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Lincoln Electric SVM159-A User's Manual

Contents

1.
2. 68LE9 JE Y 1 1 E RES 9 3 5 SHT 3 o o RS R10 1 45V 0 09 757 fh o gt MISCO 1 ui R16 6 11 1937 2761 72 86 89 109 121 135 144 25 E FR 3 pr 51100 5V SHT 4 R42 SA 1009 RISK c94 107 C105 C93 C109 C106 X24 cus c110 _ 120 18 o 15 R18 7 10 01 01 01 01 22 22 01 01 1 gio Ny n Pm Tav Tso 509 509 683320 25 T dv Tso Tso 2 1000 I 2 12 20 35 48
3. 68LE9 22 2 15V 5V o Ju 15V 12 SHT 13 9 gt 3 ao 4 RS232 RXD 1 22K ES VHCL4D da 014 Pad RS232 TXD ird 18v d M 2 Ta 3W x10 01 X30 01 Si i 50V Bs 50V VHC14D 5 5 un VE VHC140 VHCLUD 4 GREEN 7 7 we t gt SHT 134 m M 5 45485232 EUM D 18V D63 5VRS232 3v LED2 d T 00 TP7 AM fa As m m _fe Ww 5 3 790 50V ge 8 5 15 50 a N T av gt SHT 3 V ors232 45 15V E 8132 4 6 6 200 96 046 5 8 2 62V 5V 9 5 12 odi MC145407DWw ps3 1 X HCPLO601 H
4. ill a 68le9 n 0 R110 25V 099 E zio NES 1 TTSK 2 Tel 74 700v e d 13 o gt 20 ESERE x20 DATAIO 13I C86 Em DATAIO 1 05 270022 ERIT Riaz 12 5s 3 8 100 45VA 9 50 S 100K 25V 08015 AD DATAIOI amp 5 c 040 pai 2 1 D 50V 075 08213 AD_DATAIZI SHT 1 MOSI 12 507 WSLS 5 5 SW tate D RIA3 13 0832 AO 58120 D 100K SHT STROBE_AD 8 coNVST m AD_DATAI41 SHT 4 POT CS 1 11 TS 600 13 2 tc 14 vs ces Ales 08510 AD DATAISI 53v SA AD CS 20 08619 AD DATAI6I Sw 20 xis 087 6 DATAITI A D CONVERSION 02 23 vai 088
5. 68469 5 5 15 OSP_READY 36 5V gt DSP READY _34 pe apy o gt SHT 2 e EPUM SHT 1 SHT 1 E 50 vccp w bis Rw DSP REN olo smi OUTPUT ON 74 An INO wi DSP_WE sur A 13 ADCINL IOPAZ 05129 015825 c 1 3 SHT 3 14 ADCIN2 31 05855 15 Ve 5 1 139 rois Voies 185 DATA 78 15 130 SEES SHT 1 15 141 170184 184 16 ST S SHT 2 tl 55 1 SHT 1 d 142 170142 votes 181 R W SHT 1 apciNS wafe 2 2 smi 207 acr packs 160 smi DSP 01101 148 0145 1701601 ADDRILLI 78 ADCIN6 BRL DSP_CLK 2 157 DSP DI91 146 179 ADDRILOI 79 x2 94 415581 PGCKL 0 700 mm 1 0146 1 0179 212 Ami ADCIN7 PWM1 CMPL gt SHT 1 SHT 2 15SPI 25 WES
6. e J22 24016 4 ONNECTOR MOLEX MINI PCB RT L 4 PIN 285 2 515000 22__ OPTOCOUPLER PHOTO Q OV CNY17 3 VDE M 1 15000 29 OPTOCOUPLER 6007 2 OF T12704 75 TRANSISTOR 1247 AA 9001 55 A 92 03 0405 712704 73 MOSFET 4 PIN DIP 1A 100V HEIGHT NON COMPONENT Q6 112704 69 TRANSISTOR PNP TO226 0 5A 40 2 4403 SIDE RTRZRSRARTRSRSRIO 7146485 RESISTOR WW 5W 3 3K 5 5 SQ R124 R125 R126 R127 R130 EYELET DETAIL R131 R132 R133 peu RR ta 519400 16 9400 39R 9 R15 R20 R21 R22 R27 R28 819400 1080 RESISTOR MF 1 4W 10 0 1 8 PLACES R97 R98 R99 R100 R101 R106 R29 1 OR MF T 4W T 4 3 5 R49 R50 OR MF T 2W TUOUK R51 R62 R63 R74 R75 R85 R86 R87 R134 R135 R66 R69 R70 R72 R80 R82 R142 R143 puu e psc Tak Return to Section TOC Return to Master TOC 519400 4752 RESISTOR MF 1 2W47 5K 1 i
7. RECONNECT 201 Ra 126 33K 5M NO FILTER l 5 202 203 106 297 BDLT DN WITH FILTER CAPS NEGATIVE 217 1 JNP T RECTIFIER Abs m 2 166K 8 Vk UM B CuM A C22 15bpF 100V DU 4 33174A x3 T 2 33174A AU 3 31174A 975 R43 TDDK 332K 2 eo 11 11 Vh V F CONVERTER 2 DENERRL INFORMATION LAST NI WEED 1 SUPPLY VOLTAGE NET 1 4 H z 0 SUPPLY SOURCE POINT RRMA x D H r3 c 1 4W UNLESS OTHERWISE SPECIFIED MFO 1 072 54 UNLESS OTHERWISE SPECIFIED ILINLESS DTHEFWISE SPECIFIED Ohms t ELECTRICAL SYMBOLS PER E1537 CAPACITORS RESISTORE DIODES Z21 5VOKIAP 589VDC AT VREF 1 449 2
8. 64 DSP CLK we 1 1 070 1 076 sur 3 OSP 00 15 3 50 MISC 72 rs MISCO 05 1151 EMUD XE AOPC2 7 7 SHT 1 1 072 1 075 SHT 1 3 1 AT25128 SHT 3 TURN OFF_N 1317073 8 SHT 1 Eni 3 M 052 00 9 5 rue s CAPL GEPL IDPCA SHT 1 05 011 T OSS MP 31 Mp AC CAP2 0EP2 I0PCS SHT 1 1 ______05 0 54 A 05 2 DSP AUZI 151 5 8 fe 2 05 CAP3 10PC6 SHT 1 05 013 m RB S S 5 zi VREFLO CAPL IDPCT SHT 1 PSWI0 7 a 1203 DSP AGI E 21 584 100K 9 42 RESERVED XTAL2 57 08 DIA 1904 15 05 706 ET 0151 1605 As 116 DSP AI 81815818 8 TMS320F240 z miim lel zie 98 1 0 138 Hee 6 117 DSP AI6L DM m E 96 1 0138 137 05 1171 185 11118 DSP AUI 3 hook 1 097 1 0137 DSP DIB x22 x lg m PSWIZI 98 136 19 asl x x s 1 098 1 0136 05 019 8 2 15 15 5 8 5 135 1 2209 TMS320F240 9 122 Ps 215 a 3 3 8 3 S m 1 099 1 0135 0101 23010 Ato 123 100170100 170134 134 DsP Diil 24 ras DSP ADD 15 si SHT 3 MSELEN 101 0101 133 Du Aul 515 1 010 1 0133 5 0121 28 125 PSWIOI TUI 107 170107 170132 22 02 AE an Xem S Si DSP DI13 26 126 05 _ 13 o 109 129 AD_DATAIL3I 013 Voom 1010 1 0129 05 01141 2
9. Section E Troubleshooting and Section F How to Use Troubleshooting A 2 Troubleshooting GUIDE F 4 TeSt 5 15 Replacement Procedures 47 Electrical 5 Section Parts reU RR ERREUR M P 401 Series POWER WAVE 355 405 LINCOLN 5 SectionA 1 Section A 1 TABLE OF CONTENTS INSTALLATION SECTION S Installation gt g Technical Specifications 355 n A 2 2 Technical Specifications 405 3 Safety 5 eee cr rt Phy Le 4 SLACKING ess M M 4 N 4 Input Grounding Connections 1 nennen nennen neret rnn nennen nennt nennen 4 Power Cord 2 ra 4 8 Output Cables Connections and Limitations A 5 Negative Electrode Polarity 5
10. G 13 40 VDC BUSS PC BOARD ASSEMBLY 111832 NOTE Many PC Board Assemblies are now totally encapsulated and are therefore considered to be unservice able The Assembly numbers are provided on this page but the actual drawings are no longer included Return to Master TOC Q 2 0 2 5 Return to Master TOC POWER WAVE 355 405 LINCOLN 5 6 2 ELECTRICAL DIAGRAMS G2 WIRING DIAGRAM POWER WAVE 355 405 RIGHT SIDE OF MACHINE FLAT SIDE OF LED ALIGNED WITH BLACK LEAD Return to Section TOC Return to Master TOC 4 THERMAL 1403 585 YELLOW 8 LED J10A J108 J8 STATUS RED GREEN CONTROL ry LED BOARD PRIMARY RECONNECT FLAT SIDE OF LED ALIGNED WITH WHITE LEAD Je 999970505 5 Return to Section TOC Return to Master TOC REAR OF MACHINE EE OUTPUT E RECTIFIER 81 40 5 BOARD WIRE FEEDER RECEPTACLE VRECEPTACLE S H1 H2 H3 H4 H5 H6 AUXILIARY A TRANSFORMER 220V 12 12 2 LA Br N F 155 52 D 2227 T T muouczco aw 3142 532 a 4 3 sh 4 32A
11. jo EIE 5 3 o o 812 3 9 Using a 3 16 allen wrench remove four allen 15 Reconnect the nine leads 4201 4209 that Dlo bolts and washers as shown in Figure F 22 were previously removed cc At this point the board is ready for removal 16 Replace any necessary cable ties previously 10 Carefully maneuver the board out of the removed machine 17 Pre torque all screws to 25 inch Ibs before 11 Apply a thin coat of Penetrox A 13 to the tightening to 44 inch Ibs IGBT heatsinks on the back of the new switch boards mating surfaces Note Keep 18 Replace the input lead shield previously compound away from the mounting holes removed 12 Replace the four allen bolts and washers 19 Replace the case wraparound cover previously removed 13 Replace the eight capacitor terminal nuts washers and necessary leads previously removed O10 5 5 gt 218 5 2 a 14 Reconnect the three harness plugs previous ly removed Return to Section TOC Return to Master TOC POWER WAVE 355 405 LINCOLN 5 F 54 LINCOLN 2 NOTES POWER WAVE 355 405 F 54 901 Je1Se A 0 901 4 1 0 uunjeH 901 J91Se N 01 901 J91Se N 01 DOL uonoes DOL uonoes uumeg DOL uonoes 901 uonoes uumeg F 55 F 55 TROUBLESHOOTING amp REPAIR SNUBBER BOARD REMOVAL AND REPLACEMENT WARNING Service
12. 7 8 2 Q o E 5 B LEFT SIDE Return to Section TOC Return to Master TOC POWER WAVE 355 405 LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Q o E 5 B Return to Section TOC Return to Master TOC o 0 8 2 F 71 10 11 12 9 64 Allen F 71 TROUBLESHOOTING amp REPAIR OUTPUT RECTIFIER MODULES REMOVAL AND REPLACEMENT continued Under the copper plate previously removed there is an allen bolt Remove it using 9 64 allen wrench See Figure F 33 Using a 7 16 socket remove the mounting bolts at the top and bottom of the modules See Figure F 33 The output rectifier modules are ready for removal and or replacement Before replacing the diode module apply a thin even coat of Penetrox A 13 heatsink compound to the bottom surface of the diode module Note Keep the compound away from the mounting holes Press the module firmly against the sink while aligning the mounting holes Insert each outer screw through a spring washer and then a plain washer and into the holes Start threading all three screws into the heat sink 2 or 3 turns by hand 13 14 15 16 15 16 17 The screw threads may catch on the threads of the heat
13. DOL uonoes DOL uonoes uumeg D 4 NOTES POWER WAVE 355 405 LINCOLN 901 Je1Se A 0 901 4 1 0 uunjeH 901 J91Se N 01 901 J91Se N 01 DOL uonoes DOL uonoes uumeg DOL uonoes 901 uonoes uumeg Return to Master TOC Return to Master TOC Return to Master TOC o O gt o 0 2 gt c e 2 Section E 1 Section E 1 TABLE OF CONTENTS THEORY OF OPERATION SECTION Theory of Operation Section E General DescriptiOri rire esa eu ao y FEVER NER ERE E 2 Input Line Voltage Auxiliary Transformer and E 2 Switch Board and Main 1 nnne nnne nnne nnne nns 3 DC Bus Board Power board and Control nnne E 4 Output Rectifier and ChoKe EFE Na E 5 Thermal Protection E 6 Protective Circuits re Ud E 6 Over current Protection 4424444 nitet ernst nnns 6 Under Over Voltage Protection 1 2 1 1 11 1 1 11606 000 6 Insulated Gate Bipolar Transistor IGBT E 7 Pulse Width ModulatiOt ciatis inierunt E 8 M
14. AD DATACTI EIE SHT 1 SPILLATCHT 51 05 1 043 pi ALa amp 052 06 1 042 2 A0 DATAGST AD DATADI ido vos PS PSWISI DSP DI5 vou lt 9 101 21 17094 P PSWI6I 05 1 010 17049 0 AD DATABI ad 195 4 48 008 1 053 PSWITI 8 0131 17037 P7 AD DATAUZI VREFHI T2PWM T2CM 10PB4 196 ims SEL L ON E 0080 o SPICS3 1014 1o36 E DS AM gls 20 m x18 915 XINT2 10 2 5 3 1 TALES E oss S 5 011 13 5 03s BE DSP Al E TMROIR IOPB6 gH 43 SCK3 591 059 1 088 B8 SPIMOSI DSP 0101 17017 XCS20 208 17034 35 OSP_AI2 5 XINT3 10 TMRCLK IOPB7 MISO3 61 061 Vos L BSCK 1917019 1032B2 DSP AGI PEN samomo H4 2 6217062 1 085 BS 20 1 020 1 031 BL OSP_RESET Pi SUED TT FPGA_INT Guo 18 yey Ba SPICS2 CC USP Ps 2121 1030 Be DSP ALSI SHT AS SPISIMO 10 9 POT CS 64 XCS20 208 3 BMISO DSP_DS 22 9 05 16 URES sPisomio 8 5V SHT 3 1 064 1 083 1 022 1 029 ES CLK 8 5 49 DISABLE 455 671 067 10082 82 INT_1_3PH si 4 231 023 17028 8 DSP ALTI SHT ae oon 35V 5 POS SHT 1 FAN_CONTROL 691 068 1 081 BL MSELL SHT 3 24 1 021 102101 08 113 3i TCK xz spistesio 3 1 hs SHT 1 THERMAL LED 69 1 080 80 MSELO SHT 3 oo 3 46 STT_ON 7 rriow srT 05 33 5
15. C ELECTRODE SENSE D 40 VDC E PCBOARD COMPONENTS SHOWN FOR REFEFENCE NOTES ONLY ALL COMPONENTS NOT SHOWN INPUT POWER LINE FILTER IS PRESENT ONLY ON PW405 ON PW405 MOV s ARE IN THE INPUT POVER LINE FILTER PLACE A LEAD ON APPROPRIATE CONNECTION FOR INPUT VOLTAGE CONNECTION SHOWN FOR 550 579 OPERATION PW45 ONLY GO TO 415 VOLTAGE SENSE RECEPTACLE lt 1 lt 2 3 4 4 IPROPRIETARY amp CONFIDENTIAL TOLERANCE ERENS REFERENCE EQUIPMENT TYPE PLAGE DECALS S2 2 20 Ramn BY 64093 SIS 5 OF ADEGREE SUBJECT cf QAGREE ENGINEER LPetia SCALE POWERWAVE 355 405 FLAT SIDE OF LED ALIGNED WITH BLACK LEAD HERMAL YELLOW LED STATUS LED TN P FLAT SIDE OF LED RED GREEN ALIGNED WITH WHITE LEAD bb b Pl LEGEND ALL MACHINES MACHINE SCHEMATIC Now RW 74502 336 NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual ELECTRICA SYMBOLS PER E1537 THIS DOCUMENT CONTAINS PROPRIETARY INFORMATION OWNED BY LINCOLN GLOBAL INC AND MAY NOT BE DUPLICATED COMMUNICATED OTHER PARTIES OR USED FOR ANY PURPOSE WITHOUT THE EXPRESS WRITTEN PERMISSION OF LINCOLN GLOBAL INC SOLID EDGE
16. DATAIBI 5 LOK fp Tv rogos ps 132 DATAISI ADDRIGI 234 100716 3026 RE 50 68 oso 061131 DATAI6I ADDRISI 24 100615 61 MOSI 66 pos1 071130 ADDRIT 21 3 61 127 DATAIBI ADDRISI 18 PY os Cn MISO7 aire SHT 34 P0S2 08121 4442 DATU 820pF 51 820pF 51 820pF 820 gt 1_ 50 6 125 DATAISI ADDRIZI 43 12816 2011 50V 50 50 SOV THERMOSTAT 40 1 0181 1 0182 39 SHT 4 em re 09 D 1 0349 1 2W 1 20 7 SPL CSI 69 oni 0124 DATAI101 4 0 DATAIZI J6 MM ue 10202 5 1 52 7 122 152 6 vo 8 sir DVR CUR A3 vos 27 RESET RAMP ms SHT 4 1 POSS 0 5 te Voi 15 2 om 32 STR BE AD SPLCS3 71 onse 012129 DATAI121 57 10017 DATAIOI E CAPA OV 3 31 0 SHT 2 792057 Bii H8 DATASI RAW 1 0881 1 0882 DARD 5 10982 20 09 SHT 2 76 01 HT DATAM 4 NORMAR i 3 th FET A 6 8001 22 CLR CAP aia 38 5 015 46 DATANG 150 FAULT xao gt SHT 4 7 28 MPO MC68332GCPV25 RAW 221 m 221K E 1 0118 1 01182 SHT 4 m n SH 24 E VHCLUD MN ONT 8 281 Af 2 31 01282 127 2 SHT 4 QUPULON shr a 501 cSt FAULT INT 12 01381 1001382123 CRYSTAL parato
17. 2 F 14 TROUBLESHOOTING amp REPAIR INPUT FILTER CAPACITOR DISCHARGE PROCEDURE continued A WARNING ELECTRIC SHOCK can kill Have an electrician install and service this equipment Turn the input power off at the fuse box before working on equipment Do not touch electrically hot parts Prior to performing preventative maintenance perform the following capacitor discharge procedure to avoid electric shock DISCHARGE PROCEDURE 1 Remove the input power to the POWER WAVE 355 405 2 Using the 5 16 wrench remove the screws from the case wraparound cover 3 Be careful not to make contact with the capacitor terminals located at the top and bottom of the switch board Obtain a high resistance and high wattage resistor 25 1000 ohms and 25 watts minimum This resistor is not with the machine NEVER USE A SHORTING STRAP FOR THIS PROCEDURE Locate the eight capacitor terminals shown in fig ure Using electrically insulated gloves and pliers hold the body of the resistor with the pliers and con nect the resistor leads across the two capacitor terminals Hold the resistor in place for 10 sec onds DO NOT TOUCH CAPACITOR TERMINALS WITH YOUR BARE HANDS Repeat the discharge procedure for the other three capacitors Check the voltage across the terminals of all capacitors with a DC voltmeter Polarity of the capacitor terminals is marked on the PC board above the
18. DUTY CYCLE CURRENT LENGTH UP 61m 200 FT 61 76m 200 250 FT 100 275 1 0 1 0 60 350 1 0 2 0 POWER WAVE 355 405 LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Q 5 2 5 tc Return to Section TOC Return to Master TOC Q 0 8 2 4 4 INSTALLATION SAFETY PRECAUTIONS A WARNING ELECTRIC SHOCK can kill e TURN THE INPUT POWER OFF THE DISCONNECT SWITCH BEFORE ATTEMPTING TO CONNECT OR DIS CONNECT INPUT POWER LINES OUTPUT CABLES OR CONTROL CABLES Only qualified personnel should perform this installation Connect the green yellow lead of the power cord to ground per U S National Electrical Code SELECT SUITABLE LOCATION In order to assure long life and reliable operation the owner of this machine should follow these sim ple preventative measures The machine must be located where there is free cir culation of clean air such that air movement in the back out the sides and bottom will not be restricted Dirt and dust that can be drawn into the machine should be kept to a minimum Failure to observe these precautions can result in excessive operating temperatures and nuisance shutdown Keep machine dry Shelter from rain and snow Do not place on wet ground or in puddles DO NOT MOUNT OVER COMBUSTIBLE SURFACE
19. e n 50 D o 1 lt 2 lt 84 vopsvw 7 ADDRIBI 1845 Doe 2 DATAI6 021 pes 12 030 F 89 EXTAL B0 ADDRIS 8 m DATAUI 100 100 02 7 d 66 CLKOU gt SHT 4 AB poy E 0 12 5 1000 oA s None 72 X m 8a poor 140 058 1 DATAIBI 3 3 30V 7 30v 7 92 RESET 050141 150 ADDAI11 6 ato x5 82 9 olo k INPUT OUTPUT1 14 93 142 UST ADDRIL2I 5 BA DATAILO 4 4 x 6 Ji A ALL TITTY 42 QUTPUTZ Hisy 6 BER 80 sc ca 152 1131 28 800 pg B DATAILL 01 AN 10 25 91 12 M 4451BM 8802 Ta TAS TM 19 secnm oso PE AN ADDRU 4 001289 5 T m lt 05118 ADDRILSI ila DATAN 175 1340 1 79 103 R W ADUR 161 ais 001443 7 20 5 JR 2 M RESET 114 Ao 115 ADDRILTI ERA 00155 1 A sir a FPGA DONE 113 pexrr ADORTI ADORIS ijs 5 40V 112 ayer A280 ADDRI2I ADDRIT9 16 aig i 5 SHT 4 RMC 11 ADDRI3I CSB 28 C27 DA 5 FET B AS 106 m ADDR R W 100 70V 1 SHT amp Ds 110105 53 ADDRISI 28 3 1 105 5170 NM ADDRI6I 10 lerre ug 104 s171 ATUS ADDRI7 p T 102 m ADORIBI
20. TOOK 2 1 C26 0810 79 5885 C128 8 m x32 6 2 4 TH 11 TEE 2 T V 50V 54 18 50 1 56A E 10K DA CS 1 515 SV SHT amp um V PRIMARY CURRENT SHUTDOWN 0 3 09 VEER 2 Ba 20 19 pau c RLI DUCER wp SIGNAL IN 5 LV 400A OUTPUT id A Er SP 5VA 5VA 9 VOLTAGI V 330740 x ot 5 xe gt is 25 oe id TP3 50V R26 7 7 TTK 33K 775 asy 5 18 1 R23 R27 al enol 80740 Ve 8 15 2 TTK Sy salt gt R6 Dm 5 aN sat 4 xi cst xp 02 a toa 1 4 4 100 78 p 100 5 6 EET 4 4 Rho 0022 2 SEL I ON 06417 RTL RGB zt N eno 07945885 500 8403ARULO 50V 40 Sv SHT 4 4 5 50V a 1 100K 100K dom ley 25 Sor LE 21175 21175 9 R24 RZB 3 15V wa 507 101658 2 Em IN 511 TTK 0P 27688 CURRENT LIMIT ane E EM 50 Bt 00K 8112 IS AT xe 2120 4i gt C 8 475 15 100K gt i 50 M Ww Ve wt 19 CURRENT NODE CONTROL DISABLE THE V sur 2 5V gt 18 FETS AS SOON AS PRIMARY CURRENT 5v 15V lout 099 R IS GREATER THAN A REFERENCE LEVEL 15V O o 33070 gt I 9 056 5V 8 8 RIAL 02A n _ 030 4 657 4 o SHT 2 5v 01 01 _ 82 an R69 1
21. CONTA UL POSITVE NAT RECTFIEA 215 12VDE 8 7 GUT LNY17 3V 3 221 Y omz CAPACITOR PRECHARGE 296 V F CONVERTER 1 SDDVOK CAP 5 AT VREF A 244 2 1 CHANGE DN 8HZ 151 TK Macs gt R a 15V A 3 32 003 1 ENT27 3V 46 be AZ R3 dK TRANSFORMER e AL R4 5w E X 23 CAP AC TOR Lass gt d ms 5 13
22. OJO 912 10 olg iz 918 cic 5 5 RECTIFIER 7 LEGEND 21682 ALL MACHINES aA n OPTION 5 OUTLINE ur PW355 FRONT VIEW OF MACHINE Asse 4 MODEL Biss LEFT SIDE OF MACHINE iA R RED W WHITE N A 1 FOR MACHINES WITH RED BLACK AND WHITE POWER CORDS FOR SINGLE PHASE INPUT CONNECT GREEN LEAD TO GROUND PER NATIONAL ELECTRICAL SINCE COMPONENTS OR CIRCUITRY OF A PRINTED CIRCUIT BOARD MAY CHANGE WITHOUT AFFECTING Y YELLOW CODE CONNECT BLACK AND WHITE LEADS TO SUPPLY CIRCUIT WRAP RED LEAD WITH TAPE THE INTERCHANGEABILITY OF A COMPLETE BOARD THIS DIAGRAM MAY NOT SHOW THE EXACT TO PROVIDE 600V INSULATION COMPONENTS OR CIRCUITRY HAVING A COMMON CODE NUMBER FOR THREE PHASE INPUT CONNECT GREEN LEAD TO GROUND PER NATIONAL ELECTRICAL C PLACE A LEAD ON APPROPRIATE CONNECTION FOR INPUT VOLTAGE CONNECTION SHOWN IS FOR ean CODE CONNECT BLACK RED amp WHITE LEADS TO SUPPLY CIRCUIT 550 575V OPERATION PW405 ONLY GO TO 415VAC 125 71 p 2 FOR MACHINES WITH BROWN BLACK AND BLUE POWER CORDS D INPUT POWER LINE FILTER IS PRESENT ONLY ON PW405 TOP CENTER 1 J22 J41 446 t FOR SINGLE PHASE INPUT CONNECT GREEN YELLOW LEAD TO GROUND PER NATIONAL ONPW405 MOV S ARE IN THE INPUT POWER LINE FILTER PANEL VJ 12 PW405 MODEL LA 4 ELECTRICAL
23. EN 168 POWERWAVE 355 405 ELECTRICAL DIAGRAMS 0 PC BOARD ASSEMBLY SWITCH PC BOARD ReaD PART IDENTIFICATION 1 23 520500 4 0047 1000 10 11 813490 130 0 27 50 596 C2 C24 S205007 CAPACITOR PPMF 047 1600V BOX 10 25 26 111577 57 0 1 400 10 C3 C18 313490 93 CAPACITOR TAEL 27 35V 1094 C31 C32 S16668 820 50 5 4 21 520500 1 0 1 1000 1096 5 6 15 16 516668 6 4700 50 1056 7 12 13 14 20 27 28 S16668 5 022 50V 20 C29 C30 8 9 22 3166689 150 100 5 CRT CR2 514293 18 RELAY DPST 12VDC AG CDO 01 04 016 017 T12705 59 DIODE AXLDS 3A 600V UFR 07 08 09 012 014 018 019 T12199 1 DIODE AXLDS 1A 400V 020 021 021 022 023 025 026 0215 71270229 ZENER DIODE 1W 15V 5 1 4744 0216 0218 0219 0223 DZ11 DZ22 7127024 2 DIODE 1W 20V 5 1 4747 D es 024 027 0217 0220 112702 0 ZENER DIODE 1W 6 2V 5 1 4735 028 T12702 19 ZENER DIODE 1 12 5 1 4742 DZ9 DZ10 DZ12 DZ13 Ti2702 45 ZENER DIODE 1W 18V 595 TNA746A Pa 215 220 121 524016 8 CONNECTOR MOLEX MINI PCB RT L 8 PIN Return to Section TOC Return to Master TOC
24. POWER WAVE 355 405 LINCOLN 5 2 7 i 3 tc Return to Master TOC Return to Master TOC Return to Master TOC Section B 1 TABLE OF CONTENTS OPERATION SECTION IEEE Section B Salet rere B 2 General lt 2 Recommended Processes and 2222111 01000 0 B 2 Required B 3 Bla ce E E 3 Duty Cycle and Time 4 0 nnnm 3 Case Front Corittols B 3 4 8 B 4 Constant Voltage 5 Tig EE Aaa E aE B 6 Special Welding Processes 00101000 nennen nennen nnne nnns B 6 52 224 5 2555252 1554222121222212122 2 6 Pulse Welding 7 Pulse on Pulse G
25. F 33 Return to Section TOC Return to Section TOC Return to Master TOC Q o E 5 B Return to Section TOC Return to Master TOC Return to Master TOC o 0 E TROUBLESHOOTING amp REPAIR OUTPUT DIODE MODULES TEST continued Figure F 9 Snubber and Output Diode Locations Output Diode Modules LEFT SIDE POWER WAVE 355 405 LINCOLN 5 F 34 F 35 F 35 TROUBLESHOOTING amp REPAIR AUXILIARY TRANSFORMER TEST WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty For your safety and to avoid electrical shock please observe all safety notes and precautions detailed throughout this manual Return to Section TOC Return to Master TOC If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed Call 1 800 833 9353 WELD DESCRIPTION This procedure will determine if the correct voltage is being applied to the primary of auxil iary transformer and also if the correct voltage is being induced on the secondary windings of the transformer Return to Secti
26. Neu CR 209 RELAY CONVERT b Dashed ines represent copper bus connections Shown connected for 200 240 Volt Input Voltage 115 VAC 2 4200 VIF CONVERTER 2 421 7 605 421 3 3 610 EK FAN CONTROL PULSE TRANSFORMER J20 2 J20 6 J20 1 SOFT START SNUBBER BOARD Sch S24761 190 3 lt 15V J90 1 15V J90 2 GND 990 4 THERMOSTAT 503 J46 1 65 J46 2 05 x J46 3 J46 4 32A PW355 MODEL SEE BELOW FOR PW405 152 3 2 532 25 31 390 EN 170 LINCOLN B 40VDC POWER J47 3 COMMON gt J47 6 504 T 502 477 441 2 475 4 40VDC2J47 8 1 52 FEEDER COMMON gt J47 1 gt 51 DC BUS BOARD Sch M19330 J2 45 J11 224 46 12 1 3 2 3 4 426 CONNECTOR NUMBERING SEQUENCE VIEWED FROM COMPONENT SIDE OF BOARD POWER a 2421 Sch 63631 POWER GND a 342 5 40 VDC CONTROL BOARD Sch G3789 15V MAIN RELAY CONTRO
27. 0 9 16 2 5 2 a Return to Section TOC Return to Master TOC F 44 F 44 TROUBLESHOOTING AND REPAIR FAN CONTROL AND MOTOR TEST continued TEST PROCEDURE 1 Remove the input power to the POWER WAVE Perform the Input Filter Capacitor Discharge 355 405 machine 2 Using the 5 16 nut driver remove the case 4 Locate plug J22 on the main switch board Do wraparound cover not remove the plug from the board See Figure F 14 FIGURE F 14 PLUG J22 LOCATION 5 Carefully apply the correct input power to the 6 Carefully check for 115VAC at plug J22 2 machine to J22 pin 3 leads 32A to 31B C See Figure 15 WARNING HIGH VOLTAGE IS PRE SENT AT THE MAIN SWITCH BOARD FIGURE F 15 PLUG J22 Fan Lead Lead 32A Lead 31B C Fan Lead Plug J22 POWER WAVE 355 405 LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o o 5 B tc Return to Section TOC Return to Master TOC Q 7 8 2 45 F 45 TROUBLESHOOTING AND REPAIR FAN CONTROL AND MOTOR TEST continued If the 115VAC is low or not present check cir FAN CONTROL TEST PROCEDURE cuit breaker CB2 located on the front panel If the ci
28. 48 T R OR WW TN TO TA 10 519400 3322 RESISTOR MF 1 4W 33 2K 1 16 PLACES NB N G NM TT RO 717477721777 5 PLACES On MANUFACTURED AS NK 1 4 PLACES PLACES G3830 1B1 IDENTIFICATION CODE PART NO NOTES NA CAUTION THIS DEVICE IS SUBJECT TO DAMAGE BY _ STATIC ELECTRICITY LINCOLN ELECTRIC TO SEE E2454 CAPACITORS MFDNOLTS BEFORE HANDING INDUCTANCE HENRIES NB SNAP POWER TERMINALS INTO COMPONENT SIDE OF BOARD RESISTOR OHMS N C THIS AREA TO BE COVERED ON BOTH SIDES OF BOARD WHERE POSSIBLE WITH SEALANT PRIOR TO ENCAPSULATION N D INJECT SEALANT ITEM 8 THROUGH THE PC BOARD TO SEAL MODULE LEADS 16 PLACES AND ALL COMPONENT LEADS ON THE NONO COMPONENT SIDE OF THE BOARD THAT ARE COVERED BY MODULE CASE ITEM PARTNO DESCRIPTION N E FEMALE EYELET TO BE AGAINST THE NON COMPONENT SIDE AS SHOWN 1 638318 P C BOARD BLANK EYELET MUST NOT SPIN AFTER CLINCHING 2 M16100 44 ELECTRONIC MODULE A1 A2 SOLDER EYELET SO THAT SOLDER COVERS ENTIRE EYELET 3 523006 TERMINAL B211 8218 8204 8205 8209 AND ALL AROUND EYELET ON COPPER SIDE ONLY 4 M19612 CURRENT TRANSDUCER 12 T3 NO ICICLES OR SOLDER BLOBS PERMI
29. 55 VDC 460 60 115 123 VAC 111 119 VAC 575 60 O10 5 5 218 5 2 a Return to Section TOC Return to Master TOC POWER WAVE 355 405 LINCOLN G 1 ELECTRICAL DIAGRAMS 6 1 5 TABLE OF CONTENTS ELECTRICAL DIAGRAMS SECTION o ELECTRICAL DIAGRAMS umero dad SECTION G 9 WIRING DIAGRAM 84131 22 22 2 2 G 2 c ENTIRE MACHINE SCHEMATIC 04132 G 3 E CONTROL PC BOARD SCHEMATIC 1 G3789 1D0 1 G 4 d CONTROL PC BOARD SCHEMATIC 2 G3789 1D0 2 G 5 CONTROL PC BOARD SCHEMATIC 3 G3789 1D0 3 G 6 CONTROL PC BOARD SCHEMATIC 4 G3789 1D0 4 G 7 CONTROL PC BOARD ASSEMBLY S25385 355 S25425 for 405 DIGITAL POWER SUPPLY PC BOARD SCHEMATIC 3631 G 8 DIGITAL POWER SUPPLY PC BOARD ASSEMBLY 3632 SWITCH PC BOARD SCHEMATIC 111487 G 9 SWITCH PC BOARD ASSEMBLY 03830 G 10 SNUBBER PC BOARD SCHEMATIC 824761 G 11 SNUBBER PC BOARD ASSEMBLY 19532 G 12 40 VDC BUSS PC BOARD SCHEMATIC 19330
30. LINCOLN 59 ELECTRIC POWERWAVE 355 405 G 8 POWERWAVE 355 405 ELECTRICAL DIAGRAMS NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual SCHEMATIC POWER SUPPLY PRINTED CIRCUIT BOARD LINCOLN 59 ELECTRIC G 8 901 Je1Se A 0 uunjeH 901 4 1 0 uunjeH 901 J91Se N 01 901 J91Se N 01 uunjeH DOL uonoes DOL uonoes DOL uonoes DOL uonoes Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC olo O o Fle S PEN eis sis 2 o x 1 Return to Section TOC Return to Master TOC G 9 SCHEMATIC SWITCH PC BOARD RELAY SIGNAL FROM CONTADL BDARD aDFT START SIGNAL FRDM CONTROL BOA PWM DRIVE uas zu 2 1 GATE C1 JA 2 23 gt 222 i ELECTRICAL DIAGRAMS
