 11490 SERVICE MANUAL Need Help? Call 1.888.935.3877 to talk to a Service Representative Hours of Operation: 8:00 AM to 6:00 PM (ET) Mon. thru Fri. After hours? Use “Ask the Experts”...
  • Page 2 Miami, Florida 33135 or CSA Standard W117.2-1974. A Free copy of “Arc Welding Safety” booklet E205 is available from the Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199. BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE AND REPAIR PROCEDURES ARE PERFORMED ONLY BY QUALIFIED INDIVIDUALS.
  • Page 3 SAFETY ELECTRIC SHOCK can kill. ARC RAYS can burn. 3.a. The electrode and work (or ground) circuits 4.a. Use a shield with the proper filter and cover are electrically “hot” when the welder is on. plates to protect your eyes from sparks and Do not touch these “hot”...
  • Page 4 Miami, Florida 33135 or CSA Standard W117.2-1974. A Free copy of “Arc Welding Safety” booklet E205 is available from the Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199. BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE AND REPAIR PROCEDURES ARE PERFORMED ONLY BY QUALIFIED INDIVIDUALS.
  • Page 5 SAFETY ELECTRIC SHOCK can kill. ARC RAYS can burn. 3.a. The electrode and work (or ground) circuits 4.a. Use a shield with the proper filter and cover are electrically “hot” when the welder is on. plates to protect your eyes from sparks and Do not touch these “hot”...
  • Page 6 2004/108/EC. It was manufactured in conformity with a national standard that implements a harmonized standard: EN 60974-10 Electromagnetic Compatibility (EMC) Product Standard for Arc Welding Equipment. It is for use with other Lincoln Electric equipment. It is designed for industrial and professional use. Introduction All electrical equipment generates small amounts of electromagnetic emission.

  • Page 7: Safety

    SAFETY Electromagnetic Compatibility (EMC) The size of the surrounding area to be considered will depend on the structure of the building and other activities that are taking place. The surrounding area may extend beyond the boundaries of the premises. Methods of Reducing Emissions Mains Supply Welding equipment should be connected to the mains supply according to the manufacturer’s recommenda- tions.

  • Page 8: Table Of Contents

    - MASTER TABLE OF CONTENTS FOR ALL SECTIONS - Page Safety ................i-vi Installation .
  • Page 9 TABLE OF CONTENTS - INSTALLATION SECTION Installation ................A-1 Technical Specifications 355M .

