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Lincoln Electric SVM112-B User's Manual

1. AV IdSIG cy 8 2 2 9 ser ler sen ver ezr zer ozr lt 3 bb 9 0l tol 9 2 E oj EE BEES FREES BE j AEL j E L ETA 1 O 9 AL D 4 Y d 2 Zio 2 25 ms2 INVId 2 5 lt 5 Zo 2 8 8 oo a ger ser eer zer Ler oer 5 MEME 9 _ t e XL O 2 P te 1 gt E 2521p GG o pu d 111 1 L L 4 K ed cla 2 2 FEED LL E 3 X as L 91 evr zor Ler ovr dOL 22 901 Je1Se A 0 901 4 1 0 uunjeH 901 J91Se N 01 901 J91Se N 01 DOL uonoes DOL DOL DOL uonoes Return to Section Return to Master TOC Return to Section TOC O10 e 515 9 1 EIS 2 Return to Section Retur
2. 1 Remove main input supply power to the machine 2 With the 3 8 nut driver remove the 4 screws that hold the handle to the machine 3 Remove the rubber gasket cover seal from the lift bail 4 With the 5 16 nut driver remove the sheet metal screws from the case top 5 With the 5 16 nut driver remove the screws holding the right and left case sides Remove the case sides by lifting up and out 6 Perform the Capacitor Discharge Proce dure described earlier in this section of the manual F 94 F 94 TROUBLESHOOTING amp REPAIR DYNAMIC CAPACITOR BALANCE TEST continued 6 5 FIGURE F 32 CONTROL BOARD PLUG LOCATIONS 3 8 8 EIE ala dc TOP VIEW PROTECTION BD LE 16 14 6 6 14 6 4 4 4 J30 J31 J32 J33 434 435 J36 437 J38 439 GROUND PLANE lt jem a 912 CONTROL EEEED E F 8 0 8 8 12 814141 EE pum 2 6 14 10 6 44 9 2 J20 J21 J22 J23 424 425 426 J27 J28 HE dc DISPLAY TEST PROCEDURE WARNING
3. 901 Je1Se A 0 SOL 5 0 DOL 49159 0 DOL 01 DOL DOL 5 01 5 c ae 7092 07 5 ome SH p VSH lt 1 204 a Z JNVUL M ze 726 24 1062 0822 lt c o 9 YEH 5 gt ABOUT d 9 lt 5 8 52 PN eov S 7777 5 vize o 5 7 Veer Voer ocr lsod 2 4 ps o 9 9 91 lt 9 lt lt 1 lt gt 2 D LL R Lu gt T d T 9215 238 2 HH 1099 099 INANI 3019 lt lt gl GH 08 08 Hour xnv o IMS gt AGLP OBE L amp BIH HOLMS lt ri C PH 917 088 7 a ve cu 8126 50 2 1068 0822 _ 5 L va 07 eer vec PIN gu 27 5 er 8 eee erin cor 9 lt 9 5 98 um lt v lt OO id 27 gt T ES ip TH 2 iL 901 J91Se N 01 904 uonoeg oj LINCOLN Return to Section
4. PROCEDURE 1 6 Remove main input supply power to the machine With the 3 8 nut driver remove the 4 screws that hold the handle to the machine Remove the rubber gasket cover seal from the lift bail With the 5 16 nut driver remove the sheet metal screws from the case top With the 5 16 nut driver remove the screws holding the right and left case sides Remove the case sides by lifting up and out Perform the Capacitor Discharge Proce dure described earlier in this section of the manual A WARNING e Before continuing with the test procedure perform the capacitor discharge proce dure to avoid electric shock After you have completed the capacitor dis charge procedure for all four switch boards with the slot head screw driver remove the three heavy leads from the output side of the contactor With the slot head screw driver remove the two small leads L1A and L3A from the input side of the contactor POWER WAVE 450 LINCOLN amp F 184 F 184 TROUBLESHOOTING amp REPAIR O 9 MAIN INPUT CONTACTOR CR1 REMOVAL AND REPLACEMENT continued 5 5 FIGURE F 69 MAIN 5 4 2 ele 518 eic 6 21 N Ti T2 eS Return to Section Return to Master TOC Return to Section TOC O
5. DISPLAY SNUBBER BE CONTROL BOARD BOARD BOARD REPLACED Fle REPLACED REPLACED 5 9 4 oz 5 2 IF POSSIBLE QUICK CALIBRATION CALIBRATION oo 9 8 5 8 55 5 ULL le VOLTAGE ole CALIBRATION 818 2 POWER WAVE 450 LINCOLN 178 NOTES POWER WAVE 450 LINCOLN 5 F 178 901 Je1Se A 0 901 Je1se A 0 901 J91Se N 01 DOL 01 901 uonoes uumeg DOL uonoes uumeg DOL uonoes uumeg DOL uonoes uumeg Return to Section Return to Master TOC Return to Section TOC Return to Master TOC o 2 3 Return to Section Return to Master TOC o O gt o gt E tc F 179 F 179 TROUBLESHOOTING amp REPAIR DISPLAY 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 elec trical shock please observe all safety notes and precautions detailed throughout this manual If for any reason you do not understand the test pr
6. F 84 901 Je1Se A 0 DOL uonoes SOL 19159 0 DOL uonoes DOL 01 DOL uonoeg uunjeg 901 Je1se N 01 DOL uonoeg auvog TOHLNOO 2 ezr ea 262 2 rc ee eze CKOHVOS 2 08 08 180 O 18 HOLIMS HOLMS HOlIMS lt 667 Vy z 5 try we 4 lt 5 99 145 OvIVYLOLIO 2 OVAPC T D 31084 86 velg v6 vu FON eer eer OEF 067 oer ler Ler oc OU KARAM AA 8 9 L LL L 9 9 L 01 A Gn A A AA A AA A A ul ASLI AvC 6c 16 M6 rzi Tea 2 zov MEC VICE m 804 O gt wwz E 3 cc 5 o a gt 2411 gt IN lt 826 926 l ain 471009 01 1 9 1 5 u3yv3ug gt 9 gt m lt 140 5 8 lt 2 SH 1 vee 66 M l 1 e A 0 0 s N ee ome
7. ENABLE OUTPUT VOLTAGE MONITOR 3 GAIN 016 V V Viault 2 0 8 5 Q BS 5 2 CONVERTER m 100K CAP DELTA ADDS GAIN HIFTS Fo GENERAL INFORMATION TT CAP DELTA MONITOR CAPACITORS MFD 02050 UNLESS OTHERWISE SPECIFIED D s 3 RESISTORS Ohms 1 4 UNLESS OTHERWISE SPECIFIED 2 5 DIODES 1 4000 UNLESS OTHERWISE SPECIFIED SUPPLY VOLTAGE NET FREQ RANGE 0 2 5 2 POWER SUPPLY SOURCE POINT CAP1 CAP2 1 25 2 57 COMMON CONNECTION CAP1 gt CAP2 F 1 25KHz 171 1 FRAME CONNECTION E 125kHz NOTES FILENAME G2451 2DA E EARTH GROUND CONNECTION DEADBAND 375 Hz SINCE COMPONENTS OR CIRCUITRY ON A PRINTED CIRCUIT BOARD MAY CHANGE o THE LINCOLN ELECTRIC PE INVERTEC GAIN 25 NOT SHOW THE EXACT COMPONENTS OR CIRCUITRY OF CONTROLS HAVING A COMMON CODE CLEVELAND U S A _ PROTECTION PC BOARD SCHEMATIC 16958 NUMBER 0 27 9 SCALE __ 1 DATE 12 26 91 ouk TEL SUPSD G Nor 2451 NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual LINCOLN POWER
8. TRANSMIT 888282 RESET LCD A CARRIER 1 DISPLAY P POCO LEDB 2 E RS LCD RS b f DATA IN DATA OUT LOCK 14489 2 81015 10 s 18 5V e 1 0 BI DL 8 2 moug 810 2 aog Dt INFRAZ 4 9162MHz 01 gi But x NERAL aa INFRAS sous 7 1 8011 TRIMS 8 Broug p INFRA 8 0114 TRIM4 3 BOLTI 9 INFRAB 0018 5 5 CRYSTA 5 rm 515 9 16 gt 218 5 2 LE KEY E LE INFRA PIEZO ST apum OE KEY gt som 0 WATER E THERMAL PB4 33 ca ES gt PRESSURE 0114 50V BI DL 15 9 IPBT Vad MCGBHCI T fe 08 88282 10 0 10 0K 10 0K 00 LAST NO USED naui o GENERAL INFORMATION _ ELECTRICAL SYMBOLS PER E1537 C10 CAPACITORS MFD 022 50V UNLESS OTHERWISE SPECIFIED 1 0 34 0 29 RESISTORS Ohms 1 4 UNLESS OTHERWISE SPECIFIED LABELS DIODES 1 4000 UNLESS OTHERWISE SPECIFI
9. NC ANODE VB CATH FROM 11 NOISE GROUND 2K PROTECTION BOARD INTERFACE HIGH NORMAL LOW FAULT 2L GENERATE FAULT SIGNAL rimary Amps To nett 1 257 Volis on 022 SHEET 1 X20 PRIMARY OVER CURRENT SHUTDOWN 8 214 AMPS NORMAL X61 7 MINUS RAIL FAULT X61 7 PLUS RAIL o 2 0 8 5 Q BS 5 2 S OPT Vo EE 2J PRIMARY CURRENT SENSE 122 gt gt TURN ON OFF OPT FROM SERIAL LOOP Vs 928 gt 28 SERIAL LOOP PORT SWITCHES gt gt 2 SERIAL LOOP INDICATES CHANGE FROM XRF VERSION NOTES SINCE COMPONENTS OR CIRCUITRY ON A PRINTED CIRCUIT BOARD MAY CHANGE GENERAL INFORMATION WITHOUT AFFECTING THE INTERCHANGEABILITY OF A COMPLETE BOARD THIS DIAGRAM MAY R NOT SHOW THE EXACT COMPONENTS OR CIRCUITRY OF CONTROLS HAVING A COMMON CODE ELECTRICAL SYMBOLS PER E1597 NUMBER CAPACITORS 022 50V UNLESS OTHERWISE SPECIFIED RESISTORS Ohms AJAN UNLESS OTHERWISE SPECIFIED DIODES 1A 400 UNLESS OTHERWISE SPECIFIED SUPPLY VOLTAGE
10. Section Safety Precautions reisas D 2 Routine and Periodic D 2 Input Filter Capacitor DiSCHarge csccccccssssceceesssneeeeesseneeeecescaaeeeeceseaeeeeseseeeeeeessaeesessseaeeeeesees D 2 Preventive D 5 General Component D 6 POWER WAVE 450 LINCOLN amp D 1 MAINTENANCE SAFETY PRECAUTIONS WARNING ELECTRIC SHOCK can kill Only Qualified personnel should perform this maintenance Return to Section TOC Return to Master TOC e Turn the input power OFF at the disconnect switch or fuse box before working on this equipment Do not touch electrically hot parts ROUTINE AND PERIODIC MAINTENANCE Perform the following preventive maintenance at least once every six months A WARNING Prior to performing preventive maintenance it is impor tant to perform the following capacitor discharge pro cedure to avoid electric shock Return to Section TOC Return to Master TOC INPUT FILTER CAPACITOR DIS CHARGE PROCEDURE 1 Turn off input power and disconnect input power lines 2 Remove the hex head screws from the top and the sides of the machine Remove the handle
11. X lt p 7097 2 9 on SH I OvVAPZ a lt 2 A Z JNVUL M 922 726 AOEZ 022 lt E c lt Vel 802 002 9 lt lt lt gt GJ 1 v ze alH 2 o e C 9 amp amp o V V VzeroerV Voer oer v 9 4804 gt o 15 Z 91 H 9 9 lt gt LL e gt gt tc eld U3I4103H 5 lt _ UOLORINOO a SH SH 9 5 9 AN I xnv 5 IMS o ASLI OBE o 012 IH HOLIMS ula VG 04d PH FH 1 086 7 aed Z er Ve Y MN aize m lt gt 1062 0822 _ Y L yz ve E vee E e 5 A gt gt a 3504 2 A er E ee 4200 T cer 9 9 1806008 Tu 86 77 Save gt ar W 18 9 iL F 34 901 Je1Se A 0 901 Je1Se A 0 901 J91Se N 01 901 J91Se N 01 UuunjeH DOL uonoes DOL uonoes DOL uonoes DOL uonoes 35 35 TROUBLESHOOTING amp REPAIR AUXILIARY TRANSFORMER PRIMARY WIRING HARNESS TEST A WARNING Service and repair should be
12. E 5 Output Rectifier Choke 6 COntrOl zie E 7 T Power 8 e Display M E 9 Thermal Protectionss uter esee E 10 Protective 10 Over curent EE 10 5 Over Voltage 444 1 10 Field Effect Transistor FET Operation E 11 Pulse Width MOdUlation E 12 E 12 Maximum iadan diranna a ease nese nnn nnt ba dindi nnns nnn 12 FIGURE 1 POWER WAVE BLOCK LOGIC DIAGRAM MAIN OUTPUT TRAMSFORMER RECTIFIER INPUT RECTIFIER INPUT CONTACTOR RECONNECT POSITIVE LEFT SWITCH THREE BOARD PHASE INPUT FET POWER ASSEMBLY o 0 2 5 SWITCH BOARD FET ASSEMBLY NEGATIVE CONTROL BOARD Return to Master TOC POWER WAVE 450 LINCOLN B 2 2 THEORY OPERATION FIGURE E 2 INPUT VOLTAGE CIRCUIT OUTPUT RECTIFIER INPUT RECTIFIER RECONNECT MAIN TRAMSFORMER FET ASSEMBLY mnm Ee SWITCH
13. nnn nn nnn F 155 Electrical Section G Parts Man al o 261 POWER WAVE 450 LINCOLN B Section 1 Section 1 TABLE CONTENTS INSTALLATION SECTION O 5 Installation 9 5 Technical 2 rete 3 5 9 Select Suitable Location c ccccccsecscssscsscssecseecseessecseeesecseecseessecseecaessaecseesaecsaecseessecescaeeeeeeseeess A 3 ced gomr 3 4 4 55 2 5 52 2 552522255 2555223222 5 28233 A 3 Mio EE A 3 High Frequency Precautlons 2 eii iint iot trie eee e ERE ie eos A 3 Input 1 1 6 3 Ground Connection S A 4 O E Input Power Connections p MH A 4 Input Fuse and Supply Wire Considerations A 4 E Input Voltage Reconnect 4 Output
