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Lincoln Electric POWER WAVE SVM135-B Service Manual

Lincoln electric welder user manual
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RETURN TO MAIN INDEX
SVM135-B
July,2001
P P o o w w e e r r W
W a a v v e e 4 4 5 5 5 5 / / P P o o w w e e r r F F e e e e d d 1 1 0 0
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 thought-
ful operation on your part. DO
NOT INSTALL, OPERATE OR
REPAIR THIS EQUIPMENT
WITHOUT
READING
THIS
MANUAL AND THE SAFETY
PRECAUTIONS CONTAINED
THROUGHOUT. And, most
importantly, think before you act
and be careful.

SERVICE MANUAL

World's Leader in Welding and Cutting Products
Premier Manufacturer of Industrial Motors
• Sales and Service through Subsidiaries and Distributors Worldwide •
Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com

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Summary of Contents for Lincoln Electric POWER WAVE SVM135-B

  • Page 1: Service Manual

    RETURN TO MAIN INDEX SVM135-B July,2001 P P o o w w e e r r W W a a v v e e 4 4 5 5 5 5 / / P P o o w w e e r r F F e e e e d d 1 1 0 0 Safety Depends on You Lincoln arc welding and cutting equipment is designed and built...

  • Page 2: Safety

    351040, 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 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 instruc- tions et les précautions de sûreté specifiques qui parraissent dans ce manuel aussi bien que les précautions de sûreté générales suivantes: Sûreté Pour Soudage A L’Arc 1. Protegez-vous contre la secousse électrique: a.

  • Page 6: Table Of Contents

    MASTER TABLE OF CONTENTS FOR ALL SECTIONS Safety ................Installation .
  • Page 7 SECTION A-1 Installation ............... . Section A Technical Specifications - Power Feed 10 Wire Drive and Control Box .

  • Page 8: Installation

    TECHNICAL SPECIFICATIONS – POWER FEED 10 WIRE DRIVE AND CONTROL BOX WIRE DRIVE OR WIRE DRIVE SECTION OF FEEDER SPEC # TYPE LOW SPEED RATIO Speed K1540-1 Power Feed 10 50-800 IPM Wire Drive (1.27-20.3 m/m) K1538-1 Power Feed 10 50-800 IPM Boom Package# (1.27-20.3 m/m) K1541-1 Power Feed 10...

  • Page 9: Technical Specifications - Power Wave 455

    TECHNICAL SPECIFICATIONS – POWER WAVE 455 INPUT AT RATED OUTPUT - THREE PHASE ONLY Rated Output @ Input Volts 100% Duty Cycle 208V - 60Hz 450A@38V 100% 230V - 60Hz 450A@38V 100% 400V - 60Hz 450A@38V 100% 460V - 60Hz 450A@38V 100% 200V - 50Hz 450A@38V 100%...

  • Page 10: Safety Precautions

    Dirt, dust, or any foreign material that can be drawn into the welder should be kept at a minimum. Using filters on the air intake to prevent dirt from building up restricts air flow.
  • Page 11 3. Loosen the four screws inside the Control Box located along the sides of the back of the Control Box, two near the bottom and two near the mid- dle. 4. Push the Control Box upwards and then pull the Control Box away from the wire drive.

  • Page 12: Electrical Connections

    If the lead is placed in a position higher than the applied line voltage, the welder may not come on at all. If the Auxiliary (“A”) lead is placed in a position lower than...

  • Page 13: Cable Connections

    FIGURE A.2 — CONNECTION DIAGRAM ON RECONNECT/INPUT ACCESS DOOR. INPUT SUPPLY CONNECTION DIAGRAM Disconnect input power before inspecting or servicing machine. Do not operate with covers removed. Do not touch electrically live parts. Only qualified persons should install, use or service this equipment. VOLTAGE=220-230V 200-208V 220-230V...

  • Page 14: Cable Connections

    CONTROL CABLE SPECIFICATIONS The cable is a five copper conductor cable in a SO- type rubber jacket. There is one 20 gauge twisted pair for network communications. This pair has an impedance of approximately 120 ohms and a propa- gation delay per foot of < 2.1 ns. There are two 12 gauge conductors that are used to supply the 40 VDC to the network.

  • Page 15: Wire Feeder Setup

    ELECTRODE AND WORK LEADS — ELECTRODE NEGATIVE APPLICATIONS When negative electrode polarity is required, such as in some Innershield™ applications, install as above, except reverse the output connections at the power source (electrode cable to the negative (-) stud, and work cable to the positive (+) stud).
  • Page 16 A-10 RATIO CHANGE PROCEDURE 1. Pull open the pressure door. 2. Remove the Phillips head screw retaining the pinion gear to be changed and remove the gear. If the gear is not easily accessible or difficult to remove, remove the feed plate from the gearbox. To remove feed plate: a.

  • Page 17: Dip Switch Setup

    A-11 DIP SWITCH SETUP SETTING DIP SWITCHES IN THE CONTROL BOX There are two DIP switch banks on the mother board of the Control Box. They are labeled S1 and S2 and are located and oriented as shown in Figure A.3. S1 DIP Switch Bank on Control Box Motherboard (For software version S24004-2 only) Switch US 4-Step Trigger Logic...
  • Page 18 A-12 S1 DIP Switch Bank on Control Box Motherboard (For software version S24004-3 & up) Switch Standard speed gearbox limits adjustable WFS Display = inches/minute Left Display is always preset WFS CC modes override this switch regardless of position. Left Display is always preset weld cur- rent when weld current is not flowing and actual weld current when weld current is flowing Run-in = Minimum Speed Available If any option containing a Run-in setting is connected to the motherboard, it automatically...
  • Page 19 A-13 S1 DIP Switch Bank on Control Box Motherboard (For software version S24456) Switch Standard speed gearbox limits adjustable WFS Display = inches/minute Left Display is always preset WFS CC modes override this switch regardless of position. Left Display is always preset weld cur- rent when weld current is not flowing and actual weld current when weld current is flowing Run-in = Minimum Speed Available If any option containing a Run-in setting is connected to the motherboard, it automatically...
  • Page 20 A-14 Setting Wire Drive Acceleration Rate Using DIP Switch S1 on the Control Box Motherboard Acceleration 1 (slow) Acceleration 2 Acceleration 3 Acceleration 4 Acceleration 5 (fast ) (factory setting) SETTING DIP SWITCHES IN THE WIRE DRIVE There is one DIP switch bank on the control board of the wire drive.

  • Page 21: Gun And Cable Assemblies

    CYLINDER may explode if damaged. • Keep cylinder upright and chained to • Keep cylinder away from areas where it • Never lift welder with cylinder attached. • Never allow welding electrode to touch • Keep cylinder away from welding or BUILDUP OF SHIELDING GAS may harm health or kill.

