Page 1: Service Manual
POWER WAVE 355/405 For use with machine code numbers 10895, 10896 Safety Depends on You 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.
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: Electric Shock Can Kill
ELECTRIC SHOCK can kill. 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.
Page 4: Safety
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.
Page 5 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 suiv- antes: Sûreté Pour Soudage A L’Arc 1. Protegez-vous contre la secousse électrique: a.
Page 6 (89/336/EEC). It was manufactured in conformity with a national standard that implements a harmonized standard: EN 50 199 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 INSTALLATION 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 recommendations.
Page 8: Table Of Contents
MASTER TABLE OF CONTENTS FOR ALL SECTIONS Safety...i-iv Installation ...Section A Operation...Section B Accessories...Section C Maintenance ...Section D Theory of Operation ...Section E Troubleshooting and Repair...Section F How to Use Troubleshooting Guide...F-2 Troubleshooting Guide ...F-4 Test Procedures ...F-15 Replacement Procedures ...F-47 Electrical Diagrams ...Section G Parts Manual ...P-401 Series RETURN TO MAIN INDEX...
Page 9 SectionA-1 Section A-1 TABLE OF CONTENTS - INSTALLATION SECTION - Installation Technical Specifications 355 ...A-2 Technical Specifications 405 ...A-3 Safety Precautions...A-4 Stacking ...A-4 Tilting ...A-4 Input Grounding Connections ...A-4 Power Cord Connection ...A-4 Output Cables, Connections and Limitations ...A-5 Negative Electrode Polarity ...A-5 Voltage Sensing ...A-5 Power Wave to Semi-Automatic Wire Feeder...A-6 System Description ...A-7...
Page 10 Select The output cable size based upon the following chart.* Cable sizes for Combined Length of Electrode and Work Cable (Copper) 75C rated: DUTY CYCLE CURRENT 100% Lincoln Electric recommends using a minimum of 2/0 welding cable for pulse welding. INSTALLATION POWER WAVE 355 Rated DC Output Output...
Page 11: Installation
TECHNICAL SPECIFICATIONS - INPUT AC VOLTAGE & DC OUTPUT Product Ordering Input AC Name Information Voltage Amps/Volts/Duty Cycle Power 200-208 / Wave K 2152-2 220-240/ 380-415/ 3/50/60 60/50 Hz 275A / 31V /100% * Overall Length Including Handle, 21.6” (549mm) without handle. POWER WAVE 405 INPUT CURRENT Recommended Fuse Sizes Based On The U.S.
Page 12: Safety Precautions
SAFETY PRECAUTIONS WARNING ELECTRIC SHOCK can kill. • TURN THE INPUT POWER OFF AT THE DISCONNECT SWITCH BEFORE ATTEMPTING TO CONNECT OR DIS- CONNECT INPUT POWER LINES, OUTPUT CABLES, OR CONTROL CABLES. • Only qualified personnel should perform this installation. •...
Page 13: Output Cables, Connections And Limitations
Depending upon the process, inductance within the electrode and work lead cables can influence the voltage apparent at the studs of the welder. Voltage sense leads improve the accuracy of the arc condi- tions and can have a dramatic effect on performance.
Page 14 Enable the voltage sense leads as follows: TABLE A.1 Process Electrode Voltage Work Voltage Sensing 67 lead * Sensing 21 lead GMAW 67 lead required 21 lead optional GMAW-P 67 lead required 21 lead optional FCAW 67 lead required 21 lead optional GTAW Voltage sense at studs Voltage sense at studs...
Page 15: System Description
SYSTEM DESCRIPTION The POWER WAVE 355/405 and Power Feed 10/11 family of products utilize a digital communication sys- tem called Linc-Net. Simply put, Linc-Net allows large amounts of information to be passed at very high speeds between components (nodes) in the system. The system requires only two wires for communication, and because of its bus-like structure, the components may be connected to the network in any order, thus...