14. 2 3 Return to Section Return to Master TOC o O gt o v E tc F 51 F 51 TROUBLESHOOTING amp REPAIR OUTPUT SHUNT WELDING FEEDBACK TEST A 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 elec trical 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 The following procedure will determine whether the shunt amplifier board is receiving the correct supply voltage from the control board and providing the correct feedback voltage MATERIALS NEEDED Volt Ohmmeter Multimeter 5 16 Nut driver 3 8 Nut driver Machine Wiring Diagram in the Electrical Diagrams section of this manual Load Bank This procedure takes approximately 40 minutes to perform POWER WAVE 450 LINCOLN F 52 F 52 TROUBLESHOOTING amp REPAIR QUICK SHUNT TEST TEST PROCEDURE 1 Remove main input supply power to the
15. 5 5 9 Work and Electrode Cable nennen nnn nnn A 5 n A 5 E T E HI 5 Water Cooler Connection A 5 Wire Feeder 5 o 0 5 Return to Master TOC POWER WAVE 450 LINCOLN B Return to Section Return to Master TOC Return to Section TOC Return to Master TOC O10 e 5 9 16 gt Sa Return to Section Return to Master TOC A 2 A 2 INSTALLATION TECHNICAL SPECIFICATIONS POWER WAVE 450 INPUT THREE PHASE ONLY Input Voltages 200 230 400 460 575 Input Currents 500A 40 VDC 87 76 44 38 32 450A 38 VDC 75 65 38 32 28 RATED OUTPUT Duty Cycle Amps Volts at Rated Amperes 60 Duty Cycle 500 40 VDC 100 Duty Cycle 450 38 VDC Constant Open Continuous Process Circuit Voltage Current Range Current Ranges 75 Volts 5 540 Amps GMAW 50 540 Amps FCAW 40 540 Amps STICK 30 540 Amps Pulse Pulse Pulse and Background Pulse Current Range Voltage Range Time Range Frequency 5 750 Amps 5 55 Volts 100 Microsec 3 3 Sec 0 15 1000 Hz RECOMMENDED INPUT WIRE AND FUSE SIZES Type 75 C Type 75 C Type 75 C Input Input Ampere Copper Wir
16. 2 3 Return to Section Return to Master TOC o O gt o v E tc F 123 F 123 TROUBLESHOOTING amp REPAIR INTERNAL REMOTE CONTROL 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 elec trical 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 there is a fault in the circuitry that reads the control knob com mands of the K941 1 Remote Control Kit MATERIALS NEEDED Volt Ohmmeter Multimeter 5 16 Nut driver 3 8 Nut driver Trigger Circuit Wiring Diagram Figure F 46 This procedure takes approximately 45 minutes to perform POWER WAVE 450 LINCOLN Return to Section Return to Master TOC Return to Section TOC Return to Master TOC o 2 3 Return to Section Return to Master TOC
17. 9 Check voltage across terminals 9 and 12 with a 10 DC voltmeter Terminal 9 has positive polarity and terminal 12 has negative polarity Voltage should be zero If any voltage remains repeat this capac itor discharge procedure Repeat discharge procedure steps 7 8 and 9 for each of the other three Switch Boards POWER WAVE 450 LINCOLN B Return to Section Return to Master TOC Return to Section TOC Return to Master TOC O10 515 9 1 EIS Return to Section Return to Master TOC D 5 MAINTENANCE PREVENTIVE MAINTENANCE Perform the following preventive maintenance proce dures at least once every six months It is good prac tice to keep a preventive maintenance record a record tag attached to the machine works best 1 Remove the hex head screws from the sides and top of the machine Remove the handle bar and the machine wrap around cover Remove the two case sides There are hex head screws on each side Perform the input filter capacitor discharge proce dure described at the beginning of the Maintenance Section Disconnect the shunt from the negative output terminal Failure to do this could cause damage to the shunt circuitry Clean the inside of the machine with a low pres sure airstream sure to clean the following components thoroughly Refer to Figure D 4 e Display Snubb
18. PROCEDURE 1 Perform Remove main input supply power to the machine With the 3 8 nut driver remove the 4 screws that hold the handle to the machine Remove the rubber gasket cover seal from the lift bail With the 5 16 nut driver remove the sheet metal screws from the case top With the 5 16 nut driver remove the screws holding the right and left case sides Remove the case sides by lifting up and out the Capacitor Discharge Procedure described earlier in this section of the manual MAIN CONTACTOR M O V ASSEMBLY SILICONE SEALANT INPUT RECTIFIER 5MM ALLEN SCREW HEAT SINK PANEL NahWND 8 WARNING e Before continuing with the test procedure perform the capacitor discharge proce dure to avoid electric shock After you have completed the capacitor dis charge procedure for all four switch boards peel the silicone sealant away from the M O V assembly in order to expose the heads of the screws that attach the three heavy leads from the main input contactor to the input rectifier See Figure F 65 With the Phillips head screw driver remove the three heavy leads from the input rectifier With the Phillips head screw driver remove the positive and negative leads from the input rectifier POWER WAVE 450 LINCOLN amp F 172 Return to Section Return to Master TOC Return to Secti
19. NOTE Unshaded areas of Block Logic Diagram are the subject of discussion Return to Section TOC Return to Master TOC POWER WAVE 450 LINCOLN B 4 4 THEORY OPERATION FIGURE E 4 SWITCH BOARD CIRCUIT eee MAIN OUTPU TRAMSFORMER RECTIFIER INPUT CONTACTOR RECONNECT FET ASSEMBLY POSITIVE Return to Section TOC Return to Master TOC AUX Ae TRANS SWITCH SWITCH PROTECTION BOARD BOARD FET ASSEMBLY THREE PHASE 4 INPUT POWER RIGHT SHUNT 2 SNUBBER AND SENSE LEADS WATER LCD Return to Section Return to Master TOC SWITCH BOARDS There are four Switch Boards in the Power Wave each containing an input capacitor The capacitors on Switch Boards 1 and 2 are always in parallel and the capacitors on Switch Boards 3 and 4 are always in parallel When the filter capacitors are fully charged they act as power supplies for the Switch Boards The Switch Boards contain the Field Effect Transistors FETs which when switched on supply the Main Transformer primary windings with DC current flow See FET operation discussion and diagrams Figures O10 e 5 5 9 1 gt 8 cic Sa NOTE Unshaded areas of Block Logic Diagram are the subject of discussion Return to Section TOC Return to Mast
20. B 4 B 4 EIE B 4 e Controls Settings uni B 5 Case Front n cte e Erat 5 gt euer M B 6 quu M B 6 E Installing an Overlay inii tette an a aa Drs ir eee erga e B 6 Overlay B 7 Pulse GMAW FCAW Stick Overlay nennen nnne nnns nennen B 8 Weld from Memory 11 Weld from Memory Dual Procedure B 12 Dual Wire Feeders Dual Procedure B 14 ici Ir B 15 SIRO IV TEES B 17 Wire Feeder Setup Description B 18 gt Overview of Welding 24 4 20 FCAW and 1 20 Pulso EE 20 z Stick TIG Procedures snai ren EEN aa Do enu ERN M RR ERE ERR B 20 Wave Control B 20
21. DOL DOL uonoes Return to Section Return to Master TOC Return to Section TOC Return to Master TOC o 2 3 Return to Section Return to Master TOC o O gt o gt 135 135 TROUBLESHOOTING REPAIR LCD DISPLAY TEST A 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 elec trical 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 there are any faults in the LCD display on the front panel or in the associated hardware and wiring harness MATERIALS NEEDED Volt Ohmmeter Multimeter 5 16 Nut driver 3 8 Nut driver Internal Auxiliary Supply Wiring Diagram Figure F 52 This procedure takes approximately 30 minutes to perform POWER WAVE 450 LINCOLN Return to Section Re
22. Square Wave Protection PC Board Assembly 0 Shunt PC Board 5 shunt Board Assembly ret Petr pe Snubber PC Board 2 4 4420444 Snubber Board Assembly Pot Switch PC Board 5 Switch Board Assembly siiis c miens 85232 POWER WAVE 450 LINCOLN G 2 ELECTRICAL DIAGRAMS WIRING DIAGRAM POWER WAVE 450 DE OF MACHINE DISPLAY BOARD CONTROL BOARD PROTECTION BOARD POWER BOARD AREA VIEWED FROM SIDE OF MACHINE 3214 A Fe 4 128 SWITCH BD 3 9G TO SWITCH BD 3 12M 9M TORIO i D 200 208 1 MACHINE SHOWN CONNECTED FOR 440 460V i TO A SYSTEM GROUND PER NATIONAL ELECTRICAL CODE A SWITCH H2 TO TERM STRIP 220 230V 5292 1 1 1 J40 BDS Fi TO TERM STRIP 380 415V Daoa CONNECTOR 1 1 5 TO FUSE A aza A 330 4 884 BLOW FUSE 440 460V H4 TO TERM STRIP 5 TO TERM STRIP 110 330
23. 21 Pulse Wedin 22 Overload Protection canoe B 23 Thermal Protection B 23 Over Current zero B 23 Q 0 2 POWER WAVE 450 LINCOLN B Return to Section Return to Master TOC Return to Section TOC Return to Master TOC o 2 3 Return to Section Return to Master TOC o O gt o gt E tc OPERATION OPERATING INSTRUCTIONS Read and understand this entire section of operating instructions before operating the machine SAFETY INSTRUCTIONS WARNING ELECTRIC SHOCK can kill Do not touch electrically live parts or electrodes with your skin or wet cloth ing Insulate yourself from the work and ground Always wear dry insulating gloves FUMES AND GASES can be dangerous Keep your head out of fumes Use ventilation or exhaust to remove fumes from breathing zone fire or explosion 7 WELDING SPARKS can cause Keep flammable material away Do not weld on containers that have held com bustibles ARC RAYS can burn Wear eye ear and body protection Observe additional Safety Guidelines detailed in the beginning of this manual COOLANT can
24. Return to Master TOC Return to Section TOC MC6BHC11 0 RDHIGH 8 1 Vo UNDER VOLTAGE LOCKOUT z DA ADIOL DA ADIO X SWDK sew LOOP SLAVE REFERENCE VOLTAGE DAADI D nu 5 DA AD 2 DA AD 2 x20 SWOP 26 DA ADJ3 DA AD S 2r DA AD A DA AD 4 28 DA AD S DA AD S 29 DA AD 6 DA ADI6 30 DA AD 7 DA AD 7 PSD301 0 Qi 5 pani oum 24 DA AD 0 084010 Di 5 DA AD 2 x16 VOLTAGE DA AD 3 owog 026 15 s E w 22 gt RD FLASH 2 is 1 z DA ADJA 1 s 7 DA ADJS 4 3Ee 12 VOLT PROGRAMMING SUPPLY Ojo 515 9 16 gt 218 5 2 DAADU ae m OPTIONAL OUTPUT SLAVE CONTROL OPTIONAL INPUT SLAVE CONTROL 2 16 f At5 H pe FLASH 28F512 Vpp_CTRL lt HO11 SUPPORT 00019 Hott ADDRIDNTA BUS HC11 CONTROL SHEET 1 GENERAL INFORMATION LAST NO USED NUMBERS NOT USED C9 12 1458 71 72 74 76 78 82 89 92
25. Return to Section Return to Master TOC Return to Master TOC G 18 SCHEMATIC SHUNT PRINTED CIRCUIT BOARD ELECTRICAL DIAGRAMS 10 SHUNT VOLTAGE TO CURRENT 50 5mA DIODE BRIDGE PADS IN GRAPHICS ONLY Wea lt TO NEGATIVE OUTPUT STUD NOTES SINCE COMPONENTS OR CIRCUITRY ON A PRINTED CIRCUIT BOARD MAY CHANGE WITHOUT AFFECTING THE INTERCHANGEABILITY OFA COMPLETE BOARD THIS DIAGRAM MAY SHOW THE EXACT COMPONENTS OR CIRCUITRY OF CONTROLS HAVING A COMMON CODE NUMBER Ch ge Sht No 2 INPUT 3 NPUT 06 Wee 5 27 Vin 74 51 R7 392 lout FILE 21151_2BA FRAME CONNECTION GENERAL INFORMATION LABELS ELECTRICAL SYMBOLS PER E1537 A SUPPLY VOLTAGE NET TT CAPACITORS MFD 022 50V UNLESS OTHERWISE SPECIFIED Fe RESISTORS Ohms 1 4 UNLESS OTHERWISE SPECIFIED POWER SUPPLY SOURCE POINT DIODES 1 400V UNLESS OTHERWISE SPECIFIED V COMMON CONNECTION THE LINCOLN ELECTRIC CO INVERTEC V400 EARTH GROUND CONNECTION 1 6 95 11 21 0706 CLEVELAND OHIO U S A SHUNT AMPLIFIER PCB 5 SCALE _NONE SHT DATE 2 7 94 CHK SUP S D G No S 21151 NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual LINCOLN 8 POWER WAVE 450 E
