Lincoln Electric POWER WAVE SVM173-A Service Manual
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Lincoln Electric POWER WAVE SVM173-A Service Manual

Lincoln Electric POWER WAVE SVM173-A Service Manual

Lincoln electric welding system user manual
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POWER WAVE 455M/STT
Safety Depends on You
DO NOT INSTALL,
OPERATE OR REPAIR THIS
EQUIPMENT WITHOUT
READING THIS MANUAL AND
THE SAFETY PRECAUTIONS
CONTAINED THROUGHOUT.
RETURN TO MAIN MENU

SERVICE MANUAL

TM
10942 10957
11007 11008
11057 11153
11152
SVM173-A

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Summary of Contents for Lincoln Electric POWER WAVE SVM173-A

  • Page 1: Service Manual

    POWER WAVE 455M/STT Safety Depends on You DO NOT INSTALL, OPERATE OR REPAIR THIS EQUIPMENT WITHOUT READING THIS MANUAL AND THE SAFETY PRECAUTIONS CONTAINED THROUGHOUT. SERVICE MANUAL RETURN TO MAIN MENU 10942 10957 11007 11008 11057 11153 11152 SVM173-A...

  • Page 2: Safety

    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. 3.b.
  • 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 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: Table Of Contents

    - MASTER TABLE OF CONTENTS FOR ALL SECTIONS - RETURN TO MAIN MENU Page 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 Electrical Diagrams ...Section G Parts Manuals ...P438 (455M) &...
  • Page 7 Section A - INSTALLATION SECTION - Installation...Section A Technical Specifications...A-2, A-3 Safety Precautions ...A-4 Select Suitable Location...A-4 Lifting ...A-4 Stacking ...A-4 Machine Grounding...A-4 High Frequency Protection...A-4 Input Connection ...A-5 Input Fuse and Supply Wire Considerations ...A-5 Input Voltage Change Over (For Multiple Input Voltage Machines Only)...A-6 Welding with Multiple Power Waves ...A-6 Electrode and Work Cable Connections ...A-7 Negative Electrode Polarity...A-7...

  • Page 8: Installation

    TECHNICAL SPECIFICATIONS - POWER WAVE 455M (K2202-1, K2202-3) INPUT AT RATED OUTPUT - THREE PHASE ONLY INPUT VOLTS- OUTPUT CONDITIONS FREQUENCY AMPS / VOLTS / DUTY CYCLE 450A@38V.100% 208/230/460/575V - 60HZ. 570A@43V. 60% 400A@36V.100% 200/220/440/575V - 50HZ. 500A@40V. 60% OPEN CURRENT PULSE CIRCUIT...
  • Page 9 TECHNICAL SPECIFICATIONS - POWER WAVE 455M/STT (K2203-1) INPUT AT RATED OUTPUT - THREE PHASE ONLY INPUT VOLTS OUTPUT CONDITIONS 450A@38V.100% 208/230/460/575V - 60HZ. 570A@43V. 60% 400A@36V.100% 200/220/440/575V - 50HZ. 500A@40V. 60% OPEN CURRENT PULSE CIRCUIT RANGE/ FREQUENCY VOLTAGE 75 VDC 5-575/5-325 0.15 - 1000 Hz PROCESS CURRENT RANGES (DC)

  • Page 10: Safety Precautions

    • Turn the input power OFF at the dis- connect switch or fuse box before working on this equipment. Turn off the input power to any other equip- ment connected to the welding system at the discon- nect switch or fuse box before working on the equip- ment.

  • Page 11: Input Connection

    (K1761-1) CONNECTION DIAGRAM ON CONNECTION/INPUT ACCESS DOOR INPUT SUPPLY CONNECTION DIAGRAM WARNING Disconnect input power before inspecting or servicing machine. Do not operate with covers removed. ELECTRIC Do not touch electrically live parts. SHOCK Only qualified persons should install, CAN KILL use or service this equipment.

  • Page 12: Input Voltage Change Over (For Multiple Input Voltage Machines Only

    INPUT VOLTAGE CHANGE OVER (FOR MULTIPLE INPUT VOLTAGE MACHINES ONLY) Welders are shipped connected for the highest input voltage listed on the rating plate. To move this con- nection to a different input voltage, see the diagram located on the inside of the input access door. (Figure A.1.) If the main reconnect switch or link position is placed in the wrong position, the welder will not pro- duce output power.

  • Page 13: Electrode And Work Cable Connections

    When these parameters are identical, the pulsing fre- quency will be the same, helping to stabilize the arcs. Every welding gun requires a separate shielding gas regulator for proper flow rate and shielding gas cover- age. Do not attempt to supply shielding gas for two or more guns from only one regulator.

  • Page 14: Voltage Sensing

    VOLTAGE SENSING The best arc performance occurs when the Power Wave has accurate data about the arc conditions. Depending upon the process, inductance within the electrode and work lead cables can influence the volt- age apparent at the terminals of the welder. Voltage sense leads improve the accuracy of the arc conditions and can have a dramatic effect on performance.

  • Page 15: Work Voltage Sensing

    WORK VOLTAGE SENSING The Power Wave is shipped from the factory with the work sense lead enabled. For processes requiring work voltage sensing, connect the (21) work voltage sense lead from the Power Wave to the work. Attach the sense lead to the work as close to the weld as practical.

  • Page 16: Dip Switch Settings And Locations

    A-10 DIP SWITCH SETTINGS AND LOCATIONS DIP switches on the PC boards allow for custom con- figuration of the Power Wave. Access the DIP switch- es as follows: WARNING ELECTRIC SHOCK CAN KILL. • Do not touch electrically live parts or electrodes with your skin or wet cloth- ing.