Page 16: 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: Multiple Group System
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 A-10 A-10 INSTALLATION 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 355/405...
Page 19: Welding With Multiple Power Waves
A-11 WELDING WITH MULTIPLE POWER WAVES CAUTION Special care must be taken when more than one Power Wave is welding simultaneously on a single part. Arc blow and arc interference may occur or be magnified. Each power source requires a work lead from the work stud to the welding fixture.
Page 20: Dip Switch Settings And Locations
A-12 I / O RECEPTACLE SPECIFICATIONS TABLE A.2 WIRE FEEDER RECEPTACLE LEAD# FUNCTION Communication Bus L Communication Bus H Electrode Voltage Sense 0vdc +40vdc TABLE A.3 VOLTAGE SENSE RECEPTACLE LEAD# FUNCTION Work Voltage Sense TABLE A.4 RS232 RECEPTACLE LEAD# FUNCTION RS232 Receive RS232 Transmit Pin5...
Page 21 Section B-1 Section B-1 TABLE OF CONTENTS - OPERATION SECTION - Operation...Section B Safety Precautions...B-2 General Description ...B-2 Recommended Processes and Equipment ...B-2 Required Equipment ...B-3 Limitations...B-3 Duty Cycle and Time Period...B-3 Case Front Controls...B-3 Making a Weld ...B-4 Welding Adjustments ...B-4 Constant Voltage Welding ...B-5 Tig (GTAW) ...B-6 Special Welding Processes Available ...B-6...
Page 22: Operation
SAFETY PRECUATIONS Read this entire section of operating instructions before operating the machine. WARNING ELECTRIC SHOCK can kill. • Unless using cold feed feature, when feeding with gun trigger, the elec- trode and drive mechanism are always electrically energized and could remain energized several sec- onds after the welding ceases.
Page 23: Required Equipment
POWER WAVE 355/405 – Operation Semi Automatic Power Waves can only be used with Linc-Net compatible Power Feed semi-automatic wire feeders. In addition, the Power Feed semi-automatic wire feeders may require optional equipment to access certain weld modes in the Power Wave. Other models of Lincoln feeders, or any models of non-Lincoln wire feeders, cannot be used.
Page 24: Making A Weld
Power Waves 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 desired welding parameters.
Page 25: Constant Voltage Welding
In non-synergic modes, the WFS control behaves more like a conventional CV power source where WFS and voltage are independent adjustments. Therefore to maintain the arc characteristics, the operator must adjust the voltage to compensate for any changes made to the WFS. In constant current modes (stick, TIG) this control adjusts the output current, in amps.
Page 26: Tig Gtaw
TIG GTAW The TIG mode features continuous control from 5 to 425 amps. The TIG mode can be run in either the Touch Start TIG or Scratch start mode. The Arc Control level selects the starting mode. Between –10 and 0, the Touch Start TIG mode is selected.
Page 27: Pulse Welding (Gmaw-P
PULSE WELDING (GMAW-P) The pulsed-arc process is, by definition, a spray trans- fer process wherein spray transfer occurs in pulses at regularly spaced intervals. In the time between pulses, the welding current is reduced and no metal transfer occurs. Pulsed-arc transfer is obtained by operating a power source between low and high current levels.
Page 28: Pulse-On-Pulse (Gmaw-Pp
Since Arc Control varies weld droplet transfer rate, the Arc Control can be used to vary the ripple spacing in the weld bead. BENEFITS OF PULSE ON PULSE FROM LINCOLN ELECTRIC • Excellent appearance of the weld bead • Improved cleaning action • Reduced porosity Table B.2 shows WFS and Trim settings for common...
Page 29 TABLE OF CONTENTS - ACCESSORIES SECTION - Accessories...Section C Optional Equipment...C-2 Field Installed ...C-2 Compatible Lincoln Equipment...C-2 POWER WAVE 355/405...
