Page 1 Some variances may exist when troubleshooting/repairing later code numbers. POWER WAVE 455/POWER FEED 10 For use with machines having Code Numbers: 10372, 10521, 10522, 10552, 10553, 10554, 10555 Power Wave 455: 10435, 10436, 10437, 10438, 10493, 10494, 10760, Power Feed 10:...
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 SAFETY ARC RAYS can burn. ELECTRIC SHOCK can 4.a. Use a shield with the proper filter and cover kill. plates to protect your eyes from sparks and 3.a. The electrode and work (or ground) circuits the rays of the arc when welding or observing are electrically “hot”...
Page 4 SAFETY WELDING SPARKS can CYLINDER may explode cause fire or explosion. if damaged. 6.a. Remove fire hazards from the welding area. 7.a. Use only compressed gas cylinders If this is not possible, cover them to prevent containing the correct shielding gas for the the welding sparks from starting a fire.
Page 5 SAFETY 5. Toujours porter des lunettes de sécurité dans la zone de PRÉCAUTIONS DE SÛRETÉ soudage. Utiliser des lunettes avec écrans lateraux dans les zones où l’on pique le laitier. Pour votre propre protection lire et observer toutes les instruc- tions et les précautions de sûreté...
Page 6: Table Of Contents
MASTER TABLE OF CONTENTS FOR ALL SECTIONS Page Safety ................i-iv Installation .
Page 7 SECTION A-1 SECTION A-1 INSTALLATION TABLE OF CONTENTS -INSTALLATION SECTION- Installation ............... . Section A Technical Specifications - Power Feed 10 Wire Drive and Control Box .
Page 8: Installation
INSTALLATION TECHNICAL SPECIFICATIONS – POWER FEED 10 WIRE DRIVE AND CONTROL BOX WIRE DRIVE OR WIRE DRIVE SECTION OF FEEDER SPEC # TYPE LOW SPEED RATIO HIGH SPEED RATIO Wire Size Wire Size Speed Solid Cored Speed Solid Cored K1540-1 Power Feed 10 50-800 IPM .025 - 3/32 in.
Page 9: Technical Specifications - Power Wave 455
INSTALLATION TECHNICAL SPECIFICATIONS – POWER WAVE 455 INPUT AT RATED OUTPUT - THREE PHASE ONLY Rated Output @ Input Rated Output @ Input Input Volts 100% Duty Cycle Current 60% Duty Cycle Current 208V - 60Hz 450A@38V 100% 570A@43V 60% 230V - 60Hz 450A@38V 100% 570A@43V 60%...
Page 10: Safety Precautions
INSTALLATION LIFTING SAFETY PRECAUTIONS WARNING Lift the machine by the lift bail only. The lift bail is designed to lift the power source only. Do not attempt to lift the Power Wave with accessories ELECTRIC SHOCK attached to it. can kill. •...
Page 11 INSTALLATION 3. Loosen the four screws inside the Control Box 6. Replace all option panels removed from front of Control Box. located along the sides of the back of the Control Box, two near the bottom and two near the mid- dle.
Page 12: Electrical Connections
INSTALLATION INPUT FUSE AND SUPPLY WIRE ELECTRICAL CONNECTIONS CONSIDERATIONS WARNING Refer to the Technical Specifications at the begin- ning of this Installation section for recommended fuse Only a qualified electrician should connect the and wire sizes. Fuse the input circuit with the recom- input leads to the Power Wave.
Page 13: Cable Connections
INSTALLATION FIGURE A.2 — CONNECTION DIAGRAM ON RECONNECT/INPUT ACCESS DOOR. INPUT SUPPLY CONNECTION DIAGRAM VOLTAGE=200-208V W / L3 200-208V V / L2 Disconnect input power before 220-230V inspecting or servicing machine. U / L1 380-415V Do not operate with covers removed.
Page 14: Cable Connections
INSTALLATION When using an inverter type power source, use the CONTROL CABLE SPECIFICATIONS largest welding (electrode and ground) cables that are practical. At least 2/0 copper wire — even if the The cable is a five copper conductor cable in a SO- average output current would not normally require it.
Page 15: Wire Feeder Setup
INSTALLATION ELECTRODE AND WORK LEADS — SELECTING THE PROPER GEAR RATIO ELECTRODE NEGATIVE APPLICATIONS See the Technical Specifications at the front of this section for feed speed and wire size capabilities with When negative electrode polarity is required, such as high and low speed gear ratios.
Page 16 A-10 A-10 INSTALLATION 6. Tighten the screw on lower right face of feed RATIO CHANGE PROCEDURE plate. 1. Pull open the pressure door. 7. Re-attach feed plate to wire feeder if removed in Step 2. 2. Remove the Phillips head screw retaining the pinion gear to be changed and remove the gear.
Page 17: Dip Switch Setup
A-11 A-11 INSTALLATION 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 FIGURE A.3 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 A-12 INSTALLATION S1 DIP Switch Bank on Control Box Motherboard (For software version S24004-3 & up) Switch Standard speed gearbox limits adjustable High speed gearbox limits adjustable WFS Display = inches/minute WFS Display = meters/minute Left Display is always preset WFS Left Display is preset WFS when weld current is not flowing Left Display is actual weld current when weld current is flowing CC modes override this switch regardless of position.
Page 19 A-13 A-13 INSTALLATION S1 DIP Switch Bank on Control Box Motherboard (For software version S24456) Switch Standard speed gearbox limits adjustable High speed gearbox limits adjustable WFS Display = inches/minute WFS Display = meters/minute Left Display is always preset WFS Left Display is preset WFS when weld current is not flowing Left Display is actual weld current when weld current is flowing CC modes override this switch regardless of position.
Page 20 A-14 A-14 INSTALLATION Setting Wire Drive Acceleration Rate Using (All software versions) DIP Switch S1 on the Control Box Motherboard DIP SWITCH 6 DIP SWITCH 7 DIP SWITCH 8 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...
