Lincoln Electric INVERTEC POWER WAVE 450 SVM112-B Service Manual
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Lincoln Electric INVERTEC POWER WAVE 450 SVM112-B Service Manual

Lincoln electric power supply user manual
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SVM112-B
RETURN TO MAIN INDEX
February, 2001
TM
INVERTEC POWER WAVE 450
10105 thru 10610
For use with machines having Code Numbers:
Safety Depends on You
Lincoln arc welding and cutting
equipment is designed and
built with safety in mind.
However, your overall safety
can be increased by proper
installation . . . and thoughtful
operation on your part. DO
NOT INSTALL, OPERATE OR
REPAIR THIS EQUIPMENT
WITHOUT READING THIS
MANUAL AND THE SAFETY
PRECAUTIONS CONTAINED
THROUGHOUT. And, most
importantly, think before you
act and be careful.
SERVICE MANUAL
Copyright © 2001 Lincoln Global Inc.
• World's Leader in Welding and Cutting Products •
• Sales and Service through Subsidiaries and Distributors Worldwide •
Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com

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Summary of Contents for Lincoln Electric INVERTEC POWER WAVE 450 SVM112-B

  • Page 1 SVM112-B RETURN TO MAIN INDEX February, 2001 INVERTEC POWER WAVE 450 10105 thru 10610 For use with machines having Code Numbers: Safety Depends on You Lincoln arc welding and cutting equipment is designed and built with safety in mind. However, your overall safety can be increased by proper installation .

  • 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: Fumes And Gases

    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 Safety...i-iv Installation ...Section A Operation...Section B Accessories...Section C Maintenance ...Section D Theory of Operation ...Section E Troubleshooting and Repair...Section F How To Use Troubleshooting Guide ...F-2 PC Board Troubleshooting Procedures and Replacement...F-3 Troubleshooting Guide ...F-5 Test Procedures ...F-27 Removal and Replacement Procedures ...F-155 Electrical Diagrams ...Section G...
  • Page 7 Section A-1 - INSTALLATION SECTION - Installation Technical Specifications ...A-2 Safety Precautions...A-3 Select Suitable Location ...A-3 Stacking...A-3 Tilting ...A-3 Lifting ...A-3 High Frequency Precautions...A-3 Input Connections...A-3 Ground Connections...A-4 Input Power Connections ...A-4 Input Fuse and Supply Wire Considerations ...A-4 Input Voltage Reconnect Procedure ...A-4 Output Connections...A-5 Work and Electrode Cable Connections ...A-5 Size...A-5...

  • Page 8: Installation

    TECHNICAL SPECIFICATIONS - POWER WAVE 450 INPUT -THREE PHASE ONLY Input Voltages: Input Currents @ 500A/40 VDC @ 450A/38 VDC Duty Cycle 60% Duty Cycle 100% Duty Cycle Constant Open Circuit Voltage 75 Volts Pulse Current Range Voltage Range 5-750 Amps 5-55 Volts RECOMMENDED INPUT WIRE AND FUSE SIZES Input...

  • Page 9: Safety Precautions

    Read this entire installation section before you start installation. SAFETY PRECAUTIONS WARNING ELECTRIC SHOCK can kill. • Only qualified personnel should perform this installation. • Turn the input power OFF at the disconnect switch or fuse box before working on this equipment. •...

  • Page 10: Ground Connections

    CAUTION Failure to follow these instructions can cause immedi- ate failure of components within the welder. GROUND CONNECTIONS The frame of the welder must be grounded. A ground terminal marked with the symbol is located inside the reconnect/input access door for this purpose. See your local and national electrical codes for proper ground- ing methods.

  • Page 11: Output Connections

    FIGURE A.3 – FRONTPANEL/BACK PANEL 1 WORK TERMINAL 2 ELECTRODE TERMINAL 3 REMOTE CONTROL AMPHENOL RECEPTACLE To operate at 200-208 VAC: 1. Open the reconnect/input access door. 2. Move the input voltage switch to Voltage = 200- 208V position. 3. Move “A” lead to the 200-208V terminal. To operate at 220-230 VAC: 1.
  • Page 12 NOTES POWER WAVE 450...
  • Page 13 Section B-1 - OPERATION SECTION - Operation...Section B Safety Instructions ...B-2 Quick Start Reference for Process Selection Overlay...B-3 General Description ...B-4 Synergic Welding...B-4 Recommended Processes ...B-4 Operational Features and Controls ...B-4 Design Features and Advantages ...B-4 Welding Capability...B-4 Limitations ...B-4 Controls and Settings ...B-5 Case Front Controls ...B-5 Operating Overlays ...B-6...

  • Page 14: Operating Instructions

    OPERATING INSTRUCTIONS Read and understand this entire section of operating instructions before operating the machine. SAFETY INSTRUCTIONS • Insulate yourself from the work and ground. • Always wear dry insulating gloves. • Do not weld on containers that have held com- bustibles.
  • Page 15 QUICK START REFERENCE FOR USING THE PROCESS SELECTION OVERLAY Read and understand the “Controls and Settings” and “Operating Overlays” sections of this manual before using the following Quick Start Reference procedure to operate the Power Wave. NOTE: Selection of certain options may limit the selection of subsequent options.

  • Page 16: General Description

    GENERAL DESCRIPTION The INVERTEC Power Wave power source is a high performance, digitally controlled inverter welding power source capable of complex, high-speed wave- form control. It uses three-phase input power only. The Power Wave is designed to be used as a synergic welding system in conjunction with a wire feeder.

  • Page 17: Controls And Settings

    LCD display on the Power Wave shows the following: LINCOLN ELECTRIC This display is shown for a few seconds followed by another display that depends on the overlay placed on the machine. At this point, the machine is ready for operation.

  • Page 18: Operating Overlays

    The bar code allows the machine to identify the overlay. FIGURE B.2 – TYPICAL POWER WAVE OVERLAY THE LINCOLN ELECTRIC COMPANY CLEVELAND, OHIO USA C COPYRIGHT 1994 L9361-2 WELD FROM MEMORY INVERTEC POWER WAVE 350...

  • Page 19: Overlay Types

    OVERLAY TYPES Four types of overlays can be used with the Power Wave. 1. Process Overlays. These overlays are used to create, save and recall specific welding proce- dures by selecting and adjusting the various weld- ing settings that have been programmed into the Power Wave at the factory.
  • Page 20 1. LCD DISPLAY WINDOW: Power up the machine with this overlay in place. When the Power Wave is turned on, the following message appears on the display for a few seconds: LINCOLN ELECTRIC VERSION X.X This display is followed by: OVERLAY ID...
  • Page 21 3. ELECTRODE CLASS UP/DOWN: Use the ELEC- TRODE CLASS UP or DOWN keys to select from the material types available for the selected process. Press the ELECTRODE CLASS UP or DOWN key until the desired material type is dis- played. 4.
  • Page 22 B-10 10. RECALL FROM MEMORY KEY: This key is used to recall an existing procedure from memory. You can recall and use any of the previously created welding procedures that are stored in one of the eight memory locations. Simply press the RECALL FROM MEMORY key appropriate MEMORY LOCATION NUMBER key.

  • Page 23: Weld From Memory Overlay

    1. LCD DISPLAY WINDOW: Power up the machine with this overlay in place. When the Power Wave is turned on, the following message appears in the display window for a few seconds: LINCOLN ELECTRIC Version X.X This display is followed by: OVERLAY ID...

  • Page 24: Weld From Memory, Dual Procedure Overlay

    1. LCD DISPLAY WINDOW: Power up the machine with this overlay in place. When the Power Wave is turned on, the following message appears in the display window for a few seconds: LINCOLN ELECTRIC Version X.X This display is followed by: OVERLAY ID...
  • Page 25 B-13 When a pair of welding procedures are recalled from memory, the display window will show the procedure description, wire feed speed, and the preset voltage or arc length trim of the LAST pro- cedure welded with. With this overlay in place, the wire feed speed and the preset voltage or arc length trim can be changed from the wire feeder.

  • Page 26: Dual Wire Feeders, Dual Procedure Overlay

    1. LCD DISPLAY WINDOW: Power up the machine with this overlay in place. When the Power Wave is turned on, the following message appears in the display window for a few seconds: LINCOLN ELECTRIC VERSION X.X This display is followed by: OVERLAY ID NUMBER = 9 2.

  • Page 27: Limits Overlay

    1. LCD DISPLAY WINDOW: Power up the machine with this overlay in place. When the Power Wave is turned on, the following message appears in the display window for a few seconds: LINCOLN ELECTRIC Version X.X This display is followed by: OVERLAY ID...
  • Page 28 B-16 Use the LIMIT UP and LIMIT DOWN keys to change the maximum wire feed speed to the desired value. Press the SET LIMIT key again. The new maximum and old minimum wire feed speeds will be dis- played. Use the LIMIT UP and LIMIT DOWN keys to change the minimum wire feed speed to the desired value.

  • Page 29: Setup Overlay

    The present status of the water cooler is indicated by the “WATER COOLER ON” light. OPERATION FIGURE B.9 – SETUP OVERLAY THE LINCOLN ELECTRIC COMPANY CLEVELAND, OHIO USA C COPYRIGHT 1994 L9660 SETUP OVERLAY WATER COOLER ENABLED WATER COOLER PRESSURE...

  • Page 30: Wire Feeder Setup Description

    B-18 When the “WATER COOLER PRESSURE” light turns on, release the key. If this key has been pressed for 30 seconds and the ‘WATER COOLER PRESSURE’ light still did not turn on, check the water cooler for adequate fluid level. 5.
  • Page 31 B-19 Use the ELECTRODE SENSE LEAD KEY to select either the - output terminal or the electrode sense (67) lead for the positive voltage reference. The work sense (21) lead is used only in rare circum- stances. For most installations, use the WORK SENSE LEAD KEY to select the - output terminal for negative voltage reference.

  • Page 32: Overview Of Welding Procedures

    B-20 OVERVIEW OF WELDING PROCEDURES FLUX CORED ARC WELDING (FCAW) AND GMAW PROCEDURES For each wire feed speed, a corresponding voltage has been preprogrammed into the machine by welding experts. This preprogrammed voltage is the best average voltage for the procedure at the given wire feed speed.

  • Page 33: Wave Control

    B-21 TABLE B.3 – RELATIONSHIP BETWEEN VOLTAGE TRIM AND PRESET VOLTAGE Voltage Trim Relationship to Preset Voltage 60% of preset voltage 80% of preset voltage no change to preset voltage 120% of preset voltage 140% of preset voltage Explanation of Table B.3: If, for example, the minimum voltage trim is set to 0.8 and the maximum voltage trim is set to 1.4, this means that the voltage for a given wire feed speed...