  • Page 10: Installation

    Cable sizes for Combined Length of Electrode and Work Cable (Copper) 75C rated: DUTY CYCLE CURRENT LENGTH UP 200FT.(61m) 200-250 FT. (61-76m) 100% Lincoln Electric recommends using a minimum of 2/0 welding cable for pulse welding. POWER WAVE ® 355M/405M...
  • Page 11 INSTALLATION TECHNICAL SPECIFICATIONS - POWER WAVE ® INPUT AC VOLTAGE & DC OUTPUT Product Ordering Input AC Rated DC Output Output Weight Dimensions Name Information Voltage Amps/Volts/Duty Cycle Range with Cord HxWxD (continuous) 350A / 34V / 60% 14.7”x12.5”x Power 200-208 / 3 Phase 27.8”*...
  • Page 12 INSTALLATION • Open the access panel on the rear of the machine. SAFETY PRECAUTIONS • For 200 or 230: Position the large switch to 200- WARNING 230. For higher voltages: Position the large switch to ELECTRIC SHOCK can kill. 380-575. •...
  • Page 13 INSTALLATION UNDERCARRIAGE MOUNTINGS CAUTION MOUNTING HOLE LOCATIONS Excessive voltage drops caused by poor work NOTE: MOUNTING SCREWS CA N NOT PROTR UDE MORE THAN 0.5 INCHES INSIDE THE MACHINE. piece connections often result in unsatisfactory welding performance. 3.50 ----------------------------------------------------------------------- NEGATIVE ELECTRODE POLARITY 1/4-20 NUT (4 PLACES) When negative electrode polarity is required, such as 5.50...
  • Page 14 INSTALLATION 5. Replace the wrap around and screws. The PC board Enable the voltage sense leads as follows: will “read” the switch at power up, and configure the TABLE A.1 work voltage sense lead appropriately. Process Electrode Voltage Work Voltage Sensing 67 lead * Sensing 21 lead ELECTRODE VOLTAGE SENSING...
  • Page 15 INSTALLATION SYSTEM DESCRIPTION The POWER WAVE ® 355M/405M and Power Feed From a network perspective, each component in the 10/11 family of products utilize a digital communication system is considered a separate node, regardless of system called Arclink. Simply put, Arclink allows large its physical location.
  • Page 16 INSTALLATION SYSTEM SET-UP Basic Rules • Each group is required to have one user interface. No group may have more than one user interface. • Each group can have up to seven Feed Heads. Exception: Group 3 is limited to a maximum of six Feed Heads.
  • Page 17 INSTALLATION Multiple Group System FIGURE A.3 No “FH0 Allowed! Single Group Multi-Head System FIGURE A.4 No “FH0 Allowed! The Dual Head option allows the ability to maintain 2 sets of procedures. If more then 2 heads are used, odd #’s use FH1 settings, even #’s use FH2 settings.
  • Page 18 INSTALLATION A-10 A-10 Single Group Multi-Head System (Alternate Method) FIGURE A.5 No “FH0 Allowed! When standard User Interface is used in a group with multi- ple Feed Heads, all of the Feed Heads use a single set of proce- dures. POWER WAVE ®...
  • Page 19 INSTALLATION A-11 A-11 CONTROL CABLE SPECIFICATIONS WELDING WITH MULTIPLE POWER It is recommended that genuine Lincoln control cables WAVE ® be used at all times. Lincoln cables are specifically designed for the communication and power needs of CAUTION the Power Wave / Power Feed system.
  • Page 20 INSTALLATION A-12 A-12 MULTIPLE ARC UNSYNCHRONIZED SENSE LEAD AND WORK LEAD PLACEMENT GUIDELINES POWER WAVE ® 355M/405M...
  • Page 21 INSTALLATION A-13 A-13 I / O RECEPTACLE SPECIFICATIONS CONTROL BOARD DIP SWITCH: switch 1 = reserved for future use TABLE A.2 switch 2 = reserved for future use WIRE FEEDER RECEPTACLE switch 3 = reserved for future use LEAD# FUNCTION switch 4 = reserved for future use Communication Bus L switch 5 = reserved for future use...
  • Page 22 INSTALLATION A-14 A-14 CABLE INDUCTANCE, AND ITS EFFECTS Most welding applications run with the electrode being positive (+). For those applications, connect the elec- ON PULSE WELDING trode cable between the wire feeder and the positive For Pulse Welding processes, cable inductance will (+) output Twist-Mate terminal on the power source.
  • Page 23 TABLE OF CONTENTS - OPERATION SECTION Operation ................B-1 Safety Precautions ............................B-2 General Description............................B-2 Recommended Processes and Equipment....................B-2...

  • Page 24: Operation

    OPERATION SAFETY PRECAUTIONS GENERAL DESCRIPTION The Power Wave semi-automatic power source is ® Read this entire section of operating instructions designed to be a part of a modular, multi-process weld- before operating the machine. ing system. Depending on configuration, it can support constant current, constant voltage, and pulse welding modes.
  • Page 25 OPERATION POWER WAVE 355M/405M – Semi-Automatic NOTE: The POWER WAVE 355M/405M status light ® ® Operation will flash green, and sometimes red and green, for up to one minute when the machine is first turned on. This Semi Automatic Power Wave s can only be used with is a normal situation as the machine goes through a ®...
  • Page 26 ® s encom- passes a wide range of common processes and will meet most needs. If a special welding program is desired, contact the local Lincoln Electric sales repre- sentative. To make a weld, the Power Wave ® needs to know the CASE FRONT LAYOUT desired welding parameters.
  • Page 27 OPERATION In non-synergic modes, the WFS control behaves CONSTANT VOLTAGE WELDING more like a conventional CV power source where WFS Synergic CV: and voltage are independent adjustments. Therefore to For each wire feed speed, a corresponding voltage is maintain the arc characteristics, the operator must preprogrammed into the machine through special soft- adjust the voltage to compensate for any changes ware at the factory.
  • Page 28 OPERATION TIG GTAW NOTE: Later versions of weld software eliminated the Arc Control Function The TIG mode features continuous control from 5 to in TIG mode and only allow for 425 amps. The TIG mode can be run in either the “Touch Start”...
  • Page 29 OPERATION ARC GOUGING Power Mode™ is a method of high speed regulation of Gouging is basically removing metal to form a bevel or the output power whenever an arc is established. It groove in a piece of steel with controlled forced air and provides a fast response to changes in the arc.
  • Page 30 OPERATION SPECIAL WELDING PROCESSES AVAILABLE ON THIS MACHINE PULSE WELDING (GMAW-P) Pulsed MIG is an advanced form of welding that takes The pulsed-arc process is, by definition, a spray trans- the best of all the other forms of transfer while mini- fer process wherein spray transfer occurs in pulses at regularly spaced intervals.
  • Page 31 OPERATION PULSE WELDING FIGURE B.3 CURRENT WAVE FORM (PULSE) 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, back ground current, rise time, fall Current time and pulse frequency all affect the voltage.
  • Page 32 "N" of such pulses, depending on the wire feed BENEFITS OF PULSE ON PULSE FROM speed used, an identical number "N" of low energy LINCOLN ELECTRIC pulses are performed. These low energy pulses, shown in the figure below, do not transfer any filler •...
  • Page 33 TABLE OF CONTENTS - ACCESSORIES SECTION Accessories ................C-1 Optional Equipment .............................C-2 Field Installed ..........................C-2 Compatible Lincoln Equipment.......................C-2...