  • Page 22: Standard Panel Installation

    A-16 STANDARD PANEL INSTALLATION CONTROL/DISPLAY PANEL NOTE: Installation Instructions for the standard equipment panels will be required only if you have removed a standard panel and wish to reinstall it. The Control/Display Panel fits into the upper or mid- dle slots of the Control Box, and is used to adjust WFS, Amps, Voltage, and Trim.

  • Page 23: Controls And Settings

    SECTION B-1 Operation ............... . . Section B Operating Instructions .

  • Page 24: Operation

    OPERATING INSTRUCTIONS Read and understand this entire section of operating instructions before operating the machine. SAFETY INSTRUCTIONS WARNING ELECTRIC SHOCK can kill. • Do not touch electrically live parts or electrodes with your skin or wet cloth- ing. • Insulate yourself from the work and ground.

  • Page 25: Controls And Settings

    DUTY CYCLE AND WELDING CAPABILITIES The Power Feed 10 wire feeder is capable of welding at a 100% duty cycle (continuous welding). The power source will be the limiting factor in determining system duty cycle capability. The Power Wave 455 is rated 450 amps at 38 volts, 100% duty cycle, and 570 amps at 43 volts, 60% duty cycle.

  • Page 26: Power Feed Controls

    Light Condition Meaning Steady Green System OK. Power source communicating normally with wire feeder and its components. Blinking Nothing connected to Wire Feeder Green Receptacle. Recoverable system fault. See Alternating Green and Troubleshooting Section. Steady Red Non-recoverable system fault. Must turn power source off, find source of error, and turn power back on to reset.

  • Page 27: Display Control Panel

    Cold feed function: When this switch is held in the up position, the unit automatically feeds wire, but does not activate output to the power source or gas solenoid. The speed of this cold feed is factory preset to 200 IPM. It can be adjusted while the switch is held up, by rotating the WFS encoder knob on the Control Box.

  • Page 28: Weld Mode Descriptions

    6. CV/GOUGE PANEL The CV/Gouge Panel provides a fixed toggle switch selection of two power source modes. The upper position selects the generic CV/MIG mode from the power source while the lower position selects the GOUGE mode. OPTIONAL PANELS A number of Optional Features are available for use with the Power Feed 10.

  • Page 29: Wire Reel Loading - Readi-Reels, Spools Or Coils

    WIRE SPINDLE PLACEMENT The reel stand provides two mounting locations for the 2 inch diameter wire reel spindle to accommo- date various reel sizes. Each mounting location con- sists of a tube in the center of the reel stand, and a locating pin on the right side (viewed from the front) of the reel stand.

  • Page 30: Or 14 Lb (6 Kg) Innershield Coils (Figure

    TO MOUNT 10 TO 44 LB (4.5 TO 20 KG) SPOOLS [12 IN. (300 MM) DIAMETER] OR 14 LB (6 KG) INNERSHIELD COILS (FIGURE B.4): The spindle should be located in the LOWER mounting hole. (For 8 in. (200 mm) spools, a K468 spindle adapter must first be slipped onto spindle.) (For 13 to 14 lb (6 kg) Innershield coils, a K435 coil adapter must be used).

  • Page 31: Feeding Electrode And Brake Adjustment

    1. Press end of gun against a solid object that is electrically isolated from the welder output and press the gun trigger for several seconds. 2. If the wire “birdnests”, jams, or breaks at the drive roll, the drive roll pressure is too great.

  • Page 32: Wire Feed Overload Protection

    B-10 WIRE FEED OVERLOAD PROTECTION The wire drive has solid-state overload protection of the wire drive motor. If the wire drive motor becomes overloaded for an extended period of time the wire drive will issue a shutdown command to the Control Box and force its STATUS light to blink between green and red.

  • Page 33: Power Wave Options And Accessories

    SECTION C-1 Accessories ............... Section C General .

  • Page 34: Accessories

    GENERAL The following is a list of the accessories that can be used with the Power Feed 10 wire feeder and the Power Wave 455. A description of each item is given later in the section. TABLE C.1 — POWER FEED 10 AND POWER WAVE 455 ACCESSORIES. K1570-1 KP1505 Series K1543...

  • Page 35: Power Wave Options And Accessories

    3/32” (2.2 mm) Aluminum ACCESSORIES K1570-1 DUAL CYLINDER UNDERCARRIAGE This is a platform undercarriage for mounting up to two gas cylinders at the rear of the welder. WIRE FEEDER OPTIONS AND ACCESSORIES The following is a list of available Wire Feeder options.

  • Page 36: Input Cable Assemblies

    INPUT CABLE ASSEMBLIES K1543 (Control Cable Only) - Consists of a 5-con- ductor control cable with a 5-pin control cable plug, without electrode cable, and is available in lengths of 10 ft, 15 ft, 20 ft, 50 ft, and 100 ft. K1544 - Consists of a 5-conductor control cable with a 5-pin control cable plug and a 3/0 electrode cable.
  • Page 37 Feed Head Enclosure Procedure 1. Turn power off. 2. Remove the Feed Head rear access door. The Feed Head cover can be removed to aid installa- tion, but is not required. 3. Remove the plastic plug (black) from the hole at the right rear of the Feed Head and store it in the left side of the Feed Head rear compartment for future use, should the Optional Output...

  • Page 38: Reel Adapters

    10. Install an Optional Output Connector into the Control Box cabinet, if not already present. 11. Mount the Control Box cabinet to the work sta- tion fixture at this time, if desired. The four holes in the back wall of the Control Box cabinet can be used for this purpose.

  • Page 39: Conduit Adapters

    MAGNUM 200/300/400 GUNS The easiest and least expensive way to use Magnum 200/300/400 guns with the Power Feed 10 wire feed- er is to order them with the K466-10 connector kit, or to buy a completely assembled Magnum gun having the K466-10 connector (such as the K471-21, -22, and -23 dedicated Magnum 400 guns and the K497- 20 and -21 Magnum 200 guns).

  • Page 40: Dual Procedure Switch Options

    DUAL PROCEDURE SWITCH OPTIONS K683-3 DUAL PROCEDURE SWITCH Kit includes gun switch and mountings for Lincoln Innershield and Magnum guns, with 15 ft (4.5 m) control cable and 5-pin plug with two leads to con- nect to gun trigger. Connect the 5-pin plug of the K683-3 Dual Procedure Switch to the Power Feed 10 wire feeder trigger/dual procedure 5-socket receptacle.