26. WARNING WARNING MAKE SURE FILTER CAPACITORS ARE ALL AC SUPPLIES MUST BE ELECTRICAL DISCHARGED LY ISOLATED isolation transformers THE PRINTED CIRCUIT BOARDS WILL BE DAMAGED IF THE AC SUPPLIES ARE NOT 1 Construct a 115VAC pretest power supply ISOLATED as per Figure F 78 using the following Switch SPST Fuse 5 amp max P70 adapter POWER WAVE 450 LINCOLN Return to Section Return to Master TOC Return to Section TOC Return to Master TOC O o e 5 5 9 5 2 Return to Section Return to Master TOC F 202 F 202 TROUBLESHOOTING amp REPAIR PRE POWERUP SWITCH BOARD TEST PROCEDURE FOR REPLACEMENT OF SWITCH ASSEMBLY G2402 2 continued FIGURE F 78 PRETEST POWER SUPPLY PRETEST POWER 5A SWITCH FUSE ISOLATED 115 VAC x Connect the pretest power supply to plug P70 as 1 Release wire tension and pull gun trigger 2 Jumper pins D on wire feeder input con ARC START PW450 WITH WIREFEEDER neck The arc start may be initiated by any of the follow 3 Jumper pins and on front panel amphenol ing methods connector near welding output terminals POWER WAVE 450 LINCOLN B F 203 F 203 TROUBLESHOOTING amp REPAIR per Figure F 79 8 PRE POWERUP SWITCH BOARD TEST PROCEDURE 5 FOR REPLACEMENT SWITCH ASSEMBLY G2402 2 continued
27. 8 ARC START FOR PW450 ROBOTIC 3 Leave plug J103 connected to the interface 1 Construct and connect an arc start circuit as board 218 2 Install leads and an arc start switch into plug J103 pin 10 to pin 11 on the interface PC board Make sure the arc start switch leads are long enough to reach outside of the machine case FIGURE F 79 SHUNT CONNECTIONS lt 1 500 9 5 2 lt 501 5 5 54 oz TR y REEL GE lt 5 lt R RECEPTACLE lt 5 AND SWITCH J103 9 lt 541 Ca EL 12 lt lt 5 2 9 5 lt 13 522 55 14 67 o HE 18 amp 218 i 5 PRETEST MACHINE CONNECTIONS 1 Make sure the machine shunt connections 2 Remove wire from the output diode are tight heat sink thermostat The thermostat LED should turn ON See Wiring Diagram 2 Connect the Power Wave output terminals to a grid load 3 Reconnect the wire to the output diode heat 3 Turn the grid OFF sink thermostat The thermostat LED should turn back OFF PRETEST POWERUP 1 on the pretest power switch See off the pretest power switch See Figure F 78 The Power Wave should beep Figure F 78 and display SELECT A FUNCTION FET DRIVE TEST THERMOSTAT TEST Construct plug jumper as per Figure 80 1 Check the thermostat LED upper rig
28. OUTPUT lt 467 SS 8 BACKGND 468 462 5 69 SINCE COMPONENTS OR CIRCUITRY ON A PRINTED CIRCUIT BOARD MAY CHANGE 5 COMMON CONNECTION WITHOUT AFFECTING THE INTERCHANGEABILITY OF A COMPLETE BOARD THIS DIAGRAM MAY 77 FRAME CONNECTION NOT SHOW THE EXACT COMPONENTS OR CIRCUITRY OF CONTROLS HAVING A COMMON CODE NUMBER EARTH GROUND CONNECTION Ch ge Sht No EQUIP THE LINCOLN ELECTRIC CO EQUP INVERTER WELDERS 1 6 95A CLEVELAND OHIO U S A suBJcr SNUBBER P C BD SCHEMATIC NONE _ DB DATE 1 01 99 chk DB SUP S D G No M 16761 NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual LINCOLN POWER WAVE 450 3 Return to Section Return to Master TOC eel ELECTRICAL DIAGRAMS 6 21 BOARD ASSEMBLY SNUBBER IDENTIFICATION 1000 0047 400 12 047 1200 20pF 50 50 REQ D PART NO 1 520500 2 03 13490 3 5 06 C7 C8 C9 5 516668 7 10 611 612 613 4 516668 11 INVERTER WELDERS SNUBBER P C BOARD ASSEMBLY gt 9579 1 SHT NO 1 02 03 04 09 12199 N4004 071 072 073 074 075 076 DZ7 DZ8 DZ9 DZ10 2 211 0212 Return to Section Return to Master TOC eee 2702 52 1 4733 SUP S D G 2 12702 29 EQUIP N4744A 1
29. C Return to Section Return to Master TOC Return to Master TOC F 194 21 22 23 24 25 26 TROUBLESHOOTING amp REPAIR FET MODULE REMOVAL AND REPLACEMENT continued Remove the water cooler assembly in order to access the retainer clips that hold the bottom of the FET module assembly in place Complete removal of the unit should not be necessary Refer to the Water Cooler Removal and Replacement Procedure this section of the module Remove the locking bar from the top of the subframe where it secures the FET module assembly Depress the top and bottom retainer clips with the slot head Screw driver so that the FET module assembly can slide forward Slowly lift and remove the subframe mak ing sure no clips cable ties or lead con nections are still holding it With the wire cutters cut all necessary cable ties holding the FET module assem bly to the wiring harness Using needle nose pliers disconnect the leads attached to the FET module assembly all red and white leads should remain connected Refer to the Wiring Diagram to determine which leads should be disconnected The main transformer and the reconnect mod ule must be free of the FET module assembly Also disconnect the thermostat lead Carefully lift the FET module assembly and remove it from the machine With the FET module assembly removed the main transformer background choke and output choke
30. 9 Lead 102D Between 34 4 and P82 16 Install the machine case sides and top 17 Install the handle and the lift bail rubber 918 Lead 31C Between J34 pin 1 and P82 8 5 pin J 8 8 Lead 106A Between J34 7 and P82 pin D 5 Ld 2 2 Between the Protection Board and Wire Feeder 1 Receptacle Lead 328 Between J34 pin 12 and P83 pinA Lead 326 Between J34 pin 13 and P83 pin I Lead 42B Between J34 pin 10 and olo P83 pin K Lead 102B Between 34 11 and 5 5 P83 pin 10 5 Lead 31B Between J34 8 and P83 p pin J EIE Lead 105A Between J34 pin 14 212 P83 D O o Fle 5 9 9g 43 POWER WAVE 450 LINCOLN amp 101 NOWWOO gt 21 gt 21 gt 28918 0L 2 gt 01 JOULNOD ITSF gt 9 gt 92 gt 9 tc o 10H1NOO lt INVHOVIG o vor NOWWO9 gt i gt gt Z 7 lt tc 20 98 gt gt gt 8 u3MOd 2 91 gt 01 gt 0 auvog gt 2s gt 6 gt 6 9ry oj E
31. DOL 49159 0 DOL 01 901 1 0 DOL uonoeg 0 lt 7097 00 SH bn VSH d lt Le OVAFZ 24 lt o T Z JNVUL Mm 922 2 ANOEZ 022 lt m lt 2 YEH 802 002 _ 9 YZH 2 vize 2 0 LU EL cu CDA gt V V Ver oerv Voer oer Y 2 2 vol 9 91 lt 9 lt l lt gt 2 yyy Y ASL LY LU 07 n 3 eld gt lt 243 140 109 097 ae lt 5 ao SH SSH cH 097 077 5 u3yv3u8 AGLP OBE L VEZE HOLIMS VG Old lt 61 088 7 vee OM VN 8122 2 AOEZOCE 9 V L yu ve eer 062022 022 ld gt e 6 P 3504 x eer nerin Ceara A gt 9 9 A80c 00c 5 eer AST lt zi lt t O OO at 5 Se iun lt TH tog 022 901 01 DOL uonoeg 0 LINCOLN jo Return to Section Return to Master TOC Return to Section TOC Return to Master TOC o 2 3 Return
32. Overlay Overlay Figure Type Name No 1 GMAW PULSE GMAW FCAW STICK PROCESS SELECTION OVERLAY B 4 2 WELD FROM MEMORY OVERLAY B 5 2 WELD FROM MEMORY DUAL PROCEDURE OVERLAY B 6 2 DUAL WIRE FEEDERS DUAL PROCEDURES OVERLAY B 7 3 LIMITS OVERLAY B 8 3 SETUP OVERLAY 9 These overlays optional See Accessories Section for Order Numbers POWER WAVE 450 LINCOLN B Return to Section Return to Master TOC Return to Section TOC O o e 5 5 9 5 2 Return to Section Return to Master TOC Return to Master TOC OPERATION PULSE GMAW FCAW AND STICK TIG PROCESS SELECTION OVERLAY An operator can use this overlay to create a new welding procedure save a newly created welding procedure view an existing welding procedure recall an existing welding procedure and clear a memory location See Figure B 4 The steps for performing each of these functions are given below FIGURE B 4 PULSE GMAW FCAW STICK TIG PROCESS SELECTION OVERLAY a 2 PANEL 1 PULSE GMAW STICK TIG PROCESS SELECTION THE LINCOLN ELECTRIC COMPANY CLEVELAND OHIO USA COPYRIGHT 1994 POWER WAVE 450 e PULSE ef THERMAL f ELECTRODE ELECTRODE SIZE ELECTRODE GAS CLASS TYPE E EJ 1 LCD DISPLAY WINDOW 7 DISPLAY RECALL KEY 2 PROCESS SELECT KEY 8 SAVE T
33. RECTIFIER 1 Er 48 l i i Vb lt u e me 8 296 gt sus gt FROM 4 55 3 i 5 X ase r S 443 Laie gt 5 Vc 5 i i BVb F 4N 333 lt cU 2 220 230 i GD GA NOISE_GND i B c Eus eS 42 BEND mei ug 5 i m i 55 2 5 5 8 Er 445 ate 7 i 5Vo 1 8 24V 34 lt gozo d i c GND i o LESE us c eD g I s gt 27 9 asy M2 5 4 5 ur CMs eeu 4 SWITCH BOARD 42 ENT HE 1 pue 0 DISPLAY BOARD CONTROL BOARD POWERBOARD Y PROTECTION BOARD P73 T RIGHT BOTTOM i a o E B 015 020 8 PIEZO 5 04 IN PARALLEL z 5 e 5 Loge 237 m J 85 FEEDED 58 T 1B 8 5 84 44 YB OUTPUT RECTIFIER SWITCH BD 3 5 9B THRU CT TSTAT TSTAT 58 i i 2 102 2 3 9 c pem ISOLATED DC SUPPLIES TO DISPLAY BD 55 7 00 SUPPLIES TO SHUNT BD SHUNT CURRENT FROM SHUNT BD cs MAIN TRANSFORMER RIGHT SIDE 18 lom CURRENT TRANSFORMER x od 4 PRIMARY LEADS 1T 1B 4T 4B 58 8 8 ARE FEEDED THRU CURRENT TRANSFORMER 5 2 aa 5 5 E O10
34. 5 ACCESSORIES g Install new pump and v band clamp Do not apply any lubricant to pump s drive coupling Pump body is properly oriented with its strainer at the 6 00 position Tighten v clamp with 15 to 30 in Ibs of torque h Attach coolant lines to QD and reser voir i Wipe dry all areas wetted by coolant Dispose of towels in an environmentally responsible manner see Recommended Coolants j Reinstall cooler into machine 4 Motor removal or replacement Do not reuse the 4 internal tooth star washers Replace with new parts 5 Installing the fan Slide onto motor shaft until the fan is located between 0 25 to 0 50 inches from the heat exchanger Tighten set screw with 65 to 75 in lbs of torque against motor 6 flat Fan rotation is counterclockwise as viewed from fan end of motor s shaft Fan pulls air through the heat exchanger blows it over the motor then exhausts it through the reservoir POWER WAVE 450 LINCOLN 5 6 NOTES POWER WAVE 450 LINCOLN 5 C 6 901 Je1Se A 0 901 Je1se A 0 901 J91Se N 01 DOL 01 901 uonoes uumeg DOL uonoes uumeg DOL uonoes uumeg DOL uonoes uumeg Return to Master Return to Master TOC o o gt 0 iv z o 4 c tc Return to Master TOC D 1 TABLE OF CONTENTS MAINTENANCE
