Lincoln Electric POWER WAVE 355M Service Manual

Lincoln electric welder user manual
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POWER WAVE 355M/405M
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Summary of Contents for Lincoln Electric POWER WAVE 355M

  • Page 1 RETURN TO MAIN MENU POWER WAVE 355M/405M...
  • Page 8 RETURN TO MAIN MENU...
  • Page 10 Product Ordering Input AC Rated DC Output Output Weight Dimensions Name Information Voltage Amps/Volts/Duty Cycle Range with Cord HxWxD (continuous)
  • Page 11 Product Ordering Input AC Rated DC Output Output Weight Dimensions Name Information Voltage Amps/Volts/Duty Cycle Range with Cord HxWxD (continuous)
  • Page 12: Select Suitable Location

    SELECT SUITABLE LOCATION STACKING TILTING INPUT AND GROUNDING CONNECTIONS LI NC NING...
  • Page 13: Undercarriage Mountings

    UNDERCARRIAGE MOUNTINGS MOUNTING HOLE LOCATIONS NOTE: MOUNTING SCREWS CA N NOT PROTR UDE MORE THAN 0.5 INCHES INSIDE THE MACHINE. 3.50 1/4-20 NUT (4 PLACES) 5.50 10.00 11.84 4/01 M19527...
  • Page 14: Electrode Voltage Sensing

    ELECTRODE VOLTAGE SENSING...
  • Page 19 POWER W POWER WA A V V E 355/405 E 355/405 Travel Direction Connect All Welding Work Leads at the Beginning of the Joint POWER WA A V V E 355/405 POWER W E 355/405 Connect All Work Sense Leads at the End of the Joint...
  • Page 20 MULTIPLE ARC SENSE LEAD AND WORK LEAD PLACEMENT GUIDELINES...
  • Page 21: Dip Switch Settings And Locations

    CONTROL BOARD DIP SWITCH: CONTROL BOARD (DIP Switch Location) DIP SWITCH SETTINGS AND LOCATIONS...
  • Page 22 FIGURE A.3 POWER WAVE FIGURE A.4 POWER WAVE SLIDING WORK K1796 COAXIAL CABLE MEASURE FROM END OF OUTER JACKET OF CABLE WORK WORK...
  • Page 24: General Description

    GENERAL DESCRIPTION RECOMMENDED PROCESSES AND EQUIPMENT RECOMMENDED PROCESSES...
  • Page 25: Duty Cycle And Time Period

    TABLE B.1 LIMITATIONS DUTY CYCLE AND TIME PERIOD CASE FRONT CONTROLS...
  • Page 26: Welding Adjustments

    WELDING ADJUSTMENTS...
  • Page 28 TABLE B.2...
  • Page 29 WELD GROOVES CREATED BY ARC GOUGING STEEL BUTTED TOGTHER...
  • Page 30 EACH PULSE DELIVERS ONE DROPLET OF WELD MATERIAL FREQUENCY SPRAY TRANSITION CURRENT...
  • Page 32 "N" PULSES "N" PULSES HIGH HEAT LOW HEAT PULSES PULSES PEAK AMPS BACKGROUND AMPS TIME WELDING PROCEDURES FOR PULSE-ON-PULSE MATERIAL WIRE WIRE SIZE 14 ga. 10 ga. 3/16 Not Recommended COMMENTS TABLE B.3 Aluminum 4043 Aluminum 4043 Aluminum 5356 100% Ar. 100% Ar.
  • Page 36: Visual Inspection