  • Page 41: Description And Installation Of Optional Control Box Panels

    4. Position the new door between the panel holes and re-install the rod so the screw holes can be accessed. 5. Replace the two screws and tighten. 6. Swing the door into the up position. A lock may be installed through the side holes for security purposes.
  • Page 42 C-10 Constant Voltage (CV/MIG and CV/Flux Cored) Procedures When in this mode, the ARC CONTROL adjusts the inductance. (This adjustment is often referred to as “pinch”. Inductance is inversely proportional to pinch.) Increasing the ARC CONTROL setting decreases the inductance, which results in the arc getting colder and pinched tighter.
  • Page 43 C-11 Mode Selection The MODE SELECT switch is a momentary large three position toggle switch that defaults to the center (off) position. Moving the switch up advances the mode indicator in the upward direction, down advances it in the downward direction. Holding the switch in either direction will result in the indicator advancing at a high rate of speed in that direction, until the switch is released.
  • Page 44 C-12 Mode Schedule - Table on the front of the option used by the operator to correlate the displayed mode number to an actual power source mode. Due to the nature of the system, the following feature is required for safety reasons. Upon entering any constant current (CC) mode, the right encoder, labeled VOLTS, TRIM, on the Display/Control Panel acts as a “soft”...
  • Page 45 C-13 Installation is as follows: 1. Turn off power. 2. Remove the two screws from the front of the blank option panel at the location you choose to install your new option (bottom) of the Control Box cabinet. Save the screws, discard the old panel or save for future use.
  • Page 46 C-14 Installation is as follows: 1. Turn off power. 2. Remove the two screws from the front of the blank option panel at the location you choose to install your new option (bottom) of the Control Box cabinet. Save the screws, discard the old panel or save for future use.
  • Page 47 C-15 The value of the active set up parameter is shown on the MSP2 panel digital display. The value can be modi- fied with the Set switch. The Set switch is an up/down center-off momentary toggle switch. Moving the switch bat up or down adjusts the displayed value in the cor- responding direction.
  • Page 48 C-16 CONTROL BOX -- SETTING OPERATING LIMITS Upper and lower operating limits can be set for the WFS/Amps setting and the Volts/Trim setting. Doing so requires knowledge of how to set the limits, and access to the PC board in the Control Box. There are two independent sets of limits, Procedure A limits and Procedure B limits.

  • Page 49: Routine Maintenance

    SECTION D-1 Maintenance ... Section D Safety Precautions... Routine Maintenance ... Power Wave ... Wire Feeder... Periodic Maintenance ... Wire Drive Motor and Gearbox... Gun and Cable Maintenance... MAINTENANCE TABLE OF CONTENTS -MAINTENANCE SECTION- POWER WAVE 455/POWER FEED 10 SECTION D-1...

  • Page 50: Maintenance

    SAFETY PRECAUTIONS WARNING ELECTRIC SHOCK can kill. • Do not touch electrically live parts such as output terminals or internal wiring. • Only qualified personnel should perform maintenance work. Observe all additional Safety Guidelines detailed throughout this manual. ----------------------------------------------------------- ROUTINE MAINTENANCE POWER WAVE Routine maintenance consists of periodically blowing out the machine, using a low pressure airstream, to...
  • Page 51 SECTION E-1 THEORY OF OPERATION -THEORY OF OPERATION SECTION- Theory of Operation ... Section E Modular Inverter Based Welding System... System Diagram A ... System Diagram B ... System Diagram C... Power Source General Description... Input Voltage and Precharge ... Switch Boards and Main Transformer...

  • Page 52: Theory Of Operation Section

    THEORY OF OPERATION POWER SOURCE MODULAR INVERTER BASED WELDING SYSTEM The Welding Network is an assembly of welding equipment joined together by a common network communication cable. These individual welding components con- sist of a power source (Power Wave 455), a user interface (Power Feed 10 Control Box) and a modular wire drive (Power Feed 10 Wire Drive).

  • Page 53: System Diagram B

    THEORY OF OPERATION CONTROL (USER INTERFACE) INTERNAL CONNECTION POWER SOURCE SYSTEM DIAGRAM B This system utilizes two physical pieces of equipment. Refer to Figure E.2. The combi- nation Control Box (user interface) and power source (Power Wave 455) make up one of the circuit elements.

  • Page 54: Theory Of Operation

    THEORY OF OPERATION POWER SOURCE SYSTEM DIAGRAM C The power source (Power Wave 455), the Control Box (user interface) and the wire drive (Power Feed 10) are the three dis- crete and physically separate circuit compo- nents employed in this configuration. Refer to Figure E.3.

  • Page 55: Power Source General Description

    THEORY OF OPERATION INPUT CONTACTOR AUX. RECTIFIER TRANS. AUX. RECONNECT AUX. TRANS. MOTOR 115VAC RECEPTACLE POWER SOURCE GENERAL DESCRIPTION The Power Wave 455 is an inverter based welding power source that is designed to be part of a modular, multi-process welding system.

  • Page 56: Switch Boards And Main Transformer

    THEORY OF OPERATION FIGURE E.5 — SWITCH BOARDS AND MAIN TRANSFORMER. INPUT CONTACTOR AUX. RECTIFIER TRANS. AUX. RECONNECT AUX. TRANS. MOTOR 115VAC RECEPTACLE SWITCH BOARDS AND MAIN TRANSFORMER There are two switch boards in the Power Wave 455, each containing an input capaci- tor and insulated gate bipolar transistor (IGBT) switching circuitry.

  • Page 57: Control Board

    THEORY OF OPERATION INPUT CONTACTOR AUX. RECTIFIER TRANS. AUX. RECONNECT AUX. TRANS. MOTOR 115VAC RECEPTACLE CONTROL BOARD The control board performs the primary interfacing functions to establish and main- tain output control of the Power Wave 455. Refer to Figure E.6. The control board sends and receives digital command infor- mation through the wire feeder receptacle and or the RS232 connector.

  • Page 58: Output Rectifier And Choke

    THEORY OF OPERATION INPUT CONTACTOR AUX. RECTIFIER TRANS. AUX. RECONNECT AUX. TRANS. MOTOR 115VAC RECEPTACLE OUTPUT RECTIFIER AND CHOKE The output rectifier receives the AC output from the main transformer secondary and FIGURE E.7 — OUTPUT RECTIFIER AND CHOKE. TRANSFORMER LEFT SWITCH BOARD...

  • Page 59: Thermal Protection

    THEORY OF OPERATION THERMAL PROTECTION Two normally closed (NC) thermostats pro- tect the machine from excessive operating temperatures. These thermostats are wired in series and are connected to the control board. One of the thermostats is located on the heat sink of the output rectifier and the other is located near the fan.