35. SETUP THE POWER WAVE FOR PRETEST 1 Turn the input power switch to the OFF position 2 Unplug P73 See wiring diagram 3 Install the L9660 255 Calibration amp Test over lay into the Power Wave 4 Construct an isolated variable AC supply circuit as shown in Figure F 76 using the following equipment Isolation transformer 115vac 3 amps 5 amp Variac 5 amp Fuse 5 Connect the variable AC supply leads to the Power Wave input rectifier terminals AC1 T1 and AC3 T3 See Figure F 76 Make certain the variac is at zero volts output WARNING ALL AC SUPPLIES MUST BE ELECTRICALLY ISOLATED Isolation transformers THE PRINTED CIRCUIT BOARDS WILL BE DAM AGED IF THE AC SUPPLIES ARE NOT ISOLATED 6 Monitor the filter capacitor voltage as per Figure F 77 WARNING WARNING ALL METERS AND OSCILLO SCOPES MUST BE ELECTRICALLY ISOLAT ED Isolation transformers POWER WAVE 450 LINCOLN B Return to Section Return to Master TOC Return to Section TOC Return to Master TOC O o e 5 5 9 gt 5 2 Return to Section Return to Master TOC F 201 F 201 TROUBLESHOOTING amp REPAIR PRE POWERUP SWITCH BOARD TEST PROCEDURE FOR REPLACEMENT OF SWITCH ASSEMBLY G2402 2 continued FIGURE F 77 FILTER CAPACITOR VOLTAGE gt OL R9 400 VDC VOLTMETER _ 121 400 VDC gt VOLTMETER _
36. DOL 01 901 uonoes uumeg DOL uonoes uumeg DOL uonoes uumeg DOL uonoes uumeg Return to Section Return to Master TOC Return to Section TOC O o Fle 5 o 9 515 2 Return to Section Return to Master TOC Return to Master TOC F 81 F 81 TROUBLESHOOTING amp REPAIR RECONNECT SWITCH TEST 1 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 elec trical 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 there are any short circuits between the leads connected to the reconnect switch MATERIALS NEEDED Volt Ohmmeter Multimeter 5 16 Nut driver 3 8 Nut driver Phillips head screw driver Input and Reconnect Wiring Diagram Figure F 27 This procedure takes approximately 40 minutes to perform POWER WAVE 450 LINCOLN Return
37. DOL 01 901 uonoes uumeg DOL uonoes uumeg DOL uonoes uumeg DOL uonoes uumeg Return to Section Return to Master TOC Return to Section TOC Return to Master TOC o 2 3 Return to Section Return to Master TOC o O gt o v E 131 131 TROUBLESHOOTING REPAIR K941 1 REMOTE CONTROL KIT TRIGGER CIRCUIT 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 elec trical 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 there are any faults in the 24 VAC trigger circuit between the Power Wave and the K941 1 Remote Control Kit MATERIALS NEEDED Volt Ohmmeter Multimeter 5 16 Nut driver 3 8 Nut driver Short piece of jumper wire Trigger Circuit Wiring Diagram Figure F 50 This procedure tak
38. EIS 2 Return to Section Return to Master TOC Return to Master TOC F 105 TROUBLESHOOTING amp REPAIR MAIN CONTACTOR TEST continued A With the power switch SW1 OFF check to see if leads and L3A are shorted together If they are shorted visually inspect the leads If the leads are okay then power switch SW1 is faulty and must be replaced Remove leads 11 12 and from the main contactor Check if the terminals of the main contactor are still shorted If they are the main contactor is faulty and must be replaced If the terminals are not short ed the input lines themselves are shorted Reconnect leads L1 L2 L3 and to the main contactor 9 Visually inspect terminals T1 T2 and T3 of the main contactor Make sure they are not shorted together in any way If they are not shorted go to step 11 If they are shorted go to step 10 10 Remove leads T1 T2 and T3 from the main contactor A Check if the terminals of the main contac tor are still shorted If they are the main contactor is faulty and must be replaced B Reconnect leads T1 T2 and to the main contactor Remove plug J30 from the protection board Make sure that leads T1 and T3 of plug J30 between the main con tactor and the protection board are not damaged exposed or shorted together Check again for shorts across the contacts of the main contactor If the terminals are not s
39. N T J19 1 8 E T Return to Section TOC Return to Master TOC lt 021 022 023 024 025 026 Q27 Q28 Q29 un 94003001 HK 174W M RI T R66 R70 8101 8124 R131 R132 R147 8164 R169 R203 R208 R213 R215 R228 R240 R onene T ST9400 1533__ 1sakK 00K 172W 8555 z 3 E E B 4388 a oO a 1 R125 146 8148 R168 R166 R168 R172 R225 R226 R238 R239 9 515 9 16 gt 218 5 2 a 11 319400300 5011717 17 835 8159 EL 519400 1501 TSK 1 47 9400 68 8 TW R136 8138 R1 41 Ri 42 81 76 82 R183 R185 1 4W R40 R52 R55 R58 R77 R78 R86 R98 R99 R113 R116 R157 R201 R205 R211 R212 2552 V400 DISPLAY KEYPAD poe THE LINCOLN ELECTRIC CO Tree INVERTER WELDERS CLEVELAND OHIO U S A eS EE euh DISPLAY KEYPAD P C BOARD ASSEMBLY 8403 _ 2862 1 Return to Section TOC Return to Master TOC NOTE Lincoln Elec
40. Return to Master TOC Return to Section TOC Return to Master TOC o 2 3 Return to Section Return to Master TOC o O gt o gt E 31 31 TROUBLESHOOTING amp REPAIR AUXILIARY TRANSFORMER TEST 2 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 elec trical 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 correct voltage is being applied to the primary of Auxiliary Transformer 2 and also if the correct voltages are being induced on the secondary wind ings of the transformer Note Transformer 2 is not present on all models MATERIALS NEEDED Volt Ohmmeter Multimeter 5 16 Nut driver 3 8 Nut driver Input and Auxiliary Circuit Wiring Diagram Figure F 8 This procedure takes approximately 35 minutes to perform POWER WAVE 450
41. NUMBER ELECTRICAL SYMBOLS PER E1537 CAPACITORS MFD 022 50V UNLESS OTHERWISE SPECIFIED RESISTORS Ohms 1 4W UNLESS OTHERWISE SPECIFIED DIODES 1 4000 UNLESS OTHERWISE SPECIFIED SUPPLY VOLTAGE NET POWER SUPPLY SOURCE POINT 57 COMMON CONNECTION FRAME CONNECTION FILE G2240_1D2 C EARTH GROUND CONNECTION 5 Y Y 5 1 Y Y FER Y YO XX Y Y 5 EEL Y TTT THE LINCOLN ELECTRIC CO INVERTER WELDERS CLEVELAND OHIO U S A _ SCHEMATIC POWER P C BOARD SCALE __ am DATE 6 26 04 2 000010 22240 Rs Va cosmetic trace connecting ground planes 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 LINCOLN amp ea POWER WAVE 450 ELECTRICAL DIAGRAMS G 13 PC BOARD ASSEMBLY POWER 13490 141 3900 80V C3 04 05 19 020 C22 024 12 513490 25 4 135 27 29 30 35 38 C6 C7 C13 C15 016 C21 C23 23 S16668 11 1 50 025 026 028 032 034 036 037 039 0139 0140 0141 0159 0165 0166 0175 0191 155555 170007750 73400 76 001 400 51490 22 10 35 516668 5 1022750 51490 07 2 7750 13490 58 7150 13150 12 11577 58 11577 26 13020 8 518395 22 12705 34
42. T l gp 9 2 lt ft WET n eH 1 6 VE D gt 9 lt avo 9 14 717 iL 8140 6 73 ye 3 Us IZE Return to Section Return to Master TOC Return to Section TOC Return to Master TOC o 2 3 Return to Section Return to Master TOC o O gt o v E tc F 85 F 85 TROUBLESHOOTING amp REPAIR RECONNECT SWITCH TEST 2 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 elec trical 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 any leads connected to the reconnect switch are damaged MATERIALS NEEDED Volt Ohmmeter Multimeter 5 16 Nut driver 3 8 Nut driver Input Reconnect Wiring Diagram Figure F 29 This procedure takes approxima
43. 134 TVNHALNI TVNHALX3 AAVM Y4MOd c lt 1763 NOLLO31L0Ud 2 rc V 101 X0 5 6 lt lt 2 2 9 lt 1 lt lt lt 6 8 u OL 162 92 oj 662 2 2 gt 2 lt 4 lt lt lt g lt Bio s 47 O 1081NO2 A Tdsia 2 10 ger zer cor fe 41 3 5 ld e LLI Kr lt lt p lt lt a 1 7 4 0 i ct 55555 T 1 030334 Q o da pet d 2 lt 1 lt H er 8201 m 92 ov lt EE E va n E ui pom to e 2 em 4 2 e lt 27 L a EZ 7901 n 2430334 sed 84 gt gt gt eus I 48 T Z Joueuduy 9 bir nY f ser A sjouayduiy gt Livee fee ud g HO e vs AX 3 3 i 1 45 1 F 134 901 Je1Se A 0 901 4 1 0 uunjeH 901 J91Se N 01 901 J91Se N 01 DOL uonoes DOL
44. ANAND TY EN eze ERQOHYOS cRGHVOS L8GHVOS a HOLIMS HOLIMS HOLIMS HOLIMS 25 667 68 lt g zerY Yzer 19 260 143 4 OvIVHLOLdO 86 76 NOLLO310Ud eer cer OEF OEF OEF OEP LEC ler Ler o Bn AA AA L 6 9 r 1011 9S8 L OL pL o 5 AA o z Abe 667 MeL 16 M6 2 5 29 eov lt VICE Lov 8 tc gt zXnv I 2 VSH lt 2227 j a Lu gt 6 w lt VEH 02 820 0 OL 97g eer lt lt 182 5 Oo 1 m d viH a 222 amp C W eco i M mi a gt lt o e 1 vee Ore 222 Y LT n gt 6 5 82 gt 2 VET eH IH 1775 u gm 9 Le 4701 Aa o 113 vi 7 Hic d gt b gt EZE 1 lt LZE gt fed 9 ey 901 Je1Se A 0 901 4 1 0 901 J91Se N 01 901 J91Se N 01 DOL uonoes DOL uonoes DOL DOL uonoes Return to Section Return to Master TOC Return to Section TOC
45. F 48 1 2 3 RECONNECT SWITCH INPUT RECTIFIER MAIN CONTACTOR TROUBLESHOOTING amp REPAIR INPUT RECTIFIER RESISTANCE TEST continued FIGURE F 15 RECONNECT SWITCH LOCATION TEST PROCEDURE 6 With the 5 16 Remove main input supply power to the machine With the 3 8 nut driver remove the 4 screws that hold the handle to the machine Remove the rubber gasket cover seal from the lift bail With the 5 16 nut driver remove the sheet metal screws from the case top nut driver remove the screws holding the right and left case sides Remove the case sides by lifting up and out Perform the Capacitor Discharge Procedure described earlier in this section of the manual WARNING e Before continuing with the test procedure perform the capacitor discharge proce dure to avoid electric shock 7 After you have completed the capacitor dis charge procedure for all four switch boards use the 5 16 nut driver to remove the two 5 16 sheet metal screws holding the reconnect switch assembly Twist the reconnect switch out to access the lead connections on the back Use the 3 8 wrench to disconnect the two negative leads from the reconnect switch By disconnecting the leads at the recon nect switch you will not have to disturb the silicon applied to the input rectifier Electrically isolate the leads from all other leads
46. O o e 5 5 9 5 2 Er Return to Section TOC Return to Master TOC Return to Master TOC F 89 F 89 TROUBLESHOOTING amp REPAIR STATIC CAPACITOR BALANCE 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 elec trical 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 with no machine output the input capacitors are balanced Before conducting this test perform the following tests Switch Board Test to ensure that none of the switch boards are faulty Snubber and Bleeder Resistance Test to ensure that the bleeder resistors are properly connected to the switch boards Reconnect Switch Test 1 and Reconnect Switch Test 2 to ensure that input power is properly connected to the switch boards MATERIALS NEEDED Volt Ohmmeter Multimeter 5 16 Nut driver 3 8 Nut driver Snubber and Bleeder Resistor Wirin
47. 4 4 2 4 8 9 10 12 13 52 R14 R16 R18 R20 R32 R35 R41 R58 R59 R60 R61 R62 R63 R65 R72 R74 R158 R169 R170 R172 R185 R193 R198 5 R202 R210 R213 R222 R235 R239 R246 R251 R255 R257 R262 R264 R267 R268 R279 R284 R295 R296 R297 R317 R318 R319 2 0 8 5 Q BS 5 2 R110 R118 R120 R127 R135 R152 R156 R168 R171 R173 R179 R180 R183 R186 R187 R188 R189 R191 R192 R199 R203 R221 R228 R231 R258 R275 R280 R300 R301 R308 R311 R315 R17 R19 R109 3 19400 1502 eon a fl R242 R244 0 R26 R27 R30 R31 R34 R42 28 519400 4750 475 1 4W R43 R44 R45 R46 R47 R48 R49 R50 R51 R52 R53 R54 R55 R56 R57 R122 R128 R146 R147 R167 R177 R184 R33 R86 R229 R230 R119 R126 R134 R 138 R226 R121 R129 R130 R174 R 181 R278 5 11 12 990 2861 2 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 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 LINCOL ine TET machine POWER WAVE 450