  • Page 34: Pulse Welding

    B-22 In Pulse processes: The wave control adjustment allows the frequency set- ting to vary. Increasing the wave control allows the fre- quency setting to increase, and decreasing the wave control allows the frequency setting to decrease. Varying the wave control setting affects the droplet transfer and allows fine-tuning for different welding positions.

  • Page 35: Overload Protection

    B-23 OVERLOAD PROTECTION THERMAL PROTECTION The Power Wave has thermostatic protection from excessive duty cycles, overloads, loss of cooling, and high ambient temperatures. When the power source is subjected to any of these conditions or any of the con- ditions mentioned above, a thermostat will open. The yellow high temperature light on the case front comes on.
  • Page 36 NOTES POWER WAVE 450...
  • Page 37 Section C-1 Accessories...Section C Options/Accessories...C-2 Wire Feeder Setup ...C-2 Guns and Cables ...C-2 Water Cooler Usage ...C-2 Recommended Coolants...C-3 Priming the Cooler...C-3 Cooler Periodic Maintenance ...C-4 TABLE OF CONTENTS - ACCESSORIES - POWER WAVE 450 Section C-1...

  • Page 38: Accessories

    OPTIONS/ACCESSORIES • Synergic 7 wire feeder (K632-1) standard speed,or (K632-2) high speed • MAGNUM 400 gun (K471-2) or 550 gun (K598) • Internal water cooler • Undercarriages (Single [K961-1]or Dual [K962-1]Gas Cylinders) • Remote control (stick welding) K941-1 • Amptrols (Hand K963-1 or -2, Foot K870) •...

  • Page 39: Recommended Coolants

    There are two water connections on the rear of the Power Wave. See Figure C.1. Connect the water lines between these connectors and those on the wire feed- er. The water is fed through the feeder into the gun. When a water cooler is used, the water cooler must be enabled by using the Setup Overlay.

  • Page 40: Cooler Periodic Maintenance

    • Do not drop or lose drive coupling between pump and motor. • Do not discard old pump. Remove both fit- tings, Keep v-clamp, Seal old pump in a waterproof bag, Package into protective con- tainer, and Return to nearest Lincoln Electric FSS center. POWER WAVE 450...
  • Page 41 g. Install new pump and v-band clamp: • Do not apply any lubricant to pump’s drive coupling. • Pump body is properly oriented with its strainer at the 6:00 position. • Tighten v-clamp with 15 to 30 in-lbs. of torque. h.
  • Page 42 NOTES POWER WAVE 450...
  • Page 43 TABLE OF CONTENTS -MAINTENANCE- Maintenance ...Section D Safety Precautions...D-2 Routine and Periodic Maintenance ...D-2 Input Filter Capacitor Discharge...D-2 Preventive Maintenance ...D-5 General Component Locations...D-6 POWER WAVE 450...

  • Page 44: Maintenance

    SAFETY PRECAUTIONS ELECTRIC SHOCK can kill. • Do not touch electrically hot parts. ROUTINE AND PERIODIC MAINTENANCE Perform the following preventive maintenance at least once every six months. Prior to performing preventive maintenance it is impor- tant to perform the following capacitor discharge pro- cedure to avoid electric shock.

  • Page 45: Electric Shock Can Kill

    5. Locate two sets of two resistors on the left side of the machine and three sets of two resistors on the right side of the machine. See Figure D.1. Do not touch the resistors or any other internal machine component.
  • Page 46 6. Locate the #9 and #12 terminals, identified by the “Discharge” labels, on each of the four Switch Boards. See Figure D.2. 7. Using insulated, needle nose-type jumper leads and insulated gloves, connect one jumper lead to one end of the resistor obtained in step 4. Connect the other jumper lead to the other end of the resistor.

  • Page 47: Preventive Maintenance

    PREVENTIVE MAINTENANCE Perform the following preventive maintenance proce- dures at least once every six months. It is good prac- tice to keep a preventive maintenance record; a record tag attached to the machine works best. 1. Remove the hex head screws from the sides and top of the machine.

  • Page 48: General Component Locations

    MAINTENANCE FIGURE D.4 – GENERAL COMPONENT LOCATIONS 1 DISPLAY BOARD (BACK OF PANEL) 2 POWER SWITCH 3 MAIN TRANSFORMER 4 AUXILIARY TRANSFORMER 5 INPUT RECTIFIER 6 HEAT SINK FINS 7 OUTPUT TERMINALS 8 OVERLAY BAR CODE SENSORS 9 TERMINAL STRIP (LOCATION) POWER WAVE 450...
  • Page 49 Section E-1 -THEORY OF OPERATION- Theory of Operation ...Section E General Description ...E-2 Input Voltage ...E-2 Precharge (Soft Start)...E-3 Switch Boards...E-4 Main Transformer ...E-5 Output Rectifier and Choke ...E-6 Control Board...E-7 Power Board ...E-8 Display Board...E-9 Thermal Protection...E-10 Protective Circuits...E-10 Over Current Protection ...E-10 Over Voltage Protection...E-10 Field Effect Transistor (FET) Operation ...E-11...

  • Page 50: Theory Of Operation

    THEORY OF OPERATION FIGURE E.2 – INPUT VOLTAGE CIRCUIT INPUT CONTACTOR THREE PHASE INPUT POWER AUX. INPUT TRANS LINE SWITCH PROTECTION BOARD GENERAL DESCRIPTION The Power Wave is an inverter type power source that can support most welding procedures. It is modeled after a P.C.

  • Page 51: Precharge (Soft Start

    THEORY OF OPERATION INPUT CONTACTOR THREE PHASE INPUT POWER AUX. INPUT TRANS LINE SWITCH PROTECTION BOARD PRECHARGE (SOFT START) The Protection Board contains a “soft Start” circuit, which is powered by the Auxiliary Transformer. During precharge or “soft start” only two phases of the input power, with current limiting, are connected to the input rectifier.

  • Page 52: Switch Boards

    THEORY OF OPERATION FIGURE E.4 – SWITCH BOARD CIRCUIT INPUT CONTACTOR THREE PHASE INPUT POWER AUX. INPUT TRANS LINE SWITCH PROTECTION BOARD SWITCH BOARDS There are four Switch Boards in the Power Wave, each containing an input capacitor. The capacitors on Switch Boards #1 and #2 are always in parallel, and the capacitors on Switch Boards #3 and #4 are always in parallel.

  • Page 53: Main Transformer

    THEORY OF OPERATION INPUT CONTACTOR THREE PHASE INPUT POWER AUX. INPUT TRANS LINE SWITCH PROTECTION BOARD MAIN TRANSFORMER Each Switch Board assembly works as a switch pair. Each board feeds current to a primary winding of the Main Transformer. These primary currents are moni- tored by the Current Transformer (CT).

  • Page 54: Output Rectifier And Choke

    THEORY OF OPERATION FIGURE E.6 – OUTPUT RECTIFIER AND CHOKE INPUT CONTACTOR THREE PHASE INPUT POWER AUX. INPUT TRANS LINE SWITCH PROTECTION BOARD OUTPUT RECTIFIER AND CHOKE The Output Rectifier receives the AC output from the Main Transformer secondary and rectifies it to a DC level with a 40 kHz ripple.

  • Page 55: Control Board

    THEORY OF OPERATION INPUT CONTACTOR THREE PHASE INPUT POWER AUX. INPUT TRANS LINE SWITCH PROTECTION BOARD CONTROL BOARD The Control Board is at the heart of controlling the out- put of the machine. With the information it receives from the Shunt (current feedback), the voltage sensing leads, the wire feeder(s), and the other printed circuit boards, the Control Board optimizes the welding results by regulating the FETs’...

  • Page 56: Power Board

    THEORY OF OPERATION INPUT CONTACTOR THREE PHASE INPUT POWER AUX. INPUT TRANS LINE SWITCH PROTECTION BOARD POWER BOARD The Power Board provides gate drives for the FETs on the Switch Boards. It does so based on the “turn-on” signals it receives from the Control Board. One func- tion of the Power Board is to isolate the Control Board from the Switch Boards.

  • Page 57: Display Board

    THEORY OF OPERATION INPUT CONTACTOR THREE PHASE INPUT POWER AUX. INPUT TRANS LINE SWITCH PROTECTION BOARD DISPLAY BOARD The Display Board allows the operator to select from the procedures that are programmed into the machine, and it lets the Control Board know which procedure was selected.

  • Page 58: Thermal Protection

    E-10 THEORY OF OPERATION THERMAL PROTECTION Two 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 a switch board, and the other is located on the main choke.

  • Page 59: Field Effect Transistor (Fet) Operation

    E-11 THEORY OF OPERATION FIELD EFFECT TRANSISTOR (FET) OPERATION FIGURE E.10 – FIELD EFFECT TRANSISTOR OPERATION SOURCE TERMINAL SOURCE (N) SUBSTRATE (P) SOURCE (N) An FET is a type of transistor. FETs are semi- conductors well suited for high-frequency switching. Drawing A above shows an FET in a passive mode.

  • Page 60: Pulse Width Modulation

    E-12 THEORY OF OPERATION FIGURE E.11 – TYPICAL FET OUTPUTS 1 sec 20 sec The term PULSE WIDTH MODULATION is used to describe how much time is devoted to conduction in the positive and negative por- tions of the cycle. Changing the pulse width is known as MODULATION.
  • Page 61 Section F-1 -TROUBLESHOOTING & REPAIR SECTION- Troubleshooting & Repair Section...Section F How to Use Troubleshooting Guide...F-2 PC Board Troubleshooting Procedures and Replacement...F-3 Troubleshooting Guide ...F-5 Test Procedures ...F-23 Capacitor Discharge Procedure ...F-23 Auxiliary Transformer Test 1 ...F-27 Auxiliary Transformer Test 2 ...F-31 Auxiliary Transformer Primary Wiring Harness Test ...F-35 Auxiliary Transformer #1 Secondary and Wiring Harness Test ...F-39 Input Power and Wiring Harness Test ...F-43...

  • Page 62: Troubleshooting And Repair

    TROUBLESHOOTING & REPAIR HOW TO USE TROUBLESHOOTING GUIDE Service and repair should be performed by only Lincoln Electric Factory Trained Personnel. Unauthorized repairs performed on this equipment may result in danger to the technician and machine operator and will invalidate your factory warranty. For your safety and to avoid Electrical Shock, please observe all safety notes and precautions detailed throughout this manual.