  • Page 60: Insulated Gate Bipolar Transistor (Igbt) Operation

    E-10 THEORY OF OPERATION GATE SOURCE BODY REGION DRAIN DRIFT REGION BUFFER LAYER INJECTING LAYER DRAIN A. PASSIVE INSULATED GATE BIPOLAR TRANSISTOR (IGBT) OPERATION An IGBT is a type of transistor. IGBT are semiconductors well suited for high frequen- cy switching and high current applications. Example A in Figure E.8 shows an IGBT in passive mode.

  • Page 61: Pulse Width Modulation

    E-11 THEORY OF OPERATION FIGURE E.9 — TYPICAL IGBT OUTPUTS. 1 sec 24 sec PULSE WIDTH MODULATION The term Pulse Width Modulation is used to describe how much time is devoted to con- duction in the positive and negative portions of the cycle.

  • Page 62: Control Box (User Interface

    E-12 THEORY OF OPERATION FIGURE E.10 — CONTROL BOX (USER INTERFACE). NETWORK CONNECTOR (INTERNAL) AMPHENOL-INPUT NETWORK RECEPTACLE (OPTIONAL) CONTROL BOX (USER INTERFACE) The system Control Box is the main entry point for all system parameters, and from it the user can control both power source and wire feeder functions.

  • Page 63: Power Feed 10 Feed Head

    E-13 THEORY OF OPERATION FIGURE E.11 — POWER FEED 10 FEED HEAD. LEAD #67A TO POWER SOURCE OR SHUTDOWN CONTROL INPUT NETWORK RECEPTACLE NETWORK CONNECTOR (INTERNAL) POWER FEED 10 FEED HEAD The Power Feed 10 is a four roll, high per- formance, digitally controlled, modular wire feeder that operates on 40 VDC input power.
  • Page 64 E-14 E-14 NOTES POWER WAVE 455/POWER FEED 10...

  • Page 65: Pc Board Troubleshooting Procedures

    SECTION F-1 TROUBLESHOOTING AND REPAIR -TROUBLESHOOTING AND REPAIR SECTION- Troubleshooting and Repair ............Section F How to Use Troubleshooting Guide .

  • Page 66: Troubleshooting And Repair

    TROUBLESHOOTING AND REPAIR HOW TO USE TROUBLESHOOTING GUIDE 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 67: Pc Board Troubleshooting Procedures

    TROUBLESHOOTING AND REPAIR PC BOARD TROUBLESHOOTING PROCEDURES WARNING ELECTRIC SHOCK can kill. 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. ------------------------------------------------- CAUTION Sometimes machine failures appear to be due to PC board failures.
  • Page 68 TROUBLESHOOTING AND REPAIR 4. Test the machine to determine if the failure symptom has been corrected by the replacement PC board. NOTE: It is desirable to have a spare (known good) PC board available for PC board troubleshooting. NOTE: Allow the machine to heat up so that all electrical components can reach their operating temperature.

  • Page 69: Troubleshooting Guide

    The main input fuses (or breaker) repeatedly fail. 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 216-383-2531 or 1-800-833-9353.
  • Page 70 -- low or no weld output. 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 216-383-2531 or 1-800-833-9353.
  • Page 71 The Power Wave 455 won’t pro- duce full output. 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 216-383-2531 or 1-800-833-9353.
  • Page 72 The arc burns back to the tip. 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 216-383-2531 or 1-800-833-9353.
  • Page 73 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 216-383-2531 or 1-800-833-9353.
  • Page 74 LED is blinking red and green 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 216-383-2531 or 1-800-833-9353.
  • Page 75 #23 Weld table check sum (table is corrupt) 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 216-383-2531 or 1-800-833-9353.
  • Page 76 #37 Machine failed soft start 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 216-383-2531 or 1-800-833-9353.

  • Page 77: Power Feed

    The STATUS LEDs are steady green. 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 216-383-2531 or 1-800-833-9353.
  • Page 78 STATUS LEDS are steady green. 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 216-383-2531 or 1-800-833-9353.
  • Page 79 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 216-383-2531 or 1-800-833-9353.
  • Page 80 Control Box and wire drive units. 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 216-383-2531 or 1-800-833-9353.
  • Page 81 30 seconds and may repeat sequence. 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 216-383-2531 or 1-800-833-9353.
  • Page 82 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 216-383-2531 or 1-800-833-9353.
  • Page 83 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 216-383-2531 or 1-800-833-9353.
  • Page 84 Err 006 Err 020 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 216-383-2531 or 1-800-833-9353.
  • Page 85 - - - (three dashes) 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 216-383-2531 or 1-800-833-9353.
  • Page 86 F-22 PW 455 CONTROL BOARD LED DEFINITIONS LED COLOR AND NUMBER Green LED 1 Green LED 3 Green LED 4 Red LED 5 Green 6 LED Red LED 7 Green LED 8 NOTE: The only LED that changes state when the machine is running is LED 7 (Fault Indicator).

  • Page 87: Test Procedures

    INPUT FILTER CAPACITOR DISCHARGE PROCEDURE WARNING Service and repair should only be performed by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in dan- ger to the technician or machine operator and will invalidate your factory warran- ty.
  • Page 88 F-24 TROUBLESHOOTING AND REPAIR INPUT FILTER CAPACITOR DISCHARGE PROCEDURE (continued) FIGURE F.1 — CAPACITOR DISCHARGE PROCEDURE. TEST PROCEDURE 1. Remove input power to the Power Wave 455. 2. Using the 3/8 in. nutdriver, remove the left and right case sides. 3.

  • Page 89: Switch Board Test

    SWITCH BOARD TEST WARNING Service and repair should only be performed by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in dan- ger to the technician or machine operator and will invalidate your factory warran- ty.
  • Page 90 F-26 TROUBLESHOOTING AND REPAIR SWITCH BOARD TEST (continued) FIGURE F.2 — RECONNECT SWITCHES. TEST PROCEDURE 1. Remove input power to the Power Wave 455. 2. Using the 3/8 in. nutdriver, remove the case top and sides. 3. Perform the Capacitor Discharge Procedure.
  • Page 91 F-27 TROUBLESHOOTING AND REPAIR SWITCH BOARD TEST (continued) FIGURE F.3 — SWITCH BOARD TEST POINTS. 6. If any test fails replace both switch boards. See Switch Board Removal and Replacement. 7. If the switch board resistance tests are OK, check the molex pin connections and associated wiring from the switch boards to the control board.
  • Page 92 F-28 F-28 NOTES POWER WAVE 455/POWER FEED 10...