31. TROUBLESHOOTING amp REPAIR INPUT RECTIFIER TEST CONTINUED TEST PROCEDURE Remove input power to the POWER WAVE 355 405 machine Using a 5 16 nut driver remove the case wraparound cover Perform the Capacitor Discharge detailed earlier in this section Locate the input rectifier and associated leads See Figure Carefully remove the silicone sealant from leads 207 207A and 209 Using a phillips head screwdriver remove leads 207 207A and 209 from the input rectifier Use the analog ohmmeter to perform the tests detailed in Table F 2 See the Wiring Diagram Visually inspect the three MOV S for damage TP1 TP2 TP3 Replace if essary Figure F 3 Input Rectifier Small Lead H1 3 16 ALLEN BOLTS lt FRONT REAR 207 207A 209 Small Lead A To Circuit Breaker POWER WAVE 355 405 LINCOLN 5 F 21 F 21 TROUBLESHOOTING amp REPAIR INPUT RECTIFIER TEST CONTINUED Table F2 Input Rectifier Test Points TEST POINT TERMINALS ANALOG METER X10 RANGE Acceptable Meter Readings Greater than 1000 ohms Greater than 1000 ohms Greater than 1000 ohms Return to Section TOC Return to Master TOC Greater than 1000 ohms Greater than 1000 ohms Greater than 1000 ohms Less than 100 ohms Less than 100 ohms Less than 100 ohms Return to Master TOC A B C A B C A B C Return to Section TOC Less than 100 ohms Less than 100 ohms Less than 100
32. Thermostats 2 Feeder OUTPUT RECTIFIER AND CHOKE The output rectifier receives the AC output from the main transformer secondary and rectifies it to a DC voltage level Since the output choke is in series with the negative leg of the output rectifier and also in series with the welding load a filtered DC output is applied to the machine s output terminals NOTE Unshaded areas of Block Logic Diagram are the subject of discussion POWER WAVE 355 405 LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC olo OJO 5 5 9 16 g 9 5 2 a Return to Section TOC Return to Master TOC Return to Master TOC E 6 E 6 THEORY OF OPERATION THERMAL PROTECTION Three normally closed NC thermostats protect the machine from excessive operating temperatures These thermostats are wired in series and are con nected to the control board One of the thermostats is located on the heat sink of the switch board one is located on the output choke and the third thermostat is located on the DC Bus Board Excessive tempera tures may be caused by a lack of cooling air or oper ating the machine beyond its duty cycle or output rat ing If excessive operating temperatures should occur the thermostats will prevent output from the machine The yellow thermal light located on the front of the machine will be illuminated The thermostats are self resetting onc
33. ed circuit The fan operates when the welding output terminals are energized or when a thermal over tem perature condition exists Once the fan is activated it will remain on for a minimum of five minutes The fan driver circuit is housed on the switch board but it is activated from a control board signal POWER WAVE 355 405 LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC O10 515 gt 218 5 2 Return to Section TOC Return to Master TOC Return to Master TOC E 4 E 4 THEORY OF OPERATION FIGURE E 4 POWER BOARD CONTROL BOARD AND SERIAL PERIPHERAL INTERFACE SPI COMMUNICATIONS To Control Main Switch Board Board Input Input switch Rectifier Reconnect Switch E 115VAC Fan Supply 5 Auxiliary 8 220 VAC Transformer 40VDC 5 Capacitor Feedback 2 Machine Control Supply 15VDC 15VDC 5VDC Positive Output ri 5 urreni Terminal Negative Output Terminal o ri N 5 92 D 8 2 B o o ko 3 mp Yellow Thermal LED DC BUS BOARD POWER BOARD AND CONTROL BOARD DC BUS BOARD The DC Bus Board receives approximately 65VDC from the bus board rectifier
34. noodle welding NOTE The secondary limit is 570 for the standard stud and 325 amps for all single phase operation POWER WAVE 355 405 LINCOLN 5 F 11 F 11 TROUBLESHOOTING amp REPAIR Capacitor delta error The maximum voltage difference between the main capaci tors has been exceeded May be accompanied by errors 32 35 Check the output diodes Error codes that contain three or four digits are defined as fatal errors These codes generally indicate internal errors on the Control Board If cycling the input power on the machine does not clear the error try reloading the operating system If this fails replace the Control Board Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC 5 5 2 2 EIS 2 oO Return to Section TOC Return to Master TOC POWER WAVE 355 405 LINCOLN 5 F 12 LINCOLN jo NOTES POWER WAVE 355 405 F 12 901 Je1Se A 0 901 4 1 0 uunjeH 901 J91Se N 01 901 J91Se N 01 DOL uonoes DOL uonoes uumeg DOL uonoes 901 uonoes uumeg Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o o 5 B tc Return to Section TOC Return to Master TOC Q 0 8 2 TROUBLESHOOTING amp REPAIR INPU
35. 1VDL HANGE ON CAP BHZ 194 m 14 7 R135 CONNECTION NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual 199K R65 1006 WITHOUT AFFECTING THE INTERCHANGEABILITY OF COMPLETE BOARD THIS DISDRAM MAY NOT SHOW THE EXACT COMPONENTS OF CIRELIITR SINCE COMPONENTS CIRCUITRY ON A PRINTED CIRCUIT BOARD MAY CHANGE NUMBER OF CONTAOLS HAVING COMMON CODE 57 COMMON CONNECTION TF FRAME CONNECTION L11481 1C FILENAME THE LINDLULN ELECTRIC G Us THIS SHEET CONTAINS NFARMATIDN OWNED BY EARTH GRDUN THE LINCOLN ELECTRIC AND 5 NUT TD LLED DISGL 5 GA USED WITHOVT THE EXPRESS SWITCH PCB SCHEMATIC SUBJECT THE LINCOLN ELECTRIC CO CLEVELAND OHIO U S A Lem UNLEGG DTHERM SE TOLERANCE DN HOLES C ZE PEA DN 2 PLACE DEP MALE S 02 DN 3 PLATE DECIMALS 165 042 ON ALL ANGLES amp SOF DEGREE WITH PUBLISHED STANDARDS MOTER OL TOLERANCE 121 D CONTH IL BOARD G 9
36. 5 0181 1471 9147 1 0178 178 00819 91 ADCINB IOPA3 PWM2 CMP2 29 NOS SHT 1 05 077 148 018 1 0177 018 90 ADCINS IOPA2 PwM3 CMP3 96 2 S sHT 1 Ms on 8 ES kim i ind QUPULON 076126 DATAI10I SHT 3 LAU 89 ADCINLO PWMA CMP4 127 pecs 08 aki SPI CS3 lon ians 15 DATAI I 89 ADCIN11 5 5 28 mE XSHT 1 MODE PROGRAM m E SHT 1 SHT 1 SPI CS2 1 0151 1 0174 174 DATAIBI 83 ApCINI2 PWM6 CMP6 99 m Seen nowe 105 5 SHT 1 SK 1521 0152 1 017212 188 1702061206 82 ADCINI3 PWM7 CMP7 10PB0 199 STI ON sm 36 SPLCS 15 0159 vorn ln ADDRISI 187 167 1 0205 288 81 1 191 MT BAD SHT 1 SPLCSO 10161 1 0169 i69 188 0188 170204 204 ADDRIZI 80 5 PwMS CMPS 10PB2 102 SHT 1 1 0162 1 0168 168 _________________ 189 0189 1 0201 201 ADDR 3I V 1 5320 240 1631170163 1 0167 287 ACK SHT 1 DATAI 1901 0190 y g 170200 200 DSP amp 10166 166 SHT 1 DATAIO 191 1 0199 199 XCS20 208 ADDRI121 133 1 9193 170198 198 2 195194 170197 197 DATAILAI Ve DATAU3 196 520 208 E AD DATAIO 13 AD DATAIQ 131 5 to SHT 1 1 03 1 045 e3 AD DATAIBI 016 als SHT 1
37. 5 5 9 16 g 9 5 2 a Return to Section TOC Return to Master TOC POWER WAVE 355 405 LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC O10 515 2 2 5 2 Return to Section TOC Return to Master TOC Return to Master TOC A 11 A 11 INSTALLATION WELDING WITH MULTIPLE POWER WAVES CAUTION Special care must be taken when more than one Power Wave is welding simultaneously on a single part Arc blow and arc interference may occur or be magnified Each power source requires a work lead from the work stud to the welding fixture Do not combine all of the work leads into one lead The welding travel directions should be in the direction moving away from the work lead as shown below Connect all of the work sense leads from each power source to the work piece at the end of the weld For the best results when pulse welding set the wire size and wire feed speed the same for all the Power Waves When these parameters are identical the puls ing frequency will be the same helping to stabilize the arcs Every welding gun requires a separate shielding gas regulator for proper flow rate and shielding gas cover age Do not attempt to supply shielding gas for two or more guns from only one regulator If an anti spatter system is in use then each gun must have its own anti spatter system See Fi
38. P il POWERWAVE 355 405 ELECTRICAL DIAGRAMS ici SCHEMATIC DIGITAL CONTROL PC BOARD 1
39. PLUG J42 POWER BOARD CONNECTOR PLUG J42 POWER BOARD CHECK 40 VDC INPUT FROM DC BUS BOARD CHECK 15 VDC SUPPLY FROM POWER BOARD CHECK 5 VDC SUPPLY FROM POWER BOARD CHECK 15 VDC SUPPLY FROM POWER BOARD CHECK 5 VDC VOLTAGE READING 38 42 VDC 15 VDC 5 VDC 15 VDC CONNECTOR ARCLINK SUPPLY PLUG J43 FROM POWER BOARD 5 VDC 406 5 VDC 405 5 VDC POWER BOARD CHECK 5 VDC CONNECTOR RS 232 SUPPLY PLUG J43 FROM POWER BOARD POWER BOARD CHECK 5 VDC 403 CONNECTOR SPI SUPPLY FROM I 401 0 PLUG J43 POWER BOARD Q 0 8 2 o E 5 B Return to Section TOC Return to Master TOC POWER WAVE 355 405 LINCOLN 5 F 26 LINCOLN jo NOTES POWER WAVE 355 405 F 26 901 Je1Se A 0 901 4 1 0 uunjeH 901 J91Se N 01 901 J91Se N 01 DOL uonoes DOL uonoes uumeg DOL uonoes 901 uonoes uumeg Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o E 5 B Return to Section TOC Return to Master TOC Q 0 E 27 TROUBLESHOOTING amp REPAIR DC BUS BOARD TEST WARNING Service and repair should be performed by only Lincoln Electric factory traine
40. Power Board 6St i F 23 DC BUS Board 1665 2520 F 27 Output Diode Modules Test E nnns 31 Auxillary Transformer ciiin iati eer canta F 35 Current Transducer 39 Fan Control and Motor nennen nnne nnne nennen senes F 43 Replacement Procedures Control Board Removal and 00000 47 Main Switch Board Removal and F 51 Snubber Board Removal and F 55 Power Board Removal and F 57 DC Bus Board Removal and 61 Input Rectifier Removal F 65 Output Rectifier Modules Removal and Replacement F 69 Current Transducer Removal and F 73 Retest after vic EHE F 78 POWER WAVE 355 405 LINCOLN 5 Section F 1 Return to Section TOC Return to Master TOC Return to Section TOC O10 515 gt g 9 5 2 EC R
41. 22801 ST Clair Ave Cleveland Ohio 44117 1199 FAX 216 481 2309 SVM Number Page Number if necessary Your Company Your Name Please give detailed description below SD287 01 99 LINCOLN 5
42. 54 62 74 82 91107120128 13426 DATAI0 15 E R17 ud 019 00 1 332 515 E 4 14 4 4 1 amp 21K va irt 301 P n RIS 15 17 DATAUZI RI 5 175 x23 pr 175 asc Tro L 9 Q8 zu QUT 020 5103 03 6 DATAI61 tc a TOOK 35v_ S 80746AN jen 5 DATAUI SHT 4 R63 NSA VHCIAD 7 7LHCST3PW 11 Ao L Vss 05 08 c DATA 40V 51V 4T00pF 8 DATAI3I 1 24 50V t D6 06 i 1 26 907 0712 DATAIBI 18 084 35v 8 FR 100 02 Ed X 2 1000 70 C 3 VPP gt SHT 5 E JIN ROL Reg D E D gt Uis 5 02 175 Wo cip OSA m TOOK p THERMALLED 0 100k B enr A E m 14 C25 031 080 7076 1 14 1 4000F 0 18V 37 2 8 P d SF 2 INPUT ourPuri d V asv 5y a ADDRII 29 ap evo gyreyrz 16 uz los don az B ADDRIZI 24 ay pao 22 DATAIOI RLO USAN 080213 Roa 10 2 01 17 gt 7 gt ADDRISI 2342 p RIS 775 50V 63V 50V 30V 35V 15 13 ADDRIAT ZAR xz Pi DATAUZI 2 ADDRISI E p03 DATAGI SHT 4 846 N 16 2 Bs _ ADDRI amp I EN pag 40V I E ADDRITI 19 pos 0 DATAISI
43. CODE CONNECT BLUE AND BROWN LEADS TO SUPPLY CIRCUIT WRAP BLACK F 220VWINDING IS ONLY PRESENT ON PWA05 FAN SHROUD CASE FRONT BASE PDT m 9 LEAD WITH TAPE TO PROVIDE 600V INSULATION PROTECTIVE BONDING CIRCUIT eee 9 d ou FOR THREE PHASE INPUT CONNECT GREEN YELLOW GROUND PER NATIONAL ELECTRICAL g CODE CONNECT BLUE BLACK amp BROWN LEADS TO SUPPLY CIRCUIT CONNECTOR CAVITY NUMBERING SEQUENCE ELECTRICAL SYMBOLS PER E1537 VIEWEDFROM COMPONENT SIDE OF BOARD G4131 Return to Section TOC Return to Master TOC 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 LINCOLN POWERWAVE 355 405 Return to Section TOC Return to Master TOC Return to Section TOC olo o E 5 ols 0 12 8 8 e 5 2 o Return to Section TOC Return to Master TOC Return to Master TOC G 3 ELECTRICAL DIAGRAMS SCHEMATIC COMPLETE MACHINE ENGINEERING CONTROLLED CHANGE DETAIL MANUFACTURER Released from X INPUT SWI W HTE HILA BROWN INPUT pep 12 LINES V PED G GREEI GREENYELLOW COLOR FOR PW405 AUXILIARY TRANSFORMER CB2 532 25A RECONNECT SWITCH SWITCH BOARD 115 Sch 111487
44. E o B Return to Master TOC FIGURE F 34 CASE BACK SCREW LOCATIONS Bs REAR 5 5 Oja 15 5 o o0 9 2 CL 2 MM Return to Section TOC Return to Master TOC Plastic C Nut 5 16 Mounting Screws Return to Section TOC Return to Master TOC POWER WAVE 355 405 LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC olo OJO 5 5 0 9 16 218 5 2 Return to Section TOC Return to Master TOC F 75 F 75 TROUBLESHOOTING amp REPAIR CURRENT TRANSDUCER REMOVAL AND REPLACEMENT continued 5 Label and remove the four leads connected to the 9 Using a hammer and a flathead screwdriver firmly reconnect panel Pliers may be necessary tap the metal nut from the bottom of one of its ribs This tapping will loosen the nut Note Be sure to 6 Label and remove the two leads connected to the tap from the bottom so the nut loosens in a counter CB2 circuit breaker clockwise fashion if viewed from the front of the machine 7 Using a crescent wrench remove the large plastic nut from around the input power line located at bot 10 Using a 3 8 nut driver label and remove leads tom of the rear assemb
45. E 2 THEORY OF OPERATION FIGURE E 2 INPUT VOLTAGE AND PRECHARGE CURE wir Duaru Input T Input switch Rectifier 2 5 Reconnect 1 Switch 1 Fan Control 40VDC m 115VAC Fan Supply Primary Current Feedback 2 Input Relay Control Auxiliary Soft Start Control Ti V F Capacitor Feedback 2 220 VAC Transformer Machine Control Supply 15VDC 15VDC 5VDC Positive Output Terminal Negative Output Terminal Primary Current Sensor Output Voltage Sense 12065 1991 Can Supply 5 0 DC Bus Board 40VDC 30 008 o lt pS 507 RS232 Supply 5VDC Yellow Thermal LED Status Red Green LED Control Board R232 GENERAL DESCRIPTION The Power Wave semi automatic power source is designed to be a part of a modular multi process welding system Depending on configuration it can support constant current constant voltage and pulse welding modes The Power Wave power source is designed to be used with the semi automatic family of power feed wire feeders operating as a system Each component in the system has special circuitry to talk with the other system components so each component power source wire feede
46. F 5 input power is applied to the machine 4 Carefully apply input power to the Power Wave 355 405 5 Turn on the Power Wave 355 405 The LED on the DC Bus Power Supply PC Board should light FIGURE F 6 DC BUS POWER SUPPLY POWER SUPPLY PC BOARD J47 J47 15 51 v Rectifier o 477 4 52 4 4 446 J 3 Thermostat y lt ope preu 2 F J J46 POWER WAVE 355 405 LINCOLN 5 F 29 F 29 TROUBLESHOOTING amp REPAIR 8 If any of the output voltages are not correct and the input voltage is correct the DC Bus Board may be faulty O 5 5 DC BUS BOARD TEST CONTINUED 518 2 6 Check the DC Bus Board input and output 7 If all the voltages are correct the DC Bus olg voltages according to Table F 4 See Figure Board is operating properly 515 the Wiring Diagram 9 WARNING 9 If the input voltage is not correct check the e ELECT RIG SHOCK can kil leads between the DC Bus Board and the High voltage is present at the Bus Rectifier See the Wiring Diagram terminals of Capacitor C3 near where testing is to be done 10 When finished testing replace the case wraparound cover Return to Section TOC Return to Master TOC TABLE F 4 DC BUS POW
47. Figure F 7 lead to the negative terminal 3 Remove any output cables and load from the output terminals NOTE The polarity of the test leads is most important If the test leads polarity is not cor rect the test will have erroneous results Return to Section TOC Return to Master TOC POWER WAVE 355 405 LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o o E 5 B Return to Section TOC Return to Master TOC Q 0 8 2 F 33 TROUBLESHOOTING amp REPAIR OUTPUT DIODE MODULES TEST continued Figure F 8 Terminal Probes If 200 ohms is measured then the output diodes are not 5 NOTE There is a 250 ohm resistor across the welding output terminals See Wiring Diagram If less than 200 ohms is measured one or more diodes or the snubber board may be faulty Perform the Filter Capacitor Discharge detailed in the maintenance sec tion Locate the output diode modules and snub ber board See Figure Test all output diode modules individually NOTE This may require the disassembly of the leads and the snubber board from the diode modules Refer to the Output Diode Modules Removal and Replacement Procedure detailed instructions POWER WAVE 355 405 LINCOLN 5
48. IGBT group conducting for one microsecond The negative portion is the other IGBT group The dwell time off time is 48 microseconds both IGBT groups off Since only two microseconds of the 50 microsecond time period is devoted to conducting the output power is minimized MAXIMUM OUTPUT By holding the gate signal on for 24 microseconds each and allowing only two microseconds of dwell time off time during the 50 microsecond cycle the output is maximized The darkened area under the top curve can be compared to the area under the bottom curve The more dark area that is under the curve indi cates that more power is present lAn IGBT group consists of two IGBT modules feeding one transformer primary winding POWER WAVE 355 405 LINCOLN 5 o O o 9 gt 2 Return to Master Return to Master TOC Return to Master TOC Section F 1 TABLE OF CONTENTS TROUBLESHOOTING amp REPAIR SECTION Troubleshooting amp Repair Section 2 0 Section F How to Use Troubleshooting Guide F 2 PC Board Troubleshooting Procedures and Replacement F 3 Troubleshooting Guide nnn nnns F 4 Test Procedures Input Filter Capacitor Discharge F 13 Main Switch Board F 15 Input FAGCHITICH F 19
49. IGBT s In this manner the digitally con trolled high speed welding waveform is created addition the Control Board monitors the ther mostats the main transformer primary currents and input filter capacitor voltages Depending on the fault condition the Control Board will activate the thermal and or the status light and will disable or reduce the machine s output POWER WAVE 355 405 LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC O10 515 9 16 218 5 2 a Return to Section TOC Return to Master TOC THEORY OF OPERATION Bi FIGURE E 5 OUTPUT RECTIFIER AND CHOKE 5 A To Control Main Switch Board Board Positive Input Be Output Input switch Rectifier Terminal Sensor E Q Negative Reconnect 5 Output o Switch ES Ew Terminal mel Sensor Primary Current Feedback 2 Input Relay Control Soft Start Control Capacitor Feedback 2 Auxiliary 220 VAC Transformer Output Voltage Sense Fan Control 16 1891 Machine Control Supply Yellow 15VDC 15VDC 5 Thermal Power LED Board Control Board RS232 Supply 5VDC Can Supply 5VDC gt K 30 MOA O lt MS 0507 40VDC R232 Connector
50. NEEDED Return to Section TOC Return to Master TOC 3 16 Allen wrench 9 64 Allen wrench 5 16 Nut Driver 7 16 Wrench Flathead Screwdriver Penetrox A 13 Heatsink Compound Thin Knife Screwdriver This procedure takes approximately 30 minutes to perform O10 515 gt 218 5 2 a Return to Section TOC Return to Master TOC POWER WAVE 355 405 LINCOLN 5 F 70 F 70 TROUBLESHOOTING amp REPAIR OUTPUT RECTIFIER MODULES reached the Snubber Board Removal Procedure be performed After the snubber board is removed remove the four leads connected to the modules using a 3 16 Perform the Input Filter Capacitor Discharge allen wrench These leads are X4 X2 20 40 2 REMOVAL AND REPLACEMENT continued 5 5 9 8 PROCEDURE 8 cle 1 Remove input power to the POWER WAVE 5 Before the output rectifier modules can be 5 355 405 2 Using a 5 16 nut driver remove the case wrap around cover 6 Procedure detailed earlier in this section Note their positions for reassembly 4 Locate the output diode modules located behind 33 the snubber board See figure F 32 7 Remove the copper plates from the tops of the modules FIGURE F 32 OUTPUT RECTIFIER MODULE LEAD LOCATIONS Return to Section TOC Return to Master TOC Output Diode Modules Snubber Board o
51. The DC Bus Board regu lates that 65VDC to a 40VDC supply This regulated 40VDC is applied to the Power Board and the wire feed receptacles POWER BOARD The power board utilizing a switching power supply processes the 40VDC input and develops several reg ulated positive and negative DC supplies Three DC supplies are fed to the control board for machine con trol supplies A 5VDC is used for the RS232 connec tion supply Another 5VDC supply is utilized by the CAN digital communication circuitry An over or under input voltage detection and shutdown circuit is also part of the power board s circuitry P o w e r Ww Control Board 4 RS232 Supply 5VDC e Stat 5 Can Supply 5VDC o y 40VDC Connector Thermostats 2 Feeder CONTROL BOARD The Control Board performs the primary interfacing functions to establish and maintain output control of the POWER WAVE 355 405 The function generator and weld files exist within the Control Board hardware and software Digital command signals received from the user interface feed head and feedback information received from the current sensor and output voltage sensing leads are processed at the control board Software within the control board processes the com mand and feedback information and sends the appro priate pulse width modulation PWM signals See PULSE WIDTH MODULATION in this section to the switch board
52. WAVE 355 405 LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC olo OJO 5 5 218 5 2 a Return to Section TOC Return to Master TOC Return to Master TOC E 7 E 7 THEORY OF OPERATION INSULATED GATE BIPOLAR TRANSISTOR IGBT OPERATION An IGBT is a type of transistor IGBT are semiconduc tors well suited for high frequency switching and high current applications Example A in Figure E 6 shows an IGBT in passive mode There is no gate signal zero volts relative to the source and therefore no current flow The drain ter minal of the IGBT may be connected to a voltage sup ply but since there is no conduction the circuit will not supply current to components connected to the Source The circuit is turned OFF like a light switch Example B shows the IGBT in an active mode When the gate signal a positive DC voltage relative to the Source is applied to the gate terminal of the IGBT it is capable of conducting current A voltage supply con nected to the drain terminal will allow the IGBT to con duct and supply current to the circuit components coupled to the source Current will flow through the conducting IGBT to downstream components as long as the positive gate signal is present This is similar to turning ON a light switch FIGURE E 6 IGBT GATE lt BODY REGION DRAIN DRIFT REGION BU
53. around welding cables and welding machines 1 c Do not add the fuel near an open flame weld ing arc or when the engine is running Stop the engine and allow it to cool before refuel ing to prevent spilled fuel from vaporizing on contact with hot engine parts and igniting Do not spill fuel when filling tank If fuel is spilled wipe it up and do not start engine until fumes have been eliminated EMF fields may interfere with some pacemakers and welders having a pacemaker should consult their physician 1 d Keep all equipment safety guards covers and devices in posi before welding tion and in good repair Keep hands hair clothing and tools away from V belts gears fans and all other moving parts he Exposure to EMF fields in welding may have other health when starting operating or repairing equipment effects which are now not known All welders should use the following procedures in order to 1 6 some cases it may be necessary to remove safety md SN minimize exposure to EMF fields from the welding circuit guards to perform required maintenance Remove guards only when necessary and replace them when the maintenance requiring their removal is complete Always use the greatest care when working near moving parts 2 d 1 Route the electrode and work cables together Secure them with tape when possible 2 d 2 Never coil the electrode lead around your body 1 f Do not put your hands near the eng
54. board with the machine energized Return to Section TOC Return to Master TOC MATERIALS NEEDED Analog Volt Ohmmeter 5 16 in Wrench 7 16 in Wrench 5 5 218 5 2 a This procedure takes approximately 30 minutes to perform Return to Section TOC Return to Master TOC POWER WAVE 355 405 LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC O10 5 5 gt 2 2 EIS 2 Return to Section TOC Return to Master TOC F 16 F 16 TROUBLESHOOTING amp REPAIR MAIN SWITCH BOARD TEST continued FIGURE F 2 MAIN SWITCH BOARD LEAD LOCATIONS TEST PROCEDURE 1 Remove input power to the POWER WAVE 355 405 2 Using a 5 16 nut driver remove the case wraparound 3 Perform the Input Filter Capacitor Discharge Procedure detailed earlier in this section 4 5 Using a 7 16 wrench locate label and remove leads 201 202 203 204 205 206 207 and 208 from the switch board Note lead and washer placement for reassembly Clear leads Using the Analog ohmmeter perform the resis tance tests detailed in Refer to fig ure 2 for test point locations Note Test using an Analog ohmmeter on the Rx1 range Make sure the test probes are making electri cal contact with the conductor surfaces on the PC board POWER WAVE 355 405 LINCOLN 5
55. components that may have failed in your machine It also specifies the appropriate test procedure to verify that the subject component is either good or bad If there are a number of possible components check the components in the order listed to eliminate one possibility at a time until you locate the cause of your problem All of the referenced test procedures referred to in the Troubleshooting Guide are described in detail at the end of this chapter Refer to the Troubleshooting and Repair Table of Contents to locate each specific Test Procedure All of the referred to test points components terminal strips etc can be found on the referenced electrical wiring diagrams and schematics Refer to the Electrical Diagrams Section Table of Contents to locate the appropriate diagram CAUTION If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed Call 1 800 833 9353 WELD POWER WAVE 355 405 LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC O10 515 g 9 5 2 Return to Section TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING amp REPAIR PC BOARD TROUBLESHOOTING PROCEDURES WARNING N ELECTRIC SHOCK can kill Have an electrician install and ser