Page 30: 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 Welding Cable Connectors: K852-70 1/0-2/0 CABLE K852-95 2/0-3/0 CABLE COMPATIBLE LINCOLN EQUIPMENT Any Linc-Net compatible semi-automatic wire feeding...
Page 31 Section D-1 Section D-1 TABLE OF CONTENTS -MAINTENANCE- Maintenance ...Section D Capacitor Discharge Procedure ...D-2 Visual Inspection...D-2 Routine Maintenance...D-2 Periodic Maintenance ...D-2 Major Component Locations ...D-3 POWER WAVE 355/405...
Page 32 WARNING Have qualified personnel do the maintenance work. Always use the greatest care when working near moving parts. Do not put your hands near the cooling blower fan. If a problem cannot be corrected by following the instructions, take the machine to the nearest Lincoln Field Service Shop.
Page 33 FIGURE D.1 – MAJOR COMPONENT LOCATIONS 1. Center Panel 2. Case Back 3. Case Front 4. Base Assembly 5. Case Wraparound L IN W AR M OT O FF MAINTENANCE POWER WAVE 355/405...
Page 34 NOTES POWER WAVE 355/405...
Page 35 Section E-1 -THEORY OF OPERATION SECTION- Theory of Operation ...Section E General Description ...E-2 Input Line Voltage, Auxiliary Transformer and Precharge...E-2 Switch Board and Main Transformer ...E-3 DC Bus Board, Power board and Control Board ...E-4 Output Rectifier and Choke ...E-5 Thermal Protection ...E-6 Protective Circuits...E-6 Over current Protection ...E-6...
Page 36: Theory Of Operation
THEORY OF OPERATION FIGURE E.2 – INPUT VOLTAGE AND PRECHARGE Input Input switch Rectifier 115VAC Fan Supply Auxiliary Transformer 220 VAC 40VDC 42VAC Receptacle Board GENERAL DESCRIPTION Power Wave semi-automatic power source is designed to be a part of a modular, multi-process welding system.
Page 37: Switch Board And Main Transformer
THEORY OF OPERATION FIGURE E.3 – SWITCH BOARD & MAIN TRANSFORMER Input Input switch Rectifier 115VAC Fan Supply Auxiliary Transformer 220 VAC 40VDC Power Board 42VAC Receptacle Board SWITCH BOARD & MAIN TRANSFORMER There is one switch board in the POWER WAVE 355/405.
Page 38: Dc Bus Board, Power Board And Control Board
THEORY OF OPERATION FIGURE E.4 – POWER BOARD, CONTROL BOARD AND SERIAL PERIPHERAL INTERFACE (SPI) COMMUNICATIONS Input Input switch Rectifier 115VAC Fan Supply Auxiliary Transformer 220 VAC 40VDC 42VAC Receptacle Board DC BUS BOARD, POWER BOARD AND CONTROL BOARD DC BUS BOARD The DC Bus Board receives approximately 65VDC from the bus board rectifier.
Page 39: Output Rectifier And Choke
THEORY OF OPERATION FIGURE E.5 – OUTPUT RECTIFIER AND CHOKE Input Input switch Rectifier 115VAC Fan Supply Auxiliary Transformer 220 VAC 40VDC 42VAC Receptacle Board OUTPUT RECTIFIER AND CHOKE The output rectifier receives the AC output from the main transformer secondary and rectifies it to a DC voltage level.
Page 40: Thermal Protection
THEORY OF OPERATION THERMAL PROTECTION Three normally closed (NC) thermostats protect the machine from excessive operating temperatures. These thermostats are wired in series and are con- nected to the control board. One of the thermostats is located on the heat sink of the switch board, one is located on the output choke and the third thermostat is located on the DC Bus Board.
Page 41: Insulated Gate Bipolar Transistor (Igbt) Operation
THEORY OF OPERATION INSULATED GATE BIPOLAR TRANSISTOR (IGBT) OPERATION An IGBT is a type of transistor. IGBT are semiconduc- tors well suited for high frequency switching and high current applications. Example A in Figure E.6 shows an IGBT in passive mode.
Page 42: Pulse Width Modulation
THEORY OF OPERATION FIGURE E.7 — TYPICAL IGBT OUTPUTS. PULSE WIDTH MODULATION The term Pulse Width Modulation is used to describe how much time is devoted to conduction in the posi- tive and negative portions of the cycle. Changing the pulse width is known as modulation.