  • Page 17: Devicenet/Gateway Board Dip Switch, Bank (S2

    A-11 DEVICENET/GATEWAY BOARD DIP SWITCH, BANK (S2): switch 1,2 = configure the baud rate for DeviceNET Prior to S24958-6 software switch 1 switch 2 S24958-6 and later software switch 1 switch 2 Programmable value. Consult local Lincoln Technical representative. switch 5 = reserved for future use switch 6 = reserved for future use switch 7 = reserved for future use switch 8 = reserved for future use...
  • Page 18 A-12 A-12 NOTES POWER WAVE 455M/MSTT...
  • Page 19 Section B-1 - OPERATION SECTION - Operation...Section B Safety Precautions ...B-2 Graphic Symbols...B-3 General Description ...B-4 Design Features and Advantages ...B-4 Recommended Processes and Equipment...B-5 Recommended Processes...B-5 Recommended Equipment ...B-5 Required Equipment ...B-5 Limitations...B-5 Duty Cycle and Time Period...B-5 Case Front Controls ...B-6 Welding Mode Descriptions ...B-7 Constant Voltage Welding ...B-7 Pulse Welding...B-8...

  • Page 20: Operation

    SAFETY PRECAUTIONS Read this entire section of operating instructions before operating the machine. • Do not touch electrically live parts or electrodes with your skin or wet clothing. • Insulate yourself from the work and ground. • Always wear dry insulating gloves. Observe additional guidelines detailed in the beginning of this manual.

  • Page 21: Graphic Symbols

    GRAPHIC SYMBOLS THAT APPEAR ON THIS MACHINE OR IN THIS MANUAL INPUT POWER HIGH TEMPERATURE MACHINE STATUS CIRCUIT BREAKER WIRE FEEDER POSITIVE OUTPUT NEGATIVE OUTPUT 3 PHASE INVERTER INPUT POWER THREE PHASE DIRECT CURRENT OPERATION POWER WAVE 455M/MSTT SMAW GMAW FCAW GTAW OPEN CIRCUIT...

  • Page 22: Operation

    GENERAL DESCRIPTION The Power Wave power source is designed to be a part modular, multi-process welding Depending on configuration, it can support constant current, constant voltage, Surface Tension Transfer and pulse welding modes. The Power Wave power source is designed to be used with the family of Power Feed wire feeders, operating as a system.

  • Page 23: Recommended Processes And Equipment

    RECOMMENDED PROCESSES AND EQUIPMENT RECOMMENDED PROCESSES The Power Wave 455/R can be set up in a number of configurations, some requiring optional equipment or welding programs. Each machine is factory prepro- grammed with multiple welding procedures, typically including GMAW, GMAW-P, FCAW, GTAW and STT for a variety of materials, including mild steel, stainless steel, cored wires, and aluminum.

  • Page 24: Case Front Controls

    CASE FRONT CONTROLS All operator controls and adjustments are located on the case front of the Power Wave. (See Figure B.1) 1. POWER SWITCH: Controls input power to the Power Wave. 2. STATUS LIGHT: A two color light that indicates sys- tem errors.

  • Page 25: Welding Mode Descriptions

    WELDING MODE DESCRIPTIONS CONSTANT VOLTAGE WELDING For each wire feed speed, a corresponding voltage is preprogrammed into the machine through special soft- ware at the factory. The preprogrammed voltage is the best average voltage for a given wire feed speed. With synergic programs, when the wire feed speed changes, the Power Wave will automatically adjust the corre- sponding voltage.

  • Page 26: Pulse Welding

    PULSE WELDING Pulse welding procedures are set by controlling an overall “arc length” variable. When pulse welding, the arc voltage is highly dependent upon the waveform. The peak current, background current, rise time, fall time and pulse frequency all affect the voltage. The exact voltage for a given wire feed speed can only be predicted when all the pulsing waveform parameters are known.

  • Page 27: Stt Welding

    STT WELDING The pictures illustrate the wave shape of current for the process. They are not drawn to scale, and are intend- ed only for the purpose of showing how the variables affect the waveform. FIGURE B.4 – STT TRIM CONTROL CHARACTERISTICS Current Time For most programs, peak current is adjusted by wave...
  • Page 28 B-10 B-10 NOTES POWER WAVE 455M/MSTT...
  • Page 29 Section C-1 - ACCESSORIES SECTION - Accessories ...Section C Optional Equipment ...C-2 Factory Installed ...C-2 Field Installed ...C-2 TABLE OF CONTENTS POWER WAVE 455M/MSTT Section C-1...

  • Page 30: Accessories

    Recommend practice is to install a water flow sensor such as on the water return line of the torch. When fully integrated into the welding system, the sensor will prevent welding if no water flow is pre- sent.

  • Page 31: Maintenance Section

    Section D-1 - MAINTENANCE SECTION - Maintenance ...Section D Safety Precautions...D-2 Routine and Periodic Maintenance...D-2 Main Assembly (Exploded View) ...D-3 TABLE OF CONTENTS POWER WAVE 455M/MSTT Section D-1...

  • Page 32: Maintenance

    SAFETY PRECAUTIONS WARNING ELECTRIC SHOCK can kill. • Only Qualified personnel should perform this maintenance. • Turn the input power OFF at the disconnect switch or fuse box before working on this equipment. • Do not touch electrically hot parts. ROUTINE AND PERIODIC MAINTENANCE 1.
  • Page 33 FIGURE D.1 – MAIN ASSEMBLY (EXPLODED VIEW) 1. CASE FRONT ASSEMBLY 2. TRANSFORMER AND OUTPUT RECTIFIER ASSEMBLY 3. INPUT ASSEMBLY 4. CONTROL BOX AND VERTICAL DIVIDER ASSEMBLY 5. BASE, LIFT BAIL AND FAN ASSEMBLY 6. SWITCH BOARD HEATSINK ASSEMBLY 7. CASE PARTS MAINTENANCE POWER WAVE 455M/MSTT...
  • Page 34 NOTES POWER WAVE 455M/MSTT...
  • Page 35 Section E-1 - THEORY OF OPERATION SECTION - Theory of Operation ...Section E Block Logic Diagram ...E-1 General Description ...E-2 Input Voltage and Precharge ...E-3 Switch Boards and Main Transformer...E-4 DC Bus Board, Power Board, Feed Head Board, Gateway Board and Voltage Sense Board ...E-5 Power Wave Communications Diagram ...E-6 Control Board ...E-7...

  • Page 36: Theory Of Operation

    THEORY OF OPERATION FIGURE E.2 – INPUT VOLTAGE AND PRECHARGE POWER WAVE 455/R INPUT RECTIFIER RECONNECT INPUT BOARD CONTACTOR AND PRECHARGE CONTROL SIGNALS FROM CONTROL BOARD FROM CONTROL BOARD RECONNECT 115 VAC RELAY 115 VAC 65 VDC 52 VAC BUS BOARD RECTIFIER 230 VAC WATER...