56. conform to ANSI 287 standards Use suitable clothing made from durable flame resistant material to protect your skin and that of your helpers from the arc rays Protect other nearby personnel with suitable non flammable screening and or warn them not to watch the arc nor expose themselves to the arc rays or to hot spatter or metal FUMES AND GASES can be dangerous 5 a Welding may produce fumes and gases hazardous to health Avoid breathing these fumes and gases When welding keep your head out of the fume Use enough ventilation and or exhaust at the arc to keep fumes and gases away from the breathing zone When welding with electrodes which require special ventilation such as stainless or hard facing see instructions on container or MSDS or on lead or cadmium plated steel and other metals or coatings which produce highly toxic fumes keep exposure as low as possible and below Threshold Limit Values TLV using local exhaust or mechanical ventilation In confined spaces or in some circumstances outdoors a respirator may be required Additional precautions are also required when welding on galvanized steel Do not weld in locations near chlorinated hydrocarbon vapors coming from degreasing cleaning or spraying operations The heat and rays of the arc can react with solvent vapors to form phosgene a highly toxic gas and other irritating prod ucts Shielding gases used for arc welding can displace air a
57. family of products utilize a digital communication sys tem called Linc Net Simply put Linc Net allows large amounts of information to be passed at very high speeds between components nodes in the system The system requires only two wires for communication and because of its bus like structure the components may be connected to the network in any order thus simplifying the system set up Each system must contain only one power source The power source may be connected to a maximum of four feeder groups Each group containing one user interface and up to seven Feed Heads FH SEE FIGURE The UI controls all of the of that group The Ul s and FH s are assigned to groups by setting a code on the DIP switches mounted on their individual control boards For example all of the FH s to be controlled by a given UI must have their Group ID switches set to the same group number as the UI In addition each FH must be assigned a separate FH number within that group See the system set up sec tion for further details System Model Maximum Configuration From a network perspective each component in the system is considered a separate node regardless of its physical location For example even though a UI and FH may be physically mounted together they are still viewed as separate pieces nodes by the network and can only communicate via Linc Net The Linc Net connection is generally made external through the Lin
58. gt THIS SHEET CONTAINS PROPRIETARY INFORMATION OWNED BY THE LINCOLN ELECTRIC Si EARTHIGRDUND CONNECTION 0 34 0 AND IS NOT TO BE REPRODUCED DISCLOSED OR USED WITHOUT THE EXPRESS PERMISSION OF THE LINCOLN ELECTRIC z 4 olg MUSEUM THELINCOLNELECTRIC GG INVERTER WELDERS amp 2 2000 CLEVELAND OHIO U S A suasect 5 DIGITAL CONTROL c N A SINCE COMPONENTS OR CIRCUITRY ON PRINTED CIRCUIT BOARD MAY CHANGE PLACE DECIMALS 15 002 8 4 2000P 02 SUBJECT WITHOUT AFFECTING THE INTERCHANGEABILITY OF COMPLETE BOARD THIS DIAGRAM MAY ON ALL ANGLES IS_t 5 OF DEGREE SCALE NONE Em NOT SHOW THE EXACT COMPONENTS OR CIRCUITRY OF CONTROLS HAVING A COMMON CODE MATERIAL TOLERANCE 7 TO AGREE DR Date _08 02 2000 SUP S D G No G3789 100 gt WITH PUBLISHED STANDARDS 72 NUMBER m NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual POWERWAVE 355 405 ELECTRICAL DIAGRAMS SCHEMATIC DIGITAL CONTROL PC BOARD 83
59. harm cancer birth defects or other reproductive harm The Above For Diesel Engines The Above For Gasoline Engines ARC WELDING CAN BE HAZARDOUS PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH KEEP CHILDREN AWAY PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING Read and understand the following safety highlights For additional safety information it is strongly recommended that you purchase a copy of Safety in Welding amp Cutting ANSI Standard Z49 1 from the American Welding Society P O Box 351040 Miami Florida 33135 or CSA Standard W117 2 1974 A Free copy of Arc Welding Safety booklet E205 is available from the Lincoln Electric Company 22801 St Clair Avenue Cleveland Ohio 44117 1199 BE SURE THAT ALL INSTALLATION OPERATION MAINTENANCE AND REPAIR PROCEDURES ARE PERFORMED ONLY BY QUALIFIED INDIVIDUALS 1 h To avoid scalding do not remove the FOR ENGINE A Uem not remove th powered equipment TA 2 en the engine IS 1 Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running 3 1 6 Operate engines in open well ventilated areas or vent the engine exhaust fumes outdoors a ELECTRIC AND MAGNETIC FIELDS N may be dangerous 2 4 Electric current flowing through any conductor causes localized Electric and Magnetic Fields EMF Welding current creates EMF fields
60. is being operated with single phase input voltage make sure the correct lead is not connected See the Installation Auxiliary 1 Perform the Transformer Test 2 Perform the DC Bus Board Test 2 Perform the Power Board Test 3 The Bus Board rectifier and or associated filter capacitor C5 may be faulty Check and replace as necessary 4 The Control Board may be faulty The main input fuses or breaker repeatedly fail 1 Make certain the fuses or break ers are sized properly Make sure the reconnect switch and jumper lead is configured correctly for the applied input voltage 3 The welding procedure may be drawing too much input current or the duty cycle may be too high Reduce the welding cur rent and or reduce the duty cycle 1 Check the reconnect switches and associated wiring See the Wiring Diagram 2 Perform the Input Rectifier 3 Perform the Main Switch Board 4 Perform the Output Diode Module Test 5 The Input Filter Capacitors may be faulty Check and if any are faulty replace all four CAUTION 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 WELD POWER WAVE 355 405 LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC O1
61. mE 1 2 07802 n DATAISI 121501 rs 1 pe 089 SCK 14 10 SW 18 2 081013 AD_DATAILO SHT 1 CLK SRON m it 13 n 17 2 AD DATALL1 5 00 5 Look 056 055 E 7K 03 100 100 100 100 100 100 100 100 100 100 SAWTOOTH GENERATOR E 2005 200 bs AD DATA 131 a a iB ih 8 d AUS NC28 SHT 1 SYS RESET jz jz jz jz je jz 30V 4 23 o e 1 20 1 24 iw 1 2 172W 172w 172w 1 24 172w iw Z E E 15 057 ost 51 13 A 27 0101 0v 20 BRI 2 8 amp 209 PRIMARY CURRENT SENSE iig E 5VA 8 1 RES LFLOW STT SHT 1 C126 vy AD DATAIO 15 pgo sm 2 i 14 pei ___ 5 I o 70V ES AD DATAIZ 13 pe T x2 7 ADDATAI 12 pe 528 4 4 R54 R58 6 mo SES AD_DATAI4 11 MA LAD TOOK TOOK olo ve 8 ado y 8108 8106 m A gt SHT 4 s 400v Er 5 R66 N a our 7 SHT 1 TOK 100 zt lu Tak aly In 9 ag cro 7 LADIT INPUT FROM 2ND LEM 8 010 ar n 5 81 i 058 M gt goes v m iE 1 7 2 10071 20221 4102 39 20 o 100V AD DATAI9 6 res 8214 315 i M STT CURR olo C125
62. observe all safety notes and precautions detailed throughout this manual Return to Section TOC Return to Master TOC If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed Call 1 800 833 9353 WELD DESCRIPTION The following procedure will aid the technician in removing the current transducer for maintenance or replacement MATERIALS NEEDED 5 16 Nut Driver 1 4 Nut Driver 1 2 Nut driver 3 8 Nut Driver Channel Locks Return to Section TOC Return to Master TOC Flathead Screwdriver Phillips Head Screwdriver Hammer Crescent Wrench Q 0 8 2 Pliers Q 5 2 5 tc This procedure takes approximately 45 minutes to perform Return to Section TOC Return to Master TOC POWER WAVE 355 405 LINCOLN 5 F 74 F 74 TROUBLESHOOTING amp REPAIR CURRENT TRANSDUCER REMOVAL AND REPLACEMENT continued PROCEDURE 1 Remove input power to the POWER WAVE 4 Using a 5 16 nut driver ramova the four screws 355 405 from the bottom and right side of the rear assem bly See Figure F 34 2 Using a 5 16 nut driver remove the case wrap around cover 3 Perform the Input Filter Capacitor Discharge Procedure detailed earlier in this section
63. sink so be sure to get the face of the Screw into contact with the surface of the module using just hand torque Using a 7 16 socket tighten each mounting bolt to between 5 and 10 inch pounds Tighten the center allen screw to between 12 and 18 inch pounds Tighten each mounting bolt again 30 to 40 inch pounds this time Replace leads X2 X4 20 40 to their original terminals in their proper positions Torque bolts to 30 40 Inch Pounds Perform the Snubber Board Replacement Procedure detailed earlier in this section Replace the case wraparound cover FIGURE F 33 OUTPUT RECTIFIER MODULE MOUNTING BOLT LOCATIONS Mounting Bolts X4 X2 Bolts Mounting Bolts POWER WAVE 355 405 LINCOLN 5 F 72 LINCOLN jo NOTES POWER WAVE 355 405 F 72 901 Je1Se A 0 901 4 1 0 uunjeH 901 J91Se N 01 901 J91Se N 01 DOL uonoes DOL uonoes uumeg DOL uonoes 901 uonoes uumeg F 73 F 73 TROUBLESHOOTING amp REPAIR CURRENT TRANSDUCER REMOVAL AND REPLACEMENT WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty For your safety and to avoid electrical shock please
64. the POWER WAVE 355 405 in mode 200 48 and the current transducer 190 See The 2 2 Mode 200 is a constant current test mode Wiring Diagram For access to plug J90 and This mode can be accessed using a wire feed the current transducer refer to er placed in mode 200 or a laptop computer and the appropriate software Apply the grid load across the output of the POWER WAVE 355 405 Set machine output to 300 amps 11 Remove input power to the POWER WAVE and enable WELD TERMINALS Adjust the Searle grid load to obtain 300 amps on the external 12 Replace the control box top and any cable ties ammeter and check feedback voltages per previously removed Table Ton 13 Install the case wraparound cover using the A Pin 1 lead 801 to Pin 6 lead 806 should 5 16 nut driver read 2 4 VDC machine loaded to 300 amps 9 If for any reason the machine cannot be loaded to 300 amps Table F 6 shows what feedback voltage is produced at various cur rent loads Ojo O10 5 5 gt g 9 5 2 EC 10 If the correct supply voltages are applied to the current transducer and with the machine loaded the feedback voltage is missing or not correct the current transducer may be faulty Return to Section TOC Return to Master TOC POWER WAVE 355 405 LINCOLN 5 F 42 LINCOLN 2 NOTES POWER WAVE 355 405 F 42 901 Je1Se A 0 901 4 1 0 uunjeH 901 J91Se N 01 9
65. the machine clean will result in cooler operation and higher reliability Be sure to clean these areas All printed circuit boards Power switch Main transformer Input rectifier Auxiliary Transformer Reconnect Switch Area Fan Blow air through the rear louvers 2 Examine the sheet metal case for dents or breakage Repair the case as required Keep the case in good condition to insure that high voltage parts are protected and correct spacings are maintained All external sheet metal screws must be in place to insure case strength and electrical ground continuity PERIODIC MAINTENANCE Calibration of the POWER WAVE 355 405 is critical to its operation Generally speaking the calibration will not need adjustment However neglected or improper ly calibrated machines may not yield satisfactory weld performance To ensure optimal performance the cali bration of output Voltage and Current should be checked yearly POWER WAVE 355 405 LINCOLN 5 D 3 o z o oO E 5 9 2 5 o lt om Z 5 z i oc gt 2 er gt a 5 o IL 2 5 5060 z M L lt 42 Looovo YN G G GC Ww 4 16 901 Je1Se A 0 901 4 1 0 901 J91Se N 01 901 J91Se N 01 DOL uonoes DOL uonoes
66. the table below Recommended Welding Procedures for Power Mode MATERIAL Aluminum 4043 Aluminum 5356 Mild Steel Mild Steel Mild Steel Mild Steel Mild Steel Mild Steel Stainless Steel Stainless Steel WIRE E4043 E5356 L56 L56 156 156 156 156 E308L E308L WIRE SIZE 0 035 0 030 0 030 0 035 0 035 0 030 0 035 GAS 100 Ar 100 75 25 100 75 25 Tri mix Tri mix 22 ga 125 2 25 125 1 75 Not Recommended 100 0 8 Not Recommended 90 1 0 o 20 150125 150 23 120 10 120 10 100 07 100 10 80 15 50 05 E 18 ga 2003 75 200 3 0 140117 140115 110 15 110 15 100 25 100 25 110 20 110 20 5 1 46 ga 300 775 300 6 85 190 20 190 20 125 20 125120 125 30 125 30 140 25 130 27 E 14 400 90 160 23 160 23 160 3 8 2 450195 45018 0 330 50 330 45 230 35 230 35 200 50 200 45 270150 230160 POWER WAVE 355 405 LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o o E 5 B tc Return to Section TOC Return to Master TOC Q 7 8 2 INSTALLATION PULSE WELDING GMAW P The pulsed arc process is by definition a spray trans fer process wherein spray transfer occurs in pulses at regularly spaced intervals In the time between pulses the welding current is reduced and no metal transfer occurs Pulsed arc tr
67. with silicon sealant Replace the case wraparound cover FIGURE F 31 INPUT RECTIFIER CLOSE UP Small Lead H1 To Auxiliary Transformer 3 16 ALLEN BOLTS FRONT REAR 207 207A 209 Small Lead A To Circuit Breaker POWER WAVE 355 405 LINCOLN 5 F 68 LINCOLN jo NOTES POWER WAVE 355 405 F 68 901 Je1Se A 0 uunjeH 901 Je1Se A 0 901 J91Se N 01 901 J91Se N 01 DOL uonoes 901 uonoes uumeg DOL uonoes 901 uonoes uumeg F 69 i TROUBLESHOOTING amp REPAIR OUTPUT RECTIFIER MODULES REMOVAL AND REPLACEMENT WARNING Return to Section TOC Return to Master TOC Service and repair should be performed by only Lincoln Electric factory trained personnel Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty For your safety and to avoid electrical shock please observe all safety notes and precautions detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed Call 1 800 833 9353 WELD DESCRIPTION The following procedure will aid the technician in removing the output rectifier modules for maintenance or replacement MATERIALS
68. you proceed Call 1 800 833 9353 WELD DESCRIPTION The following procedure will aid the technician in removing the control board for maintenance or replacement MATERIALS NEEDED 5 16 Nut Driver 3 8 Nut Driver Flathead Screwdriver Phillips Head Screwdriver This procedure takes approximately 30 minutes to perform POWER WAVE 355 405 LINCOLN 5 F 47 F 48 F 48 TROUBLESHOOTING amp REPAIR CONTROL BOARD REMOVAL AND REPLACEMENT continued FIGURE F 17 CONTROL BOARD LOCATION Return to Section TOC Return to Master TOC 0 9 5 8 min 9 1 0 iz g 2 Control Board 51 3 tio c PROCEDURE 1 Remove input power to the POWER WAVE 4 Locate the control board behind the front panel of 355 405 the machine See Figure 17 5 Using a 5 16 nut driver remove the two screws from the bottom of the front of the machine See Figure F 18 2 Using a 5 16 nut driver remove the case wrap around cover 3 Perform the Input Filter Capacitor Discharge Procedure detailed earlier in this section FIGURE F 18 CASE FRONT SCREW REMOVAL L STATUS THERMAL olo OJO 5 5 8 8 EIS 43 Mounting Screws Ojo Phillips Head Olo Phillips Head Screws Screws o o 9 E e e 2 2 5 16 tio POWER WAVE
69. 0 515 zio 9 16 gt g 9 5 4353 a Return to Section TOC Return to Master TOC Return to Master TOC di TROUBLESHOOTING amp REPAIR TROUBLESHOOTING GUIDE PROBLEMS SYMPTOMS The machine does not have weld ing output F 5 Observe Safety Guidelines detailed in the beginning of this manual POSSIBLE AREAS OF MISADJUSTMENT S OUTPUT PROBLEMS Make sure the reconnect switch is configured correctly for the input voltage applied Primary current limit has been exceeded Possible short in output circuit Turn machine off Remove all loads from the output of the machine Turn back on If condition persists turn power off and contact an authorized Lincoln Electric Field Service Facility This problem will normally be accompanied by an error code Error codes are displayed as a series of red and green flashes by the status LED If an error code is displayed If thermal light is on wait for machine to cool RECOMMENDED COURSE OF ACTION 1 Check the reconnect switch and associated leads for loose or faulty connections See the wiring diagram 2 Perform the DC Bus Board 3 Perform Main Switch 4 Perform the 5 Perform the Output Diode Module Test 6 The control board may be faulty 7 The input filter capacitors may be faulty Check and replace if necessary The POWER WAVE 355 405 will not produce full output The input voltag
70. 01 J91Se N 01 DOL uonoes DOL uonoes uumeg DOL uonoes 901 uonoes uumeg F 43 F 43 TROUBLESHOOTING AND REPAIR FAN CONTROL AND MOTOR TEST WARNING Return to Section TOC Return to Master TOC Service and repair should be performed by only Lincoln Electric factory trained personnel Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty For your safety and to avoid electrical shock please observe all safety notes and precautions detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed Call 1 800 833 9353 WELD DESCRIPTION This test will help determine if the fan motor control board switch board or associated leads and connectors are functioning correctly Return to Section TOC Return to Master TOC MATERIALS NEEDED Voltmeter 5 16 Nut Driver This procedure takes approximately 40 minutes to perform O10 5 5 gt 218 5 2 a Return to Section TOC Return to Master TOC POWER WAVE 355 405 LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC E 5 5
71. 1 127 OSP_AIL4 o 2 15 TPUIZI 110 128 121 014 1 EE n 1 0110 1 0128 05 _ 115 2i 128 5 _ 5 TPUDI 12 127 1 DIS MSB 15 58 128 DSP AUSI o gt 709 1 0127 SHT 1 5 55 1 415591 113 1 0113 1 0126 126 DSP DI111 Vip 9 boy Gl PSWI3I 1001251125 DSP Dii2l 4 6 115 124 5 01131 pE 10124 c o PSWIAI SHT 171 FUNCEN 116 016 1 01231123 DSP DI151 5 jeu eB 117 017 1001221222 DSP D 14 5 2 0102 4 2E 0103 L 2E 010 1 2 0105 11 25 0106 d 2E 0107 Ui 4 DSP READY i19 j 120 DSP_MP 07 02 02 024 02A 02A A 4 10119 1 0120 70V 70V 70V 70V 70V 70V 1 EU PSWI amp l 520 208 3 3 3 3 3 3 PSWI7 Ve 61 1 IO gt sit oR vi En 8223 R262 Bg 3 2 MU 100 332 4 hs CE 83 R224 R s 02 wb 100 TIW 1 73 5 6 A AS 85 8240 8265 a 1 M 100 126 8 HC245 12 lus B B7 R226 R265 8 M 100 337 x R227 aa ET 10 3321 1766 RZ 1041 1288 5718267 8 A 5 I 47 0 12 13 M m x10 RB6 4 R83 B GENERAL INFORMATION LAST No USED l C47 097 C96 C98 C100 1 415 175 21510 21510 01 01 01 VHCL4D ELECTRICAL SYMBOLS PER E1537 35V 35V 50V 50V 50V D45 red CAPACITORS MFD 022 50V UNLESS OTHERWISE SPECIFIED 76 53 78 105 130156 163 208 51V 2 RESI
72. 1 2 442 m 1 000 C O TEST PROCEDURE Remove input power to the Power Wave 355 405 Using the 3 8 nut driver remove the case top apacitor Discharge Procedure Locate the Power Board and plugs J42 and J43 Do not remove plugs or leads from the Power Board Refer to Figure F 8 Carefully apply input power to the Power Wave 355 405 WARNING ELECTRIC SHOCK can kill High voltage is present when input power is applied to the machine Turn on the Power Wave 355 405 Carefully test for the correct voltages at the Power Board according to Table 4 If either of the 40 VDC voltages is low or not present at plug J41 perform the DC Bus PC See the Wiring Diagram Also perform the lf any of the DC voltages are low or not pre sent at plugs J42 and or 43 the Power Board may be faulty Install the case top using the 3 8 nut driver POWER WAVE 355 405 LINCOLN 5 F 24 F 25 F 25 TROUBLESHOOTING amp REPAIR POWER BOARD TEST CONTINUED TABLE F 3 POWER BOARD VOLTAGE CHECKS CHECK POINT TEST LOCATION DESCRIPTION CONNECTOR PLUG PIN NO IDENTITY LEAD NO OR NORMAL ACCEPTABLE Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC POWER BOARD CONNECTOR PLUG J41 POWER BOARD CONNECTOR PLUG J42 POWER BOARD CONNECTOR
73. 151 SHE 1 5 gt SHT 2 5 R203 SHT 3 PRI_OC 13 1001482122 OUTPUT ON 45 Ve gt SHT 4 TOK 221 PWRONINT 18 SOFTST C ieej MN QUT 16 XC9536 1701682 20 DISABLE 455 STA n SHT 4 18 1781 1 017 2 19 2 2 eoe 72 208 06 172 C65 CLK 8 43 11 pi 820pF 51 820pF 820pF AS 4700pF SHT 2 V O GCK1 TCK 3 Q 50V 1 2W 50V D 50 50V 15V CLK 44 yo yecK2 mL Eres i I nj gp 7 2 O J6 SHT 4 Sce 1 Too 2 21 Sio GENERAL INFORYATION _ m ia 1 SHE MPA musto n p x E xn Lu xa LU AD ELECTRICAL SYMBOLS PER E1537 R 267 X 33 L 1 00 4 34 15V 50 xros3s 50 50V 1281 2011 50V 50V Tsoy CAPACITORS MFD 022 50V UNLESS OTHERWISE SPECIFIED C M3 0 20 Y 1 LED 10 c 1E gba oars uS 28 900 RESISTORS Ohms 1 4W UNLESS OTHERWISE SPECIFIED LABELS 0 15 02 4 s 1 7 3 olo FILTER CAPACITOR VOLTAGE MONITORING E 1 D GSR 00K m she SUPPLY VOLTAGE NET t 95 J5 5 POWER SUPPLY SOURCE POINT 9 9 2 m 57 COMMON CONNECTION R33 R99 L NT 1 3 sH 4 A A FILENAME 63789 10 7H FRAME CONNECTION o gt 10K THIS SHEET CONTAINS PROPRIETARY INFORMATION OWNED BY THE LINCOLN ELECTRIC CO GROUND CONNECTION nm ak hm AND IS NOT TO BE REPRODUCED DISCLOSED OR USED WITHOUT THE EXPRESS PERMISSION OF TH
74. 1Se N 01 901 J91Se N 01 DOL uonoes DOL uonoes uumeg DOL uonoes 901 uonoes uumeg F 39 F 39 TROUBLESHOOTING AND REPAIR CURRENT TRANSDUCER TEST WARNING Return to Section TOC Return to Master TOC Service and repair should be performed by only Lincoln Electric factory trained personnel Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty For your safety and to avoid electrical shock please observe all safety notes and precautions detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed Call 1 800 833 9353 WELD ojo 515 ola 8 olo DESCRIPTION This test will help determine if the current transducer and associated wiring are functioning tio correctly MATERIALS NEEDED Volt ohmmeter 5 16 Nut Driver Grid Bank External DC Ammeter This procedure takes approximately 45 minutes to perform Ojo O10 E 5 8 gt 2 2 5 2 a Return to Section TOC Return to Master TOC POWER WAVE 355 405 LINCOLN 5 F 40 F 40 TROUBLESHOOTING AND REPAIR CURRENT TRANSDUCER TEST continued FIGURE F 12 Metal
75. 27 P22 15 STATUS 43 E SCAN 8 150 r SHT 1 WRH P27 p2ipe E ADDRILT ried idi BUSS L Jy E ADO CLOCKOUT SHT 1 4 3 ADI READY MISO 28 4 z ADORISI 2 02 wwen 2 2 1 15 STATUS LED Eo 475 1 512 BB DATAIBI i 2 a CIRCUITRY Bd tc ADDRISI 2 DATAISI FO AD4 MOSI P11 AD9 3 DE 8 T BUSS H 1 ADDRIGI ADS PL2 AD10 DATADO ajo 485 6 AD6 SCLK P13 A011 Bak 2 84 01 ADDRIBI DATAU121 ge v EA 005 PLA ADI2 05 10601 18 xTALL P15 A013 DATAS ni 5 082 N 085 150 2 141 3 62V 62V amp 16 2 XTAL2 P1 6 AD14 45V 3w Yt PLI ADLS DATAUSI LED YE 57 GREEN V x 1 8 rd ADDRIL 19 m ae EM ae DATAIO 151 Jir v 2 ON GCAN 50 50 v 026 400 253 rd D AU CAN COMMUNICATION CIRCUITRY 8 2428 400V 100 121 JB 01 8 44 98 011 50V X MUN COMMUNICATION CIRCUITRY Q 3W 5 GENERAL INFORMATION LAST NO USED J8 6 ELECTRICAL SYMBOLS PER E1537 4 CAPACITORS MFD 022 50V UNLESS OTHERWISE SPECIFIED 81 23 Lamp m V T u UNLE ols bv 1 ISOLATION BARRIER SUPPLY VOLTAGE NET am 5 POWER SUPPLY SOURCE POINT o 3 R52 28 oe 57 COMMON CONNECTION 100 T 82527 50V FILENAM 83789 10 7777 FRAME CONNECTION
76. 355 405 LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o 0 52 2 F 49 TROUBLESHOOTING amp REPAIR F 49 CONTROL BOARD REMOVAL AND REPLACEMENT continued FIGURE F 19 CONTROL BOARD ALL PLUG LOCATIONS CAUTION 8 The front of the machine may now gently be pulled forward to gain access to the Control Board Note The front of the machine cannot be removed completely only pulled forward a few inches o E 5 B Observe static precautions detailed in 9 Board Troubleshooting Procedures at the beginning of this section Beginning at the right side of the control board remove plugs J10A and J10B Note Be sure to label each plugs position upon removal See Return to Section TOC Return to Master TOC Using a phillips head screwdriver remove the two screws and their washers from above and below the input power switch See Figure F 18 Using phillips head screwdriver remove the four screws from around the two welder output termi nals on the front of the machine Seg Figure F 18 10 11 Figure F 19 Working your way across the top of the board from right to left label and remove plugs 49 8 7 J6 and J5 See Figure 19 Working your way down the left side of the board label and remove plugs J4 and J2 Se
77. 405 LINCOLN 5 SAFETY 6 Eloigner les mat riaux inflammables ou les recouvrir afin de Return to Master TOC Return to Master TOC Q 0 5 Return to Master TOC PR CAUTIONS DE S RET Pour votre propre protection lire et observer toutes les instructions et les pr cautions de s ret specifiques qui parraissent dans ce manuel aussi bien que les pr cautions de s ret g n rales suiv antes S ret Pour Soudage A L Arc 1 Protegez vous contre la secousse lectrique a Les circuits l lectrode et la pi ce sont sous tension quand la machine souder est en marche Eviter toujours tout contact entre les parties sous tension et la peau nue ou les v tements mouill s Porter des gants secs et sans trous pour isoler les mains Faire tr s attention de bien s isoler de la masse quand on soude dans des endroits humides ou sur un plancher met allique ou des grilles metalliques principalement dans les positions assis ou couch pour lesquelles une grande partie du corps peut tre en contact avec la masse Maintenir le porte lectrode la pince de masse le c ble de soudage et la machine souder en bon et s r tat defonc tionnement d Ne jamais plonger le porte lectrode dans l eau pour le refroidir Ne jamais toucher simultan ment les parties sous tension des porte lectrodes connect s deux machines souder parce que la tension entre l