  • Page 34: Accessories

    ACCESSORIES OPTIONAL EQUIPMENT FACTORY INSTALLED None Available. FIELD INSTALLED K940-Work Voltage Sense Lead Kit K1764-1-Undercarriage* K1838-1-Valet Style Undercarriage K1796-Coaxial Welding Cable-(Requires Adapter K2176-1) K2176-1 Twist-mate to Lug Adapters * Dual Cylinder Kit for K1764-1 is K1702-1 K2436-1 Ethernet/Devicenet Communication Interface Welding Cable Connectors: K852-70 1/0-2/0 CABLE K852-95 2/0-3/0 CABLE...
  • Page 35 TABLE OF CONTENTS - MAINTENANCE SECTION Maintenance ................D-1 Safety Precautions............................D-2 Capacitor Discharge Procedure........................D-2 Visual Inspection............................D-2...

  • Page 36: Maintenance

    Repeat for all four capacitors. Calibration is accomplished with our Diagnostic Utility RESISTOR software found on the Lincoln Electric Service Navigator CD or on our web site at www.lincoln- electric.com. If a welder has difficulty in being calibrated some things to look for proper configuration of the sense leads.
  • Page 37 MAINTENANCE FIGURE D.1 – MAJOR COMPONENT LOCATIONS 1. Center Panel Use parts page exploded views to also help iso- late and identify smaller parts. Parts page num- 2. Case Back bers can be found on the Master Table of 3. Case Front Contents in the front of this manual.
  • Page 38 NOTES POWER WAVE ® 355M/405M...
  • Page 39 TABLE OF CONTENTS-THEORY OF OPERATION SECTION Theory of Operation ..............E-1 General Description ...........................E-2 Input Line Voltage, Auxiliary Transformer and Precharge .................E-2 Switch Board and Main Transformer ......................E-3...

  • Page 40: Theory Of Operation

    THEORY OF OPERATION FIGURE E.2 - GENERAL DISCRIPTION Main Switch Board Board Positive Input Output Primary Input switch Rectifier Terminal Current Sensor Choke Negative Reconnect Output Terminal Switch Primary Current Sensor Primary Current Feedback(2) 115VAC Fan Supply Input Relay Control Auxiliary Soft Start Control V/F Capacitor Feedback (2)
  • Page 41 THEORY OF OPERATION FIGURE E.3 – SWITCH BOARD & MAIN TRANSFORMER To Control Main Switch Board Board Positive Input Output Primary Input switch Terminal Rectifier Current Sensor Choke Negative Reconnect Output Terminal Switch Primary Current Sensor Primary Current Feedback(2) 115VAC Fan Supply Input Relay Control Auxiliary Soft Start Control...
  • Page 42 THEORY OF OPERATION FIGURE E.4 – POWER BOARD, CONTROL BOARD AND SERIAL PERIPHERAL INTERFACE (SPI) COMMUNICATIONS To Control Main Switch Board Board Positive Input Output Primary Input switch Rectifier Terminal Current Sensor Choke Negative Reconnect Output Terminal Switch Primary Current Sensor Primary Current Feedback(2) 115VAC Fan Supply...
  • Page 43 THEORY OF OPERATION FIGURE E.5 – OUTPUT RECTIFIER AND CHOKE To Control Main Switch Board Board Positive Input Output Primary Input switch Rectifier Terminal Current Sensor Choke Negative Reconnect Output Terminal Switch Primary Current Sensor Primary Current Feedback(2) 115VAC Fan Supply Input Relay Control Auxiliary Soft Start Control...
  • Page 44 THEORY OF OPERATION THERMAL PROTECTION OVER CURRENT PROTECTION Three normally closed (NC) thermostats protect the If the average current exceeds 450 amps for one sec- machine from excessive operating temperatures. ond, then the output will be limited to 100 amps until These thermostats are wired in series and are con- the load is removed.
  • Page 45 THEORY OF OPERATION INSULATED GATE BIPOLAR TRANSISTOR (IGBT) OPERATION An IGBT is a type of transistor. IGBT are semiconduc- Example B shows the IGBT in an active mode. When tors well suited for high frequency switching and high the gate signal , a positive DC voltage relative to the current applications.
  • Page 46 THEORY OF OPERATION FIGURE E.7 — TYPICAL IGBT OUTPUTS. PULSE WIDTH MAXIMUM OUTPUT MODULATION By holding the gate signal on for 24 microseconds each, and allowing only two microseconds of dwell time The term Pulse Width Modulation is used to describe (off time) during the 50-microsecond cycle, the output how much time is devoted to conduction in the positive is maximized.
  • Page 47 TABLE OF CONTENTS - TROUBLESHOOTING AND REPAIR Troubleshooting and Repair ............. .F-1 How to Use Troubleshooting Guide ......................F-2 PC Board Troubleshooting Procedures and Replacement ...............F-3 Troubleshooting Guide ........................F-4/F-11...