  • Page 37: Input Voltage And Precharge

    THEORY OF OPERATION INPUT VOLTAGE AND PRECHARGE The Power Wave 455M can be connected for a variety of three-phase input voltages. Refer to Figure E.2. The initial input power is applied to the Power Wave 455M through a line switch located on the front of the machine.

  • Page 38: Switch Boards And Main Transformer

    THEORY OF OPERATION FIGURE E.3 - SWITCH BOARDS AND MAIN TRANSFORMER POWER WAVE 455/R INPUT RECTIFIER INPUT BOARD CONTACTOR AND PRECHARGE CONTROL SIGNALS FROM CONTROL BOARD FROM CONTROL BOARD RECONNECT 115 VAC RELAY 115 VAC 65 VDC 52 VAC BUS BOARD RECTIFIER 230 VAC WATER...
  • Page 39 THEORY OF OPERATION FIGURE E-4 – DC BUS BOARD, POWER BOARD, FEED HEAD BOARD, GATEWAY BOARD AND VOLTAGE SENSE BOARD POWER WAVE 455/R INPUT RECTIFIER INPUT BOARD CONTACTOR AND PRECHARGE CONTROL SIGNALS FROM CONTROL BOARD FROM CONTROL BOARD RECONNECT 115 VAC RELAY 115 VAC 65 VDC...
  • Page 40 THEORY OF OPERATION FIGURE E.5 – POWER WAVE 455/R COMMUNICATIONS A A r r c c L L i i n n k k Arc Link G G a a t t e e w w a a y y F F e e e e d d C C o o n n t t r r o o l l B B o o a a r r d d...

  • Page 41: Control Board

    THEORY OF OPERATION POWER WAVE 455/R INPUT RECTIFIER INPUT BOARD CONTACTOR AND PRECHARGE CONTROL SIGNALS FROM CONTROL BOARD FROM CONTROL BOARD RECONNECT 115 VAC RELAY 115 VAC 65 VDC 52 VAC BUS BOARD RECTIFIER 230 VAC WATER COOLER 115 VAC RECP.

  • Page 42: Output Rectifier And Choke

    THEORY OF OPERATION FIGURE E.7 – OUTPUT RECTIFIER, OUTPUT CHOKE AND STT CHOPPER BOARD POWER WAVE 455/R INPUT RECTIFIER INPUT BOARD CONTACTOR AND PRECHARGE CONTROL SIGNALS FROM CONTROL BOARD FROM CONTROL BOARD RECONNECT 115 VAC RELAY 115 VAC 65 VDC 52 VAC BUS BOARD RECTIFIER...

  • Page 43: 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 output rectifier, one on the DC bus, and one on the output choke.
  • Page 44 E-10 THEORY OF OPERATION Current Time Current Time GENERAL DESCRIPTION OF THE STT (SURFACE TENSION TRANSFER) PROCESS The STT process cannot be classified as either a con- stant current (CC) or a constant voltage (CV) applica- tion. The STT function produces current of a desired waveform to reduce spatter and fumes.
  • Page 45 E-11 THEORY OF OPERATION SOURCE DRAIN A. PASSIVE INSULATED GATE BIPOLAR TRANSISTOR (IGBT) OPERATION An IGBT is a type of transistor. IGBTs are semicon- ductors well suited for high frequency switching and high current applications. Drawing A shows an IGBT in a passive mode. There is no gate signal, zero volts relative to the source, and therefore, no current flow.

  • Page 46: Pulse Width Modulation

    E-12 THEORY OF OPERATION FIGURE E.10 – TYPICAL IGBT OUTPUTS 25 sec 24 sec PULSE WIDTH MODULATION The term PULSE WIDTH MODULATION (PWM) is used to describe how much time is devoted to conduc- tion in the positive and negative portions of the cycle. Changing the pulse width is known as MODULATION.
  • Page 47 Section F-1 - TROUBLESHOOTING & REPAIR SECTION - Troubleshooting & Repair ...Section F How to Use Troubleshooting Guide ...F-2 PC Board Troubleshooting Procedures...F-3 Troubleshooting Guide ...F-4 Test Procedures ...F-9 Input Filter Capacitor Discharge Procedure ...F-9 Switch Board Test ...F-11 Input Rectifier Test ...F-15 Input Contactor Test...F-19 DC Bus Power Supply PC Board Test...F-23 Power Board Test ...F-27...

  • Page 48: Troubleshooting & Repair

    In general, these tests can be con- ducted without removing the case cover. In addition to the troubleshooting information in this manual, Lincoln Electric offers a System Update Utility to reprogram digital power sources. The utility will examine the welding system allowing you to upgrade to the current release of the operating system software and welding programs available for the machine if necessary.

  • Page 49: 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 50: 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 1-888-935-3877. POSSIBLE AREAS OF...
  • Page 51 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 1-888-935-3877. detailed in the beginning of this manual.
  • Page 52 "overheats." 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 1-888-935-3877. POSSIBLE AREAS OF...
  • Page 53 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 1-888-935-3877. detailed in the beginning of this manual.
  • Page 54 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 1-888-935-3877.

  • 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-10 TROUBLESHOOTING & REPAIR INPUT FILTER CAPACITOR DISCHARGE PROCEDURE (CONTINUED) FIGURE F.1 – CAPACITOR DISCHARGE PROCEDURE TEST PROCEDURE 1. Remove input power to the Power Wave 455M. 2. Using the 3/8” nut driver, remove the left and right case sides. 3.

  • Page 57: Switch Board Test

    F-11 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 58 F-12 F-12 TROUBLESHOOTING & REPAIR SWITCH BOARD TEST CONTINUED) FIGURE F.2 – RECONNECT SWITCHES RECONNECT SWITCHES TEST PROCEDURE Capacitor Discharge Switch Board Removal and Replacement. Figure F.3 POWER WAVE 455M/MSTT...
  • Page 59 F-13 TROUBLESHOOTING & REPAIR SWITCH BOARD TEST CONTINUED) FIGURE F.3 – SWITCH BOARD TEST POINTS SWITCH BOARD -20 +19 11/12 15/16 POWER WAVE 455M/MSTT F-13 13/14 17/18...
  • Page 60 F-14 F-14 NOTES POWER WAVE 455M/MSTT...