  • Page 63: Pc Board Troubleshooting Procedures And Replacement

    • 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-shield- ing bag. This will prevent further damage and allow proper failure analysis.
  • Page 64 TROUBLESHOOTING & REPAIR DISPLAY BOARD REPLACED IF POSSIBLE QUICK VOLTAGE CALIBRATION FULL VOLTAGE CALIBRATION PC BOARD REPLACEMENT CALIBRATION REQUIREMENTS SHUNT SNUBBER AMPLIFIER BOARD BOARD REPLACED REPLACED POWER WAVE 450 CONTROL BOARD REPLACED CURRENT CALIBRATION...

  • Page 65: Troubleshooting Guide

    – no displays. If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, con- tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1- 800-833-9353.

  • Page 66: Troubleshooting Guide

    If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, con- tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1- 800-833-9353. detailed in the beginning of this manual.
  • Page 67 If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, con- tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1- 800-833-9353. detailed in the beginning of this manual.
  • Page 68 If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, con- tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1- 800-833-9353. detailed in the beginning of this manual.
  • Page 69 If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, con- tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1- 800-833-9353. detailed in the beginning of this manual.
  • Page 70 – display is on. If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, con- tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1- 800-833-9353.
  • Page 71 If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, con- tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1- 800-833-9353.
  • Page 72 “B” or vice versa. If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, con- tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1- 800-833-9353.
  • Page 73 If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, con- tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1- 800-833-9353.
  • Page 74 NOT INITIALIZED” on power-up. If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, con- tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1- 800-833-9353.
  • Page 75 The water cooler does not turn If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, con- tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1- 800-833-9353.
  • Page 76 If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, con- tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1- 800-833-9353. detailed in the beginning of this manual.
  • Page 77 Power Wave display. If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, con- tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1- 800-833-9353.
  • Page 78 Power Wave display. If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, con- tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1- 800-833-9353. detailed in the beginning of this manual.
  • Page 79 If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, con- tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1- 800-833-9353. detailed in the beginning of this manual.
  • Page 80 If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, con- tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1- 800-833-9353. detailed in the beginning of this manual.
  • Page 81 If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, con- tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1- 800-833-9353. detailed in the beginning of this manual.

  • Page 82: Pc Board Connector Locations

    F-22 F-22 TROUBLESHOOTING & REPAIR PC BOARD CONNECTOR LOCATIONS FIGURE F.1 – PC BOARD CONNECTOR LOCATIONS POWER WAVE 450...

  • Page 83: Capacitor Discharge Procedure

    TROUBLESHOOTING & REPAIR 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 elec- trical shock, please observe all safety notes and precautions detailed throughout this manual.

  • Page 84: Test Procedure

    F-24 TROUBLESHOOTING & REPAIR CAPACITOR DISCHARGE PROCEDURE (continued) TEST PROCEDURE 1. Remove main input supply power to the machine. 2. With the 3/8" nut driver, remove the screws that hold the handle to the machine. 3. Remove the rubber gasket (cover seal) from the lift bail.

  • Page 85: Electric Shock Can Kill

    F-25 TROUBLESHOOTING & REPAIR CAPACITOR DISCHARGE PROCEDURE (continued) ELECTRIC SHOCK can kill. Proceed with caution. Be careful not to touch any internal machine components during the discharge procedure. 9. Using the insulated, needle nose type jumper leads and insulated gloves, con- nect one jumper lead to one end of the resistor obtained in step 6.
  • Page 86 F-26 TROUBLESHOOTING & REPAIR CAPACITOR DISCHARGE PROCEDURE (continued) FIGURE F.4 - RESISTOR WITH LEADS CONNECTED. 11. Check the voltage across terminals #9 and #12 with the DC voltmeter. Terminal #9 has positive polarity and terminal #12 has negative polarity. Voltage should be zero. If any voltage remains, repeat this capaci- tor discharge procedure.

  • Page 87: Auxiliary Transformer Test 1

    TROUBLESHOOTING & REPAIR AUXILIARY TRANSFORMER TEST #1 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 elec- trical shock, please observe all safety notes and precautions detailed throughout this manual.
  • Page 88 F-28 TROUBLESHOOTING & REPAIR AUXILIARY TRANSFORMER TEST #1 (continued) FIGURE F.5 - TRANSFORMER T1 AND T2 LOCATION TEST PROCEDURE 1. Remove main input supply power to the machine. 2. With the 3/8" nut driver, remove the 4 screws that hold the handle to the machine. 3.

  • Page 89: Removal And Replacement Procedures

    F-29 TROUBLESHOOTING & REPAIR AUXILIARY TRANSFORMER TEST #1 (continued) 11. Remove plugs J32 and J33 from the pro- tection board. 12. Turn the main input supply power to the machine back ON. WARNING ELECTRIC SHOCK can kill. Proceed with caution. careful not to touch any internal machine compo- nents during the remainder of the test proce-...
  • Page 90 F-30 F-30 TROUBLESHOOTING & REPAIR FIGURE F.6 – INPUT AND AUXILIARY CIRCUIT WIRING DIAGRAM POWER WAVE 450...

  • Page 91: Auxiliary Transformer Test 2

    TROUBLESHOOTING & REPAIR AUXILIARY TRANSFORMER TEST #2 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 elec- trical shock, please observe all safety notes and precautions detailed throughout this manual.
  • Page 92 F-32 TROUBLESHOOTING & REPAIR AUXILIARY TRANSFORMER TEST #2 (continued) FIGURE F.7 - TRANSFORMER T1 AND T2 LOCATION TEST PROCEDURE 1. Remove main input supply power to the machine. 2. With the 3/8" nut driver, remove the 4 screws that hold the handle to the machine. 3.
  • Page 93 F-33 TROUBLESHOOTING & REPAIR AUXILIARY TRANSFORMER TEST #2 (continued) 11. To conduct this test, you will be measuring the voltage between pin 2 and pin 5 of plug J4. The plug is located in the machine undercarriage and is somewhat difficult to reach.
  • Page 94 F-34 F-34 TROUBLESHOOTING & REPAIR FIGURE F.8 – INPUT AND AUXILIARY CIRCUIT WIRING DIAGRAM POWER WAVE 450...

  • Page 95: Auxiliary Transformer Primary Wiring Harness Test

    TROUBLESHOOTING & REPAIR AUXILIARY TRANSFORMER PRIMARY WIRING HARNESS 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 electri- cal shock, please observe all safety notes and precautions detailed throughout this manual.
  • Page 96 F-36 TROUBLESHOOTING & REPAIR AUXILIARY TRANSFORMER PRIMARY WIRING HARNESS TEST (continued) FIGURE F.9 - RECONNECT PANEL/TERMINAL STRIP LOCATION 1. RECONNECT PANEL (ON LEFT SIDE) 2. TERMINAL STRIP 3. FAN MOTORS 4. AUXILIARY TRANSFORMERS TEST PROCEDURE 1. Remove main input supply power to the machine.
  • Page 97 F-37 TROUBLESHOOTING & REPAIR AUXILIARY TRANSFORMER PRIMARY WIRING HARNESS TEST (continued) 10. Check the wires that run from the recon- nect panel to the terminal strip. Look for shorts between wires caused by broken or burned insulation. See the Input and Auxiliary Circuit Wiring Diagram, Figure F.10.
  • Page 98 F-38 F-38 TROUBLESHOOTING & REPAIR FIGURE F.10 – INPUT AND AUXILIARY CIRCUIT WIRING DIAGRAM POWER WAVE 450...

  • Page 99: Auxiliary Transformer #1 Secondary And Wiring Harness Test

    AUXILIARY TRANSFORMER #1 SECONDARY AND WIRING HARNESS 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 elec- trical shock, please observe all safety notes and precautions detailed throughout this manual.
  • Page 100 F-40 TROUBLESHOOTING & REPAIR AUXILIARY TRANSFORMER #1 SECONDARY AND WIRING HARNESS TEST (continued) FIGURE F.11 - PLUG AND RECEPTACLE INSPECTION POINTS TEST PROCEDURE 1. Remove main input supply power to the machine. 2. With the 3/8" nut driver, remove the 4 screws that hold the handle to the machine.
  • Page 101 F-41 TROUBLESHOOTING & REPAIR AUXILIARY TRANSFORMER #1 SECONDARY AND WIRING HARNESS TEST (continued) 10. Check for shorts at plugs J33, J34, J35, J37, and J38 on the protection board. Inspect the board for evidence of arcing. 11. After the test is completed and the prob- lem successfully repaired, reconnect all plugs disconnected for the test.
  • Page 102 F-42 TROUBLESHOOTING & REPAIR AUXILIARY TRANSFORMER #1 SECONDARY CIRCUIT WIRING DIAGRAM COMMON COMMON COMMON COMMON COMMON COMMON COMMON FIGURE F.12 TRIG TRIG TRIG TRIG 105A 115V 102B TRIG 106A 115V 102D POWER WAVE 450 F-42...

  • Page 103: Input Power And Wiring Harness Test

    TROUBLESHOOTING & REPAIR INPUT POWER AND WIRING HARNESS 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 elec- trical shock, please observe all safety notes and precautions detailed throughout this manual.
  • Page 104 F-44 TROUBLESHOOTING & REPAIR INPUT POWER AND WIRING HARNESS TEST FIGURE F.13 - INPUT POWER INSPECTION POINTS TEST PROCEDURE 1. Remove main input supply power to the machine. 2. With the 3/8" nut driver, remove the 4 screws that hold the handle to the machine. 3.
  • Page 105 F-45 TROUBLESHOOTING & REPAIR INPUT POWER AND WIRING HARNESS TEST (continued) 9. Check for shorts or fusing at the input (top) leads to the main contactor. 10. Remove plug J30 from the protection board. Check the resistance on the J30 header (the plug mounted on the board) between pin 1 and pin 6.
  • Page 106 F-46 F-46 TROUBLESHOOTING & REPAIR FIGURE F.14 – INPUT AND AUXILIARY CIRCUIT WIRING DIAGRAM POWER WAVE 450...

  • Page 107: Input Rectifier Resistance Test

    TROUBLESHOOTING & REPAIR INPUT RECTIFIER RESISTANCE 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 elec- trical shock, please observe all safety notes and precautions detailed throughout this manual.
  • Page 108 F-48 TROUBLESHOOTING & REPAIR INPUT RECTIFIER RESISTANCE TEST (continued) FIGURE F.15 - RECONNECT SWITCH LOCATION 1. RECONNECT SWITCH 2. INPUT RECTIFIER 3. MAIN CONTACTOR TEST PROCEDURE 1. Remove main input supply power to the machine. 2. With the 3/8" nut driver, remove the 4 screws that hold the handle to the machine.
  • Page 109 F-49 TROUBLESHOOTING & REPAIR INPUT RECTIFIER RESISTANCE TEST (continued) 9. Check all leads connected to the input rectifier. Check for looseness or shorted wires. 10. Using an analog type meter, perform the resistance test Steps A through L accord- ing to the Table F.1. NOTE: If terminals AC1, AC2, and AC3 of the input rectifier are not accessible, use terminals T1, T2,...
  • Page 110 F-50 F-50 NOTES POWER WAVE 450...