  • Page 48: How To Use Troubleshooting Guide

    HOW TO USE TROUBLESHOOTING GUIDE WARNING Service and Repair should only be performed by 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. For your safety and to avoid Electrical Shock, please observe all safety notes and precautions detailed throughout this manual.
  • Page 49 Do not touch electrically hot parts. - If you return a PC board to The Lincoln Electric Company for credit, it must be in the static-shielding bag. This will prevent further damage and allow prop- CAUTION er failure analysis.
  • Page 50 CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed. Call 1-888-935-3877. POWER WAVE ®...
  • Page 51 450 amps. CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed. Call 1-888-935-3877. POWER WAVE ®...
  • Page 52 CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed. Call 1-888-935-3877. POWER WAVE ®...
  • Page 53 2. The control board may be faulty. CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed. Call 1-888-935-3877. POWER WAVE ®...
  • Page 54 WFS measured via external meter. CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed. Call 1-888-935-3877. POWER WAVE ®...
  • Page 55 TROUBLESHOOTING AND REPAIR USING THE STATUS LED TO Included in this section is information about the power source Status LED, and some basic troubleshooting TROUBLESHOOT SYSTEM PROBLEMS charts for both machine and weld performance. The Power Wave / Power Feed are best diagnosed ®...
  • Page 56 TROUBLESHOOTING AND REPAIR F-10 F-10 ERROR CODES FOR THE POWER WAVE ® The following is a list of possible error codes that the POWER WAVE 355M/405M can output via the status light ® If connected to a PF-10/11 these error codes will generally be accompanied by an “Err 006” or “Err 100” on the user interface display.
  • Page 57 TROUBLESHOOTING AND REPAIR F-11 F-11 Capacitor delta error. The maximum voltage difference between the main capaci- tors has been exceeded. May be accompanied by errors 32-35. Check the output diodes. Error codes that contain three or four digits are defined as Other fatal errors.
  • Page 58 NOTES F-12 F-12 POWER WAVE ® 355M/405M...

  • Page 59: Input Filter Capacitor Discharge Procedure

    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.
  • Page 60 TROUBLESHOOTING AND REPAIR F-14 F-14 INPUT FILTER CAPACITOR DISCHARGE PROCEDURE (continued) WARNING 4. Obtain a high resistance and high wattage resistor (25-1000 ohms and 25 watts minimum). This ELECTRIC SHOCK resistor is not with the machine. NEVER USE A can kill. SHORTING STRAP FOR THIS PROCEDURE.

  • Page 61: Main Switch Board Test

    MAIN 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.
  • Page 62 TROUBLESHOOTING AND REPAIR F-16 F-16 MAIN SWITCH BOARD TEST (continued) FIGURE F.2 – MAIN SWITCH BOARD LEAD LOCATIONS TEST PROCEDURE 1. Remove input power to the POWER WAVE ® 4. Using a 7/16” wrench locate, label and remove 355M/405M. leads 201, 202, 203, 204, 205, 206, 207 and 208 from the switch board.
  • Page 63 TROUBLESHOOTING AND REPAIR F-17 F-17 MAIN SWITCH BOARD TEST (continued) 6. If any test fails replace the switch board. See Main 8. Reconnect leads 201, 202, 203, 204, 205, 206, 207, Switch Board Removal and Replacement. and 208 to the switch board. Ensure that the leads are installed in their proper locations.
  • Page 64 TROUBLESHOOTING AND REPAIR F-18 F-18 MAIN SWITCH BOARD TEST (continued) FIGURE F.3 – PLUG J21 LEADS AND LOCATIONS PRIMARY CURRENT TRANSDUCER(S) TEST Current Transducers (CT) Test Description The two primary current transducers (CT2 and The best way to test a current transducer is by CT3) monitor the primary currents in the primary measuring the inductance.
  • Page 65 TROUBLESHOOTING AND REPAIR F-19 F-19 MAIN SWITCH BOARD TEST (continued) PROCEDURE 1. Remove the input power to the PW355M/405M 5. Using the Volt-Ohmmeter with inductance mea- machine. suring capabilities check the CT2 current trans- ducer inductance by checking from J21 pin 4 2.
  • Page 66 NOTES F-20 F-20 POWER WAVE ® 355M/405M...