48. 5 456A 6 453A 454A 1 2 3 4 5 6 oe Se G3617 1 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 LINCOL POWER WAVE 450 ELECTRICAL DIAGRAMS ae SCHEMATIC COMPLETE MACHINE TRIGGER 24V 42V amp 115V FROM PROTECTION BD 2 ARC amp WORK VOLTAGES SNUBBER BD 9 gt or 4 iN gt 167A 4 5 15 xA yb zeta d gt 128 gt 1020 105A 10 U M w 8 8 o 2 L88 p R 9 4 810 a gt 328 NE
49. Before continuing with the test procedure perform the capacitor discharge proce dure to avoid electric shock After you have completed the capacitor dis charge procedure for all four switch boards use the 5 16 nut driver to remove the two screws that hold the PC board cover Remove the cover Connect the machine negative output terminal to earth ground Connect the oscilloscope case ground to earth ground Connect the oscilloscope to plug J23 pin 4 positive side and plug J23 pin 2 nega tive side on the control board See Figure 2 for location If these connections reversed you will not be able to see the fre quency train on the oscilloscope Set the oscilloscope to be DC coupled with 2 volts division and 0 2 milliseconds division Return to Section TOC Return to Master TOC POWER WAVE 450 LINCOLN amp Return to Section Return to Master TOC Return to Section TOC O o e 5 5 9 5 2 Return to Section Return to Master TOC Return to Master TOC F 95 TROUBLESHOOTING amp REPAIR DYNAMIC CAPACITOR BALANCE TEST continued WARNING ELECTRIC SHOCK can kill With input power ON there are high voltages inside the machine including the pro tection board Do not reach into the machine or touch any internal part of the machine while power is ON 10
50. Reinstall strainer and acorn nut tightening with 75 15 in lbs of torque Wipe dry all areas wet ted by coolant Dispose of towels in an envi ronmentally responsible manner see Recommended Coolants 4 Gently rinse the reservoir s strainer under running water to thoroughly clean it 5 Remove fan shroud and inspect hoses and electrical harnesses for kinking or damage cut abrasion swelling etc Replace if necessary 6 Remove accumulated dust from cooler especially from the motor and heat exchanger by blowing it off with shop air or vacuuming it out heat exchanger fins are sharp but can be easily bent Treat them with care to avoid per sonal injury and damaging them Remove the cooler from the machine for a more thorough cleaning job 7 Motor lubrication is recommended once a year Remove plug over lube port at top of motor near fan end Add 20 drops of electric motor or SAE 10 oil then reinstall plug 8 Flush coolant from the system and replace with fresh recommended coolant at least once a year More frequent flushing may be necessary depend ing upon a user s particular system or its usage NOTE Never run the pump dry Always use a recom mended coolant otherwise pump damage may result 9 Reinstall the G3503 cooler into the Power Wave machine G3503 COOLER SERVICE 1 Preparation Always switch off the Power Wave machine power Always disconnect
51. Remove plug J30 from the protection board See Figure location of the board and plug J30 POWER WAVE 450 LINCOLN amp F 124 Return to Section Return to Master TOC Return to Section TOC O o 5 5 9 gt 5 2 Return to Section Return to Master TOC Return to Master TOC F 125 TROUBLESHOOTING amp REPAIR INTERNAL REMOTE CONTROL TEST continued WARNING ELECTRIC SHOCK can kill With input power ON there are high voltages inside the machine including the pro tection board Do not reach into the machine or touch any internal part 10 11 12 13 B Turn input power ON Turn the knob on the Remote Control Kit all the way counterclockwise With the volt ohmmeter check the voltage between plug J10 pin 6 positive and J10 pin 7 negative on the display board It should be about zero volts With the Power Wave set in the SMAW CC mode of operation turn the knob on the Remote Control Kit clockwise The voltage between plug J10 pin 6 and J10 pin 7 should increase smoothly to about 10 25 volts If this happens but the dis play shows no change in the preset cur rent value SET replace the display board If the voltage between pins 6 and 7 does not increase smoothly test the asso ciated wiring as follows Turn power switch SW1 to the OFF posi tion and disconne
52. 11 014 12 176 177 0178 0189 18 0102 Return to Section TOC Return to Master TOC 0047 3000V 1 100 RELAY 12V D DIODE HS ASBLY 1N4936 40 041 042 D1 D2 D3 D4 D5 D6 D7 D8 D17 D18 D19 024 025 027 028 029 031 032 034 035 037 038 040 D41 D42 D43 D58 09 0 D11 D12 D20 D23 D26 D30 D33 D36 D39 D46 D47 D60 015012 15 016 21 027 17277557 89988 O ODE 22 023 074 077 028 079 T12702 29 1 4744 0212 07115 1 112702 52 TNA733 740 041 32035116 HEADER 172 74 320351 12 HEADER TA EE ES Ez Ez Es 5 RT Eh 1 12199 2 12199 1 1 4007 1 4004 ro 1 1 1 1 TOK INDUCTOR J9mH ISOLATOR Q1 Q3 Q7 Q12 2N4401 Q4 Q15 2N4403 Q6 12704 61 SLOLOLOLIOLITLIOLIT 6 17221832 LAU 12218 11 119120 122188 1 5150000 T12704 68 12704 69 112704 35 112704 80 NPN TRANSISTOR TRANSISTOR NMF PNP TRANSISTOR H S ASBLY RANSISTOR P 1K 5W 8 2K 1 4W 08 010 011 Return to Section Return to Master TOC 100 1 4W gt gt g SIS 2 4 75 22 1K 1 4W 1K 1 4W 1 1 A 27 2 518395 19 0111 12704 37 5 RLRISORISS 3 11458 99 R2 R109 R104 R105 R106 819400 1822 8 108 8157 ZEE 53 58 4 2 13 14 15 56 13 319400 1000 R57 R61 R186 R190 R191 R194 0197 4 A Ro R35 R
53. 16 Replace plug J12 into the display board WARNING ELECTRIC SHOCK can kill With the input power ON there are high voltages inside the machine including the protection board Do not reach into the machine or touch any internal parts 17 Turn input power ON The LCD display will read ERROR S L NOT INITIALIZED Disregard this the test can still be per formed 18 Remove the jumper between pins D and E of the six pin amphenol receptacle 19 With the volt ohmmeter measure the volt age drop across the 150 ohm resistor between J26 pins 1 and 2 With the jumper removed the reading should be zero volts NO voltage drop 20 Replace the jumper between pins D and E of the six pin amphenol receptacle Measure the voltage drop with the jumper installed The reading should be about 2 VDC across the resistor A f 2 VDC is NOT present check the conti nuity and integrity of leads 262 and 261 and their associated pins and connectors The display board may be faulty replace the display board B If 2 VDC IS present across the resistor the control board may be faulty replace the control board 21 Turn input power to the machine OFF and connect the five leads to the main contac tor Connect all molex plugs to the PC boards and replace the cover with two sheet metal screws Install the machine case sides top handle and lift bail rubber gasket POWER WAVE 450 LINCOLN F 133
54. 2 2 2 Section F 8 How to Use Troubleshooting F 2 gt PC Board Troubleshooting Procedures and F 3 Troubleshooting eee ee eee a aan anes eter F 5 5 Test Procedures F 23 Capacitor Discharge 4 F 23 Auxiliary Transtormer Test 1 23 lee F 27 Auxillary Transformer TeSt 2 eiu nad lesa L aa see DER RR ERES RR PRA F 31 Auxiliary Transformer Primary Wiring Harness 1044444 10011 F 35 Auxiliary Transformer 1 Secondary and Wiring Harness F 39 Input Power and Wiring Harness nennen nnne F 43 Input Rectifier Resistance 0 47 Output Shunt Welding Feedback 51 Piezo Electric Alarm Buzzer 22422244 F 55 Output Rectifier Diodes Test 57 Field Effect Transistor Switch Board F 59 8 Snubber and Bleeder Resistor 0 F 75 Recon
55. 3 Return to Section Return to Master TOC o 5 117 TROUBLESHOOTING REPAIR WIRE FEEDER 2 TRIGGER CIRCUIT TEST continued 11 Remove plug J30 from the protection board See Figure F 1 for location of the board and plug J30 WARNING e ELECTRIC SHOCK can kill With the input power ON there are high voltages inside the machine Do not reach into the machine or touch any internal parts 12 Turn input power ON 13 With the volt ohmmeter check for 24 VAC between plug J13 2 and pin 4 A f 24 VAC IS present go to step 14 NOTE A voltage of 5 to 10 VDC is normal between these pins without the C to D jumper installed in the wirefeeder recepta cle B If 24 VAC is NOT present check for 24 VAC between plug J33 pin 4 and pin 1 See the Trigger Circuit Wiring Diagram Figure F 42 C If 24 VAC IS present between plug J33 pin 4 and pin 1 check the continuity and integrity of leads 373 372 102D and 106A and their associated pin connectors See the Trigger Circuit Wiring Diagram If the continuity checks are good the pro tection board may be faulty Replace the protection board D If 24 VAC is NOT present between plug J33 pin 4 and pin 1 check Auxiliary Transformer 1 the 5 amp circuit breaker and the associated wiring See the Trigger Circuit Wiring Diagram Figure F 42 14 Turn input
56. COO 1 2 J17 J16 J15 J14 J13 J12 J11 J10 TEST PROCEDURE WARNING 1 6 With the 5 16 Remove main input supply power to the machine With the 3 8 nut driver remove the 4 screws that hold the handle to the machine Remove the rubber gasket cover seal from the lift bail With the 5 16 nut driver remove the sheet metal screws from the case top nut driver remove the screws holding the right and left case sides Remove the case sides by lifting up and out Perform the described earlier in this section of the manual Capacitor Discharge e Before continuing with the test procedure perform the capacitor discharge proce dure to avoid electric shock After you have completed the capacitor discharge procedure for all four switch boards remove the PC board cover Use the 5 16 nut driver 8 Remove plug J13 from the display board 10 Place a jumper wire between pins C and D of wire feeder receptacle 2 Remove the 5 leads 3 heavy and 2 small T1 T2 T3 from main input contactor CR1 This is a safety precaution It prevents high voltage from being put on the machine during the test Wrap tape around the lead ends to insulate them and prevent them from touching POWER WAVE 450 LINCOLN amp F 116 Return to Section Return to Master TOC Return to Section TOC Return to Master TOC o HE 2