  • Page 111: Output Shunt/Welding Feedback Test

    TROUBLESHOOTING & REPAIR OUTPUT SHUNT/WELDING FEEDBACK 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 elec- trical shock, please observe all safety notes and precautions detailed throughout this manual.
  • Page 112 F-52 TROUBLESHOOTING & REPAIR TEST PROCEDURE 1. Remove main input supply power to the Power Wave 450. 2. Disconnect the Output leads from the machine. 3. If a wire feeder is connected to the Power Wave 450, release the drive roll tension so the unit will not feed wire when the trigger is activated.
  • Page 113 F-53 TROUBLESHOOTING & REPAIR OUTPUT SHUNT/WELDING FEEDBACK TEST (continued) FIGURE F.16 - SHUNT AMPLIFIER BOARD LOCATION 1. SHUNT AMPLIFIER BOARD TEST PROCEDURE 1. Remove main input supply power to the machine. 2. With the 3/8" nut driver, remove the 4 screws that hold the handle to the machine.

  • Page 114: Electric Shock

    F-54 TROUBLESHOOTING & REPAIR OUTPUT SHUNT/WELDING FEEDBACK TEST (continued) WARNING ELECTRIC SHOCK can kill. Proceed with caution. careful not to touch any inter- nal machine components during the remainder of the test procedure. 9. Check for +15 VDC between plug J50 - pin 3+ and J50 - pin 1-.

  • Page 115: Piezo-Electric Alarm Buzzer Test

    TROUBLESHOOTING & REPAIR PIEZO-ELECTRIC ALARM BUZZER 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 elec- trical shock, please observe all safety notes and precautions detailed throughout this manual.
  • Page 116 F-56 TROUBLESHOOTING & REPAIR PIEZO-ELECTRIC ALARM BUZZER TEST FIGURE F.17 - ALARM BUZZER LOCATION TEST PROCEDURE 1. Remove main input supply power to the machine. 2. With the 3/8" nut driver, remove the 4 screws that hold the handle to the machine. 3.

  • Page 117: Output Rectifier Diodes Test

    TROUBLESHOOTING & REPAIR OUTPUT RECTIFIER DIODES 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 elec- trical shock, please observe all safety notes and precautions detailed throughout this manual.
  • Page 118 F-58 TROUBLESHOOTING & REPAIR OUTPUT RECTIFIER DIODES TEST FIGURE F.18 - SNUBBER BOARD, OUTPUT TERMINAL LOCATION 1. PC BOARD FRONT/BOTTOM COVER 2. SNUBBER PC BOARD 3. NEGATIVE OUTPUT TERMINAL 4. POSITIVE OUTPUT TERMINAL TEST PROCEDURE 1. Remove main input supply power to the machine.

  • Page 119: Field Effect Transistor/Switch Board Test

    TROUBLESHOOTING & REPAIR FIELD EFFECT TRANSISTOR/SWITCH BOARD TEST Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid elec- trical shock, please observe all safety notes and precautions detailed throughout this manual.
  • Page 120 F-60 TROUBLESHOOTING & REPAIR FIELD EFFECT TRANSISTOR/SWITCH BOARD TEST FIGURE F.19 – F.E.T. SWITCH BOARD LOCATION TEST PROCEDURE 1. Remove main input supply power to the machine. 2. With the 3/8" nut driver, remove the screws that hold the handle to the machine. 3.
  • Page 121 F-61 TROUBLESHOOTING & REPAIR FIELD EFFECT TRANSISTOR/SWITCH BOARD TEST (continued) 7. Locate the two sets of two resistors on the left side of the machine and three sets of two resistors on the right side of the machine. See Figure F.20. Do not touch the resistors or any other internal machine component.
  • Page 122 F-62 TROUBLESHOOTING & REPAIR FIELD EFFECT TRANSISTOR/SWITCH BOARD TEST (continued) FIGURE F.21 - DISCHARGE LABEL 9. Using insulated, needle nose type jumper leads and insulated gloves, connect one jumper lead to one end of the resistor obtained in step 6. Connect the other jumper lead to the other end of the resistor.
  • Page 123 F-63 TROUBLESHOOTING & REPAIR FIELD EFFECT TRANSISTOR/SWITCH BOARD TEST (continued) FIGURE F.23 - SWITCH BOARD ASSEMBLY CONNECTION DECAL M16740 POWER WAVE 450 F-63 4/98...
  • Page 124 F-64 TROUBLESHOOTING & REPAIR FIELD EFFECT TRANSISTOR/SWITCH BOARD TEST (continued) Switch Board Test 1: (For Switch Board Marked CAP 1 on the Switch Board Assem- bly Connection Decal - See Figure F.23.) A. Disconnect all wiring harness leads from switch board 1. Fold the leads up so that they do not interfere with the exposed PC board terminals.
  • Page 125 F-65 TROUBLESHOOTING & REPAIR FIELD EFFECT TRANSISTOR/SWITCH BOARD TEST (continued) TABLE F.2 – SWITCH BOARD 1 RESISTANCE TEST TABLE Apply Apply Positive Negative Test Test Probe to Probe to Terminal Terminal NOTE: K ohm = ohm reading multiplied by 1000. NOTE: Always make sure that all four Switch Boards are changed at the same time.
  • Page 126 F-66 TROUBLESHOOTING & REPAIR FIELD EFFECT TRANSISTOR/SWITCH BOARD TEST (continued) TABLE F.2 – SWITCH BOARD 1 RESISTANCE TEST TABLE (Continued) Apply Apply Positive Negative Test Test Probe to Probe to Terminal Terminal NOTE: K ohm = ohm reading multiplied by 1000. NOTE: Always make sure that all four Switch Boards are changed at the same time.
  • Page 127 F-67 TROUBLESHOOTING & REPAIR FIELD EFFECT TRANSISTOR/SWITCH BOARD TEST (continued) TABLE F.3 – SWITCH BOARD 2 RESISTANCE TEST TABLE Apply Apply Positive Negative Test Test Probe to Probe to Terminal Terminal NOTE: K ohm = ohm reading multiplied by 1000. NOTE: Always make sure that all four Switch Boards are changed at the same time.
  • Page 128 F-68 TROUBLESHOOTING & REPAIR FIELD EFFECT TRANSISTOR/SWITCH BOARD TEST (continued) TABLE F.3 – SWITCH BOARD 2 RESISTANCE TEST TABLE (Continued) Apply Apply Positive Negative Test Test Probe to Probe to Terminal Terminal NOTE: K ohm = ohm reading multiplied by 1000. NOTE: Always make sure that all four Switch Boards are changed at the same time.
  • Page 129 F-69 TROUBLESHOOTING & REPAIR FIELD EFFECT TRANSISTOR/SWITCH BOARD TEST (continued) TABLE F.4 – SWITCH BOARD 3 RESISTANCE TEST TABLE Apply Apply Positive Negative Test Test Probe to Probe to Terminal Terminal NOTE: K ohm = ohm reading multiplied by 1000. NOTE: Always make sure that all four Switch Boards are changed at the same time.
  • Page 130 F-70 TROUBLESHOOTING & REPAIR FIELD EFFECT TRANSISTOR/SWITCH BOARD TEST (continued) TABLE F.4 – SWITCH BOARD 3 RESISTANCE TEST TABLE (Continued) Apply Apply Positive Negative Test Test Probe to Probe to Terminal Terminal NOTE: K ohm = ohm reading multiplied by 1000. NOTE: Always make sure that all four Switch Boards are changed at the same time.
  • Page 131 F-71 TROUBLESHOOTING & REPAIR FIELD EFFECT TRANSISTOR/SWITCH BOARD TEST (continued) TABLE F.5 – SWITCH BOARD 4 RESISTANCE TEST TABLE Apply Apply Positive Negative Test Test Probe to Probe to Terminal Terminal NOTE: K ohm = ohm reading multiplied by 1000. NOTE: Always make sure that all four Switch Boards are changed at the same time.
  • Page 132 F-72 TROUBLESHOOTING & REPAIR FIELD EFFECT TRANSISTOR/SWITCH BOARD TEST (continued) TABLE F.5 – SWITCH BOARD 4 RESISTANCE TEST TABLE (Continued) Apply Apply Positive Negative Test Test Probe to Probe to Terminal Terminal NOTE: K ohm = ohm reading multiplied by 1000. NOTE: Always make sure that all four Switch Boards are changed at the same time.

  • Page 133: Troubleshooting And Repair

    F-73 TROUBLESHOOTING & REPAIR IGBT/SWITCH BOARD TEST (G3165-1) TABLE F.6 – NOTE: This test will NOT determine if an individual IGBT device is open. Apply Apply Positive Negative Test Test Probe to Probe to Terminal Terminal NOTE: K ohm = ohm reading multiplied by 1000. NOTE: Always make sure that all four Switch Boards are changed at the same time.
  • Page 134 F-74 TROUBLESHOOTING & REPAIR IGBT/SWITCH BOARD TEST (Continued) Apply Apply Positive Negative Test Test Probe to Probe to Terminal Terminal 401/403 405/407 401/403 405/407 402/404 406/408 402/404 406/408 NOTE: K ohm = ohm reading multiplied by 1000. NOTE: Always make sure that all four Switch Boards are changed at the same time. Never mix an old style (different part number) Switch Board with a new style (new part number).

  • Page 135: Snubber And Bleeder Resistor Test

    TROUBLESHOOTING & REPAIR SNUBBER AND BLEEDER RESISTOR 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 elec- trical shock, please observe all safety notes and precautions detailed throughout this manual.
  • Page 136 F-76 TROUBLESHOOTING & REPAIR SNUBBER AND BLEEDER RESISTOR TEST FIGURE F.24 - SWITCH BOARD ASSEMBLY CONNECTION DECAL M16740 POWER WAVE 450 F-76 4/98...