  • Page 93: Output Rectifier Test

    OUTPUT RECTIFIER TEST WARNING Service and repair should only be performed by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in dan- ger to the technician or machine operator and will invalidate your factory warran- ty.
  • Page 94 F-30 TROUBLESHOOTING AND REPAIR OUTPUT RECTIFIER TEST (continued) FIGURE F.4 — OUTPUT RECTIFIER TEST. NEGATIVE (-) OUTPUT TERMINAL TEST PROCEDURE 1. Remove main input supply power to the Power Wave 455. NOTE: Later code machines have a 50 ohm resistor across the welding output ter- minals.

  • Page 95: Input Rectifier Test

    INPUT RECTIFIER TEST WARNING Service and repair should only be performed by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in dan- ger to the technician or machine operator and will invalidate your factory warran- ty.
  • Page 96 F-32 TROUBLESHOOTING AND REPAIR INPUT RECTIFIER TEST (continued) FIGURE F.5 — INPUT RECTIFIER TEST. TEST PROCEDURE 1. Remove input power to the Power Wave 455. 2. Using the 3/8 in. nutdriver, remove the case top. 3. Perform the Capacitor Discharge Procedure.

  • Page 97: Input Contactor Test

    F-33 TROUBLESHOOTING AND REPAIR INPUT RECTIFIER TEST (continued) TABLE F.2 — INPUT RECTIFIER TEST POINTS AND ACCEPTABLE READINGS. TEST POINT TERMINALS + Probe 7. If the input rectifier does not meet the acceptable readings outlined in the table, the component may be faulty. Replace.
  • Page 98 F-34 F-34 NOTES POWER WAVE 455/POWER FEED 10...
  • Page 99 INPUT CONTACTOR TEST WARNING Service and repair should only be performed by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in dan- ger to the technician or machine operator and will invalidate your factory warran- ty.
  • Page 100 F-36 TROUBLESHOOTING AND REPAIR INPUT CONTACTOR TEST (continued) FIGURE F.6 — INPUT CONTACTOR COIL. TEST PROCEDURE 1. Remove input power to the Power Wave 455. 2. Using the 3/8 in. nutdriver, remove the input access panel and case top. 3. Locate, mark, and remove the four leads (601, 601A, X4 and X4A) that are connected to the input contactor coil.

  • Page 101: Auxiliary Transformer No. 2 Test

    AUXILIARY TRANSFORMER NO. 2 TEST WARNING Service and repair should only be performed by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in dan- ger to the technician or machine operator and will invalidate your factory warran- ty.
  • Page 102 F-38 TROUBLESHOOTING AND REPAIR AUXILIARY TRANSFORMER NO. 2 TEST (continued) FIGURE F.8 — AUXILIARY TRANSFORMER NO. 2 TEST. TEST PROCEDURE 1. Remove the main input supply power to the Power Wave 455 machine. 2. Remove any load that may be connect- ed to the 115 VAC receptacle.

  • Page 103: Auxiliary Transformer No. 1 Test

    AUXILIARY TRANSFORMER NO. 1 TEST WARNING Service and repair should only be performed by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in dan- ger to the technician or machine operator and will invalidate your factory warran- ty.
  • Page 104 F-40 TROUBLESHOOTING AND REPAIR AUXILIARY TRANSFORMER NO. 1 TEST (continued) FIGURE F.9 — AUXILIARY TRANSFORMER NO. 1 TEST. POWER BOARD RECTIFIER BRIDGE TEST PROCEDURE 1. Remove the main input supply power to the Power Wave 455 machine. 2. Using the 3/8 in. nutdriver, remove the case sides and top.
  • Page 105 F-41 TROUBLESHOOTING AND REPAIR AUXILIARY TRANSFORMER NO. 1 TEST (continued) TABLE F.3 — SECONDARY VOLTAGES. LEAD IDENTIFICATION 7. Carefully apply the correct input voltage to the Power Wave 455 and check for the correct secondary voltages per Table F.3. NOTE: The secondary voltages will vary if the input line voltage varies.
  • Page 106 NOTES F-42 F-42 POWER WAVE 455/POWER FEED 10...

  • Page 107: Power Board Test

    POWER BOARD TEST WARNING Service and repair should only be performed by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in dan- ger to the technician or machine operator and will invalidate your factory warran- ty.
  • Page 108 F-44 TROUBLESHOOTING AND REPAIR POWER BOARD TEST (continued) FIGURE F.10 — POWER BOARD TEST. TEST PROCEDURE 1. Remove input power to the Power Wave 455. 2. Using the 3/8 in. nutdriver, remove the case sides and top. 3. Perform the Capacitor Discharge Procedure.

  • Page 109: Troubleshooting And Repair

    F-45 TROUBLESHOOTING AND REPAIR POWER BOARD TEST (continued) TABLE F.4 — POWER BOARD VOLTAGE CHECKS. CHECK POINT TEST LOCATION DESCRIPTION POWER PC CHECK 65 VDC BOARD SUPPLY FROM CONNECTOR POWER BOARD PLUG J32 RECTIFIER BRIDGE POWER PC CHECK +15 BOARD VDC SUPPLY CONNECTOR FROM POWER...
  • Page 110 F-46 F-46 NOTES POWER WAVE 455/POWER FEED 10...

  • Page 111: Current Transducer Test

    CURRENT TRANSDUCER TEST WARNING Service and repair should only be performed by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in dan- ger to the technician or machine operator and will invalidate your factory warran- ty.
  • Page 112 F-48 TROUBLESHOOTING AND REPAIR CURRENT TRANSDUCER TEST (continued) FIGURE F.11 — CURRENT TRANSDUCER TEST. TEST PROCEDURE 1. Remove input power to the Power Wave 455. 2. Using the 3/8 in. nutdriver remove the right side case cover. 3. Perform the Capacitor Discharge Procedure.
  • Page 113 F-49 TROUBLESHOOTING AND REPAIR CURRENT TRANSDUCER TEST (continued) TABLE F.5 — CURRENT FEEDBACK AT VARIOUS OUTPUT LOADS. OUTPUT LOAD CURRENT 9. Check the feedback voltage from the current transducer. With the Power Wave system in a constant current mode and the machine loaded to 250 amps, the current feedback voltage can be read at plug P90.
  • Page 114 F-50 F-50 NOTES POWER WAVE 455/POWER FEED 10...

  • Page 115: Drive Motor Test

    DRIVE MOTOR TEST WARNING Service and repair should only be performed by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in dan- ger to the technician or machine operator and will invalidate your factory warran- ty.
  • Page 116 F-52 TROUBLESHOOTING AND REPAIR DRIVE MOTOR TEST (continued) FIGURE F.12 — DRIVE MOTOR TEST. #551 #550 (-) BLACK #551 (+) WHITE PROCEDURE 1. Remove input power to wire feed unit. 2. Using the 3/8 in. nutdriver, remove the cover from the wire feeder. 3.