Page 21: Gun And Cable Assemblies
A-15 A-15 INSTALLATION GMAW SHIELDING GAS GUN AND CABLE ASSEMBLIES GUN AND CABLE ASSEMBLIES WITH WARNING STANDARD CONNECTION The Power Feed 10 wire feeder is equipped with a CYLINDER may explode if damaged. factory installed K1500-2 gun connection kit. This kit is for guns having a Tweco™...
Page 22: Standard Panel Installation
A-16 A-16 INSTALLATION STANDARD PANEL INSTALLATION CV/GOUGE PANEL NOTE: Installation Instructions for the standard CONTROL/DISPLAY PANEL equipment panels will be required only if you have removed a standard panel and wish to reinstall it. NOTE: Installation Instructions for the standard equipment panels will be required only if you have The CV/Gouge Panel fits into the lower position of removed a standard panel and wish to reinstall it.
Page 23 SECTION B-1 SECTION B-1 OPERATION TABLE OF CONTENTS -OPERATION SECTION- Operation ............... . . Section B Operating Instructions .
Page 24: Operation
OPERATION OPERATING INSTRUCTIONS SYSTEM DESCRIPTION Read and understand this entire section of operating The Power Wave 455 is a high performance, digitally instructions before operating the machine. controlled inverter welding power source capable of complex, high-speed waveform control. The Power Feed 10 is a high performance, digitally controlled, SAFETY INSTRUCTIONS modular wire feeder.
Page 25: Controls And Settings
OPERATION DUTY CYCLE AND WELDING CONTROLS AND SETTINGS CAPABILITIES POWER WAVE CONTROLS AND The Power Feed 10 wire feeder is capable of welding STATUS LIGHTS at a 100% duty cycle (continuous welding). The power source will be the limiting factor in determining All operator controls and adjustments are located on system duty cycle capability.
Page 26: Power Feed Controls
OPERATION FIGURE B.2 — WIRE FEEDER CONTROLS. Light Condition Meaning CONTROL BOX Steady Green System OK. Power source communicating (SHOWN ATTACHED normally with wire feeder and its TO WIRE FEEDER) components. Blinking Nothing connected to Wire Feeder Green Receptacle. Recoverable system fault. See Alternating Green and Troubleshooting Section.
Page 27: Display Control Panel
OPERATION Cold feed function: 1. Indicator Lights: When this switch is held in the up position, the unit Indicates either WFS or AMPS for the left display, automatically feeds wire, but does not activate output and VOLTS or TRIM for the right display. to the power source or gas solenoid.
Page 28: Weld Mode Descriptions
OPERATION 6. CV/GOUGE PANEL preprogrammed voltages; for example, to compen- sate for cable and fixture voltage drops. The preset The CV/Gouge Panel provides a fixed toggle switch voltages can be adjusted on the wire feeder’s voltage selection of two power source modes. The upper display.
Page 29: Wire Reel Loading - Readi-Reels, Spools Or Coils
OPERATION WIRE SPINDLE PLACEMENT FIGURE B.4 — READI-REEL MOUNTING. ADAPTER 2 IN. O.D. The reel stand provides two mounting locations for SPINDLE RETAINING the 2 inch diameter wire reel spindle to accommo- SPRING 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
OPERATION TO MOUNT 10 TO 44 LB (4.5 TO 20 4. Cut and remove only the tie wire holding the free end of the coil. Hook the free end around the rim KG) SPOOLS [12 IN. (300 MM) of the reel cover and secure it by wrapping it DIAMETER] OR 14 LB (6 KG) around.
Page 31: Feeding Electrode And Brake Adjustment
OPERATION FEEDING ELECTRODE AND 7. Install the outer wire guide by sliding over the locating pins and tightening in place. BRAKE ADJUSTMENT 8. Engage the upper drive rolls if they are in the 1. Turn the reel or spool until the free end of the “open”...
Page 32: Wire Feed Overload Protection
B-10 B-10 OPERATION WIRE FEED OVERLOAD and red for about 30 seconds before the wire drive will automatically reset. At that time, the wire drive PROTECTION will issue a shutdown over command to the Control Box that will return the system to normal operation. The wire drive has solid-state overload protection of The wire drive will force its STATUS light to solid the wire drive motor.
Page 33 SECTION C-1 SECTION C-1 ACCESSORIES TABLE OF CONTENTS -ACCESSORIES SECTION- Accessories ............... Section C General .
Page 34: Accessories
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 DUAL CYLINDER UNDERCARRIAGE KP1505 Series...
Page 35: Power Wave Options And Accessories
ACCESSORIES POWER WAVE OPTIONS AND K1570-1 DUAL CYLINDER UNDERCARRIAGE ACCESSORIES This is a platform undercarriage for mounting up to The following is a list of available Power Wave two gas cylinders at the rear of the welder. options. WIRE FEEDER OPTIONS AND FACTORY INSTALLED ACCESSORIES There are no factory installed options available for...
Page 36: Input Cable Assemblies
ACCESSORIES INPUT CABLE ASSEMBLIES in the bottom of the Control Box cabinet and store it in the bottom of the Control Box cabinet for future use, should the Optional Output K1543 (Control Cable Only) - Consists of a 5-con- Connector be removed. ductor control cable with a 5-pin control cable plug, without electrode cable, and is available in lengths of 5.
Page 37 ACCESSORIES Feed Head Enclosure Procedure RECEPTACLE (INPUT) 1. Turn power off. Power Feed Wire Feeder Optional Input Connector Installation into the Control Box 2. Remove the Feed Head rear access door. The Cabinet and Conversion to Fixture Wire Feeder Feed Head cover can be removed to aid installa- tion, but is not required.
Page 38: Reel Adapters
ACCESSORIES 10. Install an Optional Output Connector into the K363P - READI-REEL ADAPTER Control Box cabinet, if not already present. Adapts Lincoln Readi-Reel coils of electrode 30 lb 11. Mount the Control Box cabinet to the work sta- (14 kg) and 22 lb (10 kg) to a 2 in. (51 mm) spindle. tion fixture at this time, if desired.