  • Page 67: Input Rectifier Test

    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.
  • Page 68 TROUBLESHOOTING AND REPAIR F-22 F-22 INPUT RECTIFIER TEST (CONTINUED) TEST PROCEDURE 1. Remove input power to the POWER 6. Using a phillips head screwdriver, remove WAVE 355M/405M machine. leads 207, 207A, and 209 from the input ® rectifier. 2. Using a 5/16” nut driver, remove the case wraparound cover.
  • Page 69 TROUBLESHOOTING AND REPAIR F-23 F-23 INPUT RECTIFIER TEST (CONTINUED) Table F.2 Input Rectifier Test Points ANALOG METER TEST POINT TERMINALS X10 RANGE + PROBE Acceptable Meter Readings - PROBE Greater than 1000 ohms Greater than 1000 ohms Greater than 1000 ohms 207A Greater than 1000 ohms 207A...
  • Page 70 NOTES F-24 F-24 POWER WAVE ® 355M/405M...

  • Page 71: Power Board Test

    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.
  • Page 72 TROUBLESHOOTING AND REPAIR F-26 F-26 POWER BOARD TEST (CONTINUED) FIGURE F.5 – POWER BOARD TEST 12 11 10 9 TEST PROCEDURE 1. Remove input power to the Power Wave ® 6. Turn on the Power Wave ® 355M/405M. 355M/405M. Carefully test for the correct voltages at the Power Board according to Table F.4.
  • Page 73 TROUBLESHOOTING AND REPAIR F-27 F-27 POWER BOARD TEST (CONTINUED) TABLE F.3 – POWER BOARD VOLTAGE CHECKS CHECK POINT TEST CONNECTOR LEAD NO. OR NORMAL LOCATION DESCRIPTION PLUG PIN NO. IDENTITY ACCEPTABLE VOLTAGE READING POWER BOARD CHECK 40 VDC 2 (+) 38 –...
  • Page 74 NOTES F-28 F-28 POWER WAVE ® 355M/405M...

  • Page 75: Dc Bus Board Test

    DC BUS 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 76 TROUBLESHOOTING AND REPAIR F-30 F-30 DC BUS BOARD TEST (CONTINUED) FIGURE F.6 – DC BUS POWER SUPPLY POWER SUPPLY PC BOARD DC BUS BOARD W AR TEST PROCEDURE WARNING 1. Remove input power to the machine. ELECTRIC SHOCK can kill. 2.
  • Page 77 TROUBLESHOOTING AND REPAIR F-31 F-31 DC BUS BOARD TEST(CONTINUED) 6. Check the DC Bus Board input and output 7. If all the voltages are correct, the DC Bus voltages according to Table F.4. See Figure Board is operating properly. F.7 and the Wiring Diagram. 8.
  • Page 78 NOTES F-32 F-32 POWER WAVE ® 355M/405M...

  • Page 79: Output Rectifier Modules Test

    OUTPUT RECTIFIER MODULES 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 TROUBLESHOOTING AND REPAIR F-34 F-34 OUTPUT RECTIFIER MODULES TEST (continued) FIGURE F.8 – Machine Output Terminals STA A TUS THERMAL THERMAL NEGATIVE POSITIVE OUTPUT OUTPUT TERMINAL TERMINAL TEST PROCEDURE 1. Remove input power to the POWER WAVE 4. Using the analog ohmmeter test for more ®...
  • Page 81 TROUBLESHOOTING AND REPAIR F-35 F-35 OUTPUT RECTIFIER MODULES TEST (continued) Figure F.9 – Terminal Probes 5. If 200 ohms is measured then the output 9. Test all output diode modules individually. diodes are not “shorted”. Test for open diodes also. NOTE: There is a 250 ohm resistor across NOTE: This may require the disassembly of the welding output terminals.
  • Page 82 TROUBLESHOOTING AND REPAIR F-36 F-36 OUTPUT RECTIFIER MODULES TEST (continued) Figure F.10 – Snubber and Output Diode Locations Output Diode Modules Snubber Board LEFT SIDE POWER WAVE ® 355M/405M...