57. Disconnect plug J31 from the protection board If this eliminates the short the pro tection board may be faulty Replace the protection board If the short persists go to step 9C With the Phillips head screw driver remove the POS and NEG leads from the recon nect switch If this eliminates the short either the input rectifier or the harness leads POS and NEG between the input rectifier and the reconnect switch is faulty Check the harness and if it is not faulty perform the Input Rectifier Test Reconnect leads POS and NEG to the input rectifier If the short persists go to step 9D 10 11 Remove leads 9A 9C 90 12A 12B 12C and 12D from the four switch boards If this eliminates the short check these leads to make sure they are not exposed damaged or shorted If the leads are okay perform the Switch Board and the IResistor Test to find the cause of the short Reconnect leads 9A 9B 90 412A 12B 12C and 120 to the four switch boards before conduction these tests Replace the PC board cover and install the machine case sides and top Install the handle and the lift bail rubber gasket POWER WAVE 450 LINCOLN amp F 84
58. wine atl machine DO NOT switch the 27 use service this equipment connect bar with machine power 200 208V 220 230V INPUT SUPPLY CONNECTION DIAGRAM 2 CONNECT LEAD MARKED TO GROUND PER NATIONAL ELECTRICAL CODE 3 CONNECT LEAD TO DESIRED INPUT VOLTAGE RANGE 8 220 230 zA 380 4154 440 460 4 POSITION SWITCH TO DESIRED INPUT VOLTAGE RANGE WARNING 200 2080 380 415 2 440 460 Also called inverse time or thermal magnetic circuit breakers These breakers have a delay in tripping action that decreases as the mag nitude of the current increases POWER WAVE 450 LINCOLN B Return to Section Return to Master TOC Return to Section TOC Return to Master TOC o 2 3 Return to Section Return to Master TOC o 5 INSTALLATION FIGURE FRONTPANEL BACK PANEL 1 WORK TERMINAL 2 ELECTRODE TERMINAL 3 REMOTE CONTROL AMPHENOL RECEPTACLE To operate at 200 208 VAC 1 Open the reconnect input access door 2 Move the input voltage switch to Voltage 200 208V position 3 Move lead
59. 103 103 TROUBLESHOOTING amp REPAIR MAIN CONTACTOR 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 elec trical 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 trou bleshooting assistance before you proceed Call 1 800 833 9353 WELD TEST DESCRIPTION This test will determine if main input contactor CR1 and its associated wiring and compo nents are faulty or damaged MATERIALS NEEDED Volt Ohmmeter Multimeter 5 16 Nut driver 3 8 Nut driver Slot head screw driver Input and Reconnect Wiring Diagram Figure F 36 Return to Section TOC Return to Master TOC This procedure takes approximately 45 minutes to perform O10 e 515 9 1 EIS 2 Return to Section Return to Master TOC POWER WAVE 450 LINCOLN Return to Section Return to Master TOC Return to Section TOC Return to Master TOC o 2 3
60. 27 TROUBLESHOOTING amp REPAIR AUXILIARY TRANSFORMER TEST 1 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 elec trical 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 correct voltage is being applied to the primary of Auxiliary Transformer 1 and also if the correct voltages are being induced on the secondary wind ings of the transformer MATERIALS NEEDED Volt Ohmmeter Multimeter 5 16 Nut driver 3 8 Nut driver Input and Auxiliary Circuit Wiring Diagram Figure F 6 This procedure takes approximately 35 minutes to perform POWER WAVE 450 LINCOLN Return to Section Return to Master TOC Return to Section TOC Return to Master TOC o 2 3 Return to Section Return to Master TOC o p 5 F 28 TROUBLESHOOTING amp REPAI
61. Any previously created welding procedure stored in that location will be erased If you press the SAVE TO MEMORY key but decide not to save the procedure you can exit this function by pressing the DISPLAY RECALL key MEMORY LOCATION NUMBER KEYS To view information about any stored welding procedure simply press its MEMORY LOCATION NUMBER key As you hold down the selected key the procedure description and gas type of the procedure appear in the display window The process type is shown by the indicating light opposite the appropriate process symbol When you release the selected key the wire size material type and process description appear for a few seconds This function does not display the wire feed speed and voltage or arc length trim settings To view these you must recall the procedure from memo ry with the RECALL FROM MEMORY key POWER WAVE 450 LINCOLN B OPERATION 10 RECALL FROM MEMORY KEY This key is used to recall an existing procedure from memory You can recall and use any of the previously created welding procedures that are stored in one of the eight memory locations Simply press the RECALL FROM MEMORY key and then the appropriate MEMORY LOCATION NUMBER key If you press the RECALL FROM MEMORY key and then change your mind you can exit this function by pressing the DISPLAY RECALL key the memory location you select does not contain a stored welding procedure this will be indic
62. CONNECTION FOR TERM STRIP 58 54 TORS 57 010 SECONDARY PRIMARY 48 148 o i om BOTTOM BOTTOM Return to Section TOC Return to Master TOC ANIHOWW 40 AW 4 _SHTTOHBOARO ss pecu I 5 LEFT BOTTOM c 38 TERMINAL STRIP IEF KEYPAD TO P73 CONNECTION FOR NK so cde 408 TOP FAN mn BOTTOM FAN TO REC SWITCH in Y TO swt TO R7 a 12D Ht CURRENT TO REC SWITCH CONNECTION FOR TO 9D EM TRANSFORMER TO REC SWITCH 48 4B He AT 1 4B TOR N aor 47 o 2 0 ar TO SWITCH BDS RIGHT TO REC SWITCH J41 284 1 28 E TO F3 F4 401 401 R11 WORK ds TOPRIMARY 27 SWITCH TO REC SWITCH lt TO REC SWITCH THERM TOR2 TO J23 To outeur TO P82 P83 RECTIFIER ELECTRODE TO SWITCH 12 28 5 TORI 12E 1 22 1T Hotti imni 7 7 zih e 48 SWITCH THERM iod ed 4 4 SWITCH BOARD 4 7777777777777777777777777777777777777777777777777777777777777777777777777777777777777777777777777777777777 77777777777777777777
63. IKK9 0201 3 3 z e G8 TOULNOD 14810 NOLLO3LOUd ge zer 0201 9 O 471 ASS Jo T I u ar dz J 04 Er d lt a 6 di m 949 23 24 1 430734 gt lt 2 z lt 1 lt 9201 1 or lt 292 o lt 048 m i 8d oer 92 1 Joueuduiy gt lt lt 2 lt lt lt ak o i eir 46 Y Per 901 28430334 lt 9 LL ds 1 cc gt D Lov K m ug id yim 8 2 3 lt 8 lt p 0 9er LP f eer A sjoueydwuiy sjousyduuy id 4 uid g o 22 ul o 2 8 i S A 1 5 1 114 901 Je1Se A 0 901 4 1 0 uunjeH 901 J91Se N 01 901 J91Se N 01 DOL uonoes DOL DOL DOL uonoes Return to Section Return to Master TOC Return to Section TOC Return to Master TOC o 2 3 Return to Section Return to Master TOC o O gt o v E tc F 115 F 115 TROUBLESHOOTING amp REPAIR WIRE FEEDER 2 TRIGGER CIRCUIT TEST WARNING Service and repair should be performed by only Lincoln Electric factory
64. o 2 3 Return to Section Return to Master TOC o p 5 F 60 TROUBLESHOOTING amp REPAIR FIELD EFFECT TRANSISTOR SWITCH BOARD TEST FIGURE F 19 F E T SWITCH BOARD LOCATION TEST PROCEDURE 1 With the 5 16 Remove main input supply power to the machine With the 3 8 nut driver remove the screws that hold the handle to the machine Remove the rubber gasket cover seal from the lift bail With the 5 16 nut driver remove the sheet metal screws from the case top nut driver remove the screws holding the right and left case sides Remove the case sides by lifting up and out WARNING e Before continuing with the test procedure perform the following capacitor dis charge procedure to avoid electric shock 6 Obtain a high resistance and high wattage resistor 25 1000 ohms and 25 watts min imum This resistor is not supplied with the machine Secure this resistor to a piece of insulating material such as a glastic board See Figure F 22 NEVER USE A SHORTING STRAP FOR THIS PROCEDURE POWER WAVE 450 LINCOLN amp F 60 1 FET OR IGBT SWITCH BOARD ASSEMBLY F 61 F 61 TROUBLESHOOTING amp REPAIR FIELD EFFECT TRANSISTOR SWITCH BOARD TEST continued FIGURE F 20 RESISTOR LOCATIONS Return to Section TOC
65. 301 as negative apply 12 to 15 VDC to the piezo electric buzzer If the buzzer does not work replace it Ifthe buzzer does work the display board may be faulty Replace the display board Refer to the Display Board Replacement procedure in this section of the manual After the test is completed and the prob lem successfully repaired reconnect plug J15 to the display board Install the machine case sides and top Install the handle and the lift bail rubber gasket POWER WAVE 450 LINCOLN amp F 56 Return to Section Return to Master TOC Return to Section TOC O10 e 515 9 1 EIS 2 Return to Section Return to Master TOC Return to Master TOC F 57 F 57 TROUBLESHOOTING amp REPAIR OUTPUT RECTIFIER DIODES 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 elec trical 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 WEL
66. Connect the control cable between the feeder and power source The cable has different connectors on each end and will fit in only one way If only one feed er is used it must be connected to the Feeder 1 Amphenol located on the back panel in the upper left hand corner as you view the machine from the back If a second feeder is used it must be plugged into the Feeder 2 Amphenol receptacle located just to the right of the Feeder 1 Amphenol receptacle Connect the work cable between the work and the negative connection of the power source When negative electrode polarity is required such as in some Innershield applications connect the work cable between the work and the positive connec tion of the power source See Figure C 1 e Connect the feeder to a welding gas supply e Load the wire into the feeder and gun e Configure wire feeders Refer to Setup overlay in operation section GUNS AND CABLES Several MAGNUM guns are recommended for use with the Power Wave as shown in Table C 1 Place the proper liner in the gun and connect the gun to the feeder Consult the specific instructions sup plied with the gun for detailed operating instructions FIGURE WIRE FEEDER AND WATER COOLER CONNECTIONS 1 WIRE FEEDER CONNECTIONS LOCATION 2 WATER COOLER LINE IN 3 WATER COOLER LINE OUT 4 CIRCUIT BREAKER WATER COOLER 5 FILL SPOUT WATER COOLER Using a water cooled gun is