Page 39: Conduit Adapters
ACCESSORIES MAGNUM 200/300/400 GUNS K1500-2 (TWECO™ #2-#4 CONNECTION) The easiest and least expensive way to use Magnum The K1500-2 gun adapter comes factory installed on 200/300/400 guns with the Power Feed 10 wire feed- the Power Feed 10 wire feeder. Use this adapter for er is to order them with the K466-10 connector kit, or guns that have a Tweco™...
Page 40: Dual Procedure Switch Options
ACCESSORIES DUAL PROCEDURE SWITCH OPTIONS K659-1 GAS GUARD REGULATOR Adjustable flow regulator with removable adjuster key K683-3 DUAL PROCEDURE SWITCH for CO and Argon blend gases. Mounts onto feeder inlet, and reduces gas waste and arc start “blow” by Kit includes gun switch and mountings for Lincoln reducing surge caused by excess pressure in supply Innershield and Magnum guns, with 15 ft (4.5 m) hose.
Page 41: Description And Installation Of Optional Control Box Panels
ACCESSORIES 4. Position the new door between the panel holes 3. Tilt the new option panel away from the front and re-install the rod so the screw holes can be opening of the Control Box cabinet. Plug the accessed. electrical connector into the proper connector on the right side of the main printed circuit board 5.
Page 42 C-10 C-10 ACCESSORIES Constant Voltage (CV/MIG and CV/Flux Cored) Display - Displays the value or status of the active Procedures parameter. When in this mode, the ARC CONTROL adjusts the Available Modes - CV/MIG inductance. (This adjustment is often referred to as CV/ FLUX CORED “pinch”.
Page 43 C-11 C-11 ACCESSORIES Mode Selection 3. Tilt the new option panel away from the front opening of the Control Box cabinet. Plug the The MODE SELECT switch is a momentary large electrical connector into the proper connector on three position toggle switch that defaults to the center the right side of the main printed circuit board (off) position.
Page 44 C-12 C-12 ACCESSORIES Mode Schedule - Table on the front of the option that direction, until the switch is released. When the used by the operator to correlate the displayed mode indicator reaches its upper or lower limit, advancing number to an actual power source mode. ceases until the direction of the switch is changed.
Page 45 C-13 C-13 ACCESSORIES Installation is as follows: Dual Procedure Selection 1. Turn off power. The procedure switch is used to scroll the indicator to 2. Remove the two screws from the front of the select PROCEDURE A, PROCEDURE B, or the blank option panel at the location you choose to GUN switch.
Page 46 C-14 C-14 ACCESSORIES Installation is as follows: The value of the active Set Up parameter, as defined by the Set Up LED, is displayed on the MX2 panel 1. Turn off power. Set Up display. The value can be modified with the Set switch.
Page 47 C-15 C-15 ACCESSORIES The value of the active set up parameter is shown on Arc Control - Unitless characteristic, also known as the MSP2 panel digital display. The value can be modi- Inductance or Wave Control. Allows operator to vary fied with the Set switch.
Page 48 C-16 C-16 ACCESSORIES CONTROL BOX -- SETTING OPERATING LIMITS operator to adjust his Volts in synergic and non-syn- ergic CV modes. Procedure B could be set up with different limits. Limits are absolute -- they will over- Upper and lower operating limits can be set for the ride values stored in the memories.
Page 49 SECTION D-1 SECTION D-1 MAINTENANCE TABLE OF CONTENTS -MAINTENANCE SECTION- Maintenance ............................. Section D Safety Precautions..........................Routine Maintenance ......................... Power Wave ..........................Wire Feeder..........................Periodic Maintenance ........................Wire Drive Motor and Gearbox....................Gun and Cable Maintenance....................... POWER WAVE 455/POWER FEED 10...
Page 50: Maintenance
MAINTENANCE SAFETY PRECAUTIONS AVOIDING WIRE FEEDING PROBLEMS Wire feeding problems can be avoided by observing WARNING the following gun handling and feeder set up proce- dures: ELECTRIC SHOCK a. Do not kink or pull cable around sharp cor- can kill. ners.
Page 51 SECTION E-1 SECTION E-1 THEORY OF OPERATION TABLE OF CONTENTS -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 ......................
Page 52: Theory Of Operation Section
THEORY OF OPERATION FIGURE E.1 — SYSTEM DIAGRAM A. POWER SOURCE CONTROL BOX (USER INTERFACE) INTERNAL CONNECTION WIRE DRIVE MODULAR INVERTER specific requirements and also locate and identify each piece of equipment for maxi- BASED WELDING SYSTEM mum efficiency and ease of operation. The Welding Network is an assembly of welding equipment joined together by a SYSTEM DIAGRAM A...
Page 53: System Diagram B
THEORY OF OPERATION FIGURE E.2 — SYSTEM DIAGRAM B. CONTROL (USER INTERFACE) INTERNAL CONNECTION POWER SOURCE WIRE DRIVE SYSTEM DIAGRAM B The communication cable is depicted by the heavy black connector line. PC board power, communications and intelligence This system utilizes two physical pieces of between the wire drive and combination equipment.
Page 54: Theory Of Operation
THEORY OF OPERATION FIGURE E.3 — SYSTEM DIAGRAM C. CONTROL BOX (USER INTERFACE) WIRE DRIVE POWER SOURCE SYSTEM DIAGRAM C cables. All PC board power, communica- tions and intelligence are transmitted via the two cables. The power source (Power Wave 455), the Control Box (user interface) and the wire This component configuration might be drive (Power Feed 10) are the three dis-...
Page 55: Power Source General Description
THEORY OF OPERATION FIGURE E.4 — INPUT VOLTAGE AND RECHARGE. MAIN TRANSFORMER CURRENT SENSOR LEFT SWITCH BOARD OUTPUT TERMINAL DRIVE INPUT INPUT CONTACTOR RECTIFIER PRIMARY CURRENT SENSOR CAPACITOR VOLTAGE FEEDBACK CHOKE RIGHT SWITCH BOARD OUTPUT TERMINAL CAPACITOR CONTROL SIGNALS VOLTAGE DRIVE FEEDBACK THERMOSTATS...