  • Page 83: Auxiliary Transformer Test

    AUXILIARY TRANSFORMER 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 TROUBLESHOOTING AND REPAIR F-38 F-38 AUXILIARY TRANSFORMER TEST (continued) FIGURE F.11 – Auxiliary Transformer Auxiliary Transformer Secondary Lead Plugs P52 W AR M OT TEST PROCEDURE 1. Remove input power to the POWER WAVE ® 4. Locate the auxiliary transformer. See Figure 355M/405M.
  • Page 85 TROUBLESHOOTING AND REPAIR F-39 F-39 AUXILIARY TRANSFORMER TEST (continued) TABLE F.5 NORMAL EXPECTED VOLTAGE LEAD IDENTIFICATION COM 2 (31) TO 115V (532) 115 VAC 42 TO COM 1A (quick connects) 42 VAC 7. Carefully apply the correct input voltage to the WARNING POWER WAVE 355M/405M and check for...
  • Page 86 NOTES F-40 F-40 POWER WAVE ® 355M/405M...

  • Page 87: Current Transducer Test

    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 88 TROUBLESHOOTING AND REPAIR F-42 F-42 CURRENT TRANSDUCER TEST (continued) FIGURE F.13 – Metal Plate Removal & Plug J8 Location R EM O TE O FF Plug J8 TEST PROCEDURE 1. Remove input power to the POWER WAVE 6. Check for the correct DC supply voltages to the ®...
  • Page 89 TROUBLESHOOTING AND REPAIR F-43 F-43 AUXILIARY TRANSFORMER TEST (continued) TABLE F.6 EXPECTED TRANSDUCER FEEDBACK OUTPUT LOAD CURRENT VOLTAGE 8. Check the feedback voltage from the current 10. If the correct supply voltages are applied to the transducer using a resistive load bank and with current transducer, and with the machine the POWER WAVE 355M/405M in mode 200.
  • Page 90 NOTES F-44 F-44 POWER WAVE ® 355M/405M...

  • Page 91: Fan Control And Motor Test

    FAN CONTROL AND MOTOR 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 92 TROUBLESHOOTING AND REPAIR F-46 F-46 FAN CONTROL AND MOTOR TEST (continued) TEST PROCEDURE 3. Perform the Input Filter Capacitor Discharge 1. Remove the input power to the POWER Procedure. WAVE 355M/405M machine. ® 4. Locate plug J22 on the main switch board. Do 2.

  • Page 93: Replacement Procedures

    TROUBLESHOOTING AND REPAIR F-47 F-47 FAN CONTROL AND MOTOR TEST (continued) FAN CONTROL TEST PROCEDURE 7. If the 115VAC is low or not present check circuit breaker CB2 located on the front panel. If the 1. Locate plug J20 on the switch board. Do not circuit breaker is OK, perform The Auxiliary remove the plug from the switch board.
  • Page 94 NOTES F-48 F-48 POWER WAVE ® 355M/405M...

  • Page 95: Control Board Removal And Replacement

    CONTROL 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.
  • Page 96 TROUBLESHOOTING AND REPAIR F-50 F-50 CONTROL BOARD REMOVAL AND REPLACEMENT (continued) FIGURE F.18 - CONTROL BOARD LOCATION W AR Control Board PROCEDURE 1. Remove input power to the POWER WAVE ® 4. Locate the control board behind the front panel of 355M/405M.
  • Page 97 TROUBLESHOOTING AND REPAIR F-51 F-51 CONTROL BOARD REMOVAL AND REPLACEMENT (continued) FIGURE F.20 - CONTROL BOARD ALL PLUG LOCATIONS J10B J10A 8. The front of the machine may now gently be pulled forward to gain access to the Control Board. Note: CAUTION The front of the machine cannot be removed com- pletely, only pulled forward a few inches.
  • Page 98 TROUBLESHOOTING AND REPAIR F-52 F-52 CONTROL BOARD REMOVAL AND REPLACEMENT (continued) 12. Using a 3/8” nut driver remove the two mounting 14. Replace the control board. nuts from the top two corners of the control board. See Figure F.21. 13. Cut any necessary cable ties. FIGURE F.21 –...

  • Page 99: Main Switch Board Removal And Replacement

    MAIN SWITCH BOARD REMOVAL & 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 100 TROUBLESHOOTING AND REPAIR F-54 F-54 MAIN SWITCH BOARD REMOVAL & REPLACEMENT (continued) FIGURE F.22 – MAIN SWITCH BOARD LEAD LOCATIONS PROCEDURE 5. Using a 3/8” nut driver, remove the input lead 1. Remove the input power to the POWER shield from the area at the bottom of the main WAVE 355M/405M.
  • Page 101 TROUBLESHOOTING AND REPAIR F-55 F-55 MAIN SWITCH BOARD REMOVAL & REPLACEMENT (continued) FIGURE F.23 – 3/16” ALLEN BOLT LOCATION 3/16" ALLEN BOLTS 9. Using a 3/16” allen wrench remove four allen 15. Reconnect the nine leads (#201-#209) that bolts and washers as shown in Figure F.23. were previously removed.
  • Page 102 NOTES F-56 F-56 POWER WAVE ® 355M/405M...