    CAPACITOR DISCHARGE PROCEDURE RESISTOR CAPACITOR TERMINALS VISUAL INSPECTION ROUTINE MAINTENANCE PERIODIC MAINTENANCE...
  • Page 37 FIGURE D.1 – MAJOR COMPONENT LOCATIONS L IN W AR M OT O FF...
  • Page 39 Input Input switch Rectifier Reconnect Switch 115VAC Fan Supply Auxiliary Transformer 220 VAC 40VDC Power Board 42VAC Receptacle Board Main Switch Board Primary Current Sensor Primary Current Sensor Primary Current Feedback(2) Input Relay Control Soft Start Control V/F Capacitor Feedback (2) Machine Control Supply +15VDC, -15VDC, +5VDC Control Board...
  • Page 40 Input Input switch Rectifier Reconnect Switch 115VAC Fan Supply Auxiliary Transformer 220 VAC Machine Control Supply 40VDC +15VDC, -15VDC, +5VDC Power Board RS232 Supply +5VDC 42VAC Can Supply +5VDC Receptacle Board 40VDC To Control Main Switch Board Board Primary Current Sensor Choke Primary...
  • Page 41 Input Input switch Rectifier Reconnect Switch 115VAC Fan Supply Auxiliary Transformer 220 VAC Machine Control Supply 40VDC +15VDC, -15VDC, +5VDC Power Board RS232 Supply +5VDC 42VAC Can Supply +5VDC Receptacle Board Main Switch Board Primary Current Sensor Primary Current Sensor Primary Current Feedback(2) Input Relay Control Soft Start Control...
  • Page 42 Input Input switch Rectifier Reconnect Switch 115VAC Fan Supply Auxiliary Transformer 220 VAC Machine Control Supply 40VDC +15VDC, -15VDC, +5VDC Power Board RS232 Supply +5VDC 42VAC Can Supply +5VDC Receptacle Board Main Switch Board Primary Current Sensor Primary Current Sensor Primary Current Feedback(2) Input Relay Control Soft Start Control...
  • Page 43 Input Input switch Rectifier Reconnect Switch 115VAC Fan Supply Auxiliary Transformer 220 VAC Machine Control Supply 40VDC +15VDC, -15VDC, +5VDC Power Board RS232 Supply +5VDC 42VAC Can Supply +5VDC Receptacle Board Main Switch Board Primary Current Sensor Primary Current Sensor Primary Current Feedback(2) Input Relay Control Soft Start Control...
  • Page 44: Thermal Protection

    THERMAL PROTECTION PROTECTIVE CIRCUITS OVER CURRENT PROTECTION UNDER/OVER VOLTAGE PROTECTION...
  • Page 45: Insulated Gate Bipolar Transistor (Igbt) Operation

    INSULATED GATE BIPOLAR TRANSISTOR (IGBT) OPERATION SOURCE DRAIN A. PASSIVE GATE SOURCE BODY REGION DRAIN DRIFT REGION BUFFER LAYER INJECTING LAYER DRAIN B. ACTIVE POSITIVE VOLTAGE APPLIED GATE BODY REGION DRAIN DRIFT REGION BUFFER LAYER INJECTING LAYER...
  • Page 46: Pulse Width Modulation

    FIGURE E.7 — TYPICAL IGBT OUTPUTS. PULSE WIDTH MODULATION MINIMUM OUTPUT MAXIMUM OUTPUT...
  • Page 60 DISCHARGE PROCEDURE POWER RESISTOR EIGHT CAPACITOR TERMINALS INSULATED (continued) INSULATED PLIERS GLOVES...
  • Page 62 (continued)
  • Page 63 (continued) TABLE F.1. SWITCH BOARD RESISTANCE TEST...
  • Page 66 Small Lead "H1" 3/16" ALLEN To Auxiliary Transformer BOLTS #207 #207A #209 Small Lead "A" FRONT To Circuit Breaker REAR...
  • Page 70 FIGURE F.4 – POWER BOARD TEST 12 11 10 9...
  • Page 71 TABLE F.3 – POWER BOARD VOLTAGE CHECKS...
  • Page 73: Dc Bus Board Test