Page 56: Switch Boards And Main Transformer
THEORY OF OPERATION FIGURE E.5 — SWITCH BOARDS AND MAIN TRANSFORMER. MAIN TRANSFORMER CURRENT SENSOR LEFT SWITCH BOARD OUTPUT TERMINAL DRIVE INPUT INPUT CONTACTOR RECTIFIER PRIMARY CURRENT SENSOR CAPACITOR VOLTAGE FEEDBACK CHOKE RIGHT SWITCH BOARD OUTPUT TERMINAL CAPACITOR CONTROL SIGNALS VOLTAGE DRIVE THERMOSTATS...
Page 57: Control Board
THEORY OF OPERATION FIGURE E.6 — CONTROL BOARD. MAIN TRANSFORMER CURRENT SENSOR LEFT SWITCH BOARD OUTPUT TERMINAL DRIVE INPUT INPUT CONTACTOR RECTIFIER PRIMARY CURRENT SENSOR CAPACITOR VOLTAGE FEEDBACK CHOKE RIGHT SWITCH BOARD OUTPUT TERMINAL CAPACITOR CONTROL SIGNALS VOLTAGE DRIVE FEEDBACK THERMOSTATS AUX.
Page 58: Output Rectifier And Choke
THEORY OF OPERATION FIGURE E.7 — OUTPUT RECTIFIER AND CHOKE. MAIN TRANSFORMER CURRENT SENSOR LEFT SWITCH BOARD OUTPUT TERMINAL DRIVE INPUT INPUT CONTACTOR RECTIFIER PRIMARY CURRENT SENSOR CAPACITOR VOLTAGE FEEDBACK CHOKE RIGHT SWITCH BOARD OUTPUT TERMINAL CAPACITOR CONTROL SIGNALS VOLTAGE DRIVE FEEDBACK THERMOSTATS...
Page 59: Thermal Protection
THEORY OF OPERATION THERMAL PROTECTION OVER CURRENT PROTECTION Two normally closed (NC) thermostats pro- tect the machine from excessive operating If the average current exceeds 590 amps, temperatures. These thermostats are wired then the peak current will be limited to 100 in series and are connected to the control amps until the average current decreases to board.
Page 60: Insulated Gate Bipolar Transistor (Igbt) Operation
E-10 E-10 THEORY OF OPERATION FIGURE E.8 — IGBT OPERATION. POSITIVE VOLTAGE APPLIED GATE GATE SOURCE SOURCE BODY REGION BODY REGION DRAIN DRIFT REGION DRAIN DRIFT REGION BUFFER LAYER BUFFER LAYER INJECTING LAYER INJECTING LAYER DRAIN DRAIN A. PASSIVE B. ACTIVE INSULATED GATE BIPOLAR connected to the source.
Page 61: Pulse Width Modulation
E-11 E-11 THEORY OF OPERATION FIGURE E.9 — TYPICAL IGBT OUTPUTS. 1 µsec 1 µsec 48 µsec 50 µsec MINIMUM OUTPUT 24 µsec 2 µsec 24 µsec 50 µsec MAXIMUM OUTPUT PULSE WIDTH microsecond. The negative portion is the other IGBT group .
Page 62: Control Box (User Interface
E-12 E-12 THEORY OF OPERATION FIGURE E.10 — CONTROL BOX (USER INTERFACE). DISPLAY AND ENCODER PANEL (STANDARD) STATUS SMALL PANEL OPTIONS SWITCHES USER NETWORK LARGE INTERFACE CONNECTOR PANEL MOTHER- (INTERNAL) OPTIONS BOARD AMPHENOL-INPUT AMPHENOL-OUTPUT NETWORK RECEPTACLE NETWORK RECEPTACLE (OPTIONAL) (OPTIONAL) CONTROL BOX In addition to the large and smaller size options, there is a Display Panel which is...
Page 63: Power Feed 10 Feed Head
E-13 E-13 THEORY OF OPERATION FIGURE E.11 — POWER FEED 10 FEED HEAD. VOLTAGE SENSE LEAD #67A LEAD #67 DRIVE GEAR BOX MOTOR CONDUCTOR BLOCK CONTROL BOARD TACH TO POWER FEEDBACK SOURCE OR SHUTDOWN CONTROL STATUS LED DIP SWITCH GUN TRIGGER AND DUAL PROCEDURE INPUT RECEPTACLE...
Page 64 E-14 E-14 NOTES POWER WAVE 455/POWER FEED 10...
Page 65 SECTION F-1 SECTION F-1 TROUBLESHOOTING ND REP IR T BLE OF CONTENTS -TROUBLESHOOTING ND REP IR SECTION- Troubleshooting and Repair ............Section F How to Use Troubleshooting Guide .
Page 66: How To Use Troubleshooting Guide
HOW TO USE TROUBLESHOOTING GUIDE W RNING 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 TROUBLESHOOTING ND REP IR PC BO RD TROUBLESHOOTING PROCEDURES PC board can be W RNING damaged by static electricity. ELECTRIC SHOCK can kill. - Remove your body’s static charge before TTENTION Have an electrician install opening the static- Static-Sensitive and service this equip- shielding bag.
Page 68: Pc Board Troubleshooting Procedures
TROUBLESHOOTING ND REP IR 4. Test the machine to determine if the wiring harness, junction blocks, and failure symptom has been corrected by terminal strips. the replacement PC board. b. If the original problem is recreated NOTE: It is desirable to have a spare by the substitution of the original (known good) PC board available for PC board, then the PC board was the...
Page 69: Troubleshooting Guide
C UTION 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 1-888-935-3877. -----------------------------------------------------------------------------------------------------------...
Page 70 Check or replace. C UTION 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 1-888-935-3877.
Page 71 Test. C UTION 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 1-888-935-3877.
Page 72 Diagram C UTION 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 1-888-935-3877. -----------------------------------------------------------------------------------------------------------...
Page 73 Troubleshooting. C UTION 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 1-888-935-3877. -----------------------------------------------------------------------------------------------------------...