Page 43 Section F-1 TROUBLESHOOTING & REPAIR SECTION Troubleshooting & Repair Section ...Section F How to Use Troubleshooting Guide ...F-2 PC Board Troubleshooting Procedures and Replacement ...F-3 Troubleshooting Guide ...F-4 Test Procedures Input Filter Capacitor Discharge Procedure ...F-13 Main Switch Board Test ...F-15 Input Rectifier Test ...F-19 Power Board Test...F-23 DC Bus Board Test...F-27...
Page 44: Troubleshooting And Repair
TROUBLESHOOTING & REPAIR HOW TO USE TROUBLESHOOTING GUIDE 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. For your safety and to avoid Electrical Shock, please observe all safety notes and precautions detailed throughout this manual.
Page 45: Pc Board Troubleshooting Procedures
- If the PC board uses protective shorting jumpers, don’t remove them until installation is complete. - 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- er failure analysis.
Page 46: Troubleshooting Guide
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, con- tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-800-833-9353(WELD). POSSIBLE AREAS OF...
Page 47 If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, con- tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-800-833-9353(WELD). detailed in the beginning of this manual.
Page 48 If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, con- tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-800-833-9353(WELD).
Page 49 Excessively long and erratic arc. If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, con- tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-800-833-9353(WELD).
Page 50 General degradation of the weld performance. If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, con- tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-800-833-9353(WELD). POSSIBLE AREAS OF...
Page 51 TROUBLESHOOTING & REPAIR USING THE STATUS LED TO TROUBLESHOOT SYSTEM PROBLEMS The Power Wave / Power Feed are best diagnosed as a system. Each component (power source, user interface, and feed head) has a status light, and when a problem occurs it is important to note the condition of each.
Page 52 F-10 TROUBLESHOOTING & REPAIR STATUS LED ERROR CODE TABLE NOTE: The error code signal sequence is always preceded by a 2 second green light. If more than one error code is present, a 4 second off signal will separate the individual error code signals. Note that the [2 sec.
Page 53 F-11 F-11 TROUBLESHOOTING & REPAIR 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 54 F-12 F-12 NOTES POWER WAVE 355/405...
Page 55: Input Filter Capacitor Discharge Procedure
TROUBLESHOOTING & REPAIR INPUT FILTER CAPACITOR DISCHARGE PROCEDURE 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 56 F-14 TROUBLESHOOTING & REPAIR INPUT FILTER CAPACITOR DISCHARGE PROCEDURE (continued) WARNING ELECTRIC SHOCK • Have an electrician install and service this equipment. • Turn the input power off at the fuse box before working on equipment. • Do not touch electrically hot parts. •...
Page 57: Main Switch Board Test
TROUBLESHOOTING & REPAIR MAIN SWITCH BOARD TEST 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 58 F-16 TROUBLESHOOTING & REPAIR MAIN SWITCH BOARD TEST (continued) FIGURE F.2 MAIN SWITCH BOARD LEAD LOCATIONS TEST PROCEDURE 1. Remove input power to the POWER WAVE 355/405. 2. Using a 5/16” nut driver, remove the case wraparound. 3. Perform the Input Filter Capacitor Discharge Procedure detailed earlier in this section.
Page 59 F-17 TROUBLESHOOTING & REPAIR MAIN SWITCH BOARD TEST (continued) 6. If any test fails replace the switch board. See Main Switch Board Removal and Replacement. 7. If the switch board resistance tests are OK, check connections on plugs J20, J21, J22 and all asso- ciated wiring.