  • Page 103: Snubber Board Removal And Replacement

    SNUBBER 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.
  • Page 104 TROUBLESHOOTING AND REPAIR F-58 F-58 SNUBBER BOARD REMOVAL AND REPLACEMENT (continued) PROCEDURE 3. Perform the Input Filter Capacitor Discharge 1. Remove input power to the POWER WAVE ® Procedure detailed earlier in this section. 355M/405M. 4. Locate the snubber board.. See Figure F.24. 2.

  • Page 105: Power Board Removal And Replacement

    POWER 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.
  • Page 106 TROUBLESHOOTING AND REPAIR F-60 F-60 POWER BOARD REMOVAL AND REPLACEMENT (continued) FIGURE F.26 – POWER BOARD LOCATION Power Board LEFT SIDE PROCEDURE 3. Perform the Input Filter Capacitor Discharge 1. Remove input power to the POWER WAVE ® Procedure detailed earlier in this section. 355M/405M.
  • Page 107 TROUBLESHOOTING AND REPAIR F-61 F-61 POWER BOARD REMOVAL AND REPLACEMENT (continued) 7. Remove the three nuts at the corners of the board using a 3/8” nut driver. Board is ready for removal. CAUTION 8. Replace the power board. Observe static precautions detailed in PC 9.
  • Page 108 NOTES F-62 F-62 POWER WAVE ® 355M/405M...

  • Page 109: Dc Bus Board Removal And Replacement

    DC BUS 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.
  • Page 110 TROUBLESHOOTING AND REPAIR F-64 F-64 DC BUS BOARD REMOVAL AND REPLACEMENT (continued) PROCEDURE 1. Remove input power to the POWER WAVE 6. Using a phillips head screwdriver remove the two ® screws and their washers from above and below 355M/405M. the input power switch.
  • Page 111 TROUBLESHOOTING AND REPAIR F-65 F-65 DC BUS BOARD REMOVAL AND REPLACEMENT (continued) FIGURE F.29 – CASE FRONT SCREW REMOVAL STA A TUS THERMAL THERMAL Phillips Head Phillips Head Screws Screws 5/16" Mounting Screws 9. Label and remove two thermostat leads and four 13.
  • Page 112 TROUBLESHOOTING AND REPAIR F-66 F-66 DC BUS BOARD REMOVAL AND REPLACEMENT (continued) 16. Replace the two 5/16” mounting screws to the 17. Replace the case wraparound cover. bottom of the case front. POWER WAVE ® 355M/405M...

  • Page 113: Input Rectifier Removal And Replacement

    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 114 TROUBLESHOOTING AND REPAIR F-68 F-68 INPUT RECTIFIER REMOVAL AND REPLACEMENT (continued) PROCEDURE 1. Remove input power to the POWER WAVE 6. Remove the six screws from the terminals using a ® 355M/405M. flathead screwdriver. Carefully note the position of all leads and their positions upon removal. See 2.
  • Page 115 TROUBLESHOOTING AND REPAIR F-69 F-69 INPUT RECTIFIER REMOVAL AND REPLACEMENT (continued) 9. Apply a thin coat of Penetrox A-13 heatsink com- 11. Reconnect the previously removed leads to their pound to the point of contact between the input rec- proper locations. Torque to 31 inch pounds. tifier and the mounting surface.
  • Page 116 NOTES F-70 F-70 POWER WAVE ® 355M/405M...

  • Page 117: Output Rectifier Modules Removal And Replacement

    OUTPUT RECTIFIER MODULES 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 118 TROUBLESHOOTING AND REPAIR F-72 F-72 OUTPUT RECTIFIER MODULES REMOVAL AND REPLACEMENT (con’t) PROCEDURE 1. Remove input power to the POWER WAVE 6. After the snubber board is removed, remove the ® 355M/405M. four leads connected to the modules using a 3/16” allen wrench.
  • Page 119 TROUBLESHOOTING AND REPAIR F-73 F-73 OUTPUT RECTIFIER MODULES REMOVAL AND REPLACEMENT (con’t) 8. Under the copper plate previously removed, there 13. The screw threads may catch on the threads of the is an allen bolt. Remove it using a 9/64” allen heat sink, so be sure to get the face of the screw wrench.
  • Page 120 NOTES F-74 F-74 POWER WAVE ® 355M/405M...