78. 5 9 16 8 8 5 2 a Return to Section TOC Return to Master TOC F 59 F 59 TROUBLESHOOTING amp REPAIR POWER BOARD REMOVAL AND REPLACEMENT continued CAUTION Observe static precautions detailed Board Troubleshooting Procedures at the beginning of this section 5 Locate the three plug connections J41 J42 and J43 on the Power Board See figure F 26 6 Carefully disconnect the three plugs from the Power Board 7 Remove the three nuts at the corners of the board using a 3 8 nut driver Board is ready for removal 8 Replace the power board 9 Secure the new power board into its proper posi tion with the three 3 8 nuts previously removed 10 Reconnect the three plugs previously removed Plugs J41 J42 and J43 11 Replace the case wraparound cover FIGURE F 26 POWER BOARD LEAD LOCATION J42 J41 J43 POWER WAVE 355 405 LINCOLN 5 F 60 LINCOLN NOTES POWER WAVE 355 F 60 901 Je1Se A 0 901 4 1 0 uunjeH 901 J91Se N 01 901 J91Se N 01 DOL uonoes DOL uonoes uumeg DOL uonoes 901 uonoes uumeg F 61 F 61 TROUBLESHOOTING amp REPAIR DC BUS BOARD REMOVAL AND REPLACEMENT WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel Unauthorized repairs performed on this equipment may result i
79. 7 electrode sense lead is internal to the cable to the wire feeder and always connected when a wire feeder is present CAUTION Important The electrode polarity must be config ured at the feed head for all semi automatic processes Failure to do so may result in extreme ly high welding outputs POWER WAVE TO SEMI AUTOMATIC POWERFEED WIRE FEEDER INTERCON NECTIONS The POWER WAVE 355 405 and semi automatic PowerFeed family communicate via a 5 conductor con trol cable K1543 The control cable consists of two power leads one twisted pair for digital communica tion and one lead for voltage sensing The cables are designed to be connected end to end for ease of exten sion The output receptacle on the POWER WAVE 405 is on the case front The input receptacle on the Power Feed is typically located at the back of the feeder or on the bottom of the user interface Due to the flexibility of the platform the configuration may vary The following is a general description of the system For specific configuration information consult the semi automatic Power Feed instruction manual POWER WAVE 355 405 LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC OJO 5 5 gt 218 5 2 a Return to Section TOC Return to Master TOC Return to Master TOC A 7 7 INSTALLATION SYSTEM DESCRIPTION The POWER WAVE 355 405 and Power Feed 10 11
80. 75 i 509 50V 10 01 o o 1 516 19 3 50V 0 CURRENT FEEDBACK _ K fook x8 x14 x20 3 gt SHT 2 15V INTEGRATOR 3T 50 330740 i 330740 24 330740 cos 5 50 NS I 01 014 T 01 7 HE c c T 0 0 29 STUP R127 3 ner 50 50 1 lou TN V P cic 3 3000 53 DA 5 WE BER A R122 4 m 100K 1 24 R209 R128 7 150 8 1 E rd TIK o 9 3429 sie RIS 12528 5 4 z SECONDARY CURRENT SENSE tt 100K 1 24 11 538 Q 100 fal VHCLAD TT 8 5 92 877 gy 09 m 5 15V 5VA EN 100K 1 2W 159 web SHT 1 9 xo 8 PREDA i 29 18 2 uci 25 lt lt 3500 VOLTS E 57 3 EN CONNECTOR 95 OHM lt s 0 2 id 1 100MHz SHT 4 MSELO 5 pax xm 9 ceo l cah slug cso 8 i R138 nios 80 Nin 50 zv Tsw SHT 4 IDEAL VOLTAGE 8124 R125 R118 R206 27 MA 100 T50K 45VA 100K E 3 SHT 4 MSELEN R120 4 r 330740 4 267 mzel R130 27 68K RIS 1 48 BET TEK 100K E ii 1 lt GAIN lt 11 V V Ve 330140 oy 0 34 400V 15V gt R121 gt 330740 S 15 3 pis 7 t RIZ9 TP6 7 1 pes IDEAL VRD Ojo 3 1 Ate 25 70 ARCVOLTS GENERAL INFORMATION perum 035 037 041 039 3 10 O 51V 51V 9 51V 51V ELECTRI
81. CAL SYMBOLS PER E1537 B 1 2W 1 20 1 20 1 28 050 NE vA CAPACITORS MFD 022 50 UNLESS OTHERWISE SPECIFIE 4 id gt RESISTORS Ohms 1 4W UNLESS OTHERWISE SPECIFIED LABELS gt 6 5 lix Ge cm VOLTAGE FEEDBACK DIODES 1A 400V UNLESS OTHERWISE SPECIFIED SUPPLY VOLTAGE NET to iW 4 1900 E 1006 M 15V O POWER SUPPLY SOURCE POINT COMMON CONNECTIO 0 5VA 4 5 E ia M 036 038 042 A Us ols Hes 475 FILENAME 63789 10 7 FRAME CONNECTION gt 07 514 siv 51V A 51 4 ES THIS SHEET CONTAINS PROPRIETARY INFORMATION OWNED BY THE LINCOLN ELECTRIC CO lt GROUND CONNEETIUR 9 i 2W Daw 1 24 Vow xs voo AND IS NOT BE REPRODUCED DISCLOSED CR USED WITHOUT THE EXPRESS PERMISSION OF THE LINCOLN ELECTRIC URN OFF N Hi 3 SHT amp GND 9 9 sly veal Mores UNLESS OTHERWISE SPECIFIED TOLERANCE 07956 TUE LINCOLN ELECTRIC CO INVERTER WELDERS e H HOLES SIZES PER E 2056 EU z TUE 6 2 2000 S SINCE COMPONENTS OR CIRCUITRY ON PRINTED CIRCUIT BOARD MAY CHANGE ON 3 PLACE DECIMALS 18 2 002 8 4 2000P CLEVELAND ORTO suasect SCHEMATIC DIGITAL CONTROL VN WITHOUT AFFECTING THE INTERCHANGEABILITY OF A COMPLETE BOARD THIS DIAGRAM MAY ON ALL ANGLES 15 5 OF A DEGREE PG NONE us 2 E NOT SHOW THE EXACT COMPONENTS OR CIRCUITRY OF CONTROLS HAVING COMMON CODE MA
82. CPLO601 18V IS E 20 5 1w 059 MC1454070W 166 tay A Mc JL lt lt gt SHT 134 9 M 052 150pF 18V 1000 1 2W 5 058 4 Q O LOOK 18V L cas 1 2W O O 9 nj 000 SV GRS vue 410 5232 5 Vcns232 43 X16 8 Er 66 9 M MC1454070W 10 45 5232 o z 19 16 17 20 55 1 of Yor VE ces xe MC145407DW 4 pu 55 10 10 2 3 gt SHT 4 16V 18 CASAN a 16V 2 640 Vss 7 X16 u Jh 5 5 2 2 100K gt gt 4 012 m MC1454070W Ed AC 50V 1 4 5 116 us gt 55 1806 695232 V MC1454070W GREEN 2 NAE Vans M M FULL DUPLEX RS232 COMMUNICATION LINK 695232 41558 2 155 1 n 4 221k 5 5 043 D 16V SCAN pa ms LEDS gt 15V 14 GREEN x ami 1 E 5 _ 5 8 475 EE 5 89 08 6 a8 He 5 ALE AS 1 2 1 LEDE CONTROL BOARD OE VOLTAGE SUPPLIES amp S 475 d X28 axo 22 1 010 5 ES ke T GCAN z t MODEL ED SCAN 0160 SHT 1 lt INT CAN 24 NT cc 2 p252 Aon 9 5 p24 13 13 03 asv o gt SYS RESET 2j he STATUS y SHT 1 RESE P23 60V 3W 8 c 825
83. D LIMITATIONS Connect a work lead of sufficient size and length between the proper output terminal on the power source and the work Be sure the connection to the work makes tight metal to metal electrical contact To avoid interference problems with other equipment and to achieve the best possible operation route all cables directly to the work or wire feeder Avoid excessive lengths and do not coil excess cable CAUTION When using an inverter type power source like the PowerWaves use the largest welding electrode and work cables that are practical At least 2 0 copper wire even if the average output current would not normally require it When pulsing the pulse current can reach very high levels Voltage drops can become excessive leading to poor welding characteristics if undersized welding cables are used Most welding applications run with the electrode being positive For those applications connect the elec trode cable between the wire feeder and the positive output Twist Mate terminal on the power source Connect the other end of the electrode cable to the wire drive feed plate The electrode cable lug must be against the feed plate Be sure the connection to the feed plate makes tight metal to metal electrical con tact The electrode cable should be sized according to the specifications given in the output cable connec tions section Connect a work lead from the negative power source output Twist Mate te
84. E LINCOLN ELECTRIC CO HERO 3 gk J5 SOV Ch ge Sht N X INFO EQUIP 43 lt NUTESG UNLESSOTHERMISE SPECIFIED Tovenance Hers THE LINCOLN ELECTRIC CO TYPE INVERTER WELDERS TLLA 6 2 2000A iz c 1c R3 THERMOSTA SINCE COMPONENTS OR CIRCUITRY ON A PRINTED CIRCUIT BOARD MAY CHANGE ON PLACE DECIMALS 18 2 O62 8 4 2000P CEEVELANDE OIO USA suasect SCHEMATIC DIGITAL CONTROL SINGLE THREE PHASE DETECT 175 WITHOUT AFFECTING THE INTERCHANGEABILITY OF COMPLETE BOARD THIS DIAGRAM MAY oN ALL ANGLES 15 5 OF DEGREE PG NONE 5 t t t t NOT SHOW THE EXACT COMPONENTS OR CIRCUITRY OF CONTROLS HAVING COMMON CODE MATERIAL TOLERANCE 7 TO AGREE DR FM Date 08 02 2000 ci SUP S D G No C3789 1D0 NUMBER WITH PUBLISHED STANDARDS i d n A NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual LINCOLN 59 ELECTRIC POWERWAVE 355 405 ELECTRICAL DIAGRAMS aS SCHEMATIC DIGITAL CONTROL PC BOARD 2
85. EMOVAL amp REPLACEMENT continued FIGURE F 21 MAIN SWITCH BOARD LEAD LOCATIONS PROCEDURE 1 Remove the input power to the POWER WAVE 355 405 2 Using a 5 16 nut driver remove the case wrap around cover Input Filter Capacitor Discharge detailed earlier in this section Perform th Procedure CAUTION Observe static precautions detailed in PC Board Troubleshooting Procedures at the beginning of this section Failure to do so can result in perma nent damage to equipment 4 Locate the main switch board and all associat ed plug and lead connections See figure F 21 See Wiring Diagram Using a 3 8 nut driver remove the input lead shield from the area at the bottom of the main switch board Using a 7 16 socket remove leads 201 202 203 204 205 206 207 208 209 from the switch board Note lead terminal locations and washer positions upon removal Locate and disconnect the three harness plugs associated with the main switch board Plugs J20 J21 J22 See Figure F 21 Locate the eight capacitor terminals and remove the nuts using a 7 16 socket or nut driver Note the position of the washers behind each nut for replacement POWER WAVE 355 405 LINCOLN 5 TROUBLESHOOTING amp REPAIR didi MAIN SWITCH BOARD REMOVAL amp REPLACEMENT continued FIGURE F 22 3 16 ALLEN BOLT LOCATION Return to Section TOC Return to Master TOC
86. ER SUPPLY PC BOARD VOLTAGE TABLE Positive Meter Probe Negative Meter Probe Approximate Voltage Conditions Comments Test Point Test Point Reading Plug P46 Pin 1 Plug P46 Pin 3 65 75 VDC Should be same as the Lead 65 Lead 66 Bus Rectifier Plug P47 Pin 8 Plug P47 Pin 1 38 0 42 0 VDC Supply to the Wire Lead 52 Lead 51 Feeder Receptacle Plug P47 Pin 3 Plug P47 Pin 6 38 0 42 0 VDC Lead 477 Lead 475 Supply to Power Board Ojo O10 515 9 1 218 5 2 Return to Section TOC Return to Master TOC POWER WAVE 355 405 LINCOLN 5 F 30 LINCOLN jo NOTES POWER WAVE 355 405 F 30 901 Je1Se A 0 901 4 1 0 uunjeH 901 J91Se N 01 901 J91Se N 01 DOL uonoes DOL uonoes uumeg DOL uonoes 901 uonoes uumeg F 31 F 31 TROUBLESHOOTING amp REPAIR OUTPUT DIODE MODULES TEST WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty For your safety and to avoid electrical shock please observe all safety notes and precautions detailed throughout this manual Return to Section TOC Return to Master TOC If for any reason you do not understand the test procedur
87. F 17 F 17 TROUBLESHOOTING amp REPAIR E MAIN SWITCH BOARD TEST continued o 9 8 6 If any test fails replace the switch board See 8 Reconnect leads 201 202 203 204 205 206 8 2 207 and 208 to the switch board Ensure that the pe leads are installed in their proper locations Pre 515 If the switch board resistance tests are OK check Torque all leads nuts to 25 inch 16 before tight 2 E connections on plugs J20 J21 J22 and all asso ening them to 44 inch Ibs ciated wiring See wiring diagram 9 Replace the case wraparound cover using a 5 16 nut driver TABLE 1 SWITCH BOARD RESISTANCE TEST APPLY POSITIVE TEST APPLY NEGATIVE TEST NORMAL PROBE TO TERMINAL PROBE TO TERMINAL RESISTANCE READING Greater than 1000 ohms Greater than 1000 ohms Greater than 1000 ohms Greater than 1000 ohms Less than 100 ohms Less than 100 ohms Less than 100 ohms Less than 100 ohms Return to Section TOC Return to Master TOC O10 E 515 gt 2 2 5 2 a Return to Section TOC Return to Master TOC POWER WAVE 355 405 LINCOLN 5 F 18 LINCOLN jo NOTES POWER WAVE 355 405 F 18 901 Je1Se A 0 901 4 1 0 uunjeH 901 J91Se N 01 901 J91Se N 01 DOL uonoes DOL uonoes uumeg DOL uonoes 901 uonoes uumeg TROUBLESHOOTING amp REPAIR INPUT RECTIFIER TEST WARNING
88. FFER LAYER p INJECTING LAYER DRAIN A PASSIVE POSITIVE VOLTAGE f APPLIED GATE SOURCE 0222 BODY REGION DRAIN DRIFT REGION BUFFER LAYER INJECTING LAYER DRAIN B ACTIVE POWER WAVE 355 405 LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC olo OJO 5 5 9 16 218 5 2 Return to Section TOC Return to Master TOC Return to Master TOC E 8 E 8 THEORY OF OPERATION FIGURE E 7 TYPICAL IGBT OUTPUTS lusec 48 50 u sec MINIMUM OUTPUT 24usec 2usec 94 sec 50 u sec MAXIMUM OUTPUT PULSE WIDTH MODULATION The term Pulse Width Modulation is used to describe how much time is devoted to conduction in the posi tive and negative portions of the cycle Changing the pulse width is known as modulation Pulse Width Modulation PWM is the varying of the pulse width over the allowed range of a cycle to affect the output of the machine MINIMUM OUTPUT By controlling the duration of the gate signal the IGBT is turned on and off for different durations during the cycle The top drawing in Figure E 7 shows the mini mum output signal possible over a 50 microsecond time period The positive portion of the signal represents one
89. G TOLERANCE PER E2058 o9 SheetNo wo DESIGN INFORMATION _ JREFERENCE ON 2 PLACE DECIMALS IS 02 6 2 2000 5626 ON 3 PLACE DECIMALS IS 002 DRAWNBY F V ONALANGLESISs5OFADEGRE XC UF MATERIAL TOLERANCE P TO AGREE ENGINEER SUPERSEDING WITH PUBLISHED STANDARDS qp PDONOTSCALETHIS DRAWING E ______ __ EQUIPMENT TYPE INVERTER WELDERS SNUBBER P C BOARD ASSEMBLY APPROVED sCAENONE 10 6 99 DRAWNGNo 19532 1 NOTE Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting PC Board repairs will invalidate your factory warranty Individual Printed Circuit Board Components not available from Lincoln Electric This information is pro vided for reference only Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician Improper PC board repairs could result in damage to the LINCOLN je machine POWERWAVE 355 405 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC e 9 16 ols g 9 AE 2 x 1 ELECTRICAL DIAGRAMS Gis SCHEMATIC 40 VDC BUSS PC BOARD OEEGTIA 45 120 VDC 40 VDC JN 8 eo gt 3 Work Lead Disconnect Pro
90. HESE SURFACES MUST BE MAINTAINEDCO PLANAR WITHIN 010 THROUGH ENTIRE SOLDERING AND SEALING PROCESS N P SEALANT HEIGHT BETWEEN MODULES NOT TO EXCEED 17 MAX THIS SHEET CONTAINS PROPRIETARY INFORMATION OWNED BY THE LINCOLN ELECTRIC COMPANY AND IS NOT TO BE REPRODUCED DISCLOSED OR USED WITHOUT THE EXPRESS WRITTEN PERMISSION OF THE LINCOLN ELECTRIC COMPANY CLEVELAND OHIO U ERES AVER TER WELDERS PLACE DECIMALS IS 002 SUBJECT SWITCH P C BOARD ASSEMBLY TO AGREE WITH PUBLISHED STANDARDS MEE SCALE FULL DATE 5 I 2000 DRAWINGNo 0 3830 1B1 Return to Section TOC Return to Master TOC NOTE Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting PC Board repairs will invalidate your factory warranty Individual Printed Circuit Board Components are not available from Lincoln Electric This information is pro vided for reference only Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician Improper PC board repairs could result in damage to the machine POWER MIG 300 ej ELECTRICAL DIAGRAMS 6 11 SCHEMATIC SNUBBER BOARD B40 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC C4 0047 1009 olo 5 5 eis 5 2 o x 1 N
91. L VOLTAGE FREQUENCY CONVERTER 1 VOLTAGE FREQUENCY CONVERTER 1 PRIMARY CURRENT SENSE 1 PRIMARY CURFENT SENSE 41 4 CURRENTFEEDBACK 4V 500A 15V 15V CONTROL BOARD COMMON STUD VOLTAGE SENSE STUD VOLTAGE SENSE THERMAL LED gt 8 7 gt THERMAL LED gt 7 7 STATUS LED HI FOR RED 3J7 gt STATUS LED HIFOR GREEN gt 4J7 ERMOSTAT ERMOSTAT VOLTAGE FREQUENCY CONVERTER 2 VOLTAGE FREQUENCY CONVERTER 2 PRIMARY CURRENT SENSE 2 PRIMARY CURRENT SENSE 2 GND a SOFT START CONTROL PULSE TRANSFORMER GATE DRIVE PULSE TRANSFORMER GATE DRIVE 15 a FAN CONTROL POWERDOWN SIGNAL HIGH RUN POWER DOWN SIGNAL J42 4 15V a CONTROL 5 gt 2 3 5V a GND a SUPPLY 1 15 42 2 15 F5 SPI b 43 3 SPI 15 SPI b 543 6 5V SPI b 15V SPI b SUPPLY SPI GND b J43 12 R2 10 Ohms GND SPI b 5V RS232 e 5 RS232 R amp e 2443 4 SUPPLY GND e 43 9 J43 11 20 c 943 8 CHOPPER HOFFER GND 2432 SUPPLY 20 0 543 7 GND d J43 1 49 6 11 4 5 343 5 J11 3 GND 2443 10 J9 4 VOLTAGE SENSE x J11 1 LINCNET 11 2 LINCNET GND e L5 WIRE FEEDER RECEPTACLE lt LINCNET B LINCNET
92. MAW CPP eere riu erben snakes B 8 Benefits of Pulse on Pulse B 8 POWER WAVE 355 405 LINCOLN 5 Section B 1 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o pe 2 5 tc Return to Section TOC Return to Master TOC Q 0 8 2 SAFETY PRECUATIONS Read this entire section of operating instructions before operating the machine WARNING ELECTRIC SHOCK can kill Unless using cold feed feature when m e feeding with gun trigger the elec trode and drive mechanism are always electrically energized and could remain energized several sec onds after the welding ceases Do not touch electrically live parts or electrodes with your skin or wet clothing e Insulate yourself from the work and ground Always wear dry insulating gloves FUMES AND GASES can be dangerous 23 Keep your head out of fumes Use ventilation or exhaust to remove B fumes from breathing zone WELDING SPARKS can cause fire or explosion Keep flammable material away e not weld on containers that have held combustibles ARC RAYS can burn 2 Wear eye ear and body protection 2 Observe additional guidelines detailed in the beginning of this manual is OPERATION GENERAL DESCRIPTION The
93. Master TOC iid TROUBLESHOOTING amp REPAIR us STATUS LED ERROR CODE TABLE NOTE The error code signal sequence is always preceded by a 2 second green light If more than one error code is present a 4 second off signal will separate the individual error code signals Note that the 2 sec green is only displayed at the beginning of the entire code sequence not between codes if more than one error code is present Example Code 11 long red followed by one short red followed by Code 21 two long reds fol lowed by one short red 2 sec green 1 2 sec red 1 6 sec off 0 4 sec red 4 0 sec off 1 2 sec red 0 4 sec off 1 2 sec red 1 6 sec off 0 4 sec red ERROR CODES FOR THE POWER WAVE The following is a list of possible error codes that the POWER WAVE 355 405 can output via the status light see Troubleshooting the Power Wave Power Feed System using the Status LED If connected to a PF 10 11 these error codes will generally be accompanied by an 006 or 100 on the user interface display CAN communication bus off Probably due to excessive number of communication errors User interface time out error Ul is no longer responding to the Power Source The most likely cause is a fault bad connection in the communication leads or control cable 21 Unprogrammed weld mode Contact the service department for instructions on reloading the Welding Software 22 Empty
94. OSED OR USED WITHOUT THE EXPRESS PERMISSION OF UNLESS OTHERWISE SPECIFIED TOLERANCE Ch ae Sht No EQUIP ON HOLES SIZES PER 2056 THE LINCOLN ELECTRIC CO TYPE ON 2 PLACE DECIMALS IS 02 MULTI SYSTEMS 40 VDC BUSS ON 3 PLACE DECIMALS IS 002 ON ALL ANGLES IS 5 OF A DEGREE MATERIAL TOLERANCE t AGREE WITH PUBLISHED STANDARDS CLEVELAND OHIO U S A SCALE DATE NONE 09 01 99 SUBJECT POW ER SU D PLY PCB SCH EMA TIC SUP S D C SHT NO 19330 Return to Section TOC Return to Master TOC NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual POWERWAVE 355 405 LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC OJO 5 5 2 2 EIS 2 o 1 Return to Section TOC Return to Master TOC SVM ERROR REPORTING FORM We need to know if there are errors in our manuals We also value any suggestions as to additional tests or procedures that would make this SVM a better tool for you If you discover new or different Problems or Symptoms that are not covered in the three col umn troubleshooting chart please share this information with us Please include the machine s code number and how the problem was resolved Thank You Technical Services Group Lincoln Electric Co
95. OTE This diagram is for reference only It may not be accurate for all machines covered by this manual 3 POWERWAVE 355 405 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Master TOC G 12 PC BOARD ASSEMBLY SNUBBER PC BOARD C1 ELECTRICAL DIAGRAMS COPPER SIDE EYELET DETAIL MAKE PER E1911 ENCAPSULATE WITH E1844 2 COATS TEST PER E3817 SN G 12 ITEM REQ D PART NO DESCRIPTION 4 520500 4 JCAPACITOR PPMF 0047 1000V BOX 2 14648 20 RESISTOR WW 5W 150 576 S8Q R2 R4 14648 25 RESISTOR WW 5W 10 5 SQ ITEM PART NO DESCRIPTION 1 M19532 A P C BOARD BLANK 2 T13157 16 TAB TERMINAL 3 9147 11 EYELET FEMALE 4 T9147 15 EYELET MALE NOTES N A FEMALE EYELET TO BE AGAINST THE COPPER SIDE AS SHOWN EYELET MUST NOT SPIN AFTER CLINCHING N B SOLDER EYELET SO THAT SOLDER COVERS ENTIRE EYELET AND ALL AROUND EYELET ON COPPER SIDE ONLY NO ICICLES OR SOLDER BLOBS PERMITTED MANUFACTURED AS pm M19532 1A0 IDENTIFICATION CODE THIS SHEET CONTAINS PROPRIETARY INFORMATION OWNED BY THE LINCOLN ELECTRIC COMPANY AND IS NOT TO BE REPRODUCED DISCLOSED OR USED WITHOUT THE EXPRESS WRITTEN PERMISSION OF THE LINCOLN ELECTRIC COMPANY CLEVELAND OHIO U S A UN OTHERW p D TOLERAN T MANUFACTURIN
96. Plate Removal amp Plug J8 Location Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC TEST PROCEDURE 6 Check for the correct DC supply voltages to the current transducer at plug J8 See Figure 1 Remove input power to the POWER WAVE F 12 355 405 A Pin 2 lead 8024 to pin 6 lead 806 2 Using the 5 16 nut driver remove the case should read 15 VDC wraparound cover 8 Por hef DET B Pin 4 lead 804 to pin 6 lead 806 Perform the should read 15 VDC If either of the supply voltages are low or miss 4 Locate plug J8 on the control board Do not ing the control board may be faulty remove the plug from the P C Board 5 Apply the correct input power to the POWER WAVE 355 405 olo OJO 5 5 9 16 218 5 2 FIGURE F 13 Plug J8 Viewed From Lead Side of Plug 802 804 801 O 9 9 O k Plug J8 Return to Section TOC Return to Master TOC POWER WAVE 355 405 LINCOLN 5 F 41 F 41 TROUBLESHOOTING AND REPAIR CURRENT TRANSDUCER TEST continued TABLE F 6 EXPECTED TRANSDUCER FEEDBACK OUTPUT LOAD CURRENT VOLTAGE Return to Section TOC Return to Master TOC olo cle 5 8 lt 8 2 olo 8 Check the feedback voltage from the current Before replacing the current transducer check p transducer using a resistive load bank and the leads and plugs between the control board 5 3 with
97. Power Wave semi automatic power source is designed to be a part of a modular multi process weld ing system Depending on configuration it can support constant current constant voltage and pulse welding modes The Power Wave power source is designed to be used with the semi automatic family of Power Feed wire feeders operating as a system Each component in the system has special circuitry to talk with the other system components so each component power source wire feeder user interface knows what the other is doing at all times These components commu nicate with Linc Net The POWER WAVE 355 405 is a high performance digitally controlled inverter welding power source capa ble of complex high speed waveform control Properly equipped it can support the GMAW GMAW P FCAW SMAW GTAW and CAC A processes It carries an output rating of 350 Amps 34 Volts at 6096 duty cycle and 300 Amps 32 volts at 10096 duty cycle RECOMMENDED PROCESSES AND EQUIPMENT RECOMMENDED PROCESSES The POWER WAVE 355 405 can be set up in a num ber of configurations some requiring optional equip ment or welding programs Each machine is factory preprogrammed with multiple welding procedures typ ically including GMAW GMAW P FCAW GTAW and CAC A for a variety of materials including mild steel stainless steel cored wires and aluminum The POWER WAVE 355 405 is recommended for semi automatic welding and may also be suitable for basic h
98. RE SIZE 0 035 3 64 0 035 3 64 d a 14 ga 250 0 200 0 230 0 22510 ao E a 17 gu 5 10 400 0 280 0 425 0 400 0 o 5 ane 550 0 340 0 670 0 500 0 oz pg olo req 1 4 600 0 400 0 700 0 550 0 A c COMMENTS Not Recommended Not Recommended Not Recommended Not Recommended below 200 WFS below 100 WFS below 200 WFS below 200 WFS POWER WAVE 355 Return to Master TOC Return to Master TOC Q 0 5 Return to Master TOC C 1 TABLE OF CONTENTS ACCESSORIES SECTION 7 0 6 1 1 1010 mcr Section C Optional 2 C 2 Field Installed eC C 2 Compatible Lincoln nennen nnns C 2 POWER WAVE 355 405 LINCOLN 5 C 1 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC 5 5 9 16 g 9 5 2 a Return to Section TOC Return to Master TOC 2 ACCESSORIES OPTIONAL EQUIPMENT FACTORY INSTALLED None Available FIELD INSTALLED K940 Work Voltage Sense Lead Kit K1764 1 Undercarriage K1838 1 Valet Style Undercarriage K1796 Coaxial Welding Cable Requires Adapter K2176 1 K2176 1 Twist mate to Lug Adap
99. Return to Section TOC Return to Master TOC Service and repair should be performed by only Lincoln Electric factory trained personnel Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty For your safety and to avoid electrical shock please observe all safety notes and precautions detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed Call 1 800 833 9353 WELD DESCRIPTION This test will help determine if the input rectifier has shorted or open diodes Return to Section TOC Return to Master TOC MATERIALS NEEDED Analog Voltmeter Ohmmeter Multimeter 5 16 Nut Driver Phillips Head Screwdriver Wiring Diagram Ojo O10 5 5 gt g 9 5 2 EC This procedure takes approximately 25 minutes to perform Return to Section TOC Return to Master TOC POWER WAVE 355 405 LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Q o 5 B tc Return to Section TOC Return to Master TOC o 7 8 2 F 20 1 To Auxiliary Transformer
100. S Where there is a combustible surface directly under CAUTION stationary or fixed electrical equipment that surface shall be covered with a steel plate at least 06 1 6mm thick which shall extend not less than 5 90 150mm beyond the equipment on all sides STACKING POWER WAVE 355 405 cannot be stacked TILTING Place the machine directly on a secure level surface or on a recommended undercarriage The machine may topple over if this procedure is not followed INPUT AND GROUNDING CONNECTIONS Only a qualified electrician should connect the POWER WAVE 355 405 Installation should be made in accordance with the appropriate National Electrical Code all local codes and the information detailed below When received directly from the factory multiple volt age machines are internally connected for the highest voltage Always double check connections before powering up the machine Initial 200VAC 415VAC and 575VAC operation will require an Input voltage panel setup Open the access panel on the rear of the machine For 200 or 230 Position the large switch to 200 230 For higher voltages Position the large switch to 380 575 Move the A lead to the appropriate terminal POWER CORD CONNECTION A power cord is provided and wired into the machine Follow the power cord connection instructions Cord Length PW 355 10 Feet PW 405 5 Meters CAUTION Incorrect connection may result in equip