Page 74 Status LED Error Code Table. C UTION 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 1-888-935-3877.
Page 75 [0.4 sec.red] [0.4 sec.off] [0.4 sec.red] [0.4 sec.off] [0.4 sec.red] C UTION 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 1-888-935-3877.
Page 76 [0.4 sec.red] [0.4 sec.off] [0.4 sec.red] [0.4 sec.off] [0.4 sec.red] C UTION 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 1-888-935-3877.
Page 77: Power Wave
C UTION 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 1-888-935-3877.
Page 78 Power C UTION 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 1-888-935-3877.
Page 79 C UTION 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 1-888-935-3877. -----------------------------------------------------------------------------------------------------------...
Page 80 C UTION 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 1-888-935-3877.
Page 81 C UTION 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 1-888-935-3877.
Page 82 C UTION 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 1-888-935-3877.
Page 83 C UTION 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 1-888-935-3877.
Page 84 C UTION 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 1-888-935-3877. -----------------------------------------------------------------------------------------------------------...
Page 85 C UTION 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 1-888-935-3877.
Page 86 F-22 F-22 NOTES PW 455 CONTROL BO RD LED DEFINITIONS LED COLOR ND NUMBER CIRCUIT INDIC TORS Green LED 1 -15 VDC Supply Green LED 3 +15 VDC Supply Green LED 4 +5 VDC Supply Red LED 5 On when jumper removed from J26 Green 6 LED +5 VDC Communication Supply Red LED 7...
Page 87: Test Procedures
INPUT FILTER C P CITOR DISCH RGE PROCEDURE W RNING 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 war- ranty.
Page 88: Switch Board Test
F-24 F-24 TROUBLESHOOTING ND REP IR INPUT FILTER C P CITOR DISCH RGE PROCEDURE ( ontinued) FIGURE F.1 — C P CITOR DISCH RGE PROCEDURE. SWITCH BOARD CAPACITOR TERMINALS TEST PROCEDURE 6. Using the high wattage resistor (25- 1000 ohms @ 25 watts (minimum), electrically insulated gloves and pliers, 1.
Page 89 SWITCH BO RD TEST W RNING 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 war- ranty.
Page 90 F-26 F-26 TROUBLESHOOTING ND REP IR SWITCH BO RD TEST ( ontinued) FIGURE F.2 — RECONNECT SWITCHES. RECONNECT SWITCHES TEST PROCEDURE 4. Locate label and remove leads 19C and 19D from the reconnect switches with the 3/8 in. wrench. Note lead 1.
Page 91 F-27 F-27 TROUBLESHOOTING ND REP IR SWITCH BO RD TEST ( ontinued) FIGURE F.3 — SWITCH BO RD TEST POINTS. SWITCH BOARD -20 +19 11/12 13/14 15/16 17/18 6. If any test fails replace both switch 8. Reconnect leads 19C and 19D to the boards.
Page 92 F-28 F-28 NOTES POWER W VE 455/POWER FEED 10...
Page 93: Output Rectifier Test
OUTPUT RECTIFIER TEST W RNING 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 war- ranty.
Page 94 F-30 F-30 TROUBLESHOOTING ND REP IR OUTPUT RECTIFIER TEST ( ontinued) FIGURE F.4 — OUTPUT RECTIFIER TEST. NEGATIVE (-) POSITIVE (+) OUTPUT OUTPUT TERMINAL TERMINAL TEST PROCEDURE 3. With the analog ohmmeter, measure 1. Remove main input supply power to the resistance between the positive the Power Wave 455.
Page 95: Input Rectifier Test
INPUT RECTIFIER TEST W RNING 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 war- ranty.
Page 96 F-32 F-32 TROUBLESHOOTING ND REP IR INPUT RECTIFIER TEST ( ontinued) FIGURE F.5 — INPUT RECTIFIER TEST. INPUT RECTIFIER NEG (-) POS (+) TEST PROCEDURE NOTE: Some RTV sealant may have to be removed from the input rectifier terminals. The RTV should be replaced when test is 1.
Page 97: Input Contactor Test
F-33 F-33 TROUBLESHOOTING ND REP IR INPUT RECTIFIER TEST ( ontinued) T BLE F.2 — INPUT RECTIFIER TEST POINTS CCEPT BLE RE DINGS. TEST POINT TERMIN LS N LOG METER X10 R NGE + Probe - Probe cceptable Meter Readings Greater than 1000 ohms Greater than 1000 ohms Greater than 1000 ohms...
Page 98 F-34 F-34 NOTES POWER W VE 455/POWER FEED 10...
Page 99 INPUT CONT CTOR TEST W RNING 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 war- ranty.
Page 100 F-36 F-36 TROUBLESHOOTING ND REP IR INPUT CONT CTOR TEST ( ontinued) FIGURE F.6 — INPUT CONT CTOR COIL. INPUT CONTACTOR X4/X4A 601/601A TEST PROCEDURE FIGURE F.7 — INPUT CONT CTOR TEST POINTS. 1. Remove input power to the Power Wave 455.
Page 101: Auxiliary Transformer No. 2 Test
UXILI RY TR NSFORMER NO. 2 TEST W RNING 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 war- ranty.
Page 102 F-38 F-38 TROUBLESHOOTING ND REP IR UXILI RY TR NSFORMER NO. 2 TEST ( ontinued) FIGURE F.8 — UXILI RY TR NSFORMER NO. 2 TEST. TEST PROCEDURE 8. If 115 VAC is not present between pins #1 and #4, check the associated leads and plugs for loose or faulty connec- 1.
Page 103: Auxiliary Transformer No. 1 Test
UXILI RY TR NSFORMER NO. 1 TEST W RNING 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 war- ranty.
Page 104: Power Board Test
F-40 F-40 TROUBLESHOOTING ND REP IR UXILI RY TR NSFORMER NO. 1 TEST ( ontinued) FIGURE F.9 — UXILI RY TR NSFORMER NO. 1 TEST. POWER BOARD MAIN RECTIFIER BRIDGE CONTACTOR FAN MOTOR LEADS TEST PROCEDURE 4. Locate secondary leads X1 and X2 (at power board rectifier bridge).