  • Page 61: Input Rectifier Test

    F-15 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-16 F-16 TROUBLESHOOTING & REPAIR INPUT RECTIFIER TEST CONTINUED) FIGURE F.4 – INPUT RECTIFIER TEST INPUT RECTIFIER NEG (-) POS (+) TEST PROCEDURE NOTE: Capacitor Discharge POWER WAVE 455M/MSTT...
  • Page 63 F-17 TROUBLESHOOTING & REPAIR INPUT RECTIFIER TEST (CONTINUED) 6. Use the analog ohmmeter to perform the tests detailed in Table F.1. 7. If the input rectifier does not meet the acceptable readings outlined in the table, the component may be faulty. Replace. NOTE: Before replacing the input rectifier, per- form the Switch Board Test.
  • Page 64 F-18 F-18 NOTES POWER WAVE 455M/MSTT...

  • Page 65: Input Contactor 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 66 F-20 TROUBLESHOOTING & REPAIR INPUT CONTACTOR TEST (CONTINUED) TEST PROCEDURE 1. Remove input power to the Power Wave 455. 2. Using the 3/8” nut driver, remove the input access panel and case top. 3. Locate, mark, and remove the two leads (601, X4) that are connected to the input contactor coil.
  • Page 67 F-21 TROUBLESHOOTING & REPAIR INPUT CONTACTOR TEST (CONTINUED) FIGURE F.6 – INPUT CONTACTOR TEST POINTS 5. With the input contactor activated, check the continuity across the three sets of contacts. (Zero ohms or very low resistance is nor- mal.) Refer to Figure F.6. If the resistance is high, the input contactor is faulty.
  • Page 68 F-22 F-22 NOTES POWER WAVE 455M/MSTT...

  • Page 69: Dc Bus Power Supply Pc Board Test

    TROUBLESHOOTING & REPAIR DC BUS POWER SUPPLY PC 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 70 F-24 TROUBLESHOOTING & REPAIR DC BUS POWER SUPPLY PC BOARD TEST (CONTINUED) FIGURE F.7 – DC BUS POWER SUPPLY POWER SUPPLY PC BOARD DC BUS POWER SUPPLY PC BOARD CAPACITOR CAUTION! TEST PROCEDURE 1. Remove input power to the machine. 2.
  • Page 71 F-25 TROUBLESHOOTING & REPAIR DC BUS POWER SUPPLY PC BOARD TEST(CONTINUED) 6. Check the DC Bus Power Supply PC Board input and output voltages according to Table F.3. See Figure F.7 and the Wiring Diagram. If plug P46 pin 1-3 voltage is missing, perform T1 Auxiliary Transformer Test.
  • Page 72 F-26 F-26 NOTES POWER WAVE 455M/MSTT...

  • Page 73: Power 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 74 F-28 TROUBLESHOOTING & REPAIR POWER BOARD TEST (CONTINUED) TEST PROCEDURE 1. Remove input power to the Power Wave 455M. 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 75 F-29 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 76 F-30 F-30 NOTES POWER WAVE 455M/MSTT...

  • Page 77: Input Board Test

    F-31 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 78 F-32 TROUBLESHOOTING & REPAIR INPUT BOARD TEST (CONTINUED) TEST PROCEDURE 1. Remove input power to the Power Wave 455M. 2. Using the 3/8” nut driver, remove the case top, and input access cover. 3. Remove lead X4 from the coil terminal of main input contactor CR1.
  • Page 79 F-33 TROUBLESHOOTING & REPAIR INPUT BOARD FUNCTION TEST(CONTINUED) TABLE F.4 – INPUT BOARD VOLTAGE CHECKS TEST POINTS NUMBERS PLUG J61 PIN 8 (H1D) PLUG J61 PIN 6 (612) #612 PLUG J60 PIN 3 (238) PLUG J60 PIN 4 (604) PLUG J61 PIN 10 (T3) PLUG J61 PIN 2 (T1) PLUG J60 PIN 3 (238) PLUG J60 PIN 5 (232)
  • Page 80 F-34 TROUBLESHOOTING & REPAIR INPUT BOARD TEST(CONTINUED) 6. Remove input power to the Power Wave 455M. If any of the voltages are low or not present, perform the Input Contactor Test. If that checks out, the Input Board may by faulty.

  • Page 81: Stt Chopper Board Test

    TROUBLESHOOTING & REPAIR STT CHOPPER 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 82 F-36 TROUBLESHOOTING & REPAIR STT CHOPPER BOARD TEST (CONTINUED) FIGURE F.10 – STT CHOPPER BOARD TEST DETAILS CONTROL PC BOARD 9 10 11 12 13 14 15 16 4W 4R TEST PROCEDURE 1. Remove input power to the Power Wave 455M.
  • Page 83 F-37 TROUBLESHOOTING & REPAIR STT CHOPPER BOARD TEST (CONTINUED) 4. Carefully apply input power to the Power Wave 455M. WARNING ELECTRIC SHOCK can kill. High voltage is present when input power is applied to the machine. For steps 5 and 6, see Figure F.10. 5.
  • Page 84 F-38 F-38 NOTES POWER WAVE 455M/MSTT...

  • Page 85: Power Wave Current Transducer Test

    TROUBLESHOOTING & REPAIR POWER WAVE 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 86 F-40 TROUBLESHOOTING & REPAIR POWER WAVE CURRENT TRANSDUCER TEST (CONTINUED) FIGURE F.11 – POWER WAVE CURRENT TRANSDUCER TEST 211 212 213 CURRENT TRANSDUCER TEST PROCEDURE 1. Remove input power to the Power Wave 455. 2. Using the 3/8” nut driver, remove the case top and the control box cover.
  • Page 87 F-41 TROUBLESHOOTING & REPAIR POWER WAVE CURRENT TRANSDUCER TEST (CONTINUED) FIGURE F.12 – RECEPTACLE S7 TRIGGERED 5. Turn on the Power Wave 455. Check for the correct DC supply voltage to the current transducer at plug J8. See Figure F.11. A.
  • Page 88 F-42 TROUBLESHOOTING & REPAIR POWER WAVE CURRENT TRANSDUCER TEST (CONTINUED) 8. If for any reason the machine cannot be loaded to 250 amps, Table F.5 shows what feedback voltage is produced at various cur- rent loads. 9. If the correct supply voltages are applied to the current transducer, and with the machine loaded, the feedback voltage is missing or TABLE F.5 - CURRENT FEEDBACK AT VARIOUS OUTPUT LOADS...