101. STORS Ohms 1 4W UNLESS OTHERWISE SPECIFIED LABELS VCC bo 1 2W DIODES 1A 400V UNLESS OTHERWISE SPECIFIED o x18 x2 y 3 A SUPPLY VOLTAGE NET 4 cc 0 XCS20 208 10 POWER SUPPLY SOURCE POINT E 520 TMS320F2L0 1 1325 38 51 66 79 91103118 131143158170 182 195 3 1L 20 29 46 59 61 71 92 104 113 120 87 x33 01 COMMON CONNECTION gt HC245 50V FILENAME 63789 10 77 7 FRAME CONNECTION 9 Ce os CE THIS SHEET CONTAINS PROPRIETARY INFORMATION OWNED BY THE LINCOLN ELECTRIC CO Tu TS TN 17 IS NOT TO BE REPRODUCED DISCLOSED OR USED WITHOUT THE EXPRESS PERMISSION OF LINCOLN ELECTRIC EARTH GROUND CONNECTION C ge Sht No x 814 enis E er d ME THe LINCOLN ELECTRIC CO INVERTER WELDERS 6 2 2000 SINCE COMPONENTS OR CIRCUITRY ON A PRINTED CIRCUIT BOARD MAY CHANGE ON PLACE E Sr n CLEVELAND OHIO U S A SUBJECT SCHEMATIC DIGITAL CONTROL 5 5 WITHOUT AFFECTING THE INTERCHANGEABILITY OF A COMPLETE BOARD THIS DIAGRAM MAY ON ALL ANGLES 15 5 OF A DEGREE 8 4 2000P 04 SCALE NONE NOT SHOW THE EXACT COMPONENTS OR CIRCUITRY oY SHT 4 T RCUITRY OF CONTROLS HAVING COMMON CODE MATERIAL TOLERANCE Ce TO AGREE DR FM Date 08 02 2000 SUP S D G Ro 03789 100 D NUMBER WITH PUBLISHED STANDARDS 75 NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual
102. SVM159 A December 2003 POWER WAVE 355 405 For use with machine code numbers 10895 10896 Return to Master TOC View Safety Info 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 READ ING THIS MANUAL AND THE SAFETY PRECAUTIONS CON TAINED THROUGHOUT And most importantly think before you act and be careful Return to Master TOC View Safety Info 9 PLE dB 915 21 0 z 9 al SERVICE MANUAL View Safety Info Copyright 2003 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 Return to Master TOC O 2 7 o 55 3 tc Return to Master TOC Return to Master TOC Return to Master TOC SAFETY WARNING CALIFORNIA PROPOSITION 65 WARNINGS 4 Diesel engine exhaust and some of its constituents The engine exhaust from this product contains are known to the State of California to cause can chemicals known to the State of California to cause cer birth defects and other reproductive
103. Sense TABLE A 4 RS232 RECEPTACLE 253 RS232 Transmit Pin5 Pin4 Pin20 Pin6 RS232 Common DIP SWITCH SETTINGS AND LOCATIONS DIP switches on the P C Boards allow for custom con figuration of the Power Wave To access the DIP switches WARNING 1 Turn off power to the power source at the dis connect switch 2 Remove the wrap around cover from the power Source 3 The control board is on the center assembly facing the case front Locate the 8 position DIP switch and look for switch 8 of the DIP switch 4 Using a pencil or other small object slide the switch to the OFF position if the work sense lead is NOT connected Conversely slide the switch to the ON position if the work sense lead is present 12345678 A u 5 Replace the wrap around and screws The PC board will read the switch at power up and configure the Work voltage sense lead appropriately CONTROL BOARD DIP SWITCH switch 1 reserved for future use switch 2 reserved for future use switch 3 reserved for future use switch 4 reserved for future use switch 5 reserved for future use switch 6 reserved for future use switch 7 reserved for future use switch 8 work sense lead switch 8 work sense lead work sense lead not connected work sense lead connected Factory setting for Switch 8 is OFF FIGURE A 7 CONTROL BOARD DIP Switch Location
104. T FILTER CAPACITOR DISCHARGE PROCEDURE WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty For your safety and to avoid electrical shock please observe all safety notes and precautions detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed Call 1 800 833 9353 WELD DESCRIPTION This procedure will drain off any charge stored in the four large capacitors that are part of the switch board assembly This procedure MUST be performed as a safety pre caution before conducting any test or repair procedure that requires you to touch inter nal components of the machine MATERIALS NEEDED 5 16 Nut Driver Insulated Pliers Insulated Gloves High Wattage Resistor 25 1000 ohms and 25 watts minimum DC Volt Meter This procedure takes approximately 20 minutes to perform POWER WAVE 355 405 LINCOLN 5 F 13 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Q 5 2 5 tc Return to Section TOC Return to Master TOC Q 0 8
105. TERIAL TOLERANCE 47 AGREE FM 08 02 2000 90 o 63789 100 2 15V DR DATE CHK SUP S D G NO NUMBER WITH PUBLISHED STANDARDS 75 NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual LINCOLN 59 ELECTRIC POWERWAVE 355 405 ELECTRICAL DIAGRAMS di SCHEMATIC DIGITAL CONTROL PC BOARD 84
106. TTED 5 524866 POWER TERMINAL 8201 8208 6 7 8 o 0 c 5 o 9 5 o 2 3 N G AFTER SOLDERING INSPECT POWER TERMINAL CONNECTIONS 79147 17 E a TO ENSURE SOLDER HAS PROPERLY WET COMPONENT SIDE PAD ON A MINIMUM OF 3 OF THE 4 LEGS OF THE POWER TERMINAL Tatars EYELET MALE N H BAR MUST BE FREE OF ENCAPSULATION MATERIAL ON BOTH SURFACES 9062 AROUND MOUNTING HOLES AND ENTIRE LENGTH OF MOUNTING SURFACE ENCAPSULATION MATERIAL MUST NOT EXTEND BEYOND THE MOUNTING SURFACE PLANE 2 PLACES DO NOT COAT WITH ENCAPSULATION MATERIAL TOP AND BOTTOM 80 05 DIA PC BOARD HOLES TO BE FREE OF ENCAPSULATION MATERIAL AND SEALANT MAKE PER E1 91 1 FOR A DIAMETER OF 50 FOR THE LARGER HOLES AND 25 FOR THE SMALLER NN HOLES BOTH SIDES OF BOARD 4 PLACES ENCAPSULATE WITH E1 844 3 COATS 2 PLACES L THIS AREA TO BE COVERED ON COMPONENT SIDE OF BOARD WITH SEALANT PRIOR TO ENCAPSULATION MATERIAL MUST BE APPLIED FROM TOP TO Bee OE GEVICE TO UNDERSIDE OF DEVICE THEN APPLY SEALANT AROUND TEST PER E381 7 SW N M THIS AREA TO BE COVERED ON OPPOSITE COMPONENT SIDE OF BOARD WITH ITEM 8 PRIOR TO ENCAPSULATION DO NOT COAT WITH ENCAPSULATION MATERIAL ON THE TOP SURFACES NOR THE THREADS N N T
107. VHCLAD SHT 23 lt SYS_RESET 101 ni ADDRI9I 04 03 10 0 ADDRI0I T T 9 995r ADORI11 17 OQ 753 3 0 5 1 1 FPGA INT 5 ADDRI12 LOOV 400V SHT 4 srr a12p2______ADDRI121 e p 55 Sara INT CAN Slo X4 436 ADDRIL3I 37 4 SH FPGA BAD 0084 Wi f m SHT 4 33pr a68 ADDRIL 191 umo SHT 2 15V 15V s el 100V A TPUIO 6 13 Aie 0 ADDRI16 gt 5 5 US An PUOI 34 1763 ADDRI 7I ADDRIL8 o LEVEL_IN D nis FAULT TPUCHL A18 45V mai 201 02A 16V SIGNAL 34 A19 6 ADDRIIST SHT 2 5V 175 3 Pm 70 712 A20 Z DSP RESET z SHT 4 E pex 8 5 TPUT 8 VPP CTRL ADDRILTI 5 SHT 2 29 TPUCHS A222 SHT 4 Hais 9 1047 V TPUCH Az3 CAN CS SHT 2 t 0 NNUS gt F TPUCHT ADDRILLI 1o15 8 DATAUSI 9 0 EN yag 24 E SHT 4 JE Mig DATAA a 9 ADDRIL2I 5 gt 3 0 a E qu Um SHT 4 1 013 EE f 23 reumo 00 ADDRULI 19 0 1001285 DATAU121 olo 5V FAULT 885 10 21 01 38 Bu B zz 175 1 28 p223 OATAUI ADDR 20 8 cic 1 5 MEETS p3 136 DATAII ADDRIBI EN Vos 80 DATAISI 5 m2 1 AOA tev 19 p 133 DATAIAI ADDRITI 24
108. Voltage A 5 5 Power Wave to Semi Automatic Wire A 6 System Description TOT 7 2 System 8 Multiple Group Systelm ig eae X Ringe ee Ek ga RR E Re X RE A 9 Single Group Multi Head A 10 Welding with Multiple Power Waves A 11 Control Cable 11 I O Receptacle Specificatioris saa ra enn evel A 12 Dip Switch Settings and A 12 Q 0 5 Return to Master TOC POWER WAVE 355 405 LINCOLN 5 A 2 INSTALLATION A 2 TECHNICAL SPECIFICATIONS POWER WAVE 355 INPUT AC VOLTAGE amp DC OUTPUT Product Ordering Input AC Rated DC Output Output Weight Dimensions Name Information Voltage Amps Volts Duty Cycle Range with Cord HxWxD continuous Power 200 208 Wave K2152 1 220 240 350A 34V 6096 355 380 415 1 amp 3 Phase 440 480 81 5 lbs 27 8 575 37 0 kg 373 x 338 x E 706 mm 60 50 HZ 300A 32V 10096 Includes 1 amp 3 Phase Handles Overall Length Including Handle 21 6 649mm without handl
109. able from 10 0 to 10 0 with a nominal setting of 00 0 The nominal set ting of 00 0 may be displayed as OFF on some Power Feed wire feeder control panels See the Welding Mode descriptions below for detailed explanations of how the Arc Control affects each mode m Wave Control 10 0 oe F Way Control 0 00 Current r a 2857 Wave Control 10 0 Time CONSTANT VOLTAGE WELDING Synergic CV For each wire feed speed a corresponding voltage is preprogrammed into the machine through special soft ware at the factory The nominal preprogrammed volt age is the best average voltage for a given wire feed speed but may be adjusted to preference When the wire feed speed changes the Power Wave automati cally adjusts the voltage level correspondingly to main tain similar arc characteristics throughout the WFS range Non Synergic CV This type of CV mode behaves more like a conven tional CV power source Voltage and WFS are inde pendent adjustments Therefore to maintain the arc characteristics the operator must adjust the voltage to compensate for any changes made to the WFS All CV Modes Arc Control often referred to as wave control adjusts the inductance of the wave shape The wave control adjustment is similar to the pinch function in that it is inversely proportional to inductance Therefore increasing wave control greater than 0 0 results in a harsher col
110. acitors in series This is required to accom modate the higher input voltages When the input capacitors are fully charged they act as power supplies for the IGBT switching circuits When welding output is required the Insulated Gate Bipolar Transistors switch the DC power from the input capacitors on and off thus supplying a pulsed DC current to the main transformer primary windings See n this section Each IGBT switching circuit feeds current to a separate oppositely wound primary winding in the main transformer The reverse directions of current flow through the main transformer primaries and the offset timing of the IGBT switching circuits induce an AC square wave output signal at the secondary of the Recp Connector Thermostats To main transformer The two current transformers CT located on the switch board monitor these primary currents If the primary currents become abnormally high the control board will shut off the IGBTs thus dis abling the machine output The DC current flow through each primary winding is clamped back to each respective input capacitor when the IGBTs are turned off This is needed due to the inductance of the transformer primary winding The firing of the two switch boards occurs during halves of a 50 microsec ond interval creating a constant 20 KHZ output In some low open circuit Tig modes the firing frequency is reduced to 5KHZ The POWER WAVE 355 405 has a F A N fan as need
111. ainers until the proper steps have been taken to insure that such procedures will not cause flammable or toxic vapors from substances inside They can cause an explosion even though they have been cleaned For information purchase Recommended Safe Practices for the Preparation for Welding and Cutting of Containers and Piping That Have Held Hazardous Substances AWS F4 1 from the American Welding Society see address above Vent hollow castings or containers before heating cutting or welding They may explode Sparks and spatter are thrown from the welding arc Wear oil free protective garments such as leather gloves heavy shirt cuffless trousers high shoes and a cap over your hair Wear ear plugs when welding out of position or in confined places Always wear safety glasses with side shields when in a welding area Connect the work cable to the work as close to the welding area as practical Work cables connected to the building framework or other locations away from the welding area increase the possibility of the welding current passing through lifting chains crane cables or other alternate circuits This can create fire hazards or overheat lifting chains or cables until they fail 6 h Also see item 1 c CYLINDER may explode if damaged 7 Use only compressed gas cylinders containing the correct shielding gas for the process used and properly operating regulators designed for the gas and pressure us
112. and repair should be performed by only Lincoln Electric factory trained personnel Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty For your safety and to avoid electrical shock please observe all safety notes and precautions detailed throughout this manual Return to Section TOC Return to Master TOC If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed Call 1 800 833 9353 WELD DESCRIPTION The following procedure will aid the technician in removing the snubber board for mainte nance or replacement MATERIALS NEEDED Return to Section TOC Return to Master TOC 5 16 Nut Driver 7 16 Socket or Nut Driver 5 5 218 5 2 a This procedure takes approximately 15 minutes to perform Return to Section TOC Return to Master TOC POWER WAVE 355 405 LINCOLN 5 F 56 F 56 TROUBLESHOOTING amp REPAIR SNUBBER BOARD REMOVAL AND REPLACEMENT continued PROCEDURE 1 Remove input power to the POWER WAVE Perform the Input Filter Capacitor Discharge 355 405 Procedure detailed earlier in this section 2 Using a 5 16 nut driver remove the case wrap 4 Locate the snubber board See Figure F 23 a
113. ansfer is obtained by operating a power source between low and high current levels The high current level or pulse forces an electrode drop to the workpiece The low current level or background main tains the arc between pulses See Figure B 3 Pulsed MIG is an advanced form of welding that takes the best of all the other forms of transfer while mini mizing or eliminating their disadvantages Unlike short circuit pulsed MIG does not create spatter or run the risk of cold lapping The welding positions in pulsed MIG are not limited as they are with globular or spray and its wire use is definitely more efficient Unlike the spray arc process pulsing offers controlled heat input that allows better welding on thin materials lower wire feed speeds and leads to less distortion and improved overall quality and appearance This is especially important with stainless nickel and other alloys that are sensitive to heat input In GMAW P mode arc control adjusts the background current and frequency of the wave When arc control goes up the frequency increases thus increasing the droplet transfer FIGURE B 3 EACH PULSE DELIVERS ONE DROPLET OF WELD MATERIAL 40 oO lt 3 lt oO FREQUENCY gt SPRAY TRANSITION CURRENT POWER WAVE 355 LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC O10 5 5 gt 218 5 2 a R
114. ard automation applications This Power Wave is not recommended for processes other than those listed POWER WAVE 355 405 LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC O10 E 5 8 gt 2 2 5 2 Return to Section TOC Return to Master TOC B 3 B 3 OPERATION POWER WAVE 355 405 Operation Semi Automatic Semi Automatic Power Waves can only be used with Linc Net compatible Power Feed semi automatic wire feeders In addition the Power Feed semi automatic wire feeders may require optional equipment to access certain weld modes in the Power Wave Other models of Lincoln feeders or any models of non Lincoln wire feeders cannot be used All welding programs and procedures are selected through the Power Feed semi automatic user interface REQUIRED EQUIPMENT Any Linc Net compatible semi automatic wire feeding equipment Specifically the semi automatic Power Feed family PF 10 PF 10X2 PF 11 LIMITATIONS Only Linc Net compatible Power Feed semi automat ic wire feeders and users interfaces may be used Other Lincoln wire feeders or non Lincoln wire feed ers cannot be used POWER WAVE 355 405 Output Limitations The POWER WAVE 355 405 will support maximum average output current of 350 Amps 6096 duty cycle DUTY CYCLE AND TIME PERIOD The duty cycle is based upon a ten minute period A 6096 dut
115. arefully note the position of 7 Using a 3 16 allen wrench remove the two 3 Perform the Input Filter Capacitor Discharge mounting screws and washers from the input See Figure F 31 detailed earlier in this section bridge 4 Locate the input rectifier See figure F 30 8 Remove the input bridge 5 Carefully remove the silicon sealant insulating the six input rectifier terminals FIGURE F 30 INPUT RECTIFIER LOCATION INPUT RECTIFIER Return to Section TOC Return to Master TOC olo OJO 5 5 gt 2 2 5 2 Return to Section TOC Return to Master TOC POWER WAVE 355 405 LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC olo OJO 5 5 0 9 16 218 5 2 a Return to Section TOC Return to Master TOC F 67 F 67 TROUBLESHOOTING amp REPAIR INPUT RECTIFIER REMOVAL AND REPLACEMENT continued 9 Apply a thin coat of Penetrox A 13 heatsink com pound to the point of contact between the input rectifier and the mounting surface 10 Secure the new input bridge into its proper posi tion with the two 3 16 in allen mounting screws previously removed Torque to 44 inch pounds 11 12 18 Reconnect the previously removed leads to their proper locations Torque to 31 inch pounds Cover the input rectifier and its six terminals
116. ated at the rear of the machine The reconnect switch connect the two pairs of input capacitors either in a parallel lower voltage or series higher voltage configuration to accommodate the applied input voltage During the precharge time the DC input voltage is applied to the input capacitors through a current limit ing circuit The input capacitors are charged slowly and current limited voltage to frequency converter circuit located on the switch board monitors the capacitor voltages This signal is coupled to the con trol board When the input capacitors have charged to an acceptable level the control board energizes the input relays that are located on the switch board making all of the input power without current limiting available to the input capacitors If the capacitors become under or over voltage the control board will de energize the input relays and the 355 405 output will be disabled Other possible faults may also cause the input relays to drop out POWER WAVE 355 405 LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC O10 515 9 16 218 5 2 a Return to Section TOC Return to Master TOC E 3 E 3 THEORY OF OPERATION FIGURE E 3 SWITCH BOARD amp MAIN TRANSFORMER To Control 115VAC Fan Supply Input Relay Control Soft Start Cont
117. c Net Control Cable but can also be made internal ly as with the PF 10 bench model feeder The most common Linc Net configuration called a simple system consists of one power source one user interface and one feeder Under these circumstances the group and feed head ID DIP switches are ignored and the system will function regardless of their posi tion The same is true for the minimum system con sisting of a power source and one UI Example a stick welding system FIGURE A 1 POWER WAVE 355 405 LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o o 5 B tc Return to Section TOC Return to Master TOC Q 0 8 2 Simple System INSTALLATION SYSTEM SET UP Basic Rules Each group is required to have one user interface No group may have more than one user interface Each group can have up to seven Feed Heads Exception Group 3 is limited to a maximum of six Feed Heads Each system has only one power source For network purposes the PS belongs to Group 3 which is why group 3 is only allowed 6 feed heads in addition it s user interface No two feed heads can have identical Group and Feed Head numbers Group and Feed Head ID numbers must be set on the appropriate dip switches at each node Consult the PF 10 11 Instruction Manual for specific d
118. ce une endroit isol de la masse Un court circuit accidental peut provoquer un chauffement et un risque d incendie S assurer que la masse est connect e le plus pr s possible de la zone de travail qu il est pratique de le faire Si on place la masse sur la charpente de la construction ou d autres endroits loign s de la zone de travail on augmente le risque de voir passer le courant de soudage par les chaines de levage c bles de grue ou autres circuits Cela peut provoquer des risques d incendie ou d echauffement des chaines et des c bles jusqu ce qu ils se rompent Assurer une ventilation suffisante dans la zone de soudage Ceci est particuli rement important pour le soudage de t les galvanis es plomb es ou cadmi es ou tout autre m tal qui produit des fume s toxiques Ne pas souder en pr sence de vapeurs de chlore provenant d op rations de d graissage nettoyage ou pistolage La chaleur ou les rayons de l arc peuvent r agir avec les vapeurs du solvant pour produire du phosg ne gas fortement toxique ou autres produits irritants 11 Pour obtenir de plus amples renseignements sur la s ret voir le code Code for safety in welding and cutting CSA Standard W 117 2 1974 PR CAUTIONS DE S RET POUR LES MACHINES SOUDER TRANSFORMATEUR ET REDRESSEUR 1 Relier la terre le chassis du poste conformement au code de l lectricit et aux recommendations du fabricant Le disposi
119. conductive anti static or static dissipative Remove the PC board from the static shielding bag and place it directly into the equipment Don t set the PC board on or near paper plastic or cloth which could have a static charge If the PC board can t be installed immediately put it back in the static shield ing bag If the PC board uses protective shorting jumpers don t remove them until installation is complete If you return a PC board to The Lincoln Electric Company for credit it must be in the static shielding bag This will prevent further damage and allow prop er failure analysis 4 Test the machine to determine if the failure symptom has been corrected by the replacement PC board NOTE It is desirable to have a spare known good PC board available for PC board troubleshooting NOTE Allow the machine to heat up so that all electrical components can reach their operating temperature 5 Remove the replacement PC board and substitute it with the original PC board to recreate the original problem a If the original problem does not reappear by substituting the original board then the PC board was not the problem Continue to look for bad connections in the control wiring harness junction blocks and terminal strips b If the original problem is recreated by the substitution of the original board then the PC board was the problem Reinstall the replacement PC board and test the machine 6 Always i
120. d personnel Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty For your safety and to avoid electrical shock please observe all safety notes and precautions detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 1 800 833 9353 WELD TEST DESCRIPTION This test will determine if the DC Bus Power Supply PC Board is receiving and process ing the proper voltages MATERIALS NEEDED 3 8 Nut driver Volt ohmmeter Wiring Diagram This procedure should take approximately 30 minutes to perform POWER WAVE 355 405 LINCOLN 5 F 27 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC O10 5 5 218 5 2 a Return to Section TOC Return to Master TOC F 28 F 28 TROUBLESHOOTING amp REPAIR DC BUS BOARD TEST CONTINUED FIGURE F 5 DC BUS POWER SUPPLY POWER SUPPLY PC BOARD DC BUS BOARD TEST PROCEDURE WARNING 1 Remove input power to the machine 2 Using the 3 8 nut driver remove the wrap e ELECTRIC SHOCK can kill around cover High voltage is present when 3 Locate the DC Bus Board See Figure
121. der arc while decreasing the wave control to less than 0 0 provides a softer hotter arc See Figure B 2 FIGURE B 2 Ta CURRENT WAVE FORM CV POWER WAVE 355 405 LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC O10 5 5 gt 218 5 2 a Return to Section TOC Return to Master TOC B 6 B 6 OPERATION TIG GTAW The TIG mode features continuous control from 5 to 425 amps The TIG mode can be run in either the Touch Start TIG or Scratch start mode The Arc Control level selects the starting mode Between 10 and 0 the Touch Start TIG mode is selected The is controlled below 10V and the short circuit TIG touch current is maintained at approximately 25 amps independent of the preset cur rent When the tungsten is lifted an arc is initiated and the output is regulated at the preset value A setting of 0 results in the most positive arc initiation A setting of 10 reduces hot start Between 0 and 10 the Scratch starting TIG mode is selected In this range the OCV of the machine is con trolled between 50 and 70 volts SPECIAL WELDING PROCESSES AVAILABLE ON THIS MACHINE POWER MODE The Power Mode process was developed by Lincoln to maintain a stable and smooth arc at low procedure settings which are needed to weld thin metal without pop outs or burning through For Aluminum weld