Page 105 F-41 TROUBLESHOOTING ND REP IR F-41 UXILI RY TR NSFORMER NO. 1 TEST ( ontinued) T BLE F.3 — SECOND RY VOLT GES. NORM L EXPECTED LE D IDENTIFIC TION VOLT GE X1 to X2 52 VAC X3 to X5 115 VAC X3 to X4 24 VAC...
Page 106 NOTES F-42 F-42 POWER W VE 455/POWER FEED 10...
Page 107 POWER BO RD TEST W RNING 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 war- ranty.
Page 108 F-44 F-44 TROUBLESHOOTING ND REP IR POWER BO RD TEST ( ontinued) FIGURE F.10 — POWER BO RD TEST. 1 2 3 4 5 91011 TEST PROCEDURE 6. Carefully test for the correct voltages at the power board as per Table F.4. 1.
Page 109 F-45 TROUBLESHOOTING ND REP IR F-45 POWER BO RD TEST ( ontinued) T BLE F.4 — POWER BO RD VOLT GE CHECKS. NORM L LE D NO. CCEPT BLE CHECK POINT TEST CONNECTOR VOLT GE LOC TION DESCRIPTION PLUG PIN NO. IDENTITY RE DING POWER PC...
Page 110 F-46 F-46 NOTES POWER W VE 455/POWER FEED 10...
Page 111 CURRENT TR NSDUCER TEST W RNING 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 war- ranty.
Page 112: Current Transducer Test
F-48 F-48 TROUBLESHOOTING ND REP IR CURRENT TR NSDUCER TEST ( ontinued) FIGURE F.11 — CURRENT TR NSDUCER TEST. NOTE: On later codes the transducer is located on left side of the machine near the output choke. CURRENT TRANSDUCER TEST PROCEDURE 7.
Page 113 F-49 TROUBLESHOOTING ND REP IR F-49 CURRENT TR NSDUCER TEST ( ontinued) T BLE F.5 — CURRENT FEEDB CK T V RIOUS OUTPUT LO DS. EXPECTED TR NSDUCER FEEDB CK OUTPUT LO D CURRENT VOLT GE 9. Check the feedback voltage from the 11.
Page 114 F-50 F-50 NOTES POWER W VE 455/POWER FEED 10...
Page 115: Drive Motor Test
DRIVE MOTOR TEST W RNING 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 war- ranty.
Page 116: Gear Box And Drive Motor Removal And Replacement
F-52 F-52 TROUBLESHOOTING ND REP IR DRIVE MOTOR TEST ( ontinued) FIGURE F.12 — DRIVE MOTOR TEST. #551 #550 #550 (-) BLACK #551 (+) WHITE PROCEDURE 5. If the correct voltages are NOT present at the motor leads, check the associat- ed leads between the motor and plug 1.
Page 117 T CH FEEDB CK TEST W RNING 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 war- ranty.
Page 118 F-54 F-54 TROUBLESHOOTING ND REP IR T CH FEEDB CK TEST ( ontinued) FIGURE F.13 — T CH FEEDB CK TEST. BLACK (BLUE) WIRE FEED CONTROL BOARD TEST PROCEDURE 5. With the gun trigger activated and the motor running, check the feedback voltage at plug J4 pin #2 (blue wire) 1.
Page 119 VOLT GE SENSE PC BO RD TEST W RNING 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 war- ranty.
Page 120 F-56 F-56 TROUBLESHOOTING ND REP IR VOLT GE SENSE PC BO RD TEST ( ontinued) FIGURE F.14 — VOLT GE SENSING BO RD TEST. 1 2 3 4 5 6 NOTE: Inspect the molex plug connector pins on the Voltage Sense Board. If any of them are gold plated the P.C.
Page 121 DU L ENCODER PC BO RD TEST W RNING 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 war- ranty.
Page 122 F-58 F-58 TROUBLESHOOTING ND REP IR DU L ENCODER PC BO RD TEST ( ontinued) FIGURE F.15 — DU L ENCODER TEST. CONTROL BOARD DISPLAY BOARD 1 2 3 4 5 6 78 TEST PROCEDURE 6. While rotating the wire feed speed (WFS) control check for a “pulsing”...
Page 123 CONTROL C BLE CONTINUITY TEST W RNING 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 war- ranty.
Page 124 F-60 F-60 TROUBLESHOOTING ND REP IR CONTROL C BLE CONTINUITY TEST ( ontinued) FIGURE F.16 — C BLE CONTINUITY TEST. WIRE FEEDER END POWER SOURCE END T BLE F.6 CONTROL C BLE PIN ND LE D DESIGN TIONS. FIVE PIN MPHENOL T FIVE PIN MPHENOL T POWER SOURCE END WIRE FEEDER/CONTROL BOX END...
Page 125: Component Replacement Procedures
ND REPL CEMENT W RNING 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 war- ranty.
Page 126 F-62 F-62 TROUBLESHOOTING ND REP IR G S SOLENOID REMOV L ND REPL CEMENT ( ontinued) FIGURE F.17 — G S SOLENOID REMOV L ND REPL CEMENT. MOUNTING SCREW BRASS FITTING SOLENOID HOSE HOSE FITTING PROCEDURE INST LL TION 1. Remove input power to the wire feeder. 1.
Page 127 ND REPL CEMENT W RNING 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 war- ranty.
Page 128 F-64 F-64 TROUBLESHOOTING ND REP IR WIRE FEEDER CONTROL BO RD REMOV L ND REPL CEMENT ( ontinued) FIGURE F.18 — WIRE FEEDER CONTROL BO RD REMOV L ND REPL CEMENT. LOCKING WIRE FEEDER CONTROL BOARD PROCEDURE INST LL TION 1.
Page 129 ND REPL CEMENT W RNING 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 war- ranty.