  • Page 137: Test Procedure

    F-77 TROUBLESHOOTING & REPAIR SNUBBER AND BLEEDER RESISTOR TEST (continued) TEST PROCEDURE 1. Remove main input supply power to the machine. 2. With the 3/8" nut driver, remove the 4 screws that hold the handle to the machine. 3. Remove the rubber gasket (cover seal) from the lift bail.
  • Page 138 F-78 TROUBLESHOOTING & REPAIR SNUBBER AND BLEEDER RESISTOR TEST (continued) C. With the volt/ohmmeter, check for 25 ohms resistance between lead #404 and #9F. If the measurement reads between 20 and 30 ohms, resistor R4 and leads #404 and #9F are okay. Go to step D. If the measurement does not read between 20 and 30 ohms, check for continuity in leads #404 and #9F.
  • Page 139 F-79 TROUBLESHOOTING & REPAIR FIGURE F.25 – SNUBBER AND BLEEDER RESISTOR WIRING DIAGRAM SWITCH BOARD SWITCH BOARD SWITCH BOARD SWITCH BOARD (401) (12E) (12A) TO RECONNECT SWITCH (402) (9E) (9A) TO RECONNECT SWITCH (403) (12F) (12B) TO RECONNECT SWITCH (404) (9F) (9B) TO RECONNECT SWITCH...
  • Page 140 F-80 F-80 NOTES POWER WAVE 450...
  • Page 141 TROUBLESHOOTING & REPAIR RECONNECT SWITCH TEST 1 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 elec- trical shock, please observe all safety notes and precautions detailed throughout this manual.
  • Page 142 F-82 TROUBLESHOOTING & REPAIR 1. RECONNECT PANEL 2. RECONNECT SWITCH 3. LEAD CONNECTIONS TEST PROCEDURE 1. Remove main input supply power to the machine. 2. With the 3/8" nut driver, remove the 4 screws that hold the handle to the machine. 3.

  • Page 143: Reconnect Switch Test 1

    F-83 TROUBLESHOOTING & REPAIR RECONNECT SWITCH TEST 1 (continued) For 380 or 460 VAC: A. Check that the following leads are connect- ed together at the reconnect switch: #9A, #9B, #9K, and POS. B. Check that the following leads are con- nected together at the reconnect switch: #9C, #9D, #9J, #12A, #12B, and #12J.
  • Page 144 F-84 F-84 TROUBLESHOOTING & REPAIR FIGURE F.27 – INPUT AND RECONNECT WIRING DIAGRAM POWER WAVE 450...
  • Page 145 TROUBLESHOOTING & REPAIR RECONNECT SWITCH TEST 2 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 elec- trical shock, please observe all safety notes and precautions detailed throughout this manual.

  • Page 146: Reconnect Switch Test 2

    F-86 TROUBLESHOOTING & REPAIR RECONNECT SWITCH TEST 2 (continued) TEST PROCEDURE 1. Remove main input supply power to the machine. 2. With the 3/8" nut driver, remove the 4 screws that hold the handle to the machine. 3. Remove the rubber gasket (cover seal) from the lift bail.
  • Page 147 F-87 TROUBLESHOOTING & REPAIR RECONNECT SWITCH TEST 2 (continued) • Lead #9A between the reconnect switch and switch board #1. • Lead #9B between the reconnect switch and switch board #2. • Lead #9C between the reconnect switch and switch board #3. •...
  • Page 148 F-88 F-88 TROUBLESHOOTING & REPAIR FIGURE F.29 – INPUT AND RECONNECT WIRING DIAGRAM POWER WAVE 450...

  • Page 149: Static Capacitor Balance Test

    TROUBLESHOOTING & REPAIR STATIC CAPACITOR BALANCE 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 elec- trical shock, please observe all safety notes and precautions detailed throughout this manual.
  • Page 150 F-90 TROUBLESHOOTING & REPAIR STATIC CAPACITOR BALANCE TEST (continued) FIGURE F.30 - BLEEDER RESISTORS R9 AND R10 LOCATION TEST PROCEDURE 1. Remove main input supply power to the machine. 2. With the 3/8" nut driver, remove the 4 screws that hold the handle to the machine.

  • Page 151: Electric Shock

    F-91 TROUBLESHOOTING & REPAIR STATIC CAPACITOR BALANCE TEST (continued) WARNING ELECTRIC SHOCK can kill. With input supply power ON, there are high voltages inside the machine. Do not reach into the machine or touch any internal part of the machine, including resistors R9 and R10. Use insulated gloves to measure the resistance across these resistors.
  • Page 152 F-92 TROUBLESHOOTING & REPAIR Figure F.31 – SNUBBER AND BLEEDER RESISTOR WIRING DIAGRAM SNUBBER AND BLEEDER RESISTOR WIRING DIAGRAM SWITCH BOARD SWITCH BOARD SWITCH BOARD SWITCH BOARD (401) (12E) (12A) TO RECONNECT SWITCH (402) (9E) (9A) TO RECONNECT SWITCH (403) (12F) (12B) TO RECONNECT SWITCH...

  • Page 153: Dynamic Capacitor Balance Test

    TROUBLESHOOTING & REPAIR DYNAMIC CAPACITOR BALANCE 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 elec- trical shock, please observe all safety notes and precautions detailed throughout this manual.

  • Page 154: Top View

    F-94 TROUBLESHOOTING & REPAIR DYNAMIC CAPACITOR BALANCE TEST (continued) FIGURE F.32- CONTROL BOARD PLUG LOCATIONS PROTECTION BD GROUND PLANE CONTROL BD TEST PROCEDURE 1. Remove main input supply power to the machine. 2. With the 3/8" nut driver, remove the 4 screws that hold the handle to the machine.
  • Page 155 F-95 TROUBLESHOOTING & REPAIR DYNAMIC CAPACITOR BALANCE TEST (continued) WARNING ELECTRIC SHOCK can kill. With input power ON, there are high voltages inside the machine, including the pro- tection board. Do not reach into the machine or touch any internal part of the machine while power is ON.
  • Page 156 F-96 F-96 TROUBLESHOOTING & REPAIR FIGURE F.33 – INPUT AND RECONNECT WIRING DIAGRAM POWER WAVE 450...

  • Page 157: Internal And Auxiliary Supply Voltage Test

    TROUBLESHOOTING & REPAIR INTERNAL AND AUXILIARY SUPPLY VOLTAGE 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 elec- trical shock, please observe all safety notes and precautions detailed throughout this manual.
  • Page 158 F-98 TROUBLESHOOTING & REPAIR INTERNAL AND AUXILIARY SUPPLY VOLTAGE TEST (continued) TEST PROCEDURE 1. Remove main input supply power to the machine. 2. With the 3/8" nut driver, remove the 4 screws that hold the handle to the machine. 3. Remove the rubber gasket (cover seal) from the lift bail.
  • Page 159 F-99 TROUBLESHOOTING & REPAIR INTERNAL AND AUXILIARY SUPPLY VOLTAGE TEST (continued) C. Protection Board: 115 VAC Between J34 - pin 8 and J34 - pin 12 (Power Wave 450 only) 42 VAC Between J34 - pin 10 and J34 - pin 12 24 VAC Between J34 - pin 11 and J34 - pin 12...
  • Page 160 F-100 TROUBLESHOOTING & REPAIR INTERNAL AND AUXILIARY SUPPLY VOLTAGE TEST (continued) 13. With the Volt/ohmmeter, check the follow- ing leads for continuity: A. Between the Protection Board and Wire Feeder 2 Receptacle: Lead #32D Between J34 - pin 5 and P82 - pin A Lead #32E Between J34 - pin 6 and P82...
  • Page 161 F-101 TROUBLESHOOTING & REPAIR FIGURE F.34 – INTERNAL AUXILIARY SUPPLY WIRING DIAGRAM TRIG TRIG 105A 115V 102B COMMON COMMON TRIG 106A 115V 102D COMMON COMMON POWER WAVE 450 F-101...
  • Page 162 F-102 F-102 NOTES POWER WAVE 450...

  • Page 163: Main Contactor Test

    F-103 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 elec- trical shock, please observe all safety notes and precautions detailed throughout this manual.
  • Page 164 F-104 TROUBLESHOOTING & REPAIR MAIN CONTACTOR TEST (continued) TEST PROCEDURE 1. Remove main input supply power to the machine. 2. With the 3/8" nut driver, remove the 4 screws that hold the handle to the machine. 3. Remove the rubber gasket (cover seal) from the lift bail.
  • Page 165 F-105 TROUBLESHOOTING & REPAIR MAIN CONTACTOR TEST (continued) A. With the power switch SW1 OFF, check to see if leads L1A and L3A are shorted together. If they are shorted, visually inspect the leads. If the leads are okay, then power switch SW1 is faulty and must be replaced.
  • Page 166 F-106 F-106 TROUBLESHOOTING & REPAIR FIGURE F.36 – INPUT AND RECONNECT WIRING DIAGRAM POWER WAVE 450...

  • Page 167: Serial Loop Wiring Harness Test

    TROUBLESHOOTING & REPAIR SERIAL LOOP WIRING HARNESS 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 elec- trical shock, please observe all safety notes and precautions detailed throughout this manual.
  • Page 168 F-108 TROUBLESHOOTING & REPAIR SERIAL LOOP WIRING HARNESS TEST (continued) FIGURE F.37 - WIRE FEEDER AMPHENOL LOCATIONS 1. WIRE FEEDER CONNECTIONS (ON BACK PANEL) TEST PROCEDURE 1. Remove main input supply power to the machine. 2. With the 3/8" nut driver, remove the 4 screws that hold the handle to the machine.
  • Page 169 F-109 TROUBLESHOOTING & REPAIR SERIAL LOOP WIRING HARNESS TEST (continued) B. Check for loose or broken leads between the following pins: P83 - pin L and J27 - pin 1 on the control board (lead #111A) P83 - pin M and J27 - pin 4 on the control board (lead #112A) C.
  • Page 170 F-110 TROUBLESHOOTING & REPAIR FIGURE F.38 – SERIAL LOOP WIRING DIAGRAM Serial Loop Master Transmit & Receive Lines Display Board Port Switch Open: DK Board S.L. Comunication enabled Closed: DK Board S.L. Comunication disabled Port Switch Open: WF1 S.L. Comunication enabled Closed: WF1 S.L.

  • Page 171: Wire Feeder 1 Trigger Circuit Test

    TROUBLESHOOTING & REPAIR WIRE FEEDER 1 TRIGGER CIRCUIT 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 elec- trical shock, please observe all safety notes and precautions detailed throughout this manual.
  • Page 172 F-112 TROUBLESHOOTING & REPAIR WIRE FEEDER 1 TRIGGER CIRCUIT TEST (continued) FIGURE F.39 - DISPLAY BOARD PLUG LOCATIONS J16 J15 TEST PROCEDURE 1. Remove main input supply power to the machine. 2. With the 3/8" nut driver, remove the 4 screws that hold the handle to the machine.