122. driver remove the case wrap around cover Perform the nput Filter Capacitor Discharge detailed earlier in this section Locate the DC Bus Board See Figure 27 Using a 5 16 nut driver remove the two screws from the bottom of the front of the machine See Figure F 28 Using a phillips head screwdriver remove the two screws and their washers from above and below the input power switch See Figure F 28 Using a phillips head screwdriver remove the four screws mounting the two welder output terminals on the front of the machine See Figure F 28 The front of the machine may now gently be pulled forward to gain access to the DC Bus Board Note The front of the machine cannot be removed completely only pulled forward a few inches FIGURE F 27 DC BUS BOARD LOCATION DC BUS BOARD POWER WAVE 355 LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o 5 B tc Return to Section TOC Return to Master TOC Q 0 8 2 F 63 F 63 TROUBLESHOOTING amp REPAIR DC BUS BOARD REMOVAL AND REPLACEMENT Continued FIGURE F 28 CASE FRONT SCREW REMOVAL 17 status THERMAL 9999990009099 6 00000000000 Phillips Head Screws Phillips Head Screws 5 16 Mou
123. e POWER WAVE 355 INPUT CURRENT Recommended Fuse Sizes Base On The U S National Electrical Code And Maximum Machine Outputs Input 50 60 Hz Output Recommended Voltage Phases 300Amps 350Amps Line Fuse size Notes 32Volts 10096 34Volts 60 AWG Recommended Recommended 230 69 85 125A Note 2 Re commended Recommended Recommended Recommended 415 41 64 80A Note 2 36 42 70A 50A 460 Note 2 Note 2 Note 1 Not rated is indicated by 4 x s in the box on the rating plate 575 Note 2 When operating on these inputs the line cord should be changed to an input conductor of 6 AWG or larger OUTPUT CABLES CONNECTIONS AND LIMITATIONS Select The output cable size based upon the following chart Cable sizes for Combined Length of Electrode and Work Cable Copper 75C rated DUTY CYCLE CURRENT LENGTH UP 200FT 61m 200 250 FT 61 76m Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC O10 515 gt g 9 5 2 1 1 1 3 3 3 3 3 3 3 3 100 300 1 0 1 0 60 350 1 0 2 0 Lincoln Electric recommends using minimum of 2 0 welding cable for pulse welding Return to Section TOC Return to Master TOC POWER WAVE 355 405 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Ojo O10 515 gt 218 5 2 a Return t
124. e The fan motor may be accessed by the removal of the rear panel detailed in Current Transducer Removal Replacement Procedure 4 Replace the case wrap around cover FIGURE F 16 PLUG J20 Lead 716 Plug J20 Lead 715 POWER WAVE 355 405 LINCOLN 5 F 46 LINCOLN 2 NOTES POWER WAVE 355 405 F 46 901 Je1Se A 0 901 4 1 0 uunjeH 901 J91Se N 01 901 J91Se N 01 DOL uonoes DOL uonoes uumeg DOL uonoes 901 uonoes uumeg Return to Section TOC Return to Master TOC Return to Section TOC 5 5 218 5 2 a Return to Section TOC Return to Master TOC Return to Master TOC F 47 TROUBLESHOOTING amp REPAIR CONTROL BOARD REMOVAL AND REPLACEMENT WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty For your safety and to avoid electrical shock please observe all safety notes and precautions detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical troubleshooting assistance before
125. e Figure F 19 POWER WAVE 355 405 LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o 5 B tc Return to Section TOC Return to Master TOC Q 7 8 2 F 50 12 18 15 16 17 18 TROUBLESHOOTING amp REPAIR F 50 CONTROL BOARD REMOVAL AND REPLACEMENT continued Using a 3 8 nut driver remove the two mounting nuts from the top two corners of the control board See Figure F 20 Cut any necessary cable ties 14 Replace the control board FIGURE F 20 CONTROL BOARD MOUNTING SCREW LOCATION Mounting Nuts 3 8 Replace the two 3 8 mounting nuts at the top two corners of the control board Replace any previously removed cable ties Replace plugs 842 8394 25 26 847 48 29 J10B and J10A previously removed Replace the two screws and their washers from above and below the input power switch 19 20 21 Replace the four screws from around the two welder output terminals on the front of the machine Replace the two case front mounting screws at the bottom of the front of the machine Replace the case wraparound cover POWER WAVE 355 405 LINCOLN 5 F 51 F 51 TROUBLESHOOTING amp REPAIR MAIN SWITCH BOARD REMOVAL AND REPLACEMENT WARNING Service and repair should be performed by o
126. e may be too low limiting the output capabili ty of the machine Make cer tain the input voltage is correct for the machine and the recon nect switch and jumper lead configuration are correct The output current or voltage may not be calibrated correctly Check the values displayed on the Power Feed 10 11 versus readings on an external voltage and ammeter The welding current may be too high The machine will fold back to 100 amps if the weld ing current exceeds 450 amps 1 Perform the Output Rectifier 2 Perform the Main Switch 3 Perform the Test l 4 Perform the Current Transducer Test 5 The control board may be faulty CAUTION 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 WELD POWER WAVE 355 405 LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Q 9 2 5 tc Return to Section TOC Return to Master TOC Q 0 52 2 F 6 Observe Safety Guidelines detailed in the beginning of this manual PROBLEMS SYMPTOMS The machine regularly overheats and the yellow thermal light is ON indicating a thermal overload An attached wire feed
127. e the machine cools sufficiently If the thermostat shutdown was caused by excessive output or duty cycle and the fan is operating normally the power switch may be left on and the reset should occur within a 15 minute period If the fan is not turn ing or the air intake louvers are obstructed then the power must be removed from the machine and the fan problem or air obstruction corrected PROTECTIVE CIRCUITS Protective circuits are designed into the POWER WAVE 355 405 to sense trouble and shut down the machine before damage occurs to the machine s internal components OVER CURRENT PROTECTION If the average current exceeds 450 amps for one sec ond then the output will be limited to 100 amps until the load is removed If the peak current exceeds 600 amps for 150 ms the output will be limited to 100 amps until the load is removed UNDER OVER VOLTAGE PROTECTION Protective circuits are included on the switch and con trol boards to monitor the voltage across the input capacitors In the event that a capacitor pair voltage is too high or too low the machine output will be dis abled The protection circuits will prevent output if any of the following conditions exist 1 Voltage across a capacitor pair exceeds 467 volts High line surges or improper input voltage connections 2 Voltage across a capacitor pair is under 190 volts Due to improper input voltage connections 3 Any major internal component damage POWER
128. ear the error turn power source off and back on to reset Non recoverable hardware fault Generally indicates nothing is connected to the POWER WAVE 355 405 wire feeder recep tacle See Trouble Shooting Section Blinking Red Not applicable 3 HIGH TEMPERATURE LIGHT thermal overload A yellow light that comes on when an over temper ature situation occurs Output is disabled and the fan continues to run until the machine cools down When cool the light goes out and output is enabled 4 CB1 WIRE FEEDER CIRCUIT BREAKER Protects 40 volt DC wire feeder power supply POWER WAVE 355 405 LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o 0 2 5 tc Return to Section TOC Return to Master TOC Q 0 8 2 OPERATION FIGURE 1 CASE FRONT LAYOUT POWER WAVE 355 405 Internal POWER CIRCUIT BREAKER Protects 115 volt AC circuit LEAD CONNECTOR SENSE LEAD DIAGNOSTIC CONNECTOR RS 232 WIRE FEEDER RECEPTACLE 5 PIN NEGATIVE TWIST MATE TERMINAL 10 POSITIVE TWIST MATE TERMINAL NOMINAL PROCEDURES The Power Wave is designed to operate with 3 4 elec trode stick out for CV and Pulse processes COND FRINGE PROCEDURES Excessively short or long electrode stick
129. ed All hoses fittings etc should be suitable for the application and maintained in good condition Always keep cylinders in an upright position securely chained to an undercarriage or fixed support Oylinders should be located Away from areas where they may be struck or subjected to physical damage safe distance from arc welding or cutting operations and any other source of heat sparks or flame Never allow the electrode electrode holder or any other electrically hot parts to touch a cylinder Keep your head and face away from the cylinder valve outlet when opening the cylinder valve Valve protection caps should always be in place and hand tight except when the cylinder is in use or connected for use Read and follow the instructions compressed gas cylinders associated equipment and CGA publication Precautions for Safe Handling of Compressed Gases in Oylinders available from the Compressed Gas Association 1235 Jefferson Davis Highway Arlington VA 22202 FOR ELECTRICALLY powered equipment 8 a Turn off input power using the disconnect switch at the fuse box before working on the equipment Install equipment in accordance with the U S National Electrical Code all local codes and the manufacturer s recommendations Ground the equipment in accordance with the U S National Electrical Code and the manufacturer s recommendations Mar 95 POWER WAVE 355
130. ed in the Pulse on Pulse modes it does the same things it does in the other pulsed modes decreasing the Arc Control decreases the droplet transfer and weld deposition rate Increasing the Arc Control increases the droplet transfer and weld deposition rate Since Arc Control varies weld droplet transfer rate the Arc Control can be used to vary the ripple spacing in the weld bead BENEFITS OF PULSE ON PULSE FROM LINCOLN ELECTRIC Excellent appearance of the weld bead Improved cleaning action Reduced porosity Table B 2 shows WFS and Trim settings for common aluminum types and wire sizes when welding with Pulse on Pulse The welds made to obtain the values in the table were fillet welds in the flat position The val ues in the table can be helpful as a starting point to establish a welding procedure From there adjust ments need to be made to set the proper procedure for each specific application out of position other types of joints etc The comments on the table below show values of WFS below which it is not recommended to weld The rea son is that below these values the weld transfer will change from a spray arc to a short arc which is not advisable when welding aluminum WELDING PROCEDURES FOR PULSE ON PULSE LINCOLN 5 MATERIAL Aluminum 4043 Aluminum 4043 Aluminum 5356 Aluminum 5356 GAS 10096 Ar 10096 Ar 10096 Ar 10096 Ar WIRE E4043 E4043 E5356 E5356 WI
131. ed metallic components Earthing of the Workpiece Where the workpiece is not bonded to earth for electrical safety not connected to earth because of its size and position e g ships hull or building steelwork a connection bonding the workpiece to earth may reduce emissions in some but not all instances Care should be taken to prevent the earthing of the workpiece increasing the risk of injury to users or damage to other electrical equipment Where necessary the connection of the workpiece to earth should be made by a direct connection to the workpiece but in some countries where direct connection is not permitted the bonding should be achieved by suitable capacitance selected according to national regulations Screening and Shielding Selective screening and shielding of other cables and equipment in the surrounding area may alleviate problems of interference Screening of the entire welding installation may be considered for special applications 1 Portions of the preceding text are contained in 50199 Electromagnetic Compatibility EMC product standard for arc welding equipment 3 1 96H 1 1 POWER WAVE 355 LINCOLN 5 MASTER TABLE OF CONTENTS FOR ALL SECTIONS RETURN TO MAIN INDEX Page TQ i iv Clu EET Section A Operation MM HEU Section B ACC ESSONNES ei ohio ss cence te success Uri Section C Maintenance RR Section D Theory of Operation
132. ed welding parameters The Power Feed PF family of feeders communicate settings to the Power Wave through control cable connection Arc length wire feed speed arc control etc are all communicated digitally via the control cable WELDING ADJUSTMENTS All adjustments are made on the system component known as the User Interface Control Box which con tains the switches knobs and digital displays neces sary to control both the Power Wave and a Power Feed wire feeder Typically the Control Box is supplied as part of the wire feeder It can be mounted directly on the wire feeder itself the front of the power source or mounted separately as might be done in a welding boom installation Because the Control Box can be configured with many different options your system may not have all of the following adjustments Regardless of availability all controls are described below For further information consult the Power Feed wire feeder instruction manu al WFS AMPS In synergic welding modes synergic CV pulse GMAW WFS wire feed speed is the dominant control parameter controlling all other variables The user adjusts WFS according to factors such as weld size penetration requirements heat input etc The Power Wave then uses the WFS setting to adjust its output characteristics output voltage output current accord ing to pre programmed settings contained in the Power Wave POWER WAVE 355 405 LINCOLN 5 Return
133. ensing The standard POWER WAVE 355 405 default to the work stud work sense lead disabled For processes requiring work voltage sensing connect the 21 work voltage sense lead K940 from the Power Wave work sense lead receptacle to the work piece Attach the sense lead to the work piece as close to the weld as practical but not in the return current path Enable the work voltage sensing in the Power Wave as follows WARNING Do not touch electrically live parts or electrodes with your skin or wet clothing e e Insulate yourself from the work and ground Always wear dry insulating gloves 1 Turn off power to the power source at the disconnect switch 2 Remove the wrap around cover from the power source 3 The control board is on the center assembly facing the case front Locate the 8 position DIP switch and look for switch 8 of the DIP switch 4 Using a pencil or other small object slide the switch to the OFF position if the work sense lead is NOT connected Conversely slide the switch to the ON position if the work sense lead is present 123456 78 5 Replace the wrap around and screws The PC board will read the switch at power up and configure the work voltage sense lead appropriately ELECTRODE VOLTAGE SENSING Enabling or disabling electrode voltage sensing is automatically configured through software The 6
134. er will not function correctly Apparently the wire feeder is not being powered up TROUBLESHOOTING amp REPAIR TROUBLESHOOTING GUIDE POSSIBLE AREAS OF MISADJUSTMENT S FUNCTION PROBLEMS 1 The welding application may be exceeding the recommended duty cycle of the POWER WAVE 355 405 Dirt and dust may have clogged the cooling channels inside the machine Air intake and exhaust louvers may be blocked due to inade quate clearance around the machine Make certain the fan as needed FA N is operating properly The fan should operate when welding voltage is present and or when there is an over temperature condition Make certain the wire feeder control cable is connected to the wire feeder receptacle See the Wiring Diagram Check the two circuit breakers located at the front of the machine Reset if tripped The wire feeder or control cable may be faulty F 6 RECOMMENDED COURSE OF ACTION 1 The 115VAC fan motor is con trolled by the control board via the main switch board Perform the Fan Motor And Control 1 A thermostat or associated cir cuitry may be faulty See the wiring diagram normally closed thermostat is located on the output choke one on the DC Bus Board and the other is located on the main switch board heat sink See the wiring diagram Note The Main Switch Board Removal Procedure be required to gain access to the heat sink
135. es deux pinces peut tre le total de la tension vide des deux machines Si on utilise la machine souder comme une source de courant pour soudage semi automatique ces precautions pour le porte lectrode s applicuent aussi au pistolet de soudage 2 Dans le cas de travail au dessus du niveau du sol se prot ger contre les chutes dans le cas ou on recoit un choc Ne jamais enrouler le c ble lectrode autour de n importe quelle partie du corps Uncoup d arc peut tre plus s v re qu un coup de soliel donc a Utiliser un bon masque avec un verre filtrant appropri ainsi qu un verre blanc afin de se prot ger les yeux du rayon nement de l arc et des projections quand on soude ou quand on regarde l arc b Porter des v tements convenables afin de prot ger la peau de soudeur et des aides contre le rayonnement de l arc c Prot ger l autre personnel travaillant proximit au soudage l aide d crans appropri s et non inflammables Des gouttes de laitier en fusion sont mises de l arc de soudage Se prot ger avec des v tements de protection libres de l huile tels que les gants en cuir chemise paisse pan talons sans revers et chaussures montantes Toujours porter des lunettes de s curit dans la zone de soudage Utiliser des lunettes avec crans lateraux dans les zones l on pique le laitier pr venir tout risque d incendie d aux tincelles Quand on ne soude pas poser la pin
136. es or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed Call 1 800 833 9353 WELD DESCRIPTION This test will help determine if any of the output diodes are shorted Return to Section TOC Return to Master TOC MATERIALS NEEDED Analog Voltmeter Ohmmeter Wiring Diagram 5 5 218 5 2 a This procedure takes approximately 20 minutes perform Return to Section TOC Return to Master TOC POWER WAVE 355 405 LINCOLN 5 F 32 F 32 TROUBLESHOOTING amp REPAIR OUTPUT DIODE MODULES TEST continued FIGURE F 7 Machine Output Terminals Return to Section TOC Return to Master TOC L status THERMAL 9999900000000 00000000000 z o E o 3 5 Return to Master TOC olo e e NEGATIVE POSITIVE B 5 OUTPUT OUTPUT D TERMINAL TERMINAL oz 9 8 TEST PROCEDURE 5 1 Remove input power to the POWER WAVE 4 Using the analog ohmmeter test for more 355 405 than 200 ohms resistance between positive and negative output terminals Positive test 2 Locate the output terminals on the front lead to the positive terminal Negative test panel of the machine See
137. etails regarding dip switch settings Feed head 0 not allowed Exception Simple sys tem ignores all ID numbers therefore FHO will func tion Each node must be connected to the Linc Net com munication network The order of connection is not important as each node is identified by it s unique Group and Feed Head ID number as defined on it s dip switches See Figures A 2 thru A 5 FIGURE A 2 POWER WAVE 355 405 LINCOLN 5 Group and Feed Head ID numbers are ignored in a simple system A 9 A 9 INSTALLATION Multiple Group System FIGURE A 3 No Allowed Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Single Group Multi Head System FIGURE A 4 No Allowed The Dual Head option allows the ability to maintain 2 sets of procedures If more then 2 heads are used odd 45 use FH1 settings even 5 use FH2 settings OJO 5 5 gt 218 5 2 a Return to Section TOC Return to Master TOC POWER WAVE 355 405 LINCOLN 5 A 10 A 10 INSTALLATION Single Group Multi Head System Alternate Method FIGURE A 5 No FHO Allowed When a standard User Interface is used in a group with multi ple Feed Heads all of the Feed Heads use a pamamasa i single set of proce Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC OJO
138. eturn to Master TOC B 8 B 8 INSTALLATION PULSE ON PULSE GMAW PP Pulse on Pulse is a Lincoln process specifically designed for use in welding relatively thin less than 1 4 thick aluminum See the table below It gives weld beads with very consistent uniform ripple In Pulse on Pulse modes two distinct pulse types are used instead of the single pulse type normally used in GMAW P A number of high energy pulses are used to obtain spray transfer and transfer metal across the arc Such pulses are shown in the figure below After a number N of such pulses depending on the wire feed speed used an identical number N of low energy pulses are performed These low energy pulses shown in the figure below do not transfer any filler metal across the arc and help to cool the arc and keep the heat input low N PULSES 1 N PULSES HIGH HEAT LOW HEAT PULSES PULSES PEAK BACKGROUND AMPS TIME The Peak Current Background Current and Frequency are identical for the high energy and low energy pulses In addition to cooling the weld down the major effect of the low energy pulses is that they form a weld ripple Since they occur at very regular time intervals the weld bead obtained is very uniform with a very consistent ripple pattern In fact the bead has its best appearance if no oscillation of the welding gun whipping is used See the figure below When Arc Control is us
139. eturn to Master TOC Q 0 E 37 37 TROUBLESHOOTING amp REPAIR AUXILIARY TRANSFORMER NO 1 TEST continued TABLE F 5 LEAD IDENTIFICATION NORMAL EXPECTED VOLTAGE COM 2 31 TO 115V 532 115 VAC 42 TO COM 14A quick connects 42 VAC 7 Carefully apply the correct input voltage to the POWER WAVE 355 405 and check for the cor rect secondary voltages per table F 5 sure the reconnect jumper lead and switch are configured correctly for the input voltage being applied Make sure circuit breaker CB3 is functioning properly NOTE The secondary voltages will vary if the input line voltage varies If the correct secondary voltages are present the auxiliary transformer is functioning proper ly If any of the secondary voltages are miss ing or low check to make certain the primary is configured correctly for the input voltage applied See Wiring Diagram WARNING High voltage is present at primary of Auxiliary Transformer 9 If the correct input voltage is applied to the primary and the secondary voltage s are not correct the auxiliary transformer may be faulty 10 Remove the input power to the POWER WAVE 355 405 11 Install the case wraparound cover using a 5 16 nut driver POWER WAVE 355 405 LINCOLN 5 F 38 LINCOLN jo NOTES POWER WAVE 355 405 F 38 901 4 1 0 901 Je1Se A 0 901 J9
140. eturn to Section TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING amp REPAIR HOW TO USE TROUBLESHOOTING GUIDE CAUTION 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 This Troubleshooting Guide is provided to help you locate and repair possible machine malfunctions Simply follow the three step procedure listed below Step 1 LOCATE PROBLEM SYMPTOM Look under the column labeled PROBLEM SYMPTOMS This column describes possible symptoms that the machine may exhibit Find the listing that best describes the symptom that the machine is exhibiting Symptoms grouped into three main categories Output Problems Function Problems and LED Function Problems Step 2 PERFORM EXTERNAL TESTS The second column labeled POSSIBLE AREAS OF MISADJUSTMENT S lists the obvious external possibilities that may contribute to the machine symptom Perform these tests checks in the order listed general these tests can be conducted without removing the case wrap around cover Step 3 PERFORM COMPONENT TESTS The last column labeled Recommended Course of Action lists the most likely
141. green and sometimes red and green for up to one minute when the machine is first turned on This is a normal situation as the machine goes through a self test at power up INDICATION 1 System OK Power source communicating nor mally with wire feeder and its components Occurs during a reset and indicates the POWER WAVE 355 405 is mapping identifying each component in the system Normal for first 1 10 seconds after power is turned on or if the system configuration is changed during opera tion Non recoverable system fault If the PS Status light is flashing any combination of red and green errors are present in the POWER WAVE 355 405 Read the error code before the machine is turned off Error Code interpretation through the Status light is detailed in the Service Manual Individual code digits are flashed in red with a long pause between digits The codes will be separated by a green light There may be more than one error code indicated To clear the error turn power source off and back on to reset Non recoverable hardware fault Generally indi cates nothing is connected to the POWER WAVE 355 405 wire feeder receptacle See Trouble Shooting Section Not applicable POWER WAVE 355 405 LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC Ojo O10 E 515 gt 2 2 5 2 Return to Section TOC Return to Master TOC Return to
142. gure A 6 CONTROL CABLE SPECIFICATIONS It is recommended that genuine Lincoln control cables be used at all times Lincoln cables are specifically designed for the communication and power needs of the Power Wave Power Feed system CAUTION The use of non standard cables especially in lengths greater than 25 feet can lead to communi cation problems system shutdowns poor motor acceleration poor arc starting and low wire dri ving force wire feeding problems The K1543 series of control cables can be connected end to end for ease of extension Do not exceed more than 100 feet 30 5 m total control cable length FIGURE A 6 POWER WAVE 355 405 TWO POWER WAVES Travel Direction POWER WAVE 355 405 Connect All Work Sense Leads at the End of the Joint Connect All Welding Work Leads at the Beginning of the Joint POWER WAVE 355 405 LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o 2 5 tc Return to Section TOC Return to Master TOC Q 0 8 2 12 INSTALLATION RECEPTACLE SPECIFICATIONS TABLE A2 WIRE FEEDER RECEPTACLE LEAD FUNCTION Communication Bus L Communication Bus H Electrode Voltage Sense 40vdc TABLE A 3 VOLTAGE SENSE RECEPTACLE LEAD FUNCTION Work Voltage