  • Page 89: Stt Current Transducer Test

    TROUBLESHOOTING & REPAIR STT 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 90 F-44 TROUBLESHOOTING & REPAIR STT CURRENT TRANSDUCER TEST (CONTINUED) FIGURE F.13 – STT CURRENT TRANSDUCER TEST TEST PROCEDURE 1. Remove input power to the Power Wave 455. 2. Using the 3/8” nut driver, remove the case top and the control box cover. 3.
  • Page 91 F-45 TROUBLESHOOTING & REPAIR STT CURRENT TRANSDUCER TEST (CONTINUED) FIGURE F.14 – RECEPTACLE S7 TRIGGERED 5. Turn on the Power Wave 455M. Check for the correct DC supply voltage to the current transducer at plug J8. A. Pin 8 (lead 812+) to pin 7 (lead 816-) should read +15 VDC.
  • Page 92 F-46 TROUBLESHOOTING & REPAIR STT CURRENT TRANSDUCER TEST (CONTINUED) 8. If for any reason the machine cannot be loaded to 50 amps, Table F.6 shows what feedback voltage is produced at various cur- rent loads. S.T.T. stud is limited to 325 amps.

  • Page 93: Output Rectifier Test

    F-47 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 94 F-48 TROUBLESHOOTING & REPAIR OUTPUT RECTIFIER TEST (CONTINUED) NEGATIVE (-) OUTPUT TERMINAL TEST PROCEDURE 1. Remove main input supply power to the Power Wave 455M. 2. Remove any output load that may be con- nected to the Power Wave 455M. 3.

  • Page 95: Auxiliary Transformer No. 1 Test

    TROUBLESHOOTING & REPAIR AUXILIARY TRANSFORMER NO. 1 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 96 F-50 TROUBLESHOOTING & REPAIR AUXILIARY TRANSFORMER NO. 1 TEST (CONTINUED) FIGURE F.16 – AUXILIARY TRANSFORMER NO. 1 TEST FAN MOTOR LEADS POWER BOARD RECTIFIER BRIDGE TEST PROCEDURE 1. Remove the main input power to the Power Wave 455 machine. 2. Using the 3/8” nut driver, remove the case top.
  • Page 97 F-51 TROUBLESHOOTING & REPAIR AUXILIARY TRANSFORMER NO. 1 TEST (CONTINUED) LEAD IDENTIFICATION X1 to X2 X3 to X5 X3 to X4 7. Carefully apply the correct input voltage to the Power Wave 455M. WARNING ELECTRIC SHOCK can kill. High voltage is present at prima- ry of the Auxiliary Transformer.
  • Page 98 F-52 F-52 NOTES POWER WAVE 455M/MSTT...

  • Page 99: Auxiliary Transformer No. 2 Test

    TROUBLESHOOTING & REPAIR AUXILIARY TRANSFORMER NO. 2 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 100 F-54 TROUBLESHOOTING & REPAIR AUXILIARY TRANSFORMER NO. 2 TEST (CONTINUED) FIGURE F.17 – AUXILIARY TRANSFORMER NO. 2 TEST TEST PROCEDURE 1. Remove the main input power to the Power Wave 455M machine. 2. Remove any load that may be connected to the 115 VAC receptacle.

  • Page 101: 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 102 F-56 F-56 TROUBLESHOOTING & REPAIR INPUT RECTIFIER REMOVAL AND REPLACEMENT CONTINUED) FIGURE F.18 – INPUT RECTIFIER REMOVAL AND REPLACEMENT INPUT RECTIFIER NEG (-) POS (+) REMOVAL PROCEDURE REPLACEMENT PROCEDURE Capacitor Discharge POWER WAVE 455M/MSTT...

  • Page 103: Input Contactor Removal And Replacement

    TROUBLESHOOTING & REPAIR INPUT CONTACTOR 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 F-58 TROUBLESHOOTING & REPAIR INPUT CONTACTOR REMOVAL AND REPLACEMENT (CONTINUED) FIGURE F.19 – INPUT CONTACTOR REMOVAL AND REPLACEMENT REMOVAL PROCEDURE 1. Remove input power to the Power Wave 455M. 2. Using the 3/8” nut driver, remove the case top, and input access panel. 3.

  • Page 105: Auxiliary Transformer No. 1 Removal And Replacement Procedure

    AUXILIARY TRANSFORMER NO. 1 REMOVAL AND REPLACEMENT 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 106 F-60 TROUBLESHOOTING & REPAIR AUXILIARY TRANSFORMER NO. 1 REMOVAL AND REPLACEMENT PROCEDURE (CONTINUED) FIGURE F.20 – AUXILIARY TRANSFORMER NO. 1 REMOVAL AND REPLACEMENT FAN MOTOR LEADS POWER BOARD RECTIFIER BRIDGE REMOVAL PROCEDURE 1. Remove input power to the Power Wave 455.
  • Page 107 F-61 TROUBLESHOOTING & REPAIR AUXILIARY TRANSFORMER NO. 1 REMOVAL AND REPLACEMENT PROCEDURE (CONTINUED) 6. Remove leads X1 and X2 from the power board rectifier bridge. F.20. 7. Cut X3 and X5 from the fan motor leads. Leave enough lead length to splice in the new transformer leads.
  • Page 108 F-62 F-62 NOTES POWER WAVE 455M/MSTT...