  • Page 173: Electric Shock Can Kill

    F-113 TROUBLESHOOTING & REPAIR WIRE FEEDER 1 TRIGGER CIRCUIT TEST (continued) 11. Remove plug J30 from the protection board. See Figure F.1 for location of the board and plug J30. WARNING ELECTRIC SHOCK can kill. With the input power ON, there are high voltages inside the machine.
  • Page 174 F-114 F-114 TROUBLESHOOTING & REPAIR FIGURE F.40 – TRIGGER CIRCUIT WIRING DIAGRAM (296) (293) POWER WAVE 450...

  • Page 175: Wire Feeder 2 Trigger Circuit Test

    TROUBLESHOOTING & REPAIR WIRE FEEDER 2 TRIGGER CIRCUIT 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 elec- trical shock, please observe all safety notes and precautions detailed throughout this manual.
  • Page 176 F-116 TROUBLESHOOTING & REPAIR WIRE FEEDER 2 TRIGGER CIRCUIT TEST (continued) FIGURE F.41 - DISPLAY BOARD PLUG LOCATIONS J16 J15 TEST PROCEDURE 1. Remove main input supply power to the machine. 2. With the 3/8" nut driver, remove the 4 screws that hold the handle to the machine.
  • Page 177 F-117 TROUBLESHOOTING & REPAIR WIRE FEEDER 2 TRIGGER CIRCUIT TEST (continued) 11. Remove plug J30 from the protection board. See Figure F.1 for location of the board and plug J30. WARNING ELECTRIC SHOCK can kill. With the input power ON, there are high voltages inside the machine.
  • Page 178 F-118 F-118 TROUBLESHOOTING & REPAIR FIGURE F.42 – TRIGGER CIRCUIT WIRING DIAGRAM (296) (293) POWER WAVE 450...

  • Page 179: Trigger Circuit And Wiring Harness Test

    TROUBLESHOOTING & REPAIR TRIGGER CIRCUIT AND WIRING HARNESS 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 elec- trical shock, please observe all safety notes and precautions detailed throughout this manual.
  • Page 180 F-120 TROUBLESHOOTING & REPAIR TRIGGER CIRCUIT AND WIRING HARNESS TEST (continued) FIGURE F.43 - PROTECTION BOARD PLUG/HEADER LOCATIONS PROTECTION BD TEST PROCEDURE 1. Remove main input supply power to the machine. 2. With the 3/8" nut driver, remove the 4 screws that hold the handle to the machine.
  • Page 181 F-121 TROUBLESHOOTING & REPAIR AUXILIARY TRANSFORMER #1 SECONDARY CIRCUIT WIRING DIAGRAM COMMON COMMON COMMON TRIG TRIG TRIG TRIG 115V COMMON COMMON TRIG 115V COMMON COMMON FIGURE F.44 105A 102B 106A 102D POWER WAVE 450 F-121...
  • Page 182 F-122 F-122 NOTES POWER WAVE 450...

  • Page 183: Internal Remote Control Test

    TROUBLESHOOTING & REPAIR INTERNAL REMOTE CONTROL 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 elec- trical shock, please observe all safety notes and precautions detailed throughout this manual.
  • Page 184 F-124 TROUBLESHOOTING & REPAIR INTERNAL REMOTE CONTROL TEST (continued) FIGURE F.45 - DISPLAY BOARD PLUG LOCATIONS J16 J15 TEST PROCEDURE 1. Remove main input supply power to the machine. 2. With the 3/8" nut driver, remove the 4 screws that hold the handle to the machine. 3.
  • Page 185 F-125 TROUBLESHOOTING & REPAIR INTERNAL REMOTE CONTROL TEST (continued) WARNING ELECTRIC SHOCK can kill. With input power ON, there are high voltages inside the machine, including the pro- tection board. Do not reach into the machine or touch any internal part. 10.
  • Page 186 F-126 F-126 TROUBLESHOOTING & REPAIR FIGURE F.46 – TRIGGER CIRCUIT WIRING DIAGRAM (296) (293) POWER WAVE 450...

  • Page 187: K941-1 Remote Control Kit Test

    TROUBLESHOOTING & REPAIR K941-1 REMOTE CONTROL KIT 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 elec- trical shock, please observe all safety notes and precautions detailed throughout this manual.
  • Page 188 F-128 TROUBLESHOOTING & REPAIR K941-1 REMOTE CONTROL KIT TEST (continued) FIGURE F.47 - 6-PIN AMPHENOL LOCATION 1. MACHINE FRONT PANEL 2. REMOTE CONTROL AMPHENOL RECEPTACLE (6-PIN) TEST PROCEDURE 1. Remove the Remote Control Kit from the power source. 2. Perform the following tests. If any test fails, the Remote Control Kit is faulty and should be replaced.
  • Page 189 F-129 F-129 TROUBLESHOOTING & REPAIR FIGURE F.48 – TRIGGER CIRCUIT WIRING DIAGRAM (296) (293) POWER WAVE 450...
  • Page 190 F-130 F-130 NOTES POWER WAVE 450...

  • Page 191: K941-1 Remote Control Kit Trigger Circuit Test

    TROUBLESHOOTING & REPAIR K941-1 REMOTE CONTROL KIT TRIGGER CIRCUIT 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 elec- trical shock, please observe all safety notes and precautions detailed throughout this manual.
  • Page 192 F-132 TROUBLESHOOTING & REPAIR K941-1 REMOTE CONTROL KIT TRIGGER CIRCUIT TEST (continued) FIGURE F.49 - DISPLAY BOARD PLUG LOCATIONS J16 J15 TEST PROCEDURE NOTE: Before troubleshooting the remote con- trol trigger circuit, troubleshoot the remote control kit itself. Refer to the K941-1 Remote Control Kit Test in this section of the manual.
  • Page 193 F-133 TROUBLESHOOTING & REPAIR K941-1 REMOTE CONTROL KIT TRIGGER CIRCUIT TEST (continued) 11. Remove plug J30 from the protection board. See Figure F.1 for location of the board and plug J30. WARNING ELECTRIC SHOCK can kill. With the input power ON, there are high volt- ages inside the machine.
  • Page 194 F-134 F-134 TROUBLESHOOTING & REPAIR FIGURE F.50 – TRIGGER CIRCUIT WIRING DIAGRAM (296) (293) POWER WAVE 450...

  • Page 195: Lcd Display Test

    F-135 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 elec- trical shock, please observe all safety notes and precautions detailed throughout this manual.
  • Page 196 F-136 TROUBLESHOOTING & REPAIR FIGURE F.51 - DISPLAY BOARD PLUG LOCATIONS J16 J15 TEST PROCEDURE 1. Remove main input supply power to the machine. 2. With the 3/8" nut driver, remove the 4 screws that hold the handle to the machine. 3.
  • Page 197 F-137 TROUBLESHOOTING & REPAIR WARNING ELECTRIC SHOCK can kill. With input power ON, there are high voltages inside the machine. Do not reach into the machine or touch any internal part. 10. Turn input power ON. 11. With the volt/ohmmeter, check the follow- ing voltages between plug J16 pins at the display board (without removing plug J16 from the display board):...
  • Page 198 F-138 TROUBLESHOOTING & REPAIR FIGURE F.52 – INTERNAL AUXILIARY SUPPLY WIRING DIAGRAM TRIG TRIG 105A 115V 102B COMMON COMMON TRIG 106A 115V 102D COMMON COMMON POWER WAVE 450 F-138...

  • Page 199: Calibration Procedures

    F-139 F-139 TROUBLESHOOTING & REPAIR CALIBRATION PROCEDURES POWER WAVE PC BOARD REPLACEMENT CALIBRATION PROCEDURES If the display board is replaced, the display sensor cal- ibration and a voltage calibration must be performed for optimum performance. If the calibration is not done the voltage may be accurate only to within 3 volts.
  • Page 200 F-140 F-140 NOTES POWER WAVE 450...

  • Page 201: Sensor Calibration Test (For Display Board

    TROUBLESHOOTING & REPAIR SENSOR CALIBRATION TEST (FOR DISPLAY BOARD) 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 elec- trical shock, please observe all safety notes and precautions detailed throughout this manual.

  • Page 202: Select A Function

    F-142 TROUBLESHOOTING & REPAIR SENSOR CALIBRATION TEST (FOR DISPLAY BOARD) (continued) FIGURE F.53 - SENSOR LOCATION BEHIND OVERLAY 1. LEADS 300, 301 TO PLUG J15 ON DISPLAY BOARD 2. PIEZO-ELECTRIC ALARM BUZZER PROCEDURE 1. Turn the machine ON with no overlay in place.

  • Page 203: Quick Voltage Calibration

    TROUBLESHOOTING & REPAIR QUICK VOLTAGE CALIBRATION 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 elec- trical shock, please observe all safety notes and precautions detailed throughout this manual.
  • Page 204 F-144 TROUBLESHOOTING & REPAIR QUICK VOLTAGE CALIBRATION (continued) FIGURE F.54 - TEST AND CALIBRATION OVERLAY PROCEDURE 1. Before changing or disturbing the display board, power up the machine with the L9660-255 Test and Calibration overlay in place. See Figure F.54. 2.

  • Page 205: Full Voltage Calibration

    TROUBLESHOOTING & REPAIR FULL VOLTAGE CALIBRATION 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 elec- trical shock, please observe all safety notes and precautions detailed throughout this manual.
  • Page 206 F-146 TROUBLESHOOTING & REPAIR FULL VOLTAGE CALIBRATION(continued) FIGURE F.55 - TEST AND CALIBRATION OVERLAY PROCEDURE 1. The voltage calibration numbers are stored in the display board. They are program- mable from the front panel using the Test and Calibration Overlay. 2.

  • Page 207: Full Voltage Calibration Using A Welding Arc

    TROUBLESHOOTING & REPAIR FULL VOLTAGE CALIBRATION USING A WELDING ARC 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 elec- trical shock, please observe all safety notes and precautions detailed throughout this manual.
  • Page 208 F-148 TROUBLESHOOTING & REPAIR FULL VOLTAGE CALIBRATION(continued) FIGURE F.55a - TEST AND CALIBRATION OVERLAY PROCEDURE 1. The voltage calibration numbers are stored in the display board. They are programma- ble from the front panel using the Test and Calibration Overlay. 2.
  • Page 209 F-149 TROUBLESHOOTING & REPAIR FULL VOLTAGE CALIBRATION(continued) – POLARITY (+21A) + POLARITY – POLARITY NOTE: Do not attempt to weld for –Polarity (+21A). Set the number to the same as recorded for +Polarity (+67A). Also for +Polarity and –Polarity, move the volt- meter sense lead from the conductor block of the wire feeder to the positive output terminal on the front of the...
  • Page 210 F-150 F-150 NOTES POWER WAVE 450...