143. he Snubber Board Replacement 29 30 31 32 33 34 35 36 The rear of the machine may now be placed back into its original position Using a 3 8 wrench replace leads 4202 203 206 and 207A previously removed from the reconnect switches Tighten the metal nut previously removed from the inside of the rear wall on the back of the machine Channel locks may be necessary Replace the large plastic nut from around input power line located at the back of the machine Replace the four leads to the reconnect panel in their proper locations Replace the two CB2 circuit breaker leads previ ously removed Using a 5 16 nut driver replace the four screws from the rear assembly Replace the case wraparound cover POWER WAVE 355 405 LINCOLN 5 F 78 F 78 TROUBLESHOOTING amp REPAIR RETEST AFTER REPAIR Retest a machine If it is rejected under test for any reason that requires you to remove any part which could affect the machine s electrical characteristics Return to Section TOC Return to Master TOC OR If you repair or replace any electrical components INPUT IDLE AMPS AND WATTS Input Volts Hertz Maximum Idle Amps Maximum Idle KW 208 60 230 60 400 60 460 60 575 60 Return to Section TOC Return to Master TOC MAXIMUM OUTPUT VOLTAGES Input Volts Hertz Output Terminals X1 X2 115 Volt Receptacles No load 208 60 230 60 OCV 10 Amp Load 400 60 50 70 VDC 48 5
144. he technician or machine operator and will invalidate your factory warranty For your safety and to avoid electrical shock please observe all safety notes and precautions detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed Call 1 800 833 9353 WELD Return to Section TOC Return to Master TOC DESCRIPTION This test will help determine if the power board is receiving the correct voltages and also if the power board is regulating and producing the correct DC voltages MATERIALS NEEDED Volt Ohmmeter 3 8 Nut Driver Wiring Diagram O10 515 gt 218 5 2 a This procedure takes approximately 30 minutes perform Return to Section TOC Return to Master TOC POWER WAVE 355 405 LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Ojo O10 5 5 818 5 2 Return to Section TOC Return to Master TOC Perform the TROUBLESHOOTING amp REPAIR POWER BOARD TEST CONTINUED FIGURE 4 POWER BOARD TEST J43 1211109 8 7 J42 J41 6 5 4 4 3 3 2
145. he voltage sensing is enabled but the sense leads are missing improperly connected or if the electrode polarity switch is improperly configured extremely high welding outputs may occur The ELECTRODE sense lead 67 is built into the con trol cable and is automatically enabled for all semi automatic processes The WORK sense lead 21 con nects to the Power Wave at the four pin connector By default the WORK voltage is monitored at the output stud in the POWER WAVE 355 405 For more infor mation on the WORK sense lead 21 Voltage Sensing in the following paragraph Return to Section TOC Return to Master TOC POWER WAVE 355 405 LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC Ojo O10 515 218 5 2 a Return to Section TOC Return to Master TOC Return to Master TOC A 6 A 6 INSTALLATION Enable the voltage sense leads as follows TABLE A 1 Electrode Voltage Sensing 67 lead 67 lead required 67 lead required 67 lead required Voltage sense at studs Voltage sense at studs 67 lead required Voltage sense at studs Work Voltage Sensing 21 lead 21 lead optional 21 lead optional 21 lead optional Voltage sense at studs Voltage sense at studs 21 lead optional Voltage sense at studs The electrode voltage 67 sense lead is integral to the control cable to the wire feeder Work Voltage S
146. ine fan Do not attempt to override the governor or idler by pushing on the throttle control rods while the engine is running AX 1 g To prevent accidentally starting gasoline engines while turning the engine or welding generator during maintenance work disconnect the spark plug wires distributor cap or magneto wire as appropriate LINCOLN 8 2 d 3 Do not place your body between the electrode and work cables If the electrode cable is on your right side the work cable should also be on your right side 2 d 4 Connect the work cable to the workpiece as close as possible to the area being welded 2 d 5 Do not work next to welding power source Return to Master TOC Return to Master TOC Q 0 5 Return to Master TOC SAFETY 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 Insulate yourself from work and ground using dry insulation Make certain the insulation is large enough to cover your full area of physical contact with work and ground In addition to the normal safety precautions if welding must be performed under electrically hazardous conditions in damp locations or while wearing wet clothing on metal structures such as floors gratings or scaffolds
147. ing it provides excellent control and the ability to maintain constant arc length This results in improved welding performance in two primary types of applications Short Arc MIG at low procedure settings Aluminum MIG welding Power Mode is a method of high speed regulation of the output power whenever an arc is established It provides a fast response to changes in the arc The higher the Power Mode Setting the longer the arc If a welding procedure is not established the best way to determine the Power Mode Setting is by experimenta tion until the desired output result is established In the Power Mode variables need to be set Wire Feed Speed Output Arc Control Setting up a Power Mode procedure is similar to set ting a CV MIG procedure Select a shielding gas appropriate for a short arc process For steel use 75 25 Ar CO2 shield gas For Stainless select a Helium blend Tri Mix For Aluminum use 10096 Ar Start by setting the wire feed speed based upon mate rial thickness and appropriate travel speed Then adjust the Output knob as follows For steel listen for the traditional frying egg sound of a good short arc MIG procedure to know you have the process set correctly For aluminum simply adjust the Output knob until the desired arc length is obtained Note the Volts display is simply a relative number and DOES NOT correspond to voltage Some procedure recommendations appear in
148. inimum Maximum 2 1 0 nennen nennen nne E 8 FIGURE E 1 PW 355 BLOCK LOGIC DIAGRAM To Control Main Switch Board Board 20 o9 p 5 Positive Input switch Rectifier __ curent Sensor n 21 2 ZN Q Negative econnec gt utpu o Switch Terminal o EM o qom 2 Sensor o FN 3 o 1 8 115VAC Fan Suppl 7 Primary Current Feedback 2 10 PRY 5 Input Relay Control 5 Auxiliary 8 Soft Start Control 8 P T amp V F Capacitor Feedback 2 E 220 VAC Transformer 8 2 o e Machine Control Supply Yellow 40VDC 15VDG 15VDC 5VDC Thermal a Power v LED e Board Control Board 5232 Supply 5VDC esie 5 Can Supply 5VDC 2 2 Arc Electrode c gt Link Sense Board Wire Feeder p Thermostats 2 To Feeder POWER WAVE 355 405 LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC O10 515 gt 218 5 2 a Return to Section TOC Return to Master TOC E 2
149. irs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty For your safety and to avoid electrical shock please observe all safety notes and precautions detailed throughout this manual Return to Section TOC Return to Master TOC If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed Call 1 800 833 9353 WELD DESCRIPTION The following procedure will aid the technician in removing the input rectifier for maintenance or replacement MATERIALS NEEDED Return to Section TOC Return to Master TOC 3 16 Allen wrench 5 16 Nut Driver Flathead Screwdriver Penetrox A 13 Heatsink Compound Silicon Sealant This procedure takes approximately 30 minutes to perform Ojo O10 5 5 gt 218 5 2 a Return to Section TOC Return to Master TOC POWER WAVE 355 405 LINCOLN 5 F 66 F 66 TROUBLESHOOTING amp REPAIR INPUT RECTIFIER REMOVAL AND REPLACEMENT continued all leads and their positions upon removal 2 Using a 5 16 nut driver remove the case Figure F 31 wraparound cover jo ER 5 8 PROCEDURE 8 5 1 Remove input power to the POWER WAVE 6 Remove the six screws from the terminals using a 813 355 405 flathead screwdriver C
150. ly See Figure 5 202 203 206 207A from the reconnect switches See Figure F 35 8 Locate the steel nut located directly on the other side of the rear assembly behind the plastic nut that was previously removed See Figure F 35 FIGURE F 35 LEAD LOCATIONS b 4 POWER WAVE 355 405 LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Q o E 5 B Return to Section TOC Return to Master TOC o 7 52 2 F 76 F 76 TROUBLESHOOTING amp REPAIR CURRENT TRANSDUCER REMOVAL AND REPLACEMENT continued The back of the machine may now gently be pulled away to gain access to the current trans ducer Note The rear of the machine cannot be removed completely Carefully swing the rear of the machine open to the left while facing the rear of the machine Perform the Snubber Board Removal Remove leads 2 and 20 from the output diode module Remove leads X4 and 40 from the other output diode module 16 17 18 19 20 Using a 3 8 wrench remove the three mounting screws from the output diode heatsink assembly Take note placement of insulation for reassembly See Figure 6 Cut any necessary cable ties and carefully remove the heavy lead from
151. may affect many kinds of electrical equipment other nearby welding equipment radio and TV reception numerical controlled machines telephone systems computers etc Be aware that interference may result and extra precautions may be required when a welding power source is used in a domestic establishment Installation and Use The user is responsible for installing and using the welding equipment according to the manufacturer s instructions If electromagnetic disturbances are detected then it shall be the responsibility of the user of the welding equipment to resolve the situation with the technical assistance of the manufacturer In some cases this remedial action may be as simple as earthing grounding the welding circuit see Note In other cases it could involve constructing an electromagnetic screen enclosing the power source and the work complete with associated input filters In all cases electromagnetic disturbances must be reduced to the point where they are no longer troublesome Note welding circuit may or may not be earthed for safety reasons according to national codes Changing the earthing arrangements should only be authorized by a person who is competent to assess whether the changes will increase the risk of injury e g by allowing parallel welding current return paths which may damage the earth circuits of other equipment Assessment of Area Before installing welding equipment the user shall make an assessment of poten
152. ment damage Single Phase Input PW 355 Connect green lead to ground per National Electrical Code Connect black and white leads to power Wrap red lead with tape to provide 600V insulation Three Phase Input PW 355 Connect green lead to ground per National Electric Code Connect black red and white leads to power Lead Color Single Phase Three Phase Green Connect to Connect to ground per NEC ground per NEC Power Lead Power Lead Power Lead Black White Tape provide 600V insulation Single Phase Input PW 405 Connect green yellow lead to ground per National Electrical Code Connect blue and brown leads to power Wrap black lead with tape to provide 600V insulation Three Phase Input PW 405 Connect green yellow lead to ground per National Electric Code Connect black blue and brown leads to power POWER WAVE 355 405 LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC O10 515 gt 218 5 2 Return to Master A 5 A 5 INSTALLATION UNDERCARRIAGE MOUNTINGS MOUNTING HOLE LOCATIONS NOTE MOUNTING SCREWS CAN NOT PROTRUDE MORE THAN 0 5 INCHES INSIDE THE MACHINE i 72 350 1 9 My 4 20 NUT 4 51 05150 o IUU ef I 1000 2 11 84 4 01 M19527 OUTPUT CABLES CONNECTIONS AN
153. n danger to the technician or machine operator and will invalidate your factory warranty For your safety and to avoid electrical shock please observe all safety notes and precautions detailed throughout this manual Return to Section TOC Return to Master TOC If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed Call 1 800 833 9353 WELD DESCRIPTION The following procedure will aid the technician in removing the DC Bus Board for mainte nance or replacement MATERIALS NEEDED Return to Section TOC Return to Master TOC 5 16 Nut Driver 3 8 Open End Wrench Flat Head Screwdriver Phillips Head Screwdriver O10 515 gt g 9 5 2 EC This procedure takes approximately 40 minutes to perform Return to Section TOC Return to Master TOC POWER WAVE 355 LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o E 5 B tc Return to Section TOC Return to Master TOC o 7 8 2 F 62 F 62 TROUBLESHOOTING amp REPAIR DC BUS BOARD REMOVAL AND REPLACEMENT Continued PROCEDURE 1 Remove input power to the POWER WAVE 355 405 Using a 5 16 nut
154. nd cause injury or death Always use enough ventilation especially in confined areas to insure breathing air is safe Read and understand the manufacturer s instructions for this equipment and the consumables to be used including the material safety data sheet MSDS and follow your employer s safety practices MSDS forms are available from your welding distributor or from the manufacturer Also see item 1 b Mar LINCOLN 8 95 Return to Master TOC Return to Master TOC Q 0 E Return to Master TOC WELDING SPARKS gt 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 Avoid welding near hydraulic lines Have a fire extinguisher readily available Where compressed gases are to be used at the job site special precautions should be used to prevent hazardous situations Refer to Safety in Welding and Cutting ANSI Standard Z49 1 and the operating information for the equipment being used When not welding make certain no part of the electrode circuit is touching the work or ground Accidental contact can cause overheating and create a fire hazard Do not heat cut or weld tanks drums or cont
155. ndicate that this procedure was followed when warranty reports are to be submitted NOTE Following this procedure and writing on the warranty report INSTALLED AND SWITCHED PC BOARDS TO VERIFY PROBLEM will help avoid denial of legitimate PC board warranty claims POWER WAVE 355 405 LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o 5 2 5 tc Return to Section TOC Return to Master TOC Q 0 52 2 dii TROUBLESHOOTING amp REPAIR im Observe Safety Guidelines detailed in the beginning of this manual PROBLEMS SYMPTOMS Major physical or electrical damage is evident when the sheet metal cover is removed POSSIBLE AREAS OF MISADJUSTMENT S OUTPUT PROBLEMS 1 Contact your local authorized Lincoln Electric Field Service Facility for technical assistance TROUBLESHOOTING GUIDE RECOMMENDED COURSE OF ACTION 1 Contact the Lincoln Electric Service Department 1 800 833 9353 WELD The machine is dead no output no LED s Make sure the input line switch is in the ON position Check the main input line fuses If open replace Check the 15 amp circuit break er CB1 Reset if tripped Also check CB3 Make sure the reconnect switch and jumper lead is configured correctly for the applied input voltage If the machine
156. near moving parts Do not put your hands near the cooling blower fan If a problem cannot be corrected by following the instructions take the machine to the nearest Lincoln Field Service Shop ELECTRIC SHOCK can kill Do not touch electrically live parts or electrode with skin or wet clothing insulate yourself from work and ground Always wear dry insulating gloves EXPLODING PARTS can cause injury A Failed parts can explode or cause other parts to explode when power is applied Always wear a face shield and long sleeves when servicing See additional warning information throughout this Manual CAPACITOR DISCHARGE PROCEDURE 1 Obtain a power resistor 25 ohms 25 watts 2 Hold resistor body with electrically insulated glove DO NOT TOUCH TERMINALS Connect the resis tor terminals across the two studs in the position shown Hold in each position for 1 second Repeat for all four capacitors RESISTOR 3 Use a DC voltmeter to check that voltage is not present across the terminals on all four capaci tors VISUAL INSPECTION Clean interior of machine with a low pressure air stream Make a thorough inspection of all compo nents Look for signs of overheating broken leads or other obvious problems Many problems can be uncovered with a good visual inspection ROUTINE MAINTENANCE 1 Every 6 months or so the machine should be cleaned with a low pressure airstream Keeping
157. nly Lincoln Electric factory trained personnel Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty For your safety and to avoid electrical shock please observe all safety notes and precautions detailed throughout this manual Return to Section TOC Return to Master TOC If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed Call 1 800 833 9353 WELD DESCRIPTION The following procedure will aid the technician in removing the main switch board for main tenance or replacement Return to Section TOC Return to Master TOC MATERIALS NEEDED 5 16 Nut Driver Flathead Screwdriver 7 16 mm Socket 3 16 Allen Wrench 3 8 Nut Driver This procedure takes approximately 35 minutes to perform 5 5 218 5 2 a Return to Section TOC Return to Master TOC POWER WAVE 355 405 LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Q o E 5 B Return to Section TOC Return to Master TOC o 0 8 2 F 52 TROUBLESHOOTING amp REPAIR pus MAIN SWITCH BOARD R
158. nting Screws 9 Label and remove two thermostat leads and four 13 Reconnect previously removed leads to their prop leads from the bus rectifier er locations 10 Using a 3 8 open end wrench remove the three 14 Replace the four phillips head screws mounting DC Bus Board mounting nuts See Figure F 29 the two welder output terminals to the front of the machine 11 Replace the DC Bus Board 15 Replace the two phillips head screws from above 12 Secure the new DC Bus Board in its proper loca and below the input power switch tion using the 3 8 mounting nuts FIGURE F 29 CASE FRONT SCREW REMOVAL J47 Bus Rectifier 3 8 Mounting Nuts 1 840111 c X gt 3 o o 9 POWER WAVE 355 LINCOLN 5 F 64 F 64 TROUBLESHOOTING amp REPAIR DC BUS BOARD REMOVAL AND REPLACEMENT Continued 16 Replace the two 5 16 mounting screws to the bottom of the case front 17 Replace the case wraparound cover Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC 5 5 gt 2 2 EIS 2 oO Return to Section TOC Return to Master TOC POWER WAVE 355 LINCOLN 5 F 65 F 65 TROUBLESHOOTING amp REPAIR INPUT RECTIFIER REMOVAL AND REPLACEMENT WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel Unauthorized repa
159. o Section TOC Return to Master TOC A 3 A 3 INSTALLATION TECHNICAL SPECIFICATIONS POWER WAVE 405 INPUT AC VOLTAGE amp DC OUTPUT Rated DC Output Amps Volts Duty Cycle Dimensions HxWxD Ordering Information Voltage Output Range continuous Weight with Cord 350A 34V 60 200 208 3 Phase 220 240 320A 33V 60 380 415 1 Phase 3 50 60 14 7 12 5 27 8 373 318 706 mm K 2152 2 86 5lbs 37 4 kg Wave 405 60 50 Hz 275A 31V 10096 1 Phase 300A 32V 10096 3 Phase Includes handles Overall Length Including Handle 21 6 649mm without handle POWER WAVE 405 INPUT CURRENT Recommended Fuse Sizes Based On The U S National Electrical Code And Maximum Machine Outputs Input 50 60 Hz Output Recommended Voltage 300Amps Line Cord Size Fuse Size 32Volts 100 Size mm 350Amps 34Volts 60 200 220 380 400 415 80A 80A 50A 50A Phases 31 Volts 100 275Amps 33Volts 60 320Amps Line Cord Size mm Fuse Size Not Recommended Not Recommended 1 Not rated is indicated by 4 x s in the box on the rating plate 2 When operating on these inputs the line cord should be changed to an input conductor of 6 AWG or larger OUTPUT CABLES CONNECTIONS AND LIMITATIONS Select the output cable size based upon the following chart Cable sizes for Combined Length of Electrode and Work Cable Copper 75C rated
160. ohms Less than 100 ohms Less than 100 ohms Less than 100 ohms Greater than 1000 ohms Greater than 1000 ohms Greater than 1000 ohms OU OU O10 E 5 9 16 EIS 2 oO 1 9 f the input rectifier does not meet the 11 If the input rectifier is faulty see the acceptable readings outlined in Table F 2 Input Rectifier Bridge Removal amp the component may be faulty Replace Replacement procedure Note Before replacing the input rectifier 12 Replace the case wraparound cover check the input power switch and per form the Main Switch Board Test Also check for leaky or faulty filter capacitors 10 If the input rectifier is good be sure to reconnect leads 207 207A and 209 to the correct terminals and torque to 31 inch Ibs Apply silicone sealant Return to Section TOC Return to Master TOC POWER WAVE 355 405 LINCOLN 5 F 22 LINCOLN jo NOTES POWER WAVE 355 405 F 22 901 Je1Se A 0 uunjeH 901 Je1Se A 0 901 J91Se N 01 901 J91Se N 01 DOL uonoes 901 uonoes uumeg DOL uonoes 901 uonoes uumeg F 23 F 23 TROUBLESHOOTING amp REPAIR POWER BOARD TEST WARNING Return to Section TOC Return to Master TOC Service and repair should be performed by only Lincoln Electric factory trained personnel Unauthorized repairs performed on this equipment may result in danger to t
161. on TOC Return to Master TOC MATERIALS NEEDED Volt ohmmeter Multimeter 5 16 Nut Driver Wiring Diagram This procedure takes approximately 25 minutes to perform 5 5 218 5 2 a Return to Section TOC Return to Master TOC POWER WAVE 355 405 LINCOLN 5 F 36 F 36 TROUBLESHOOTING amp REPAIR 9 9 AUXILIARY TRANSFORMER TEST continued E FIGURE F 10 Auxiliary Transformer 5 aye ale Auxiliary SJS Transformer 2 8 Secondary Lead Plugs P52 o 3 5 B Return to Master TOC TEST PROCEDURE olo 1 Remove input power to the POWER WAVE 4 Locate the auxiliary transformer See Figure 355 405 10 5 5 2 Using a 5 16 nut driver remove the case 5 Locate the secondary leads and plug 52 15 wraparound cover See Figure 10 and 11 gt _ 9 3 Perform the Input Capacitor Discharge cle detailed earlier in this section 5 5 2 c FIGURE F 11 Plug Lead Connections Viewed From Transformer Lead Side of Plug PW405 Only 220V 532 115V Ojo ele Plug P52 8 5 o 01 15 2 cle Com 2 als 31 amp 2 POWER WAVE 355 405 LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o E 5 B Return to Section TOC R
162. outs may function only on a limited basis if at all MAKING A WELD A WARNING The serviceability of a product or structure utiliz ing the welding programs is and must be the sole responsibility of the builder user Many variables beyond the control of The Lincoln Electric Company affect the results obtained in applying these programs These variables include but are not limited to welding procedure plate chemistry and temperature weldment design fabrication methods and service requirements The available range of a welding program may not be suitable for all applications and the build user is and must be solely responsible for welding program selection The steps for operating the Power Wave will vary depending upon the options installed in the user inter face control box of the welding system The flexibility of the Power Wave system lets the user customize operation for the best performance First consider the desired welding process and the part to be welded Choose an electrode material diam eter shielding gas and process GMAW GMAW P etc Second find the program in the welding software that best matches the desired welding process The stan dard software shipped with the Power Waves encom passes a wide range of common processes and will meet most needs If a special welding program is desired contact the local Lincoln Electric sales repre sentative To make a weld the Power Wave needs to know the desir
163. r user interface knows what the other is doing at all times These components com municate with Linc Net a digital communications sys tem The POWER WAVE 355 405 is a high performance digitally controlled inverter welding power source capable of complex high speed waveform control Properly equipped it can support the GMAW GMAW P FCAW SMAW GTAW and CAC A processes It car ries an output rating of 350 Amps 34 Volts at 60 duty cycle and 300 Amps 32 volts at 100 duty cycle INPUT LINE VOLTAGE AUXILIARY TRANSFORMER amp PRECHARGE The POWER WAVE 355 405 can be connected for a variety of three phase or single phase input voltages The initial power is applied to the 355 405 through a line switch located on the front of the machine Two Connector Thermostats 2 phases of the input voltage are applied to the auxiliary transformer The auxiliary transformer develops three different secondary voltages The 115VAC is applied via the main switch board to the fan motor The 42VAC is rectified and filtered The 65VDC produced by the Bus board rectifier is used by the Bus board to provide 40VDC to the power board 40VDC is also applied to the wire feeder receptacle PW405 models have an additional 220VAC winding that is connected to a 220 AC receptacle The input voltage is rectified by the input rectifier and the resultant DC voltage is applied to the switch board through the reconnect switch assembly loc