Page 60 F-18 F-18 NOTES POWER WAVE 355/405...
Page 61: Input Rectifier Test
F-19 TROUBLESHOOTING & REPAIR 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 F-20 TROUBLESHOOTING & REPAIR INPUT RECTIFIER TEST (CONTINUED) TEST PROCEDURE 1. Remove input power to the POWER WAVE 355/405 machine. 2. Using a 5/16” nut driver, remove the case wraparound cover. 3. Perform Capacitor Procedure detailed earlier in this section. 4.
Page 63: Replacement Procedures
F-21 TROUBLESHOOTING & REPAIR INPUT RECTIFIER TEST (CONTINUED) TEST POINT TERMINALS + PROBE 207A 207A 207A 9. If the input rectifier does not meet the acceptable readings outlined in Table F.2 the component may be faulty. Replace Note: Before replacing the input rectifier, check the input power switch and per- form the Main Switch Board Test.
Page 64 F-22 F-22 NOTES POWER WAVE 355/405...
Page 65: Power Board Test
F-23 TROUBLESHOOTING & REPAIR 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 66 F-24 TROUBLESHOOTING & REPAIR POWER BOARD TEST (CONTINUED) TEST PROCEDURE 1. Remove input power to the Power Wave 355/405. 2. Using the 3/8” nut driver, remove the case top. 3. Perform Capacitor Procedure. 4. Locate the Power Board and plugs J42 and J43.
Page 67 F-25 TROUBLESHOOTING & REPAIR POWER BOARD TEST (CONTINUED) TABLE F.3 – POWER BOARD VOLTAGE CHECKS CHECK POINT TEST LOCATION DESCRIPTION POWER BOARD CHECK 40 VDC CONNECTOR INPUT FROM PLUG J41 DC BUS BOARD POWER BOARD CHECK +15 CONNECTOR VDC SUPPLY FROM PLUG J42 POWER BOARD POWER BOARD...
Page 68 F-26 F-26 NOTES POWER WAVE 355/405...
Page 69: Dc Bus Board Test
F-27 TROUBLESHOOTING & REPAIR 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 70 F-28 TROUBLESHOOTING & REPAIR DC BUS BOARD TEST (CONTINUED) FIGURE F.5 – DC BUS POWER SUPPLY POWER SUPPLY PC BOARD W AR TEST PROCEDURE 1. Remove input power to the machine. 2. Using the 3/8” nut driver, remove the wrap- around cover.
Page 71 F-29 TROUBLESHOOTING & REPAIR DC BUS BOARD TEST(CONTINUED) 6. Check the DC Bus Board input and output voltages according to Table F.4. See Figure F.6 and the Wiring Diagram. WARNING ELECTRIC SHOCK can kill. High voltage is present at the terminals of Capacitor C3 near where testing is to be done.
Page 72 F-30 F-30 NOTES POWER WAVE 355/405...
Page 73: Output Diode Modules Test
TROUBLESHOOTING & REPAIR OUTPUT DIODE MODULES TEST 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 74 F-32 TROUBLESHOOTING & REPAIR OUTPUT DIODE MODULES TEST (continued) NEGATIVE OUTPUT TERMINAL TEST PROCEDURE 1. Remove input power to the POWER WAVE 355/405. 2. Locate the output terminals on the front panel of the machine. See Figure F.7. 3. Remove any output cables and load from the output terminals.
Page 75 F-33 TROUBLESHOOTING & REPAIR OUTPUT DIODE MODULES TEST (continued) 5. If 200 ohms is measured then the output diodes are not “shorted”. NOTE: There is a 250 ohm resistor across the welding output terminals. See Wiring Diagram 6. If less than 200 ohms is measured, one or more diodes or the snubber board may be faulty.
Page 76 F-34 F-34 TROUBLESHOOTING & REPAIR OUTPUT DIODE MODULES TEST (continued) Figure F.9 Snubber and Output Diode Locations Output Diode Modules Snubber Board LEFT SIDE POWER WAVE 355/405...
Page 77: Auxiliary Transformer Test
TROUBLESHOOTING & REPAIR AUXILIARY TRANSFORMER TEST 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 78 F-36 TROUBLESHOOTING & REPAIR AUXILIARY TRANSFORMER TEST (continued) Auxiliary Transformer Secondary Lead Plugs P52 W AR TEST PROCEDURE 1. Remove input power to the POWER WAVE 355/405. 2. Using a 5/16” nut driver, remove the case wraparound cover. 3. Perform the Input Capacitor Discharge Procedure detailed earlier in this section.