  • Page 109: Auxiliary Transformer No. 2 Removal And Replacement Procedure

    AUXILIARY TRANSFORMER NO. 2 REMOVAL AND REPLACEMENT 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 110 F-64 TROUBLESHOOTING & REPAIR AUXILIARY TRANSFORMER NO. 2 REMOVAL AND REPLACEMENT PROCEDURE (CONTINUED) FIGURE F.21 – AUXILIARY TRANSFORMER NO. 2 REMOVAL AND REPLACEMENT CB4 CIRCUIT BREAKER & 115V RECEPTACLE LEADS 33/32 REMOVAL PROCEDURE 1. Remove input power to the Power Wave 455.
  • Page 111 F-65 TROUBLESHOOTING & REPAIR AUXILIARY TRANSFORMER NO. 2 REMOVAL AND REPLACEMENT PROCEDURE (CONTINUED) REPLACEMENT PROCEDURE 1. Carefully place the transformer into the Power Wave 455. 2. Install the two mounting screws that hold the transformer to the machine base using the 3/8”...
  • Page 112 F-66 F-66 NOTES POWER WAVE 455M/MSTT...

  • Page 113: Control, Feed Head, Or Voltage Sense Pc Board Removal And Replacement

    CONTROL, FEED HEAD, OR VOLTAGE SENSE PC 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 114 F-68 TROUBLESHOOTING & REPAIR CONTROL, FEED HEAD, OR VOLTAGE SENSE PC BOARD REMOVAL AND REPLACEMENT (CONTINUED) FIGURE F.22 – CONTROL OR FEED HEAD BOARD REMOVAL AND REPLACEMENT CONTROL BOARD REMOVAL PROCEDURE 1. Remove input power to the Power Wave 455M. 2.
  • Page 115 F-69 TROUBLESHOOTING & REPAIR CONTROL, FEED HEAD, OR VOLTAGE SENSE PC BOARD REMOVAL AND REPLACEMENT (CONTINUED) FIGURE F.23 – VOLTAGE SENSE BOARD REMOVAL AND REPLACEMENT VOLTAGE SENSE BOARD 9. Tilt back the rear of the control box to access the PC board mounting nuts. Using the 3/8”...
  • Page 116 F-70 TROUBLESHOOTING & REPAIR CONTROL, FEED HEAD, OR VOLTAGE SENSE PC BOARD REMOVAL AND REPLACEMENT (CONTINUED) 3. Secure the rear of the control box in place using two screws and the 3/8” nut driver. 4. Press the Voltage Sense Board onto its standoffs.

  • Page 117: Gateway Pc Board Removal And Replacement

    TROUBLESHOOTING & REPAIR GATEWAY PC 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 118 F-72 TROUBLESHOOTING & REPAIR GATEWAY PC BOARD REMOVAL AND REPLACEMENT (CONTINUED) FIGURE F.24 – GATEWAY BOARD REMOVAL AND REPLACEMENT DEVICENET/ GATEWAY BOARD (LOCATED BEHIND FRONT COVER) REMOVAL PROCEDURE 1. Remove input power to the Power Wave 455. 2. Using the phillips head screw driver, remove the six screws from the case front cover.

  • Page 119: Stt Current Transducer Removal And Replacement

    STT 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 120 F-74 TROUBLESHOOTING & REPAIR STT CURRENT TRANSDUCER REMOVAL AND PLACEMENT (CONTINUED) FIGURE F.25 – STT CURRENT TRANSDUCER REMOVAL AND REPLACEMENT PROCEDURE STT OUTPUT TERMINAL (TOP RIGHT) REMOVAL PROCEDURE 1. Remove input power to the Power Wave 455. 2. Using the 3/8” nut driver, remove the case top and right side.
  • Page 121 F-75 TROUBLESHOOTING & REPAIR STT CURRENT TRANSDUCER REMOVAL AND REPLACEMENT (CONTINUED) 6. With the 5/16” open end wrench, remove the small screw from the STT output termi- nal. Label and remove the small leads. See the Wiring Diagram. 7. Using the 3/4” wrench, remove the bolt, lock washer and flat washer from the STT output terminal.
  • Page 122 F-76 F-76 NOTES POWER WAVE 455M/MSTT...

  • Page 123: Power Wave Current Transducer Removal And Replacement

    POWER WAVE 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 124 F-78 TROUBLESHOOTING & REPAIR POWER WAVE CURRENT TRANSDUCER REMOVAL AND REPLACEMENT (CONTINUED) FIGURE F.26 – POWER WAVE CURRENT TRANSDUCER REMOVAL AND REPLACEMENT PROCEDURE CURRENT TRANSDUCER HEAVY LEAD BOLTED CONNECTION (BEHIND CASE FRONT) REMOVAL PROCEDURE 1. Remove input power to the Power Wave 455.
  • Page 125 F-79 TROUBLESHOOTING & REPAIR POWER WAVE CURRENT TRANSDUCER REMOVAL AND REPLACEMENT (CONTINUED) 9. Using the phillips head screw driver, remove the screws and lock washers that hold the transducer to the front panel. 10. Remove the Power Wave current trans- ducer.
  • Page 126 F-80 F-80 NOTES POWER WAVE 455M/MSTT...

  • Page 127: Output Rectifier, Stt Chopper Board And Rectifier Module Removal And Replacement

    OUTPUT RECTIFIER, STT CHOPPER BOARD AND RECTIFIER MODULE 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 128 F-82 TROUBLESHOOTING & REPAIR OUTPUT RECTIFIER, STT CHOPPER BOARD AND RECTIFIER MODULE REMOVAL AND REPLACEMENT (CONTINUED) FIGURE F.27 – OUTPUT RECTIFIER, STT CHOPPER BOARD AND RECTIFIER MODULE RECTIFIER ASSEMBLY REMOVAL PROCEDURE 1. Remove input power to the Power Wave 455. 2.
  • Page 129 F-83 TROUBLESHOOTING & REPAIR OUTPUT RECTIFIER, STT CHOPPER BOARD AND RECTIFIER MODULE REMOVAL AND REPLACEMENT (CONTINUED) 7. Using the needle-nose pliers, remove leads #292 and #291 from the rectifier ther- mostat. 8. Disconnect plug J10 from the STT Chopper Board. 9.
  • Page 130 F-84 TROUBLESHOOTING & REPAIR OUTPUT RECTIFIER, STT CHOPPER BOARD AND RECTIFIER MODULE REMOVAL AND REPLACEMENT (CONTINUED) RECTIFIER MODULE REMOVAL AND REPLACEMENT PROCEDURE 1. Using the 9/64” allen wrench, remove the cap screw from the center of the rectifier module that is to be replaced. 2.