  • Page 211: Current Calibration

    F-151 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 elec- trical shock, please observe all safety notes and precautions detailed throughout this manual.
  • Page 212 F-152 TROUBLESHOOTING & REPAIR CURRENT CALIBRATION (continued) 2. Locate the 10 turn trimmer potentiometer located on the control board. It is the only trimmer on the board. If the trimmer is not accessible with the control board installed, then the board must be removed and laid on the top of the PC board compartment.
  • Page 213 F-153 TROUBLESHOOTING & REPAIR CURRENT CALIBRATION (continued) FIGURE F.58 – TEST AND CALIBRATION OVERLAY PROCEDURE 1. Install the Test and Calibration Overlay and apply power to the machine. See Figure F.58. 2. Press the Manual Procedure Entry Key (64). The machine should display the following: PROCESS 1 SETUP 3.
  • Page 214 F-154 F-154 NOTES POWER WAVE 450...

  • Page 215: T1 Auxiliary Transformer Removal And Replacement

    TROUBLESHOOTING & REPAIR T1 AUXILIARY TRANSFORMER 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 elec- trical shock, please observe all safety notes and precautions detailed throughout this manual.
  • Page 216 F-156 TROUBLESHOOTING & REPAIR T1 AUXILIARY TRANSFORMER REMOVAL AND REPLACEMENT (continued) FIGURE F.59 - T1 AUXILIARY TRANSFORMER LOCATION 1. AUXILIARY TRANSFORMER T1 2. MOUNTING SCREW (2) PROCEDURE 1. Remove main input supply power to the machine. 2. With the 3/8" nut driver, remove the 4 screws that hold the handle to the machine.

  • Page 217: Water Cooler Removal And Replacement

    For later model coolers (Inlet & Outlet on lower left of machine back) 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.
  • Page 218 F-158 TROUBLESHOOTING & REPAIR WATER COOLER REMOVAL AND REPLACEMENT (continued) FIGURE F.60 - WATER COOLER LOCATION PROCEDURE NOTE: These instructions may vary slightly with later model coolers. See instruc- tions included with cooler kit. 1. Remove main input supply power to the machine.
  • Page 219 F-159 TROUBLESHOOTING & REPAIR WATER COOLER REMOVAL AND REPLACEMENT (continued) 10. With the 9/16" open end wrench, remove the circuit breaker. 11. Locate and disconnect plug J4, behind the water cooler. Plug J 4, a large molex plug, has two leads (H1A and H3A). Double-check that these are the leads feeding the plug;...
  • Page 220 F-160 F-160 NOTES POWER WAVE 450...

  • Page 221: Water Cooler Disassembly

    TROUBLESHOOTING & REPAIR WATER COOLER DISASSEMBLY 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 elec- trical shock, please observe all safety notes and precautions detailed throughout this manual.
  • Page 222 F-162 TROUBLESHOOTING & REPAIR WATER COOLER DISASSEMBLY (continued) FIGURE F.61 - WATER COOLER DISASSEMBLY (EARLY MODEL) PROCEDURE 1. Remove main input supply power to the machine. 2. With the 3/8" nut driver, remove the 4 screws that hold the handle to the machine. 3.
  • Page 223 F-163 TROUBLESHOOTING & REPAIR WATER COOLER DISASSEMBLY (continued) Reservoir Removal A. After you have completed the capacitor discharge procedure for all four switch boards, remove the water cooler assembly. Refer to the Water Cooler Removal and Replacement Procedure in this section of the manual.
  • Page 224 F-164 F-164 NOTES POWER WAVE 450...

  • Page 225: T2 Auxiliary Transformer Removal And Replacement

    TROUBLESHOOTING & REPAIR T2 AUXILIARY TRANSFORMER 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 elec- trical shock, please observe all safety notes and precautions detailed throughout this manual.
  • Page 226 F-166 TROUBLESHOOTING & REPAIR T2 AUXILIARY TRANSFORMER REMOVAL AND REPLACEMENT (continued) FIGURE F.62 - T2 AUXILIARY TRANSFORMER LOCATION 1. BASE 2. AUXILIARY TRANSFORMER T2 3. MOUNTING SCREW (2) PROCEDURE 1. Remove main input supply power to the machine. 2. With the 3/8" nut driver, remove the 4 screws that hold the handle to the machine.

  • Page 227: Fan Motor Removal And Replacement

    TROUBLESHOOTING & REPAIR FAN MOTOR 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 elec- trical shock, please observe all safety notes and precautions detailed throughout this manual.
  • Page 228 F-168 TROUBLESHOOTING & REPAIR FAN MOTOR REMOVAL AND REPLACEMENT (continued) FIGURE F.63 - FAN MOTOR LOCATION PROCEDURE 1. Remove main input supply power to the machine. 2. With the 3/8" nut driver, remove the 4 screws that hold the handle to the machine. 3.
  • Page 229 F-169 TROUBLESHOOTING & REPAIR FAN MOTOR REMOVAL AND REPLACEMENT (continued) FIGURE F.64 - MACHINE BACK SECURED TO LIFT BAIL. 11. With the 3/4" wrench, remove the lead connected to the rear positive (+) output terminal. 12. Swing the back panel up and secure it to the lift bail.
  • Page 230 F-170 F-170 NOTES POWER WAVE 450...

  • Page 231: 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 elec- trical shock, please observe all safety notes and precautions detailed throughout this manual.
  • Page 232 F-172 TROUBLESHOOTING & REPAIR INPUT RECTIFIER REMOVAL AND REPLACEMENT (continued) FIGURE F.65 - INPUT RECTIFIER LOCATION PROCEDURE 1. Remove main input supply power to the machine. 2. With the 3/8" nut driver, remove the 4 screws that hold the handle to the machine. 3.
  • Page 233 F-173 TROUBLESHOOTING & REPAIR INPUT RECTIFIER REMOVAL AND REPLACEMENT (continued) 10. With the 5 mm Allen wrench and the 10 mm open end wrench, remove the two screws mounting the input rectifier to the heat sink panel. 11. When replacing the input rectifier, apply a thin, even coating of Dow Corning 340 Joint Compound (Lincoln T12837) to the mating surfaces between the input rectifi-...
  • Page 234 F-174 F-174 NOTES POWER WAVE 450...

  • Page 235: Printed Circuit Board Removal And Replacement

    PRINTED CIRCUIT BOARD REMOVAL AND REPLACEMENT (CONTROL BOARD, POWER BOARD, 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 elec- trical shock, please observe all safety notes and precautions detailed throughout this manual.
  • Page 236 F-176 TROUBLESHOOTING & REPAIR PRINTED CIRCUIT BOARD REMOVAL AND REPLACEMENT (CONTROL BOARD, POWER BOARD, AND PROTECTION BOARD) (continued) PROCEDURE 1. Remove main input supply power to the machine. 2. With the 3/8" nut driver, remove the 4 screws that hold the handle to the machine. 3.
  • Page 237 F-177 TROUBLESHOOTING & REPAIR PRINTED CIRCUIT BOARD REMOVAL AND REPLACEMENT (CONTROL BOARD, POWER BOARD, AND PROTECTION BOARD) (continued) CAUTION Be sure to follow the recommended static-free methods for handling printed circuit boards. Failure to do so can result in permanent dam- age to the equipment.
  • Page 238 F-178 F-178 NOTES POWER WAVE 450...

  • Page 239: Display Board Removal And Replacement

    TROUBLESHOOTING & REPAIR DISPLAY 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 elec- trical shock, please observe all safety notes and precautions detailed throughout this manual.
  • Page 240 F-180 TROUBLESHOOTING & REPAIR DISPLAY BOARD REMOVAL AND REPLACEMENT (continued) FIGURE F.68 - DISPLAY BOARD REMOVAL 1. MOLEX PLUG HEADERS (8) 2. KEY PAD RIBBON CONNECTOR 3. LCD DISPLAY WINDOW 4. LCD CONNECTOR 5. MOUNTING PIN HOLE NOTE: Before changing or disturbing the dis- play board follow the procedure outlined under QUICK VOLTAGE CALIBRATION (Fig.
  • Page 241 F-181 TROUBLESHOOTING & REPAIR DISPLAY BOARD REMOVAL AND REPLACEMENT (continued) 8. Carefully remove the key pad ribbon con- nector from the right side of the display board. 9. Carefully remove the connector to the LCD display. CAUTION Do not touch the sensors located on the left side of the display board when you handle it for removal or replacement.
  • Page 242 F-182 F-182 NOTES POWER WAVE 450...

  • Page 243: Main Input Contactor (Cr1) Removal And Replacement

    TROUBLESHOOTING & REPAIR MAIN INPUT CONTACTOR (CR1) REMOVAL 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 elec- trical shock, please observe all safety notes and precautions detailed throughout this manual.
  • Page 244 F-184 TROUBLESHOOTING & REPAIR MAIN INPUT CONTACTOR (CR1) REMOVAL AND REPLACEMENT (continued) PROCEDURE 1. Remove main input supply power to the machine. 2. With the 3/8" nut driver, remove the 4 screws that hold the handle to the machine. 3. Remove the rubber gasket (cover seal) from the lift bail.
  • Page 245 F-185 TROUBLESHOOTING & REPAIR MAIN INPUT CONTACTOR (CR1) REMOVAL AND REPLACEMENT (continued) 9. With the slot head screw driver, remove the two small leads (T1 and T3) from the output side of the contactor. 10. With the slot head screw driver, remove the two contactor coil leads (#324 and #326) from the contactor.
  • Page 246 F-186 F-186 NOTES POWER WAVE 450...

  • Page 247: Output Rectifier Bridge Removal And Replacement

    TROUBLESHOOTING & REPAIR OUTPUT RECTIFIER BRIDGE REMOVAL 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 elec- trical shock, please observe all safety notes and precautions detailed throughout this manual.
  • Page 248 F-188 TROUBLESHOOTING & REPAIR OUTPUT RECTIFIER BRIDGE REMOVAL AND REPLACEMENT (continued) FIGURE F.70 - OUTPUT RECTIFIER BRIDGE LOCATION PROCEDURE 1. Remove main input supply power to the machine. 2. With the 3/8" nut driver, remove the 4 screws that hold the handle to the machine. 3.
  • Page 249 F-189 TROUBLESHOOTING & REPAIR OUTPUT RECTIFIER BRIDGE REMOVAL AND REPLACEMENT (continued) 9. Cut all necessary cable ties on the right side of the machine and disconnect all necessary leads (two heavy and two small leads) from the right side of the output rectifier bridge.
  • Page 250 F-190 TROUBLESHOOTING & REPAIR OUTPUT RECTIFIER BRIDGE REMOVAL AND REPLACEMENT (continued) FIGURE F.72 – CABLE TIE LOCATIONS PRIMARY HARNESS ASSEMBLY (BLACK) 13. For reassembly, attach the glastic insulat- ed angle mounting pieces to the heat sink first. Slide the bridge into position and then fasten the bottom tab to the sub- frame with the bolt, split-ring lock washer and nut.