    DC BUS BOARD TEST...
  • Page 74 DC BUS BOARD TEST ( ONTINUED) FIGURE F.5 – DC BUS POWER SUPPLY POWER SUPPLY PC BOARD DC BUS BOARD W AR FIGURE F.6 – DC BUS POWER SUPPLY POWER SUPPLY PC BOARD Rectifier Thermostat...
  • Page 75 DC BUS BOARD TEST( ONTINUED) TABLE F.4 – DC BUS POWER SUPPLY PC BOARD VOLTAGE TABLE...
  • Page 78 STA A TUS NEGATIVE POSITIVE OUTPUT OUTPUT TERMINAL TERMINAL (continued) THERMAL THERMAL...
  • Page 79 (continued)
  • Page 80 Output Diode Modules Snubber Board LEFT SIDE...
  • Page 82 Auxiliary Transformer Secondary Lead Plugs P52 W AR M OT PW405 Only (220V) Plug P52 (continued) (115V) Com 2 (31)
  • Page 83 (continued)
  • Page 86 R EM O TE O FF (continued) Plug J8 Plug J8...
  • Page 87 (continued)
  • Page 90 Fan Lead Lead 32A Fan Lead Lead 31B(C) Plug J22...
  • Page 91 Lead 716- Plug J20 Lead 715+...
  • Page 94: Control Board

    W AR STA A TUS Phillips Head Screws 5/16" Mounting Screws (continued) Control Board THERMAL THERMAL Phillips Head Screws...
  • Page 95 (continued) J10B J10A...
  • Page 96 (continued) Mounting Nuts (3/8")
  • Page 99 3/16" ALLEN BOLTS...
  • Page 102 Snubber Board LEFT SIDE Lead 30 Lead B1 Lead 10...
  • Page 104 Power Board LEFT SIDE...
  • Page 108 DC BUS BOARD...
  • Page 109 Phillips Head Screws 3/8" Mounting Nuts STA A TUS THERMAL THERMAL Phillips Head Screws 5/16" Mounting Screws Rectifier Thermostat...
  • Page 112 INPUT RECTIFIER...
  • Page 113 Small Lead "H1" 3/16" ALLEN To Auxiliary Transformer BOLTS #207 #207A #209 Small Lead "A" FRONT To Circuit Breaker REAR...
  • Page 116 Output Diode Modules Snubber Board LEFT SIDE...
  • Page 117 Mounting Bolts X4 X2 3/16" Allen Bolts 9/64" Allen Bolts Mounting Bolts...
  • Page 120 Plastic REAR 5/16" Mounting Screws...
  • Page 121 #206 #202 #207A #203...
  • Page 122 3/8" MOUNTING BOLTS...
  • Page 124: Retest After Repair

    RETEST AFTER REPAIR...
  • Page 126 WIRING DIAGRAM - POWER WAVE 355/405 INPUT N.A. C1,C3 SWITCH 3200/300 1010 1020 N.D. 1001 1002 3200/300 C2,C4 PRIMARY RECONNECT 207A MAIN TRANSFORMER ( 380-575VAC POSITION ) INPUT N.E. BRIDGE N.C. 380- 200- 415V 208V 207A 550- 440- 220- 575V 460V 230V OUTPUT...
  • Page 127 G4132 ENGINEERING CONTROLLED CHANGE DETAIL: Released from "X" MANUFACTURER: RECONNECT SWITCH N.B. N.C. INPUT SWITCH WHITE (BROWN) INPUT LINES (BLACK) BLACK (BLUE) GREEN (GREEN/YELLOW) 6.0A ( ) COLOR FOR PW405 N.D. Dashed lines represent copper bus connections. Shown connected for 200 - 240 Volt Input Voltage AUXILIARY TRANSFORMER...
  • Page 128 This diagram is for reference only. It may not be accurate for all machines covered by this manual.
  • Page 129 This diagram is for reference only. It may not be accurate for all machines covered by this manual.
  • Page 130 This diagram is for reference only. It may not be accurate for all machines covered by this manual.
  • Page 131 This diagram is for reference only. It may not be accurate for all machines covered by this manual.
  • Page 132 NOT SHOW THE EXACT COMPONENTS OR CIRCUITRY OF CONTROLS HAVING A COMMON CODE NUMBER. 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 133 This diagram is for reference only. It may not be accurate for all machines covered by this manual.
  • Page 134 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 135 6-2-2000 S24761 This diagram is for reference only. It may not be accurate for all machines covered by this manual.
  • 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 This diagram is for reference only. It may not be accurate for all machines covered by this manual.

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