  • Page 131: Switch Board And Filter Capacitor Removal And Replacement

    SWITCH BOARD AND FILTER CAPACITOR 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 132 F-86 TROUBLESHOOTING & REPAIR SWITCH BOARD AND FILTER CAPACITOR REMOVAL AND REPLACEMENT (CONTINUED) FIGURE F.28 – SWITCH BOARD AND FILTER CAPACITOR REMOVAL AND REPLACEMENT REMOVAL PROCEDURE NOTE: Observe all static electricity precau- tions. Lead and plug references below use a slash (/) to indicate machine right side/left side wire number differences.
  • Page 133 F-87 TROUBLESHOOTING & REPAIR SWITCH BOARD AND FILTER CAPACITOR REMOVAL AND REPLACEMENT (CONTINUED) 7. Using the 7/16” wrench, remove leads 13/14 or 17/18 from the switch board. 8. Using the 7/16” wrench, remove leads 11/12 or 15/16 from the switch board. 9.

  • Page 134: Retest After Repair

    F-88 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 135 Section G-1 - ELECTRICAL DIAGRAMS SECTION - Electrical Diagrams ...Section G Wiring Diagram (Code 10942) (G4212)...G-2 Wiring Diagram (Codes 10957 - 11311) (G4420)...G-3 Schematic - Complete Machine (Code 10942) (G4211) ...G-4 Schematic - Complete Machine (Codes 10957 - 11311) PG 1 of 3 (G4421)...G-5 Schematic - Complete Machine (Codes 10957 - 11311) PG 2 of 3 (G4421)...G-6 Schematic - Complete Machine (Codes 10957 - 11311) PG 3 of 3 (G4421)...G-7 Schematic - Chopper PC Board (STT Models only) (L11340-2) ...G-8...

  • Page 136: Electrical Diagrams

    WIRING DIAGRAM - ENTIRE MACHINE - CODE 10942 (G4212) TO TP6 TO J9 CONTROL BOARD DEVICE NET TO TP3 GATEWAY BOARD 202A TO R1 WORK .05/600V ARCLINK RECEPTACLE DEVICENET CONNECTOR +24V J2VS +24V GND CAN_H CAN_L ROBOTIC/ 153B MODULE WIREDRIVE J82 AND J1 154B INTERFACE...

  • Page 137: Wiring Diagram (Code 10942) (G4212

    WIRING DIAGRAM - ENTIRE MACHINE - CODES 10957 - 11311 (G4420) ETHERNET / DEVICENET DEVICENET MODULE MODULE N.D. 153B 154B DEVICENET CONNECTOR +24V +24V GND CAN_H CAN_L ETHERNET CONNECTOR RJ 45 TYPE ETHERNET PORT J710 J70 & J71 ARE NOT USED ONLY PRESENT IF FEEDHEAD THE ETHERNET CONNECTION MODULE IS PRESENT...
  • Page 138 SCHEMATIC - ENTIRE MACHINE - CODE 10942 (G4211) G4211 CHANGE DETAIL: Released from "X" ENGINEERING CONTROLLED MANUFACTURER: RECONNECT SWITCH INPUT 380-460V 208-230V RECTIFIER N.A., FEED HD BD N.B. 3J83 SOLENOID +40VDC N.A. 4J83 SOLENOID INPUT INPUT BOARD MOTOR "+" 1J83 1J60 2J60 2J83...
  • Page 139 SCHEMATIC - ENTIRE MACHINE - CODES 10957 - 11311 PG 1 OF 3 (G4421) G4421 CHANGE DETAIL: CONTROL BOARD, CHANGED 2J4 TO 3J4 ENGINEERING CONTROLLED MANUFACTURER: SWITCH BOARD #1 Undervoltage = 200V Schematic: L11385 Overvoltage = 467V (Located on left side of Machine) 3500uF 500V RECONNECT...
  • Page 140 SCHEMATIC - ENTIRE MACHINE - CODES 10957 - 11311 PG 2 OF 3 (G4421) G4421 CONTROL BOARD, CHANGED 2J4 TO 3J4 ENGINEERING CONTROLLED CHANGE DETAIL: MANUFACTURER: CONTROL BOARD CONTROL BOARD Schematic: G3789 Located on left side of control box THERMAL LED YELLOW THERMAL THERMAL LED...
  • Page 141 SCHEMATIC - ENTIRE MACHINE - CODES 10957 - 11311 PG 3 OF 3 (G4421) CONTROL BOARD, CHANGED 2J4 TO 3J4 G4421 ENGINEERING CONTROLLED CHANGE DETAIL: MANUFACTURER: ETHERNET MODULE (OPTIONAL K2207) Devicenet Board DIP Switch Switch Object Instance LSB (see Table 1) Object Instance MSB (see Table 1) Description of LED functions on the Power Wave 455M Equipment Group 1 Select...

  • Page 142: Schematic - Chopper Pc Board (Stt Models Only) (L11340-2

    ELECTRICAL DIAGRAMS SCHEMATIC - CHOPPER PC BD - (STT MODELS ONLY) (L11340-2) NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. POWER WAVE 455M/MSTT...

  • Page 143: Pc Board Assembly - Chopper Pc Board (Stt Models Only) (G3339-2

    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 144: Schematic - Devicenet/Gateway Pc Board (Robotic Model Only) Pg 1 Of 2 (G3821-2

    G-10 ELECTRICAL DIAGRAMS G-10 SCHEMATIC - DEVICENET/GATEWAY PC BOARD (ROBOTIC MODEL ONLY) PG 1 OF 2 (G3821-2) NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. POWER WAVE 455M/MSTT...

  • Page 145: Schematic - Devicenet/Gateway Pc Board (Robotic Model Only) Pg 2 Of 2 (G3821-2

    G-11 ELECTRICAL DIAGRAMS G-11 SCHEMATIC - DEVICENET/GATEWAY PC BOARD (ROBOTIC MODEL ONLY) PG 2 OF 2 (G3821-2) NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. POWER WAVE 455M/MSTT...

  • Page 146: Pc Board Assembly - Devicenet/Gateway Pc Board (Robotic Model Only) (L11046-2

    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. Improper PC board repairs could result in...