164. rcuit breaker is OK perform Check plug J22 circuit breaker CB2 and associated leads for loose or faulty connections See the Wiring Diagram Energize the weld output terminals with the PW 355 405 in mode 200 This mode can be accessed using a wire feeder placed in mode 200 or a laptop computer and the appropriate software Carefully check for 115VAC at plug J22 pin 1 to J22 pin 4 fan leads If the 115VAC is present and the fan is not running then the fan motor may be faulty Also check the associated leads between plug J22 and the fan motor for loose or faulty con nections See the Wiring Diagram WARN ING HIGH VOLTAGE IS PRESENT AT THE SWITCH BOARD If the 115VAC is NOT present in the previous Step then proceed to the fan control test 1 Locate plug J20 on the switch board Do not remove the plug from the switch board See Figure F 14 and F 16 2 Energize the weld output terminals Select Weld Terminals ON and carefully check for 15VDC at plug J20 pin 6 to J20 pin 2 leads 715 to 716 See Figure 16 If the 15VDC is present and the fan is not running then the switch board may be faulty If the 15VDC is not present when the weld terminals are energized then the control board may be faulty Also check plugs J20 J7 and all asso ciated leads for loose or faulty connections See the Wiring Diagram WARNING HIGH VOLTAGE IS PRESENT AT THE SWITCH BOARD 3 Remove the input power to the POWER WAVE 355 405 Not
165. ring of the mains supply Consideration should be given to shielding the supply cable of permanently installed welding equipment in metallic conduit or equivalent Shielding should be electrically continuous throughout its length The shielding should be connected to the welding power source so that good electrical contact is maintained between the conduit and the welding power source enclosure Maintenance of the Welding Equipment The welding equipment should be routinely maintained according to the manufacturer s recommendations All access and service doors and covers should be closed and properly fastened when the welding equipment is in operation The welding equipment should not be modified in any way except for those changes and adjustments covered in the manufacturers instructions In particular the spark gaps of arc striking and stabilizing devices should be adjusted and maintained according to the manufacturer s recommendations Welding Cables The welding cables should be kept as short as possible and should be positioned close together running at or close to the floor level Equipotential Bonding Bonding of all metallic components in the welding installation and adjacent to it should be considered However metallic components bonded to the work piece will increase the risk that the operator could receive a shock by touching these metallic components and the electrode at the same time The operator should be insulated from all such bond
166. rminal to the work piece The work piece connection must be firm and secure especially if pulse welding is planned For additional Safety information regarding the elec trode and work cable set up See the standard SAFE TY INFORMATION located in the front of the Instruction Manuals CAUTION Excessive voltage drops caused by poor work piece connections often result in unsatisfactory welding performance NEGATIVE ELECTRODE POLARITY When negative electrode polarity is required such as in some Innershield applications reverse the output connections at the power source electrode cable to the negative Twist Mate terminal and work cable to the positive Twist Mate terminal When operating with electrode polarity negative the Electrode Sense Polarity DIP switch must be set to the Negative position on the Wire Drive Feed Head PC Board The default setting of the switch is positive electrode polarity Consult the Power Feed instruction manual for further details VOLTAGE SENSING The best arc performance occurs when the PowerWaves have accurate data about the arc condi tions Depending upon the process inductance within the electrode and work lead cables can influence the voltage apparent at the studs of the welder Voltage sense leads improve the accuracy of the arc condi tions and can have a dramatic effect on performance Sense Lead Kits K940 10 25 or 50 are available for this purpose CAUTION If t
167. rol Main Switch Board Board 5 89 141 N Positive Input T Output Input switch Rectifier Current Terminal EX Sensor o Q Negative Reconnect Output o Switch 2 2 Terminal 5 Current 8 Fan Sensor 25 7 0 g Primary Current Feedback 2 2 g 7 5 Auxiliary 220 VAC Transformer 40VDC V F Capacitor Feedback 2 Machine Control Supply 15VDC 15VDC 5VDC Teu amp is 1891 Yellow Thermal LED o r Ww a Power e Board Control Board 85232 Supply 5VDC 5 Can Supply 5VDC id o n DC Arc Electrode y Link Sense A 40VDC Feeder R232 SWITCH BOARD amp MAIN TRANSFORMER There is one switch board in the POWER WAVE 355 405 This board incorporates two pairs of input capacitors two insulated gate bipolar transistor IGBT switching circuits a fan motor drive circuit and a volt age frequency capacitor feedback circuit The two capacitors in a pair are always in series with each other When the reconnect switch is in the lower volt age position the capacitor pairs are in parallel Thus two series capacitors in parallel with two series capac itors When the reconnect switch is in the high voltage position the two capacitor pairs are in series Thus four cap
168. round cover Return to Section TOC Return to Master TOC FIGURE F 23 SNUBBER BOARD LOCATION Snubber Board Return to Section TOC Return to Master TOC LEFT SIDE 5 Remove small lead B1 from the board See 8 Replace the snubber board Figure F 24 9 Replace the bolts leads and washers previously 6 Remove the four bolts using a 7 16 socket Two removed Torque bolt to 30 40 Inch Lbs of these bolts have leads 30 and 10 connected to them Note the position of all leads and associ 10 Reconnect small lead B1 previously removed ated washers upon removal 11 Replace the case wraparound cover 7 Carefully remove the snubber board FIGURE F 24 SNUBBER BOARD LEADS CLOSE UP OJO 5 5 g 9 5 2 a Lead B1 Lead 10 POWER WAVE 355 405 LINCOLN 5 Return to Section TOC Return to Master TOC F 57 F 57 TROUBLESHOOTING amp REPAIR POWER BOARD REMOVAL AND REPLACEMENT WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty For your safety and to avoid electrical shock please observe all safety notes and precautions detailed throughout this manual Return to Section TOC Return to Master TOC If for any reason
169. t may have opened Reset Circuit breaker CB3 in recon nect area may have opened Reset On PW 405 models the circuit breaker CB4 protects the 220VAC receptacle Reset if tripped 5 Code Explanations F 8 TROUBLESHOOTING GUIDE RECOMMENDED COURSE OF ACTION 1 Perform the Transformer Test See Fault Code Explanations General degradation of the weld performance Check for feeding problems bad connections excessive loops in cabling etc Verify weld mode is correct for processes The power source may require calibration Check the actual current dis played on the Power Feed 10 vs actual current measured via external meter Check the actual voltage dis played on the Power Feed 10 vs actual voltage measured via external meter Checkthe actual WFS displayed on the Power Feed 10 vs actual WFS measured via external meter Perform the Voltage and Current Calibration Procedure 2 Perform the Current Transducer Test 2 Perform the Output Diode Module Test The control board may be faulty CAUTION 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 WELD POWER WAVE 355 405 LINCOLN 5 Return to Section TOC Return to Master TOC Re
170. tection Circuitry 21 100 100 ir C m 27 35V 600V id D3 3A D4 1A 30V G ENERAL INFORMAATIO LAST NO USED 7 Mov 2 17 LED 1 5 DZ 6 ELECTRICAL SYMBOLS PER E1537 CAPACITORS MFD UNLESS OTHERWISE SPECIFIED RESISTORS Ohms UNLESS OTHERWISE SPECIFIED UNLESS OTHERWISE SPECIFIED NOTES N A SINCE COMPONENTS OR CIRCUITRY ON PRINTED CIRCUIT BOARD MAY CHANGE WITHOUT AFFECTING THE INTERCHANGEABILITY OF COMPLETE BOARD THIS DIAGRAM MAY NOT SHOW THE EXACT COMPONENTS OR CIRCUITRY OF CONTROLS HAVING COMMON CODE NUMBER E M19330_1BA F 1 1 FRAME CONNECTIO ot THE LINCOLN ELECTRIC CO EARTH GROUND CO THE LINCOLN ELECTRIC CO SUPPLY VOLTAGE NET POWER SUPPLY SOURCE POINT COMMON CONNECTION THIS SHEET CONTAINS PROPRIETARY INFORMATION OWNED BY IS NOT TO BE REPRODUCED DISCL
171. terminals Voltage should be zero any voltage remains repeat this capacitor dis charge procedure FIGURE F 1 LOCATION OF INPUT FILTER CAPACITOR TERMINALS EIGHT CAPACITOR TERMINALS POWER RESISTOR INSULATED PLIERS INSULATED GLOVES POWER WAVE 355 405 LINCOLN 5 F 15 F 15 TROUBLESHOOTING amp REPAIR MAIN SWITCH BOARD TEST WARNING Return to Section TOC Return to Master TOC Service and repair should be performed by only Lincoln Electric factory trained personnel Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty For your safety and to avoid electrical shock please observe all safety notes and precautions detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed Call 1 800 833 9353 WELD DESCRIPTION This test will help determine if the power section of the switch boards are functioning cor rectly This test will NOT indicate if the entire PC board is functional This resistance test is preferable to a voltage test with the machine energized because this board can be damaged easily In addition it is dangerous to work on this
172. ters Dual Oylinder Kit for K1764 1 is K1702 1 Welding Cable Connectors K852 70 1 0 2 0 CABLE K852 95 2 0 3 0 CABLE COMPATIBLE LINCOLN EQUIPMENT Any Linc Net compatible semi automatic wire feeding equipment Specifically the semi automatic Power Feed family PF 10 PF 10X2 PF 11 POWER WAVE 355 405 LINCOLN 5 Section D 1 Section D 1 TABLE OF CONTENTS MAINTENANCE 2 Maintenance SRM Section D gt Capacitor Discharge Procedure sessssssssseseseseseennen nennen nennen nennt entres D 2 5 OM sce ees 2 5 Routine Maintenance TANE E HEAR D 2 Periodic 0 2 Major Component Locations e ER o n FEE RR nna FER na D 3 Return to Master TOC o O P o 0 gt gt c 5 tc Return to Master TOC POWER WAVE 355 405 LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC O10 515 zio gt 218 5 2 a Return to Section TOC Return to Master TOC Return to Master TOC D 2 D 2 MAINTENANCE WARNING Have qualified personnel do the maintenance work Always use the greatest care when working
173. the diode heatsink using a 1 2 nut driver Remove the output diode heatsink assembly through the rear of the machine Remove plug 8990 from the current transducer Using a 3 8 nut driver remove the two mounting nuts from the current transducer FIGURE F 36 OUTPUT HEATSINK MOUNTING SCREW LOCATION 3 8 MOUNTING POWER WAVE 355 405 LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC OJO 5 5 gt 2 2 EIS 2 oO Return to Section TOC Return to Master TOC Return to Master TOC F 77 21 22 23 24 25 26 2T 28 F 77 TROUBLESHOOTING amp REPAIR CURRENT TRANSDUCER REMOVAL AND REPLACEMENT continued Replace the current transducer Replace the two 3 8 mounting nuts previously removed Reconnect plug J90 to the current transducer Replace any necessary cable ties previously cut From the rear of the machine replace the heavy flex lead to the bottom of the output diode heatsink assembly using a 1 2 wrench Note Don t forget to include all washers Replace the output diode heatsink assembly pre viously removed using a 3 8 wrench Note Be sure to place insulation in its original location Replace leads X2 420 X4 840 previously removed from the two output diode modules Torque to 30 40 inch Ibs Perform t
174. thermostat 1 Check for 40 on pin D and pin at the Power Wave wire feeder receptacle See Wiring Diagram If 40 volts DC is Not present at the Power Wave wire feeder receptacle perform the Board Test 2 Check the DC Bus Board rectifi er See Wiring Diagram 3 Perform the T1 Auxiliary trans 4 If the 40 volts DC is present at the Power Wave wire feeder receptacle the problem is in the control cable or the wire drive control box CAUTION 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 WELD POWER WAVE 355 405 LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Q 5 2 5 tc Return to Section TOC Return to Master TOC Q 0 8 2 7 Observe Safety Guidelines TROUBLESHOOTING amp REPAIR TROUBLESHOOTING GUIDE detailed in the beginning of this manual PROBLEMS SYMPTOMS The machine often noodle welds with a particular procedure The output is limited to approximately 100 amps POSSIBLE AREAS OF MISADJUSTMENT S FUNCTION PROBLEMS The machine may be trying to deliver too much power When the average outp
175. tial electromagnetic problems in the surrounding area The following shall be taken into account other supply cables control cables signaling and telephone cables above below and adjacent to the welding equipment radio and television transmitters and receivers computer and other control equipment safety critical equipment e g guarding of industrial equipment the health of the people around e g the use of pacemakers and hearing aids equipment used for calibration or measurement the immunity of other equipment in the environment The user shall ensure that other equipment being used in the environment is compatible This may require additional protection measures the time of day that welding or other activities are to be carried out L10093 POWER WAVE 355 LINCOLN 5 Return to Master TOC Return to Master TOC O gt o 9 gt c 5 tc Return to Master TOC vi vi INSTALLATION ELECTROMAGNETIC COMPATIBILITY EMC The size of the surrounding area to be considered will depend on the structure of the building and other activities that are taking place The surrounding area may extend beyond the boundaries of the premises Methods of Reducing Emissions Mains Supply Welding equipment should be connected to the mains supply according to the manufacturer s recommendations If interference occurs it may be necessary to take additional precautions such as filte
176. tif de montage ou la piece souder doit tre branch une bonne mise la terre 2 Autant que possible l installation et l entretien du poste seront effectu s par un lectricien qualifi 3 Avant de faires des travaux l interieur de poste la debranch er l interrupteur la boite de fusibles 4 Garder tous les couvercles et dispositifs de s ret leur place Mar 93 POWER WAVE 355 405 LINCOLN 5 Return to Master TOC Return to Master TOC o 7 E Return to Master TOC INSTALLATION ELECTROMAGNETIC COMPATIBILITY EMC Conformance Products displaying the CE mark are in conformity with European Community Council Directive of 3 May 1989 on the approximation of the laws of the Member States relating to electromagnetic compatibility 89 336 EEC It was manufactured in conformity with a national standard that implements a harmonized standard EN 50 199 Electromagnetic Compatibility EMC Product Standard for Arc Welding Equipment It is for use with other Lincoln Electric equipment It is designed for industrial and professional use Introduction electrical equipment generates small amounts of electromagnetic emission Electrical emission may be transmitted through power lines or radiated through space similar to a radio transmitter When emissions are received by other equipment electrical interference may result Electrical emissions
177. to Section TOC Return to Master TOC Return to Section TOC Ojo 5 5 gt 2 2 EIS 2 1 Return to Section TOC Return to Master TOC Return to Master TOC B 5 B 5 OPERATION In non synergic modes the WFS control behaves more like a conventional CV power source where WFS and voltage are independent adjustments Therefore to maintain the arc characteristics the operator must adjust the voltage to compensate for any changes made to the WFS In constant current modes stick TIG this control adjusts the output current in amps VOLTS TRIM In constant voltage modes synergic CV standard CV the control adjusts the welding voltage In pulse synergic welding modes pulse GMAW only the user can change the Trim setting to adjust the arc length It is adjustable from 0 500 to 1 500 A Trim set ting of 1 000 is a good starting point for most condi tions WELDING MODE May be selected by name CV MIG CC Stick Crisp Gouge etc or by a mode number 10 24 71 etc depending on the Control Box options Selecting a welding mode determines the output characteristics of the Power Wave power source For a more complete description of the welding modes available in the Power Wave see the explanation below ARC CONTROL Also known as Inductance or Wave Control Allows operator to vary the arc characteristics from soft to harsh in all weld modes It is adjust
178. turn to Section TOC Return to Master TOC Q 5 2 5 tc Return to Section TOC Return to Master TOC Q 0 52 2 F 9 TROUBLESHOOTING amp REPAIR USING THE STATUS LED TO TROUBLESHOOT SYSTEM PROBLEMS The Power Wave Power Feed are best diagnosed as a system Each component power source user interface and feed head has a status light and when a problem occurs it is important to note the condition of each In addition errors displayed on the user interface in most cases indicate only that a problem exists in the power source not what the problem may be Therefore prior to cycling power to the sys tem check the power source status light for error sequences as noted below This is especially important if the user interface displays Err 006 or Err 100 LIGHT CONDITION Status LED is solid green no blinking Status LED is blinking green Status LED is blinking red and green Status LED is solid red no blinking Status LED is blinking red Included in this section is information about the power source Status LED and some basic trou bleshooting charts for both machine and weld perfor mance The STATUS LIGHT is a two color light that indicates system errors Normal operation is a steady green light Error conditions are indicated in the following chart NOTE The POWER WAVE 355 405 status light will flash
179. ut current exceeds a maximum limit the machine will phase back to protect itself Adjust the proce dure or reduce the load to lower the current draw from the Power Wave machine F 7 RECOMMENDED COURSE OF ACTION 1 Perform the Transducer Test 2 The control board may be faulty Excessively long and erratic arc Check for proper configuration and implementation of voltage sensing circuits Check the connections between the voltage sense receptacle and the control board See the Wiring Diagram 2 The control board may be faulty CAUTION 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 WELD POWER WAVE 355 405 LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o 9 2 5 tc Return to Section TOC Return to Master TOC Q 0 8 2 TR TROUBLESHOOTING amp REPAIR Observe Safety Guidelines detailed in the beginning of this manual PROBLEMS SYMPTOMS Auxiliary receptacle is dead no auxiliary voltage A fault or error code is displayed POSSIBLE AREAS OF MISADJUSTMENT S FUNCTION PROBLEMS Circuit breaker CB1 on case fron
180. vice this equipment Turn the input power OFF at the fuse box before working on equipment Do not touch electrically hot parts CAUTION Sometimes machine failures appear to be due to PC board failures These problems can sometimes be traced to poor electrical connections To avoid prob lems when troubleshooting and replacing PC boards please use the following procedure 1 Determine to the best of your technical ability that the PC board is the most likely component causing the failure symptom 2 Check for loose connections at the PC board to assure that the PC board is properly connected 3 If the problem persists replace the suspect PC board using standard practices to avoid static electrical damage and electrical shock Read the warning inside the static resistant bag and perform the following procedures PC board can be damaged by static electricity Remove your body s static charge before opening the static shielding bag Wear an anti static wrist strap For safety use a 1 Meg ohm resistive cord connected to a grounded part of the equipment frame ATTENTION Static Sensitive If you don t have a wrist strap touch an un painted grounded part of the equipment frame Keep touching the frame to prevent static build up Be sure not to touch any electrically live parts at the same time Devices Handle only at Static Safe Workstations Tools which come in contact with the PC board must be either
181. weld table Contact the service department for instructions on reloading the Welding Software 23 Weld table checksum error Contact the service department for instructions on reloading the Welding Software 31 Primary overcurrent error Excessive Primary current present May be related to a short in the main transformer or output rectifier Capacitor A under voltage Low voltage on the main capacitors May be caused by improper input configuration Capacitor B under voltage When accompanied by an overvoltage error on the same side it indicates no capacitor voltage present on that side and is usually the result of an open or short in the primary side of the machine Capacitor A overvoltage Excessive voltage on the main capacitors May be caused by improper input configuration Capacitor B overvoltage When accompanied by an under voltage error on the same side it indicates no capacitor voltage present on that side and is usually the result of an open or short in the primary side of the machine Thermal error Indicates over temperature Usually accompanied by ther mal LED Check fan operation Be sure process does not exceed duty cycle limit of the machine WILL _ Capacitor precharge failed Usually accompanied by codes 32 35 Secondary overcurrent error The secondary weld current limit has been exceeded When this occurs the machine output will phase back to 100 amps typically resulting in a condition referred to as
182. when in cramped positions such as sitting kneeling or lying if there is a high risk of unavoidable or accidental contact with the workpiece or ground use the following equipment Semiautomatic DC Constant Voltage Wire Welder DC Manual Stick Welder AC Welder with Reduced Voltage Control In semiautomatic or automatic wire welding the electrode electrode reel welding head nozzle or semiautomatic welding gun are also electrically hot Always be sure the work cable makes a good electrical connection with the metal being welded The connection should be as close as possible to the area being welded Ground the work or metal to be welded to a good electrical earth ground Maintain the electrode holder work clamp welding cable and welding machine in good safe operating condition Replace damaged insulation Never dip the electrode in water for cooling Never simultaneously touch electrically hot parts of electrode holders connected to two welders because voltage between the two can be the total of the open circuit voltage of both welders When working above floor level use a safety belt to protect yourself from a fall should you get a shock Also see Items and 8 22 ARC RAYS can burn 4 a Use a shield with the proper filter and cover plates to protect your eyes from sparks and the rays of the arc when welding or observing open arc welding Headshield and filter lens should
183. y cycle represents 6 minutes of welding and 4 minutes of idling in a ten minute period CASE FRONT CONTROLS All operator controls and adjustments are located on the case front of the Power Wave See Figure B 1 POWER SWITCH Controls input power to the Power Wave 2 STATUS LIGHT A two color light that indicates sys tem errors Normal operation is a steady green light Error conditions are indicated per table B 1 NOTE The POWER WAVE 355 405 status light will flash green and sometimes red and green for up to one minute when the machine is first turned on This is a normal situation as the machine goes through a self test at power up condition 000000 Condition Steady Green System OK Power source communicating normal MS L md Occurs during a reset and indicates the POWER WAVE 355 405 is mapping identi fying each component in the system Normal for first 1 10 seconds after power is turned on or if the system configuration is changed during operation TABLE 1 Non recoverable system fault If the PW Status light is flashing any combination of red and green errors are present in the POWER WAVE 355 405 Read the error code before the machine is turned off Error Code interpretation through the Status light is detailed in the Individual code digits are flashed in red with a long pause between digits If more than one code is present the codes will be sepa rated by a green light To cl
184. you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed Call 1 800 833 9353 WELD DESCRIPTION The following procedure will aid the technician in removing the power board for maintenance or replacement MATERIALS NEEDED Return to Section TOC Return to Master TOC 5 16 Nut Driver 3 8 Nut Driver olo OJO 5 5 218 5 2 a This procedure takes approximately 25 minutes to perform Return to Section TOC Return to Master TOC POWER WAVE 355 405 LINCOLN 5 F 58 F 58 TROUBLESHOOTING amp REPAIR POWER BOARD REMOVAL AND REPLACEMENT continued FIGURE F 25 POWER BOARD LOCATION Return to Section TOC Return to Master TOC Power Board o o 3 5 Return to Master TOC LEFT SIDE olo E e S8 o PEN 12 9 2 818 2 PROCEDURE 3 Perform the Filter Capacitor Discharge 1 Rs input power to the POWER WAVE Procedure detailed earlier in this section 4 Locate the power board See Figure E25 2 Using a 5 16 nut driver remove the case wrap around cover Return to Section TOC Return to Master TOC POWER WAVE 355 405 LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC olo OJO 5

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