Page 79 F-37 TROUBLESHOOTING & REPAIR AUXILIARY TRANSFORMER NO.1 TEST (continued) LEAD IDENTIFICATION COM 2 (31) TO 115V (532) 42 TO COM 1A (quick connects) 7. Carefully apply the correct input voltage to the POWER WAVE 355/405 and check for the cor- rect secondary voltages per table F.5.
Page 80 F-38 F-38 NOTES POWER WAVE 355/405...
Page 81: Current Transducer Test
TROUBLESHOOTING AND REPAIR CURRENT TRANSDUCER TEST 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 82 F-40 TROUBLESHOOTING AND REPAIR CURRENT TRANSDUCER TEST (continued) FIGURE F.12 Metal Plate Removal & Plug J8 Location R EM O TE O FF TEST PROCEDURE 1. Remove input power to the POWER WAVE 355/405. 2. Using the 5/16” nut driver, remove the case wraparound cover.
Page 83 F-41 TROUBLESHOOTING AND REPAIR CURRENT TRANSDUCER TEST (continued) OUTPUT LOAD CURRENT 8. Check the feedback voltage from the current transducer using a resistive load bank and with the POWER WAVE 355/405 in mode 200. Mode 200 is a constant current test mode. This mode can be accessed using a wire feed- er placed in mode 200 or a laptop computer and the appropriate software.
Page 84 F-42 F-42 NOTES POWER WAVE 355/405...
Page 85: Fan Control And Motor Test
TROUBLESHOOTING AND REPAIR FAN CONTROL AND MOTOR TEST 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 86 F-44 TROUBLESHOOTING AND REPAIR FAN CONTROL AND MOTOR TEST (continued) TEST PROCEDURE 1. Remove the input power to the POWER WAVE 355/405 machine. 2. Using the 5/16” nut driver, remove the case wraparound cover. 5. Carefully apply the correct input power to the machine.
Page 87: Replacement Procedures
F-45 TROUBLESHOOTING AND REPAIR FAN CONTROL AND MOTOR TEST (continued) 7. If the 115VAC is low or not present check cir- cuit breaker CB2 located on the front panel. If the circuit breaker is OK, perform The Auxiliary Transformer Test. Check plug J22, circuit breaker CB2 and associated leads for loose or faulty connections.
Page 88 F-46 F-46 NOTES POWER WAVE 355/405...
Page 89: Control Board Removal And Replacement
TROUBLESHOOTING & REPAIR CONTROL BOARD REMOVAL AND REPLACEMENT 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-48 TROUBLESHOOTING & REPAIR CONTROL BOARD REMOVAL AND REPLACEMENT (continued) FIGURE F.17 - CONTROL BOARD LOCATION W AR PROCEDURE 1. Remove input power to the POWER WAVE 355/405. 2. Using a 5/16” nut driver remove the case wrap- around cover. 3.
Page 91 See Figure F.18. 7. Using a phillips head screwdriver remove the four screws from around the two welder output termi- nals on the front of the machine. See Figure F.18. J10A 8.
Page 92 14. Replace the control board. 19. Replace the four screws from around the two welder output terminals on the front of the machine. 20. Replace the two case front mounting screws at the bottom of the front of the machine.
Page 93: Main Switch Board Removal And Replacement
TROUBLESHOOTING & REPAIR MAIN SWITCH BOARD REMOVAL AND REPLACEMENT 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 94 F-52 TROUBLESHOOTING & REPAIR MAIN SWITCH BOARD REMOVAL & REPLACEMENT (continued) FIGURE F.21 – MAIN SWITCH BOARD LEAD LOCATIONS PROCEDURE 1. Remove the input power to the POWER WAVE 355/405. 2. Using a 5/16” nut driver remove the case wrap- around cover.
Page 95 F-53 TROUBLESHOOTING & REPAIR MAIN SWITCH BOARD REMOVAL & REPLACEMENT (continued) FIGURE F.22 – 3/16” ALLEN BOLT LOCATION 9. Using a 3/16” allen wrench remove four allen bolts and washers as shown in Figure F.22. At this point, the board is ready for removal. 10.
Page 96 F-54 F-54 NOTES POWER WAVE 355/405...
Page 97: Snubber Board Removal And Replacement
TROUBLESHOOTING & REPAIR SNUBBER BOARD REMOVAL AND REPLACEMENT 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 98 F-56 TROUBLESHOOTING & REPAIR SNUBBER BOARD REMOVAL AND REPLACEMENT (continued) PROCEDURE 1. Remove input power to the POWER WAVE 355/405. 2. Using a 5/16” nut driver remove the case wrap- around cover. FIGURE F.23 – SNUBBER BOARD LOCATION Snubber Board 5.