  • Page 117: Tach Feedback Test

    TACH FEEDBACK TEST WARNING Service and repair should only be performed by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in dan- ger to the technician or machine operator and will invalidate your factory warran- ty.
  • Page 118 F-54 TROUBLESHOOTING AND REPAIR TACH FEEDBACK TEST (continued) FIGURE F.13 — TACH FEEDBACK TEST. BLACK TEST PROCEDURE 1. Remove input power from the wire feeder unit. 2. Using the 3/8 in. nutdriver, remove the cover from the wire feeder. 3. Locate plug J4 on the control board. Refer to Figure F.13.

  • Page 119: Voltage Sense Pc Board Test

    VOLTAGE SENSE PC BOARD TEST WARNING Service and repair should only be performed by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in dan- ger to the technician or machine operator and will invalidate your factory warran- ty.
  • Page 120 F-56 TROUBLESHOOTING AND REPAIR VOLTAGE SENSE PC BOARD TEST (continued) FIGURE F.14 — VOLTAGE SENSING BOARD TEST. 1 2 3 4 5 6 TEST PROCEDURE 1. Remove input power from the wire feed unit. 2. Using the 3/8 in. nutdriver, remove the cover from the wire feeder.

  • Page 121: Dual Encoder Pc Board Test

    DUAL ENCODER PC BOARD TEST WARNING Service and repair should only be performed by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in dan- ger to the technician or machine operator and will invalidate your factory warran- ty.
  • Page 122 F-58 TROUBLESHOOTING AND REPAIR DUAL ENCODER PC BOARD TEST (continued) FIGURE F.15 — DUAL ENCODER TEST. DISPLAY BOARD 1 2 3 4 5 6 78 TEST PROCEDURE 1. Remove input power from control box assembly. 2. Using the Phillips head screwdriver, remove the display/encoder assembly panel from the Control Box.

  • Page 123: Control Cable Continuity Test

    CONTROL CABLE CONTINUITY TEST WARNING Service and repair should only be performed by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in dan- ger to the technician or machine operator and will invalidate your factory warran- ty.
  • Page 124 F-60 TROUBLESHOOTING AND REPAIR CONTROL CABLE CONTINUITY TEST (continued) FIGURE F.16 — CABLE CONTINUITY TEST. WIRE FEEDER END TABLE F.6 CONTROL CABLE PIN AND LEAD DESIGNATIONS. FIVE PIN AMPHENOL AT POWER SOURCE END TEST PROCEDURE 1. Disconnect the input power to the Power Wave 455 machine.

  • Page 125: Component Replacement Procedures

    GAS SOLENOID REMOVAL AND REPLACEMENT WARNING Service and repair should only be performed by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in dan- ger to the technician or machine operator and will invalidate your factory warran- ty.
  • Page 126 F-62 TROUBLESHOOTING AND REPAIR GAS SOLENOID REMOVAL AND REPLACEMENT (continued) FIGURE F.17 — GAS SOLENOID REMOVAL AND REPLACEMENT. PROCEDURE 1. Remove input power to the wire feeder. 2. Using the 3/8 in. nutdriver, remove the cover from the wire feeder. 3.

  • Page 127: Wire Feeder Control Board Removal And Replacement

    TROUBLESHOOTING AND REPAIR WIRE FEEDER CONTROL BOARD REMOVAL Service and repair should only be performed by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in dan- ger to the technician or machine operator and will invalidate your factory warran- ty.
  • Page 128 F-64 TROUBLESHOOTING AND REPAIR WIRE FEEDER CONTROL BOARD REMOVAL AND REPLACEMENT (continued) FIGURE F.18 — WIRE FEEDER CONTROL BOARD REMOVAL AND REPLACEMENT. PROCEDURE 1. Remove input power to the wire feeder. 2. Using the 3/8 in. nutdriver, remove the cover from the wire feeder. 3.

  • Page 129: Tach (Hall Effect) Assembly Removal And Replacement

    TACH (HALL EFFECT) ASSEMBLY REMOVAL AND REPLACEMENT WARNING Service and repair should only be performed by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in dan- ger to the technician or machine operator and will invalidate your factory warran- ty.
  • Page 130 F-66 TROUBLESHOOTING AND REPAIR TACH (HALL EFFECT) ASSEMBLY REMOVAL AND REPLACEMENT (continued) FIGURE F.19 — TACH REMOVAL AND REPLACEMENT. REMOVAL PROCEDURE 1. Remove input power to the wire feeder. 2. Using the 3/8 in. nutdriver, remove the case cover. 3. Locate the tach assembly on the top of the gear box.

  • Page 131: Gear Box And Drive Motor Removal And Replacement

    TROUBLESHOOTING AND REPAIR GEAR BOX AND DRIVE MOTOR REMOVAL Service and repair should only be performed by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in dan- ger to the technician or machine operator and will invalidate your factory warran- ty.
  • Page 132 F-68 TROUBLESHOOTING AND REPAIR GEAR BOX AND DRIVE MOTOR REMOVAL AND REPLACEMENT (continued) FIGURE F.20 — GEAR BOX AND DRIVE MOTOR REMOVAL AND REPLACEMENT. DRIVE MOTOR GEAR BOX #551 #550 (BLACK) (WHITE) INSULATION PROCEDURE 1. Remove the input power to the wire drive unit.
  • Page 133 F-69 TROUBLESHOOTING AND REPAIR GEAR BOX AND DRIVE MOTOR REMOVAL AND REPLACEMENT (continued) 7. Using the needlenose pliers, discon- nect the gas hose from the brass gun connector block. 8. Using the 7/16 in. socket wrench, remove the four mounting bolts, lock washers, and flat washers from the glastic base insulator.
  • Page 134 F-70 F-70 NOTES POWER WAVE 455/POWER FEED 10...

  • Page 135: Switch Board And Filter Capacitor Removal And Replacement

    SWITCH BOARD AND FILTER CAPACITOR REMOVAL AND REPLACEMENT WARNING Service and repair should only be performed by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in dan- ger to the technician or machine operator and will invalidate your factory warran- ty.
  • Page 136 F-72 TROUBLESHOOTING AND REPAIR SWITCH BOARD AND FILTER CAPACITOR REMOVAL AND REPLACEMENT (continued) FIGURE F.21 — SWITCH BOARD AND FILTER CAPACITOR REMOVAL AND REPLACEMENT. REMOVAL PROCEDURE NOTE: Observe all static electricity precau- tions. 1. Remove input power to the Power Wave 455.
  • Page 137 F-73 TROUBLESHOOTING AND REPAIR SWITCH BOARD AND FILTER CAPACITOR REMOVAL AND REPLACEMENT (continued) 8. With the slot head screwdriver, remove the two nylon mounting screws at the bottom of the switch board. Note placement of the shake-proof washers and fiber spacers. 9.