67. E 3 E 3 THEORY OF OPERATION FIGURE PRECHARGE CIRCUIT OUTPUT TRAMSFORMER RECTIFIER U CONTACTOR RECONNECT POSITIVE Return to Section TOC Return to Master TOC LEFT SWITCH THREE BOARD PHASE INPUT FET POWER ASSEMBLY 1 AUX RIGHT SWITCH BOARD FET ASSEMBLY NEGATIVE SNUBBER AND SENSE LEADS CONTROL BOARD LCD DISPLAY DISPLAY BOARD Return to Section Return to Master TOC PRECHARGE SOFT START The Protection Board contains a soft Start circuit which is powered by the Auxiliary Transformer During precharge or soft start only two phases of the input power with current limiting are connected to the input rectifier This AC input voltage is rectified and the DC voltage is applied through the Reconnect Switches to the input capacitors located on the Switch Boards The Protection Board monitors the voltage across the capacitors When the capacitors have charged to an acceptable level the Protection Board energizes the Main Input Contactor making all three phases of input power available to the input capacitors At this point the Power Wave is in the Run Mode of operation If the capacitors become under or overvoltaged the Protection Board will de energize the Main Input Contactor and the machine output will be disabled O10 5 5 9 Sa
68. F 145 TROUBLESHOOTING amp REPAIR FULL VOLTAGE CALIBRATION 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 elec trical 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 PROCEDURE DESCRIPTION This procedure is necessary if the display board is replaced and the Quick Voltage Calibration is NOT possible The Full Voltage Calibration is also necessary if the snubber and or control boards are replaced MATERIALS NEEDED A Test and Calibration Overlay L9660 255 A 300 amp 30 volt resistive grid load A MIG welding load may be used if a grid load is not available Choose an argon rich 30 volt spray procedure See the topic Full Voltage Calibration Using a Welding Arc in this section of the manual A calibrated DC voltmeter accurate to 30 0 volts 0 1 volt A set of jumper leads to access the remote voltage sensing leads in the wire feeder amphenol receptacles SETUP PROCEDURE 1 Using the jumper leads connect 21A
69. LINCOLN amp ine LINCOLN machine POWER WAVE 450 Return to Section TOC Return to Master TOC G20 ELECTRICAL DIAGRAMS G 20 SCHEMATIC SNUBBER PRINTED CIRCUIT BOARD lt e cm WU NW Return to Section TOC Return to Master TOC cm wo J60 NG s cS nr TOOK 8 100 100 51 SW I 2 D1 egre lt LN TO CONTROL BOARD 10 0K Return to Section TOC Return to Master TOC COSMETIC TRACE J62 4 TO J61 5 461 22 100 JL x 33074 33074 50V Ji R19 2 gt gt 1 100 461 gt gt 461 e 461 2 0211 C10 CH DZ12 15V 0 5562 15V 1W 1W CHASSIS R11 50V 50V 40 100W 77 0 y c c 2 0 8 5 Q BS 5 2 c Te GENERAL INFORMATION LAST NO USED ELECTRICAL SYMBOLS PER E1537 R 24 12 CAPACITORS 022 50 UNLESS OTHERWISE SPECIFIED 0 13 RESISTORS Ohms 1 4W UNLESS OTHERWISE SPECIFIED LABELS 0 5 J62 DIODES 1 4000 UNLESS OTHERWISE SPECIFIED SU SUPPLY VOLTAGE NET NOTES V POWER SUPPLY SOURCE POINT c
70. POWER WAVE 450 LINCOLN amp F 48 Return to Section Return to Master TOC Return to Section TOC Return to Master TOC o 2 3 Return to Section Return to Master TOC o p 5 F 49 TROUBLESHOOTING amp REPAIR INPUT RECTIFIER RESISTANCE TEST continued 9 Check all leads connected to the input 10 rectifier Check for looseness or shorted wires Using an analog type meter perform the resistance test Steps A through L accord ing to the Table F 1 NOTE If terminals AC1 AC2 and AC3 of the input rectifier are not easily accessible use terminals T1 T2 and respectively of main con tactor CR1 for the resistance mea surements Similarly if terminals POS and NEG of the input rectifier are not easily accessible use ter minals POS and NEG of the recon nect switch for the resistance mea surements 11 After the test is completed and the prob lem successfully repaired reconnect the negative leads to the reconnect switch Fasten the reconnect switch assembly back into position on the machine NOTE If input rectifier was shorted other components may be faulty Perform Switch Board Test check for leaky or shorted capacitors 12 Install the machine case sides and top 13 Install the handle and the lift bail rubber gasket TABLE 1 INPU
71. Return to Section Return to Master TOC o p 5 F 104 TROUBLESHOOTING amp REPAIR MAIN CONTACTOR TEST continued FIGURE F 35 MAIN CONTACTOR TEST PROCEDURE 1 6 Remove main input supply power to the machine With the 3 8 nut driver remove the 4 screws that hold the handle to the machine Remove the rubber gasket cover seal from the lift bail With the 5 16 nut driver remove the sheet metal screws from the case top With the 5 16 nut driver remove the screws holding the right and left case sides Remove the case sides by lifting up and out Perform the Capacitor Discharge Procedure described earlier in this section of the manual WARNING Before continuing with the test procedure perform the capacitor discharge proce dure to avoid electric shock 7 After you have completed the capacitor dis charge procedure for all four switch boards visually inspect the input terminals L1 L2 13 of the main contactor Make sure they are not shorted together If they are shorted go to step 8 If they are not short ed go to step 9 8 With the slot head screw driver remove leads L1A and L3A from the main contactor POWER WAVE 450 LINCOLN amp F 104 Return to Section Return to Master TOC Return to Section TOC O10 e 515 9 1 gt
72. average output current exceeds 540 amps the peak output cur rent is folded back to 100 amps Erratic output or greater than 6 None Replace shunt and lead assembly amps reading on display with no output Return to Section TOC Return to Master TOC O o e 5 9 gt 5 2 CAUTION If for any reason you do not understand the test procedures or are unable to perform the test repairs safely tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed Call 1 800 833 9353 Return to Section TOC Return to Master TOC POWER WAVE 450 LINCOLN 22
73. s reservoir has a nominal liquid capaci ty of 1 6 gallons PRIMING THE COOLER 1 Select a recommended coolant and fill cooler to specified level see Fig C 2 2 Attach desired water cooled accessory gun and wire feeder or TIG torch to cooler s QDs 3 Prime the cooler a Install the Set up overlay b Keep accessories hose lengths horizontal either coiled or straight and no higher than 4 feet of the specified coolant level Switch on the Power Wave machine Press the WATER COOLER ENABLE button so that the WATER COOLER ENABLED light is illuminated Press the PRIME WATER COOLER button until the WATER COOLER PRESSURE light is steadily illuminated 4 Check coolant level Add more if required Figure C 2 Rear Panel of Power Wave Reservoir Screen 0 25 to 0 50 inches Visible Coolant Level Do Not Use Any prepacked welding industry coolant mixture such as those offered by Miller OKI Bernhard or Dynaflux These coolants contain sub stances which attack plastic components and may shorten the life of the system Once added these substances are virtually impossible to purge from the system DO NOT USE OIL BASED COOLANTS OF ANY TYPE K961 1 Single Cylinder Undercarriage Designed for quick installation in the field Consists of a front caster assembly a rear platform assembly a handle and an upper cylinder support K962 1 Dual Cyli
74. screws that hold the handle to the machine Remove the rubber gasket cover seal from the lift bail With the 5 16 nut driver remove the sheet metal screws from the case top nut driver remove the screws holding the right and left case sides Remove the case sides by lifting up and out Perform the Procedure described earlier in this section of the manual WARNING Before continuing with the test procedure perform the capacitor discharge proce dure to avoid electric shock After you have completed the capacitor dis charge procedure for all four switch boards remove the PC board cover Use the 5 16 nut driver Remove plugs J34 J37 and J38 from the protection board See Figure 1 loca tion Continue with the following checks NOTE Do not remove plug J33 from the pro tection board A With the volt ohmmeter check for continu ity between J37 pin 1 and J37 pin 4 of header J37 There should be no continuity Connect a jumper between J34 pin 11 and J34 pin 14 of header J34 of the pro tection board This simulates the closing of the trigger on wire feeder 1 or the remote Capacitor Discharge ity again between J37 pin 1 and J37 pin 4 of header J37 There should be continu ity now Remove the jumper With the volt ohmmeter check for continu ity between J37 pin 2 and J37 pin 3 of header J37 There should be no continuity Connect a
75. top leads to the main contactor 10 Remove plug J30 from the protection board Check the resistance on the J30 header the plug mounted on the board between pin 1 and pin 6 Resistance should be very high If resistance is low or zero ohms the protection board is faulty Return to Section TOC Return to Master TOC 11 Check plug J30 and associated wires for shorts or damaged connections See the Input and Auxiliary Circuit Wiring Diagram Figure F 14 12 If any of the tests reveal signs of heavy current flow check the switch boards and the input rectifier Refer to Switch Board Test and the Input Rectifier Resistance Test in this section of the manual Return to Section TOC Return to Master TOC 13 After the test is completed and the prob lem successfully repaired reconnect all plugs disconnected for the test 14 Install the PC board cover 15 Install the machine case sides and top 16 Install the handle and the lift bail rubber gasket olo o 5 5 9 gt 5 2 Return to Section Return to Master TOC POWER WAVE 450 LINCOLN amp TROUBLESHOOTING amp REPAIR FIGURE F 14 INPUT AND AUXILIARY CIRCUIT WIRING DIAGRAM F 46 DOL 01 SOL 5 0
76. 1 SWITCH GND Return to Section TOC Return to Master TOC 1N4936 D34 42 25 n gt J42 J44 LD amp CURRENT CON a 7 OPTIONAL 13VDC FAN 444 5Vb gt 4 301 48 95 gt pr 4 40 4 5 gt 1 00K 1 00 1 00 30mA NB 4285 Used on 1A NC 7 Used 1B gt gt gt gt 01 5232 544 Used on 18 PWR gate 2 5Vb ep 15Va e501 15Vb lt gt gt MAS MAN 5 301 4 gt 94 7 1N4936 1116 7192 42 DO 40mAe 4 i me a A 27V 5 Oma limit 1N4936 CURRENT SOURCE rj Ojo 515 9 16 218 5 2 2 21 2 21 29112916 025 114936 15 n 059 1 5402 18 20 4usec max ae FET DRIVE 1 FET DRIVE 2 042 18 e 1 NOTES NA SINCE COMPONENTS OR CIRCUITRY ON A PRINTED CIRCUIT BOARD MAY CHANGE WITHOUT AFFECTING THE INTERCHANGEABILITY OF A COMPLETE BOARD THIS DIAGRAM MAY GENERAL INFORMATION NOT SHOW THE EXACT COMPONENTS OR CIRCUITRY OF CONTROLS HAVING A COMMON CODE _