Page 99: Power Board Removal And Replacement
TROUBLESHOOTING & REPAIR POWER BOARD REMOVAL AND REPLACEMENT 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 F-58 TROUBLESHOOTING & REPAIR POWER BOARD REMOVAL AND REPLACEMENT (continued) FIGURE F.25 POWER BOARD LOCATION Power Board PROCEDURE 1. Remove input power to the POWER WAVE 355/405. 2. Using a 5/16” nut driver remove the case wrap- around cover. LEFT SIDE 3.
Page 101 F-59 TROUBLESHOOTING & REPAIR POWER BOARD REMOVAL AND REPLACEMENT (continued) CAUTION Observe static precautions detailed in PC Board Troubleshooting Procedures at the beginning of this section. 5. Locate the three plug connections. J41, J42 and J43 on the Power Board. See figure F.26. 6.
Page 102 F-60 F-60 NOTES POWER WAVE 355...
Page 103: Dc Bus Board Removal And Replacement
TROUBLESHOOTING & REPAIR DC BUS BOARD REMOVAL AND REPLACEMENT 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 See Figure F.28. 7. Using a phillips head screwdriver remove the four screws mounting the two welder output terminals on the front of the machine. See Figure F.28. 8. The front of the machine may now gently be pulled forward to gain access to the DC Bus Board.
Page 105 13. Reconnect previously removed leads to their prop- er locations. 14. Replace the four phillips head screws mounting the two welder output terminals to the front of the machine. 15. Replace the two phillips head screws from above and below the input power switch.
Page 106 F-64 F-64 TROUBLESHOOTING & REPAIR DC BUS BOARD REMOVAL AND REPLACEMENT (Continued) 16. Replace the two 5/16” mounting screws to the bottom of the case front. 17. Replace the case wraparound cover. POWER WAVE 355...
Page 107: Input Rectifier Removal And Replacement
TROUBLESHOOTING & REPAIR INPUT RECTIFIER REMOVAL AND REPLACEMENT 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 108 F-66 TROUBLESHOOTING & REPAIR INPUT RECTIFIER REMOVAL AND REPLACEMENT (continued) PROCEDURE 1. Remove input power to the POWER WAVE 355/405. 2. Using a 5/16” nut driver remove the case wraparound cover. 3. Perform the Input Filter Capacitor Discharge Procedure detailed earlier in this section. 4.
Page 109 F-67 TROUBLESHOOTING & REPAIR INPUT RECTIFIER REMOVAL AND REPLACEMENT (continued) 9. Apply a thin coat of Penetrox A-13 heatsink com- pound to the point of contact between the input rectifier and the mounting surface. 10. Secure the new input bridge into its proper posi- tion with the two 3/16”in.
Page 110 F-68 F-68 NOTES POWER WAVE 355/405...
Page 111: Output Rectifier Modules Removal And Replacement
TROUBLESHOOTING & REPAIR OUTPUT RECTIFIER MODULES REMOVAL AND 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 112 F-70 TROUBLESHOOTING & REPAIR OUTPUT RECTIFIER MODULES REMOVAL AND REPLACEMENT (continued) PROCEDURE 1. Remove input power to the POWER WAVE 355/405. 2. Using a 5/16” nut driver remove the case wrap- around cover. 3. Perform the Input Filter Capacitor Discharge Procedure detailed earlier in this section.
Page 113 F-71 TROUBLESHOOTING & REPAIR OUTPUT RECTIFIER MODULES REMOVAL AND REPLACEMENT (continued) 8. Under the copper plate previously removed, there is an allen bolt. Remove it using a 9/64” allen wrench. See Figure F.33. 9. Using a 7/16” socket remove the mounting bolts at the top and bottom of the modules.
Page 114 F-72 F-72 NOTES POWER WAVE 355/405...
Page 115: Current Transducer Removal And Replacement