  • Page 138: Meter Accuracy Check

    TROUBLESHOOTING AND REPAIR POWER WAVE 455 / PF-10 METER ACCURACY CHECK Service and repair should only be performed by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in dan- ger to the technician or machine operator and will invalidate your factory warran- ty.

  • Page 139: Control Or Power Board Removal And Replacement

    CONTROL OR POWER BOARD REMOVAL AND REPLACEMENT WARNING Service and repair should only be performed by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in dan- ger to the technician or machine operator and will invalidate your factory warran- ty.
  • Page 140 F-76 TROUBLESHOOTING AND REPAIR CONTROL OR POWER BOARD REMOVAL AND REPLACEMENT (continued) FIGURE F.22 — CONTROL OR POWER BOARD REMOVAL AND REPLACEMENT. REMOVAL PROCEDURE 1. Remove input power to the Power Wave 455. 2. Using the 3/8 in. nutdriver, remove the case top and sides.
  • Page 141 F-77 TROUBLESHOOTING AND REPAIR CONTROL OR POWER BOARD REMOVAL AND REPLACEMENT (continued) INSTALLATION PROCEDURE 1. Install either the power or control board to the PC board assembly and secure it in place using the Phillips head mount- ing screws. 2. Carefully slide the power and control PC board assembly into place, making sure to clear the lead harnesses on the right and left side of the PC board com-...
  • Page 142 F-78 F-78 NOTES POWER WAVE 455/POWER FEED 10...

  • Page 143: Auxiliary Transformer No. 1 Removal And Replacement Procedure

    TROUBLESHOOTING AND REPAIR AUXILIARY TRANSFORMER NO. 1 REMOVAL AND Service and repair should only be performed by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in dan- ger to the technician or machine operator and will invalidate your factory warran- ty.
  • Page 144 F-80 TROUBLESHOOTING AND REPAIR AUXILIARY TRANSFORMER NO. 1 REMOVAL AND REPLACEMENT PROCEDURE (continued) FIGURE F.23 — AUXILIARY TRANSFORMER NO. 1 REMOVAL AND REPLACEMENT PROCEDURE. POWER BOARD RECTIFIER BRIDGE REMOVAL PROCEDURE 1. Remove input power to the Power Wave 455. 2. Using the 3/8 in. nutdriver, remove the case top, sides and input access panel.
  • Page 145 F-81 TROUBLESHOOTING AND REPAIR AUXILIARY TRANSFORMER NO. 1 REMOVAL AND REPLACEMENT PROCEDURE (continued) 8. Cut the X3 lead that is connected to the input board. Leave enough lead length to splice in the new transformer lead. 9. Locate, label, and remove primary lead H1 from circuit breaker CB4.
  • Page 146 F-82 F-82 NOTES POWER WAVE 455/POWER FEED 10...

  • Page 147: Main Input Contactor Removal And Replacement

    MAIN INPUT CONTACTOR REMOVAL AND REPLACEMENT WARNING Service and repair should only be performed by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in dan- ger to the technician or machine operator and will invalidate your factory warran- ty.
  • Page 148 F-84 TROUBLESHOOTING AND REPAIR MAIN INPUT CONTACTOR REMOVAL AND REPLACEMENT (continued) FIGURE F.24 — MAIN INPUT CONTACTOR REMOVAL AND REPLACEMENT. REMOVAL PROCEDURE 1. Remove input power to the Power Wave 455. 2. Using the 3/8 in. nutdriver, remove the case top, sides, and input access panel.
  • Page 149 F-85 TROUBLESHOOTING AND REPAIR MAIN INPUT CONTACTOR REMOVAL AND REPLACEMENT (continued) REPLACEMENT PROCEDURE 1. Carefully place the input contactor into position. 2. Install the three mounting screws that hold the input contactor to the metal housing bracket using the 5/16 in. nutdriver.
  • Page 150 F-86 F-86 NOTES POWER WAVE 455/POWER FEED 10...

  • Page 151: Input Rectifier Removal And Replacement

    INPUT RECTIFIER REMOVAL AND REPLACEMENT WARNING Service and repair should only be performed by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in dan- ger to the technician or machine operator and will invalidate your factory warran- ty.
  • Page 152 F-88 TROUBLESHOOTING AND REPAIR INPUT RECTIFIER REMOVAL AND REPLACEMENT (continued) FIGURE F.25 — INPUT RECTIFIER REMOVAL AND REPLACEMENT. REMOVAL PROCEDURE 1. Remove input power to the Power Wave 455. 2. Using the 3/8 in. nutdriver, remove the case top, sides, and input access panel.

  • Page 153: Output Rectifier And Module Removal And Replacement

    TROUBLESHOOTING AND REPAIR OUTPUT RECTIFIER AND MODULE REMOVAL Service and repair should only be performed by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in dan- ger to the technician or machine operator and will invalidate your factory warran- ty.
  • Page 154 F-90 TROUBLESHOOTING AND REPAIR OUTPUT RECTIFIER AND MODULE REMOVAL AND REPLACEMENT (continued) FIGURE F.26 — OUTPUT RECTIFIER AND MODULE REMOVAL AND REPLACEMENT. RECTIFIER ASSEMBLY REMOVAL PROCEDURE 1. Remove input power to the Power Wave 455. 2. Using the 3/8 in. nutdriver, remove the case top and sides.
  • Page 155 F-91 TROUBLESHOOTING AND REPAIR OUTPUT RECTIFIER AND MODULE REMOVAL AND REPLACEMENT (continued) RECTIFIER MODULE REMOVAL AND REPLACEMENT PROCEDURE 1. Using the 9/64 in. Allen wrench, remove the cap screw from the center of the rectifier module that is to be replaced.
  • Page 156 F-92 F-92 NOTES POWER WAVE 455/POWER FEED 10...

  • Page 157: Power Source Error Interpretation Guide

    F-93 FLOWCHART - POWER SOURCE ERROR INTERPRETATION GUIDE Perform the Contactor Test. Perform the Switch Perform Input Board Test. Codes 32, 33, 34, Pass Board Test on both and 35? sides. Perform the Input Rectifier Test. Fail Replace as Necessary. Replacement board(s) must have identical part number (including the "dash number").