  • Page 121: Current Transducer Removal And Replacement

    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 122 TROUBLESHOOTING AND REPAIR F-76 F-76 CURRENT TRANSDUCER REMOVAL AND REPLACEMENT (continued) PROCEDURE 1. Remove input power to the POWER WAVE 4. Using a 5/16” nut driver remove the four screws ® 355M/405M. from the bottom and right side of the rear assem- bly.
  • Page 123 TROUBLESHOOTING AND REPAIR F-77 F-77 CURRENT TRANSDUCER REMOVAL AND REPLACEMENT (continued) 5. Label and remove the four leads connected to the 9. Using a hammer and a flathead screwdriver, firmly reconnect panel. Pliers may be necessary. tap the metal nut from the bottom of one of its ribs. This tapping will loosen the nut.
  • Page 124 TROUBLESHOOTING AND REPAIR F-78 F-78 CURRENT TRANSDUCER REMOVAL AND REPLACEMENT (continued) 11. The back of the machine may now gently be pulled 16. Using a 3/8” wrench, remove the three mounting away to gain access to the current transducer. screws from the output diode heatsink assembly. Note: The rear of the machine cannot be removed Take note placement of insulation for reassembly.
  • Page 125 TROUBLESHOOTING AND REPAIR F-79 F-79 CURRENT TRANSDUCER REMOVAL AND REPLACEMENT (continued) 21. Replace the current transducer. 29. The rear of the machine may now be placed back into its original position. 22. Replace the two 3/8” mounting nuts previously removed. 30.

  • Page 126: Retest After Repair

    TROUBLESHOOTING AND REPAIR F-80 F-80 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. If you repair or replace any electrical components. INPUT IDLE AMPS AND WATTS Input Volts/Hertz Maximum Idle Amps...
  • Page 127 TABLE OF CONTENTS - DIAGRAM SECTION Electrical Diagrams ..............G-1 Wiring Diagram (G4131) .
  • Page 128 ELECTriCaL DiaGramS WiriNG DiaGram - pOWErWaVE 355/405 - G4131 WIRING DIAGRAM - POWER WAVE 355/405 RIGHT SIDE OF MACHINE INPUT N.A. C1,C3 FLAT SIDE OF LED ALIGNED WITH 3200/300 SWITCH BLACK LEAD THERMAL 1010 1020 1002 1020 54 53 YELLOW 1103 1104 1001...
  • Page 129 ELECTriCaL DiaGramS SChEmaTiC - COmpLETE maChiNE ENGINEERING CONTROLLED CHANGE DETAIL: Released from "X" MANUFACTURER: SWITCH BOARD J20-4 (Sch. L11487) MAIN INPUT CONTROL BOARD RELAY J20-8 (Sch. G3789) J6-9 +15V RECONNECT SWITCH J6-2 MAIN RELAY CONTROL J6-16 VOLTAGE / FREQUENC Y CONVERTER #1 (+) N.C.
  • Page 130 ELECTriCaL DiaGramS SChEmaTiC - DiGiTaL CONTrOL pC bOarD #1 NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. pOWEr WaVE ® 355m/405m...
  • Page 131 ELECTriCaL DiaGramS SChEmaTiC - DiGiTaL CONTrOL pC bOarD #2 NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. pOWEr WaVE ® 355m/405m...
  • Page 132 ELECTriCaL DiaGramS SChEmaTiC - DiGiTaL CONTrOL pC bOarD #3 NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. pOWEr WaVE ® 355m/405m...
  • Page 133 ELECTriCaL DiaGramS SChEmaTiC - DiGiTaL CONTrOL pC bOarD #4 NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. pOWEr WaVE ® 355m/405m...
  • Page 134 EARTH GROUND CONNECTION THIS SHEET CONTAINS PROPRIETARY INFORMATION OWNED BY THE LINCOLN ELECTRIC COMPANY AND IS NOT TO BE REPRODUCED, DISCLOSED OR USED WITHOUT THE EXPRESS WRITTEN PERMISSION OF THE LINCOLN ELECTRIC COMPANY, CLEVELAND, OHIO U.S.A. UNLESS OTHERWISE SPECIFIED TOLERANCE "X"...
  • Page 135 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. pOWEr WaVE ® 355m/405m...
  • Page 136 Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician.
  • Page 137 G-11 G-11 ELECTriCaL DiaGramS SChEmaTiC - SNubbEr pC bOarD 6-2-2000 S24761 NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. pOWEr WaVE ® 355m/405m...
  • Page 138 Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician.
  • Page 139 G-13 G-13 ELECTriCaL DiaGramS SChEmaTiC - 40 VDC buSS pC bOarD NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. pOWEr WaVE ® 355m/405m...

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