TROUBLESHOOTING & REPAIR CURRENT TRANSDUCER REMOVAL AND REPLACEMENT 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 116 F-74 TROUBLESHOOTING & REPAIR CURRENT TRANSDUCER REMOVAL AND REPLACEMENT (continued) PROCEDURE 1. Remove input power to the POWER WAVE 355/405. 2. Using a 5/16” nut driver remove the case wrap- around cover. 3. Perform the Input Filter Capacitor Discharge Procedure detailed earlier in this section. FIGURE F.34 –...
Page 117 F-75 TROUBLESHOOTING & REPAIR CURRENT TRANSDUCER REMOVAL AND REPLACEMENT (continued) 5. Label and remove the four leads connected to the reconnect panel. Pliers may be necessary. 6. Label and remove the two leads connected to the CB2 circuit breaker. 7. Using a crescent wrench, remove the large plastic nut from around the input power line located at bot- tom of the rear assembly.
Page 118 F-76 TROUBLESHOOTING & REPAIR CURRENT TRANSDUCER REMOVAL AND REPLACEMENT (continued) 11. The back of the machine may now gently be pulled away to gain access to the current trans- ducer. Note: The rear of the machine cannot be removed completely. 12.
Page 119 F-77 TROUBLESHOOTING & REPAIR CURRENT TRANSDUCER REMOVAL AND REPLACEMENT (continued) 21. Replace the current transducer. 22. Replace the two 3/8” mounting nuts previously removed. 23. Reconnect plug #J90 to the current transducer. 24. Replace any necessary cable ties previously cut. 25.
Page 120: Retest After Repair
F-78 TROUBLESHOOTING & 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 Volts/Hertz 208/60 230/60 400/60...
Page 121 ELECTRICAL DIAGRAMS -ELECTRICAL DIAGRAMS SECTION- ELECTRICAL DIAGRAMS ............SECTION G WIRING DIAGRAM (G4131) .
Page 122 WIRING DIAGRAM - POWERWAVE 355/405 - G4131 WIRING DIAGRAM - POWER WAVE 355/405 INPUT N.A. C1,C3 SWITCH 3200/300 1010 1020 1001 N.D. 1002 3200/300 C2,C4 PRIMARY RECONNECT 207A ( 380-575VAC POSITION ) INPUT N.E. BRIDGE N.C. 380- 200- 415V 208V 207A 440- 550-...
Page 123: Electrical Diagrams
SCHEMATIC - COMPLETE MACHINE G4132 ENGINEERING CONTROLLED CHANGE DETAIL: Released from "X" MANUFACTURER: RECONNECT SWITCH N.C. N.B. INPUT SWITCH WHITE (BROWN) INPUT LINES (BLACK) BLACK (BLUE) GREEN (GREEN/YELLOW) ( ) COLOR FOR PW405 6.0A Dashed lines represent N.D. copper bus connections. AUXILIARY TRANSFORMER 2.5A...
Page 124 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. POWERWAVE 355/405...
Page 125 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. POWERWAVE 355/405...
Page 126 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. POWERWAVE 355/405...
Page 127 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. POWERWAVE 355/405...
Page 128 SCHEMATIC - POWER SUPPLY PRINTED CIRCUIT BOARD … ¬ü» ÌÔÙÛüß ™ ® ± … ™ Û —¥¥ Ã ‡‚ ÁË Ì‰ü¬ Ó ÌÛÒ Ó Î “Á ÙÛ üÓˆ Ì ¬‡ Ô‡‚ËÛÓÒ … … ¬ü»Ì ÔÙÛ üß ¨ ® ™¥ ’ ‘Ì„...
Page 129 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. POWERWAVE 355/405...
Page 130 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 131 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. POWERWAVE 355/405...
Page 132 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 133 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. POWERWAVE 355/405...
Page 134 Your Company__________________________ Your Name_____________________________ Please give detailed description below: ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ SD287 01/99 Thank You, Technical Services Group Lincoln Electric Co. 22801 ST. Clair Ave. Cleveland, Ohio 44117-1199 FAX 216-481-2309...

This manual is also suitable for:

Power wave 355 Power wave 405

Lincoln Electric POWER WAVE 355/405 SVM159-A Service Manual

Master for All Sections

Safety

Installation

Operation

Operation

Accessories

Theory of Operation

Troubleshooting & Repair Section

Quick Links

SERVICE MANUAL

Chapters

Troubleshooting

Related Manuals for Lincoln Electric POWER WAVE 355/405 SVM159-A

Summary of Contents for Lincoln Electric POWER WAVE 355/405 SVM159-A

This manual is also suitable for:

Table of Contents