  • Page 158: Performance Troubleshooting Guide

    F-94 FLOWCHART - PERFORMANCE TROUBLESHOOTING GUIDE A NOTE ON VOLTAGE SENSING: All CV and Pulse modes utilize the electrode sense lead (lead #67) built into the control cable. As with any sense lead it's performance is only as good as the worst connection. For diagnostic purposes, an external sense lead can be used to bypass the entire electrode sense network.

  • Page 159: Functional Troubleshooting Guide

    F-95 FLOWCHART - FUNCTIONAL TROUBLESHOOTING GUIDE See UI Error Chart for Error 006? additional error codes. Status Light on the PS Communication Fault. Check Wiring and Solid Condition of Flashing Linc-Net Cables for Status light Red and Green open circuit Flashing Green System is stuck in Remapping loop.
  • Page 160 ELECTRICAL DIAGRAMS TABLE OF CONTENTS -ELECTRICAL DIAGRAMS SECTION- ELECTRICAL DIAGRAMS ............SECTION G POWER WAVE 455 WIRING DIAGRAM - CODE 10372 .
  • Page 161 NOTES POWER WAVE 455/POWER FEED 10...

  • Page 162: Electrical Diagrams

    Power Wave 455 Wiring Diagram - Code 10372 CONTROL BOARD TO J20 WORK .05/600V TO CB1 POWER BOARD WIRE FEEDER RECEPTACLE USER INTERFACE VOLTAGE SENSE RECEPTACLE RS232 CONNECTOR 10A CIRCUIT BREAKER POWER BOARD WORK ELECTRODE 10A CIRCUIT BREAKER 110V RECEPTACLE N.A.

  • Page 163: Power Wave 455 Wiring Diagram - Code 10555

    Power Wave 455 Wiring Diagram - Code 10555 TO J20 CONTROL BOARD TO TP3 202A TO R1 WORK .05/600V POWER BD WIRE FEEDER RECEPTACLE J21A USER INTERFACE J21B VOLTAGE SENSE RECEPTACLE RS232 CONNECTOR 10A CIRCUIT POWER BD BREAKER WORK ELECTRODE 110V RECEPTACLE 202A WORK...

  • Page 164: Power Wave 455 Wiring Diagram - Code 10553

    Power Wave 455 Wiring Diagram - Code 10553 CONTROL BOARD WORK WIRE FEEDER RECEPTACLE VOLTAGE SENSE RECEPTACLE RS232 CONNECTOR 10A CIRCUIT BREAKER 110V RECEPTACLE 10A CIRCUIT BREAKER N.B. PLACE SWITCH IN APPROPRIATE POSITION FOR INPUT VOLTAGE. CONNECTION SHOWN IS FOR 550-575V OPERATION. N.C.

  • Page 165: Power Feed 10 Control Box Wiring Diagram

    Power Feed 10 Control Box Wiring Diagram 512B 500F (J5) N.A. 512C (J4) N.A. 500C 512A 500D (J3) N.A. 500E 541A (J2) 542A (USED FOR N.A. 500A BENCH SET 540A 541D (J1) 542D N.A. 500D 540D MIDDLE BOTTOM PANEL PANEL PANEL 400D 400C...

  • Page 166: Power Feed 10 Wire Drive Wiring Diagram

    Power Feed 10 Wire Drive Wiring Diagram VOLTAGE SENSING CONNECTION R.F. TOROID P.M. MOTOR/GEARBOX (J1) 512B (J2) VOLTAGE SENSE SELECT P.C. BOARD (J2) (J1) SOLENOID NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The wiring diagram specific to your code is pasted inside one of the enclosure panels of your machine. ELECTRICAL DIAGRAMS TO USER INTERFACE...

  • Page 167: Power Feed 10 Machine Schematic

    VOLTAGE SENSE SELECT PCB 512B (SOLID STATE) J6 INPUT RECEPTACLE ELECTRODE VOLTAGE SENSE TO WELDER NOTES: OPTIONAL OUTPUT RECEPTACLE IS REFERENCED (J9) ON WIRE DRIVE AND (J8) ON USER INTERFACE CONTROL BOX. WIRE COLOR CODE B = BLACK U = BLUE...

  • Page 168: Power Wave 455 Machine Schematic - Code 10372

    N.A. PC BOARD COMPONENTS SHOWN FOR REFERENCE ONLY. ALL COMPONENTS ARE NOT SHOWN. THIS SHEET CONTAINS PROPRIETARY INFORMATION UNLESS OTHERWISE SPECIFIED TOLERANCE EQUIP. THE LINCOLN ELECTRIC CO. THE LINCOLN ELECTRIC CO. ON HOLE SIZES PER E2056 OWNED BY AND IS TYPE ON 2 PLACE DECIMALS IS .02...

  • Page 169: Power Wave 455 Machine Schematic - Code 10555

    ONLY. ALL COMPONENTS ARE NOT SHOWN. N.B. L4 IS WOUND ON ONE COMMON CORE. UNLESS OTHERWISE SPECIFIED TOLERANCE Ch'ge. Sht. No. THIS SHEET CONTAINS PROPRIETARY INFORMATION EQUIP. THE LINCOLN ELECTRIC CO. THE LINCOLN ELECTRIC CO. MANUFACTURING TOLERANCE PER E2056 XB-UF OWNED BY AND IS...

  • Page 170: Power Wave 455 Machine Schematic - Code 10553

    NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. N.A. CONTROL BOARD Ch'ge. Sht. No. THIS SHEET CONTAINS PROPRIETARY INFORMATION UNLESS OTHERWISE SPECIFIED TOLERANCE EQUIP. THE LINCOLN ELECTRIC CO. THE LINCOLN ELECTRIC CO. MANUFACTURING TOLERANCE PER E2056 OWNED BY AND IS TYPE ON 2 PLACE DECIMALS IS CLEVELAND, OHIO U.S.A.

  • Page 171: Power Wave 455 Control Pc Board Schematic (1

    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 172: Power Wave 455 Control Pc Board Schematic (2

    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 173 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 174: Power Wave 455 Power Pc Board Schematic

    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 175: Power Wave 455 Input Pc Board Schematic

    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 176: Power Wave 455 Switch Pc Board Schematic - Code 10372 & 10555

    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 177: Power Wave 455 Switch Pc Board Schematic - Code 10553

    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 178: Power Feed 10 Mother Control Pc Board Schematic

    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 179: Power Feed 10 Control Pc Board Schematic

    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 180: Power Feed 10 Display Pc Board Schematic

    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 181: Power Feed 10 Encoder Pc Board Schematic

    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 182: Power Feed 10 Voltage Sense Pc Board Schematic

    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.

This manual is also suitable for:

Power wave 455Power feed 10

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