Page 130 F-66 F-66 TROUBLESHOOTING ND REP IR T CH (H LL EFFECT) SSEMBLY REMOV L ND REPL CEMENT ( ontinued) FIGURE F.19 — T CH REMOV L ND REPL CEMENT. LOCK HALL EFFECT DEVICE TACH ASSEMBLY REMOV L PROCEDURE REPL CEMENT PROCEDURE 1.
Page 131 ND REPL CEMENT W RNING 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 war- ranty.
Page 132 F-68 F-68 TROUBLESHOOTING ND REP IR GE R BOX ND DRIVE MOTOR REMOV L ND REPL CEMENT ( ontinued) FIGURE F.20 — GE R BOX ND DRIVE MOTOR REMOV L ND REPL CEMENT. DRIVE MOTOR MOUNTING BOLT INSPECTION COVER GEAR BOX WIRE #551 #550...
Page 133 F-69 TROUBLESHOOTING ND REP IR F-69 GE R BOX ND DRIVE MOTOR REMOV L ND REPL CEMENT ( ontinued) 7. Using the needlenose pliers, discon- 2. Tighten the two Allen type screws at nect the gas hose from the brass gun the bottom of the wire drive unit using connector block.
Page 134 F-70 F-70 NOTES POWER W VE 455/POWER FEED 10...
Page 135 ND REPL CEMENT W RNING 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 war- ranty.
Page 136 F-72 F-72 TROUBLESHOOTING ND REP IR SWITCH BO RD ND FILTER C P CITOR REMOV L ND REPL CEMENT ( ontinued) FIGURE F.21 — SWITCH BO RD ND FILTER C P CITOR REMOV L ND REPL CEMENT. MOUNTING SCREW (4X) MOLEX PLUG SWITCH BOARD...
Page 137 F-73 F-73 TROUBLESHOOTING ND REP IR SWITCH BO RD ND FILTER C P CITOR REMOV L ND REPL CEMENT ( ontinued) 8. With the slot head screwdriver, remove or threaded area of terminals. the two nylon mounting screws at the 5.
Page 138 POWER W VE 455 / PF-10 METER CCUR CY CHECK W RNING 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 war- ranty.
Page 139 ND REPL CEMENT W RNING 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 war- ranty.
Page 140 F-76 F-76 TROUBLESHOOTING ND REP IR CONTROL OR POWER BO RD REMOV L ND REPL CEMENT ( ontinued) FIGURE F.22 — CONTROL OR POWER BO RD REMOV L ND REPL CEMENT. COMPARTMENT COVER CONTROL POWER BOARD BOARD REMOV L PROCEDURE 6.
Page 141 F-77 F-77 TROUBLESHOOTING ND REP IR CONTROL OR POWER BO RD REMOV L ND REPL CEMENT ( ontinued) INST LL TION PROCEDURE 4. Connect two molex plugs and black and white wires with quick disconnects to the power PC board. 1.
Page 142 F-78 F-78 NOTES POWER W VE 455/POWER FEED 10...
Page 143 REPL CEMENT PROCEDURE W RNING 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 war- ranty.
Page 144 F-80 F-80 TROUBLESHOOTING ND REP IR UXILI RY TR NSFORMER NO. 1 REMOV L REPL CEMENT PROCEDURE ( ontinued) FIGURE F.23 — UXILI RY TR NSFORMER NO. 1 REMOV L ND REPL CEMENT PROCEDURE. RECONNECT TERMINALS POWER BOARD RECTIFIER BRIDGE MAIN CONNECTOR MOUNTING...
Page 145 F-81 F-81 TROUBLESHOOTING ND REP IR UXILI RY TR NSFORMER NO. 1 REMOV L REPL CEMENT PROCEDURE ( ontinued) 8. Cut the X3 lead that is connected to hold the transformer to the fan baffle the input board. Leave enough lead and the machine base using the 3/8 in.
Page 146 F-82 F-82 NOTES POWER W VE 455/POWER FEED 10...
Page 147 ND REPL CEMENT W RNING 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 war- ranty.
Page 148 F-84 F-84 TROUBLESHOOTING ND REP IR M IN INPUT CONT CTOR REMOV L ND REPL CEMENT ( ontinued) FIGURE F.24 — M IN INPUT CONT CTOR REMOV L ND REPL CEMENT. MOUNTING SCREW (3X) X4/X4A 601/601A REMOV L PROCEDURE remove the small T2 lead. Label leads for reassembly.
Page 149 F-85 F-85 TROUBLESHOOTING ND REP IR M IN INPUT CONT CTOR REMOV L ND REPL CEMENT ( ontinued) REPL CEMENT PROCEDURE 5. Install the two small leads T1 and T3 to the quick-disconnect terminals. 1. Carefully place the input contactor into 6.
Page 150 F-86 F-86 NOTES POWER W VE 455/POWER FEED 10...
Page 151 ND REPL CEMENT W RNING 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 war- ranty.
Page 152 F-88 F-88 TROUBLESHOOTING ND REP IR INPUT RECTIFIER REMOV L ND REPL CEMENT ( ontinued) FIGURE F.25 — INPUT RECTIFIER REMOV L ND REPL CEMENT. INPUT RECTIFIER NEG (-) POS (+) REMOV L PROCEDURE 7. Carefully remove the module. 1. Remove input power to the Power REPL CEMENT PROCEDURE Wave 455.
Page 153 ND REPL CEMENT W RNING 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 war- ranty.
Page 154 F-90 F-90 TROUBLESHOOTING ND REP IR OUTPUT RECTIFIER ND MODULE REMOV L ND REPL CEMENT ( ontinued) FIGURE F.26 — OUTPUT RECTIFIER ND MODULE REMOV L ND REPL CEMENT. TRANSFORMER LEADS RECTIFIER MODULE POSITIVE THERMOSTAT OUTPUT LEAD HEATSINK MOUNT BOLTS (4X) HEATSINK RECTIFIER SSEMBLY...
Page 155 F-91 F-91 TROUBLESHOOTING ND REP IR OUTPUT RECTIFIER ND MODULE REMOV L ND REPL CEMENT ( ontinued) RECTIFIER MODULE REMOV L RECTIFIER SSEMBLY ND REPL CEMENT REPL CEMENT PROCEDURE PROCEDURE 1. Position the assembly in place with the mounting bolts. 1.