  • Page 147: Schematic - Control Pc Board (All Codes) Pg 1 Of 4 (G3789-2

    G-13 ELECTRICAL DIAGRAMS G-13 SCHEMATIC - CONTROL PC BOARD (ALL CODES) PG 1 OF 4 (G3789-2) NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. POWER WAVE 455M/MSTT...

  • Page 148: Schematic - Control Pc Board (All Codes) Pg 2 Of 4 (G3789-2

    G-14 ELECTRICAL DIAGRAMS G-14 SCHEMATIC - CONTROL PC BOARD (ALL CODES) PG 2 OF 4 (G3789-2) NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. POWER WAVE 455M/MSTT...

  • Page 149: Schematic - Control Pc Board (All Codes) Pg 3 Of 4 (G3789-2

    G-15 ELECTRICAL DIAGRAMS G-15 SCHEMATIC - CONTROL PC BOARD (ALL CODES) PG 3 OF 4 (G3789-2) NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. POWER WAVE 455M/MSTT...

  • Page 150: Schematic - Control Pc Board (All Codes) Pg 4 Of 4 (G3789-2

    G-16 ELECTRICAL DIAGRAMS G-16 SCHEMATIC - CONTROL PC BOARD (ALL CODES) PG 4 OF 4 (G3789-2) NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. POWER WAVE 455M/MSTT...

  • Page 151: Pc Board Assembly - Control Pc Board (All Codes) (L11088-2

    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. Improper PC board repairs could result in damage...

  • Page 152: Schematic - Digital Power Supply Pc Board (All Codes) (G3631-3

    G-18 ELECTRICAL DIAGRAMS G-18 SCHEMATIC - DIGITAL POWER SUPPLY PC BOARD (ALL CODES) (G3631-3) NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. POWER WAVE 455M/MSTT...

  • Page 153: Pc Board Assembly - Digital Power Supply Pc Board (All Codes) (G3632-3

    Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your factory warranty. Individual Printed Circuit Board Components are not available from Lincoln Electric. This information is provided for reference only. 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. Improper PC board repairs could result in damage to the machine.

  • Page 154: Schematic - Feedhead Pc Board #1 (Robotic Model Only) Pg 1 Of 3 (G3823-3

    G-20 ELECTRICAL DIAGRAMS G-20 SCHEMATIC - FEEDHEAD PC BOARD #1 (ROBOTIC MODEL ONLY) PG 1 OF 3 (G3823-3) NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. POWER WAVE 455M/MSTT...

  • Page 155: Schematic - Feedhead Pc Board #2 (Robotic Model Only) Pg 2 Of 3 (G3823-3

    G-21 ELECTRICAL DIAGRAMS G-21 SCHEMATIC - FEEDHEAD PC BOARD #2 (ROBOTIC MODEL ONLY) PG 2 OF 3 (G3823-3) NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. POWER WAVE 455M/MSTT...

  • Page 156: Schematic - Feedhead Pc Board #3 (Robotic Model Only) Pg 3 Of 3 (G3823-3

    G-22 ELECTRICAL DIAGRAMS G-22 SCHEMATIC - FEEDHEAD PC BOARD #3 (ROBOTIC MODEL ONLY) PG 3 OF 3 (G3823-3) NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. POWER WAVE 455M/MSTT...

  • Page 157: Pc Board Assembly - Feedhead Pc Board (Robotic Model Only) (L11087-3

    Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your factory warranty. Individual Printed Circuit Board Components are not available from Lincoln Electric. This information is provided for reference only. 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. Improper PC board repairs could result in damage to the machine.

  • Page 158: Schematic - Input Pc Board (All Codes) (M19528-2

    G-24 ELECTRICAL DIAGRAMS G-24 SCHEMATIC - INPUT PC BOARD (ALL CODES) (M19528-2) NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. POWER WAVE 455M/MSTT...

  • Page 159: Pc Board Assembly - Input Pc Board (All Codes) (L11396-2

    Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your factory warranty. Individual Printed Circuit Board Components are not available from Lincoln Electric. This information is provided for reference only. 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. Improper PC board repairs could result in damage to the machine.

  • Page 160: Schematic - Switch Pc Board (All Codes) (L11385-3

    G-26 ELECTRICAL DIAGRAMS G-26 SCHEMATIC - SWITCH PC BOARD (ALL CODES) (L11385-3) NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. POWER WAVE 455M/MSTT...

  • Page 161: Pc Board Assembly - Switch Pc Board (All Codes) (G3734-3

    G-27 PC BOARD ASSEMBLY - SWITCH PC BOARD (ALL CODES) (G3734-3) G3734-3 REVISED MAKE SPECIFICATION CHANGE DETAIL: ENGINEERING CONTROLLED MANUFACTURER: NOTES : N.A. CAUTION: THIS DEVICE IS SUBJECT TO DAMAGE BY STATIC ELECTRICITY. SEE E2454 BEFORE HANDLING. N.D. FEMALE EYELET TO BE AGAINST THE COPPER SIDE AS SHOWN. EYELET MUST NOT SPIN AFTER CLINCHING.

  • Page 162: Schematic - Voltage Sense Pc Board (Robotic Model Only) (S24779-3

    G-28 ELECTRICAL DIAGRAMS G-28 SCHEMATIC - VOLTAGE SENSE PC BOARD (ROBOTIC MODEL ONLY) (S24779-3) NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. POWER WAVE 455M/MSTT...

  • Page 163: Pc Board Assembly - Voltage Sense Pc Board (Robotic Model Only) (M19540-3

    Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your factory warranty. Individual Printed Circuit Board Components are not available from Lincoln Electric. This information is provided for reference only. 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. Improper PC board repairs could result in damage to the machine.

  • Page 164: Schematic - 40 Vdc Bus Pc Board (All Codes) (M19330-2

    G-30 ELECTRICAL DIAGRAMS G-30 SCHEMATIC - 40 VDC BUS PC BOARD (ALL CODES) (M19330-2) NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. POWER WAVE 455M/MSTT...
  • Page 165 Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your factory warranty. Individual Printed Circuit Board Components are not available from Lincoln Electric. This information is provided for reference only. 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. Improper PC board repairs could result in damage to the machine.

This manual is also suitable for:

Power wave 455m/stt

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