  • Page 251: Fet Module Removal And Replacement

    TROUBLESHOOTING & REPAIR FET 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 elec- trical shock, please observe all safety notes and precautions detailed throughout this manual.
  • Page 252 F-192 TROUBLESHOOTING & REPAIR FET MODULE REMOVAL AND REPLACEMENT (continued) FIGURE F.73 - FET MODULE LOCATION PROCEDURE 1. Remove main input supply power to the machine. 2. With the 3/8" nut driver, remove the 4 screws that hold the handle to the machine. 3.
  • Page 253 F-193 TROUBLESHOOTING & REPAIR FET MODULE REMOVAL AND REPLACEMENT (continued) FIGURE F.74 - LIFT BAFFLE/BAIL REMOVAL 9. With the wire cutters, cut all necessary cable ties. 10. Disconnect the leads to the output rectifi- er bridge. Cut all necessary cable ties. 11.
  • Page 254 F-194 TROUBLESHOOTING & REPAIR FET MODULE REMOVAL AND REPLACEMENT (continued) 21. Remove the water cooler assembly in order to access the retainer clips that hold the bottom of the FET module assembly in place. (Complete removal of the unit should not be necessary.) Refer to the Water Cooler Removal...
  • Page 255 F-195 TROUBLESHOOTING & REPAIR FET MODULE REMOVAL AND REPLACEMENT (continued) 30. Install the water cooler assembly. Refer to the Water Cooler Removal and Replace- ment Procedure in this section of the module. 31. With the 7/16" wrench, connect the heavy current-carrying flat copper strap running from the shunt amplifier to the output rec- tifier bridge.
  • Page 256 F-196 F-196 NOTES POWER WAVE 450...

  • Page 257: Main Transformer Removal And Replacement

    TROUBLESHOOTING & REPAIR MAIN TRANSFORMER 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 elec- trical shock, please observe all safety notes and precautions detailed throughout this manual.
  • Page 258 F-198 TROUBLESHOOTING & REPAIR MAIN TRANSFORMER/CHOKE REMOVAL AND REPLACEMENT (continued) FIGURE F.75 - MAIN TRANSFORMER LOCATION PROCEDURE 1. Remove main input supply power to the machine. 2. With the 3/8" nut driver, remove the 4 screws that hold the handle to the machine. 3.
  • Page 259 PRE-POWERUP SWITCH BOARD TEST PROCEDURE FOR REPLACEMENT OF SWITCH ASSEMBLY G2402-2 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 elec- trical shock, please observe all safety notes and precautions detailed throughout this manual.

  • Page 260: Pre-Powerup Switch Board Test Procedure

    F-200 TROUBLESHOOTING & REPAIR PRE-POWERUP SWITCH BOARD TEST PROCEDURE FOR REPLACEMENT OF SWITCH ASSEMBLY G2402-2 (continued) FILTER CAPACITOR POLARITY TEST 1. Perform this procedure with the input power removed. Perform the CAPACITOR DIS- CHARGE Procedure to remove any charge from the input filter capacitors. 2.
  • Page 261 VOLTMETER 400 VDC VOLTMETER WARNING MAKE SURE FILTER CAPACITORS ARE DISCHARGED 1. Construct a 115VAC pretest power supply as per Figure F.78 using the following: Switch (SPST) Fuse (5 amp max) P70 adapter ALL AC SUPPLIES MUST BE ELECTRICAL- LY ISOLATED (isolation transformers). THE...
  • Page 262 FIGURE F.78 - PRETEST POWER SUPPLY ISOLATED 115 VAC Connect the pretest power supply to plug P70 as per Figure F.78. See wiring diagram. ARC START PW450 WITH WIREFEEDER The arc start may be initiated by any of the follow-...
  • Page 263 F-203 TROUBLESHOOTING & REPAIR PRE-POWERUP SWITCH BOARD TEST PROCEDURE FOR REPLACEMENT OF SWITCH ASSEMBLY G2402-2 (continued) ARC START FOR PW450 ROBOTIC 1. Construct and connect an arc start circuit as per Figure F.79. 2. Install leads and an arc start switch into plug J103 pin 10 to pin 11 on the interface PC board.
  • Page 264 F-204 TROUBLESHOOTING & REPAIR PRE-POWERUP SWITCH BOARD TEST PROCEDURE FOR REPLACEMENT OF SWITCH ASSEMBLY G2402-2 (continued) FIGURE F.80 - PC BOARD RECEPTACLE 1. Unplug P23 and insert jumper plug into PC board receptacle. See Figure F.80. 2. Turn ON the preset power switch. Figure F.78.
  • Page 265 F-205 TROUBLESHOOTING & REPAIR PRE-POWERUP SWITCH BOARD TEST PROCEDURE FOR REPLACEMENT OF SWITCH ASSEMBLY G2402-2 (continued) 20V/Div SNUBBER SIGNAL TEST 1. Adjust the grid for a “light” load. 2. Turn ON the variable AC supply applied to the primary circuit. See Figure F.76. 3.
  • Page 266 F-206 TROUBLESHOOTING & REPAIR PRE-POWERUP SWITCH BOARD TEST PROCEDURE FOR REPLACEMENT OF SWITCH ASSEMBLY G2402-2 (continued) 5V/Div 460VAC RECONNECT 1. Reconfigure the machine for 460VAC operation. 2. Turn ON the variable AC supply applied to the primary circuit. See Figure F.76. 3.
  • Page 267 F-207 TROUBLESHOOTING & REPAIR PRE-POWERUP SWITCH BOARD TEST PROCEDURE FOR REPLACEMENT OF SWITCH ASSEMBLY G2402-2 (continued) 5V/Div 8. Turn the variable AC primary supply to zero volts and then turn it OFF. See Figure F.76. 9. Once the filter capacitor voltage drops to zero, turn the arc start switch OFF.
  • Page 268 F-208 TROUBLESHOOTING & REPAIR PRE-POWERUP SWITCH BOARD TEST PROCEDURE FOR REPLACEMENT OF SWITCH ASSEMBLY G2402-2 (continued) FIGURE F.84 - PRIMARY CURRENT SIGNAL 10V/Div 5. Press the MANUAL PROCEDURE ENTRY Key on the Calibration and Test Overlay and change the Power Wave to “Process 1 Setup 1 -8”...
  • Page 269 TABLE OF CONTENTS ELECTRICAL DIAGRAMS Electrical Diagrams Section...Section G Wiring Diagram ...G-2 Schematic Complete Machine ...G-3 Control PC Board Schematic (1 of 4)...G-4 Control PC Board Schematic (2 of 4)...G-5 Control PC Board Schematic (3 of 4)...G-6 Control PC Board Schematic (4 of 4)...G-7 Control PC Board Assembly ...G-8 Display PC Board Schematic (1 of 2)...G-9 Display PC Board Schematic (2 of 2)...G-10...
  • Page 270 ELECTRICAL DIAGRAMS WIRING DIAGRAM - POWER WAVE 450 NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The wiring diagram specific to your code is pasted inside one of the enclosure panels of your machine. POWER WAVE 450...
  • Page 271 ELECTRICAL DIAGRAMS SCHEMATIC - COMPLETE MACHINE NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. POWER WAVE 450...
  • Page 272 ELECTRICAL DIAGRAMS SCHEMATIC - CONTROL PC BOARD #1 NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. POWER WAVE 450...
  • Page 273 ELECTRICAL DIAGRAMS SCHEMATIC - CONTROL PC BOARD #2 NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. POWER WAVE 450...
  • Page 274 ELECTRICAL DIAGRAMS SCHEMATIC - CONTROL PC BOARD #3 NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. POWER WAVE 450...
  • Page 275 ELECTRICAL DIAGRAMS SCHEMATIC - CONTROL PC BOARD #4 NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. POWER WAVE 450...
  • Page 276 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 277 ELECTRICAL DIAGRAMS SCHEMATIC - DISPLAY PC BOARD (SHEET 1) NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. POWER WAVE 450...
  • Page 278 G-10 G-10 ELECTRICAL DIAGRAMS SCHEMATIC - DISPLAY PC BOARD (SHEET 2) NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. POWER WAVE 450...
  • Page 279 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 280 G-12 G-12 ELECTRICAL DIAGRAMS SCHEMATIC - POWER PRINTED CIRCUIT BOARD NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. POWER WAVE 450...
  • Page 281 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 282 G-14 G-14 ELECTRICAL DIAGRAMS SCHEMATIC - PROTECTION PRINTED CIRCUIT BOARD NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. POWER WAVE 450...
  • Page 283 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 284 G-16 SCHEMATIC -SQUARE WAVE PROTECTION PRINTED CIRCUIT BOARD ELECTRICAL DIAGRAMS NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. EQUIP. THE LINCOLN ELECTRIC CO. TYPE CLEVELAND, OHIO U.S.A. SUBJECT SCALE SHT.
  • Page 285 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 286 G-18 G-18 ELECTRICAL DIAGRAMS SCHEMATIC - SHUNT PRINTED CIRCUIT BOARD NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. POWER WAVE 450...
  • Page 287 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 288 G-20 G-20 ELECTRICAL DIAGRAMS SCHEMATIC - SNUBBER PRINTED CIRCUIT BOARD NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. POWER WAVE 450...
  • Page 289 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 290 G-22 G-22 ELECTRICAL DIAGRAMS SCHEMATIC-SWITCH PRINTED CIRCUIT BOARD NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. POWER WAVE 450...
  • Page 291 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 292: Electrical Diagrams

    MODEM CABLE NOTE: Lincoln Electric assumes no responsibility for liabilities resulting from board level troubleshooting. PC Board repairs will invalidate your factory warranty. This Printed Circuit Board schematic is provided for reference only. It may not be totally applicable to your machine’s specific PC board version. This dia- gram is intended to provide general information regarding PC board function.
  • Page 293 Your Company__________________________ Your Name_____________________________ Please give detailed description below: ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ SD287 01/99 Thank You, Technical Services Group Lincoln Electric Co. 22801 ST. Clair Ave. Cleveland, Ohio 44117-1199 FAX 216-481-2309...

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