Page 156 F-92 F-92 NOTES POWER W VE 455/POWER FEED 10...
Page 157 F-93 F-93 TROUBLESHOOTING AND REPAIR FLOWCHART - POWER SOURCE ERROR INTERPRETATION GUIDE Power Source Error Interpretation Guide Start (Semi Automatic PW-455, PW455/STT) If the PS Status light is flashing any combination of red and green, (For Codes 10555 and Below) errors are present in the PW-455.
Page 158 F-94 F-94 TROUBLESHOOTING AND REPAIR FLOWCHART - PERFORMANCE TROUBLESHOOTING GUIDE Performance Test Configuration (USE STD Performance Troubleshooting Guide STUD)** Alternate CV Configuration: GMAW (.045 Steel - 3/8" Plate) Grid Load (300A / 30V) Mode = 5 Alternate CC Configuration: (Semi Automatic PW-455, PW455/STT) Mode = 201 WFS =400 ipm Grid Load (300A / 30V)
Page 159 F-95 F-95 TROUBLESHOOTING AND REPAIR FLOWCHART - FUNCTIONAL TROUBLESHOOTING GUIDE Functional Troubleshooting Guide See UI Error Chart for (Semi Automatic PW-455, PW455/STT) Error 006? Error 100? additional error codes. Turn On (For Codes 10555 and Below) Condition of Main UI Display UI Status Status Light on the PS Other...
Page 160 POWER WAVE 455 WIRING DIAGRAM - CODE 10372 ....... G-2...
Page 161 NOTES POWER WAVE 455/POWER FEED 10...
Page 162: Electrical Diagrams
ELECTRICAL DIAGRAMS Power Wave 455 Wiring Diagram - Code 10372 LEFT SIDE OF MACHINE CONTROL BOARD 10A CIRCUIT TO SW1 612B BREAKER TO CB4 TO J20 612A AUXILIARY TRANSFORMER #1 WORK POWER BD. RECTIFIER (440-460) .05/600V TO CB1 TO P80...
Page 163: Power Wave 455 Wiring Diagram - Code 10555
ELECTRICAL DIAGRAMS Power Wave 455 Wiring Diagram - Code 10555 LEFT SIDE OF MACHINE TO J20 CONTROL BOARD TO SW1 TO TP3 612B 10A CIRCUIT 202A TO CB4 TO R1 WORK BREAKER 612A ELECTRODE AUXILIARY TRANSFORMER #1 WORK SOLID STATE (440-460) TO POWER BD.
Page 164: Power Wave 455 Wiring Diagram - Code 10553
ELECTRICAL DIAGRAMS Power Wave 455 Wiring Diagram - Code 10553 LEFT SIDE OF MACHINE CONTROL BOARD 10A CIRCUIT BREAKER AUXILIARY TRANSFORMER #1 SOLID WORK STATE RELAY MAIN CHOKE 6A CIRCUIT BREAKER WIRE FEEDER N.D. RECEPTACLE CURRENT TRANSDUCER POWER BOARD THIS AREA VIEWED FROM REAR OF MACHINE N.B.
Page 165: Power Feed 10 Control Box Wiring Diagram
ELECTRICAL DIAGRAMS Power Feed 10 Control Box Wiring Diagram 512B (J1) 500F N.F. (J5) N.A. 512C (J1) N.F. (J4) RED/GREEN N.A. 500C STATUS LED N.C. 512A 500D (J3) N.A. (P7) (J7 ON WIRE DRIVE OR ON INPUT RECEPTACLE SHOWN) N.B. 500E N.B.
Page 166: Power Feed 10 Wire Drive Wiring Diagram
ELECTRICAL DIAGRAMS Power Feed 10 Wire Drive Wiring Diagram VOLTAGE SENSING TO USER CONNECTION INTERFACE 2 STEP/ COLD INCH/ RECEPTACLE IF USED 4 STEP GAS PURGE R.F. DUAL (J7) TOROID PROCEDURE N.B. 512A TRIGGER P.M. 512A N.D. N.D. N.E. (J8) N.E.
Page 167: Power Feed 10 Machine Schematic
ELECTRICAL DIAGRAMS POWER FEED 10 MACHINE SCHEMATIC J8 OPTIONAL INPUT RECEPTACLE. IF CONFIGURED AS BOOM, CONNECTS VIA J9 OPTIONAL J6 INPUT ARCLINK CABLE FROM WIRE DRIVE (J9) OUTPUT RECEPTACLE WIRE DRIVE CONTROL PCB OR POWER WAVE 455. RECEPTACLE (BOOM) COMMUNICATION - COMMUNICATION - J6 OPTIONAL 541D...
Page 168: Power Wave 455 Machine Schematic - Code 10372
ELECTRICAL DIAGRAMS Enhanced Diagram POWER WAVE 455 MACHINE SCHEMATIC - CODE 10372 RECONNECT N.A. SWITCH INPUT SWITCH BOARD #1 (LEFT) RECTIFIER 380-460V 208-230V N.A. S5 RS232 CONTROL BOARD CONNECTOR CURRENT TRANSDUCER 1J21 CURRENT FEEDBACK RS232 RECEIVE 3J25 .022u MAIN TRANSFORMER T1...
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. INVERTER WELDERS THE LINCOLN ELECTRIC CO. MANUFACTURING TOLERANCE PER E2056 XB-UF OWNED BY...
Page 170: Power Wave 455 Machine Schematic - Code 10553
N.C. T1 PRIMARY CONNECTIONS SHOWN FOR REFERENCE ONLY. Ch'ge. Sht. No. THIS SHEET CONTAINS PROPRIETARY INFORMATION UNLESS OTHERWISE SPECIFIED TOLERANCE EQUIP. THE LINCOLN ELECTRIC CO. INVERTER WELDERS SEE WIRING DIAGRAM FOR 460/575 SWITCHING. THE LINCOLN ELECTRIC CO. MANUFACTURING TOLERANCE PER E2056...
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.

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