77. 12M and 9G QM Then test for 7 5 K ohms resistance across R10 directly If the measurement does not read between 6 75 and 8 25 K ohms replace resistor R10 Reconnect quick connect terminals 405 406 9 12 on switch board 3 Switch Board 4 Switch Board 4 is Marked CAP 4 on the Switch Board Assembly Connection Label See Figure F 24 A B C Remove quick connect terminals 407 408 9 and 12 from switch board 4 With the volt ohmmeter check for 25 ohms resistance between lead 407 and 12H If the measurement reads between 20 and 30 ohms resistor R7 and leads 407 and 12H are okay Go to step C If the measurement does not read between 20 and 30 ohms check for continuity in leads 407 and 12H Then test for 25 ohms resistance across R3 directly If the measurement does not read between 20 and 30 ohms replace resistor R7 With the volt ohmmeter check for 25 ohms resistance between lead 408 and 9H If the measurement reads between 20 and 30 ohms resistor R8 and leads 408 and are okay Go to step D If the measurement does not read between 20 and 30 ohms check for continuity in leads 408 and Then test for 25 ohms resistance across R8 directly If the measurement does not read between 20 and 30 ohms replace resistor R8 Reconnect quick connect terminals 407 408 9 and 12 on switch board 4 Install the machine case sides and top Install the handle
78. 519400 2672 26 7 1 4W 519400 4752 47 5 1 4W 519400 1501 5K 1 4W 45 519400 6810 681 1 4W 19400 3322 33 2K 1 4W Return to Section TOC Return to Master TOC G 9 ELECTRICAL DIAGRAMS SCHEMATIC DISPLAY PC BOARD SHEET 1 1 c52 x12 025 T nj T Mo6850CS 74HC4040 14489 14489 8 Return to Section TOC Return to Master TOC 585232 DES 9 180 PIEZO BUZZER CIRCUITRY HV 5RS232 NU FROM POWER BOARD H LED32 GND 74HC4040 LED33 1 029 POWER DOWN 18081 4 e 688232 Q gt gt 5 BL DL O 15 88823257 Hes 3 ese 115 64 585282 RW es 00 801 4 IGRS232 ge 02 BI DL2 888232 gt 9 e 08 BI DLS ISOLATED POWER amp SIGNALS UN pa 18 BDL I P os BDL am 8 06 1 025 07 BI DLI7 gt e vec 082 9 2 gt 5 5232 Return to Section Return to Master TOC
79. C o SNUBBER 1 60 1 518248 EADER 8248 EADER oA ER 62 ONNECTOR 59 19400 1002 10 1 4W R22 R23 R24 3 R2 R5 T14649 7 710W 4 86 59 10 81112 10 20620 1003 100K 17211 N N NJN TIN 4 RIARIT R18 R19 1 2 519400 1000 LEM TP1 TP2 TP3 13640 18 D 515128 18__ N CAPACITORS MFD VOLTS SUBJECT DATE 2 25 24 CHK DB Po 160J Pp O 00 1 4W SCALE FULL THE LINCOLN ELECTRIC CO CLEVELAND OHIO U S A Return to Section TOC Return to Master TOC ______ ___________ __ A WITH PUBLISHED STANDARDS UNLESS OTHERWISE SPECIFIED TOLERANCE ON HOLE SIZES PER E2056 2 PLACE DECIMALS 15 02 3 PLACE DECIMALS IS 0028 ON ALL ANGLESIS 5 DEGREE MATERIAL TOLERANCE TO AGREE 515 9 16 218 5 2 NOT BE REPRODUCED DISCLOSED OR USED THE LINCOLN ELECTRIC CO THIS SHEET CONTAINS PROPRIETARY INFORMATION OWNED BY THE LINCOLN ELECTRIC CO AND 15 WITHOUT THE EXPRESS PERMISSION OF 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 warran
80. If Test C is good but Tests A and B are not cor rect check the 5 amp circuit breaker located on the front panel of the machine See the Input and Auxiliary Circuit Wiring Diagram Figure F 6 If all the secondary voltages are wrong or miss ing check the associated wiring to the trans former primary These voltages are most eas ily checked at the terminal strip The correct voltages are as follows H1 to H2 200 208 H1 to H3 220 230 H1 to H4 380 415 VAC H1 to H5 440 460 If these voltages are wrong or missing check the associated wiring to the transformer prima ry Check the leads at power switch S1 See the Input and Auxiliary Circuit Wiring Diagram If the correct voltages are applied to the pri mary and the secondary voltages are incorrect the transformer may be faulty Replace the transformer Refer to the procedure this section of the manual 14 After the test is completed and the prob lem successfully repaired reconnect plugs J30 J32 and J33 to the protection board 15 Reconnect plug J5 to the T2 transformer 16 Reconnect the 5 leads to the main con tactor CR1 17 Install the PC board cover 18 Install the machine case sides and top 19 Install the handle and the lift bail rubber gasket POWER WAVE 450 LINCOLN amp F 29 30 30 TROUBLESHOOTING amp REPAIR
81. LINCOLN Return to Section Return to Master TOC Return to Section TOC Return to Master TOC o 2 3 Return to Section Return to Master TOC o p 5 F 36 RECONNECT PANEL ON LEFT SIDE TERMINAL STRIP FAN MOTORS AUXILIARY TRANSFORMERS TROUBLESHOOTING amp REPAIR AUXILIARY TRANSFORMER PRIMARY WIRING HARNESS TEST continued FIGURE F 9 RECONNECT PANEL TERMINAL STRIP LOCATION TEST PROCEDURE 1 6 Remove main input supply power to the machine With the 3 8 nut driver remove the 4 screws that hold the handle to the machine Remove the rubber gasket cover seal from the lift bail With the 5 16 nut driver remove the sheet metal screws from the case top With the 5 16 nut driver remove the screws holding the right and left case sides Remove the case sides by lifting up and out Perform the Capacitor Discharge Procedure described in this section of the manual A WARNING Before continuing with the test procedure perform the capacitor discharge proce dure to avoid electric shock 7 After you have completed the capacitor discharge procedure for all four switch boards remove the PC board cover Use the 5 16 nut driver 8 Remove the 5 leads 3 heavy and 2 small T1 T2 T3 fro
82. NOTE Unshaded areas of Block Logic Diagram are the subject of discussion POWER WAVE 450 LINCOLN 8 7 7 THEORY OF OPERATION FIGURE E 7 CONTROL BOARD INPUT RECTIFIER INPUT CONTACTOR RECONNECT THREE PHASE INPUT FET POWER ASSEMBLY mE MAIN OUTPU TRAMSFORMER RECTIFIER CHOKE POSITIVE ARI Return to Section Return to Master TOC LINE SWITCH SWITCH PROTECTION BOARD BOARD FET ASSEMBLY NEGATIVE SHUNT C SNUBBER AND SENSE LEADS WATER LCD Return to Section Return to Master TOC CONTROL BOARD The Control Board is at the heart of controlling the out put of the machine With the information it receives from the Shunt current feedback the voltage sensing leads the wire feeder s and the other printed circuit boards the Control Board optimizes the welding results by regulating the FETs switching times which in turn control the output of the machine The Control Board also monitors the thermal protection devices and the regulation and fault signals produced on the Protection Board O o e S9 9 gt cic 5 5 NOTE Unshaded areas of Block Logic Diagram are the subject of discussion Return to Section TOC Return to Master TOC POWER WAVE 450 LINCOLN 8 Return to Section Return to Master TOC Return to Section TOC Return to Master T
83. Power Wave 450 2 Disconnect the Output leads from the machine Return to Section TOC Return to Master TOC 3 If a wire feeder is connected to the Power Wave 450 release the drive roll tension so the unit will not feed wire when the trigger is activated 4 Turn on the Power Wave 450 and activate the gun trigger and hold for several sec onds Trigger the machine on and off sev eral times in this manner and observe the display The l reading should be less than five amps when the machine is trig gered and NOT welding 5 f after several trigger cycles the value is at or above 5 amps the shunt assembly is suspect and should be replaced Return to Section TOC Return to Master TOC 6 If the value is below 5 amps when the trigger is activated and not welding the sta bility of the shunt assembly is at an accept able level 7 To further test the shunt assembly continue with the output shunt welding feedback test O10 e 515 9 16 gt EIS 2 Return to Section Return to Master TOC POWER WAVE 450 LINCOLN Return to Section Return to Master TOC Return to Section TOC Return to Master TOC o 2 3 Return to Section Return to Master TOC o p 5 F 53 1 SHUNT AMPLIFIER BOARD TROUBLESHOOTING amp RE
84. Press the Voltage Calibration function 32 The machine should display the following VOLTAGE WIRE POLARITY 67A 5 Press the Enter Key 133 on the lower right side of the overlay The machine should display the following ADJUST TO 30V CALIBRATION XX NOTE Here XX indicates a particular cali bration number for a given voltage sensing point WARNING The machine s output terminals will be electri cally HOT when the Enter Key is pressed 6 With the machine loaded monitor the refer ence voltage only external voltmeter It is the only important reading Adjust the volt age using the Arrow Keys 100 and 101 until the reference voltmeter reads 30 0 volts Press the Enter Key 6a If using a synergic 7 wire feeder press enter then adjust to the desired w f s Note the gun will be electrically hot at this time A CAUTION WHEN LOADING THE MACHINE WITH THE CASE PARTS REMOVED BE CAREFUL NOT TO OVERHEAT THE MACHINE 7 Repeat the process by pressing the Voltage Calibration function again The next volt age sensing point lead may be selected by pressing the down Arrow Key 101 The above procedure must be repeated six times to set the six sensing points leads to 30 0 volts The six test points leads are the following Polarity 67A Polarity 67B Polarity 21A Polarity 21B Polarity Polarity 8 If the display board is replaced or dis turbed perfor
85. REFERENCE Vret V UNITY GAIN DIFFERENTIAL AMPLIFIER 100K UNITY GAIN AMPLIFIER 016 1894 a 2F VOLTAGE FEEDBACK 2G PROGRAMMABLE VREF Peu Pee ALL GROUNDS MEET HERE AND ONLY HERE J21 lt lt CONNECTED IN GRAPHICS ONLY p AD 1 Vo v V NOISE GROUND lt gt 10 TO VOLTAGE ANALOG CIRCUITRY SHEE UNLESS OTHERWISE SPECIFIED TOLERANCE 8 13 998 HOLES SIZES PER E 2068 ON 2 PLACE DECIMALS IS O2 ON 3 PLACE DECIMALS IS 002 ON ALL ANGLES IS 5 OF A DEGREE MATERIAL TOLERANCE 1 TO AGREE CLAMP CIRCUIT FOR TRANSIENTS ABOVE 5 0V SUPPLY RAIL MV VMT 1 0K VV NOISE GROUND NOISE GROUND NOTES NA SINCE COMPONENTS OR CIRCUITRY ON A PRINTED CIRCUIT BOARD MAY CHANGE WITHOUT AFFECTING THE INTERCHANGEABILITY OF A COMPLETE BOARD THIS DIAGRAM MAY NOT SHOW THE EXACT COMPONENTS OR CIRCUITRY OF CONTROLS HAVING A COMMON CODE NUMBER GENERAL INFORMATION ELECTRICAL SYMBOLS PER E1537 CAPACITORS 022 50V UNLESS OTHERWISE SPECIFIED RESISTORS Ohms 1 4W__ UNLESS OTHERWISE SPECIFIED LABELS DIODES 1A 4000 UNLESS OTHERWISE SPECIFIED SUPPLY VOLTAGE NET O POWER SUPPLY source POINT COMMON CONNECTION
86. TY 23898 s 8 FOOT AMPTROL RECEPTACLE AUXILIARY TRANSFORMER 2 N D E a i 1 how 2 83 881 NOTES SINCE COMPONENTS OR CIRCUITRY OF A PRINTED gt D gt 1088 Lyras gt Aw 4 44 200 CIRCUIT BOARD MAY CHANGE WITHOUT AFFECTING S E 1020 9602 i 440 460 YYY THE INTERCHANGEABILITY OF A COMPLETE BOARD M T oss 4 i i THIS DIAGRAM MAY NOT SHOW THE EXACT o 8 Hio nl pni i 8830 5 lt WATER COOLER i CIRCUITRY HAVING d 5 c i 8 i 0 N B 01 THRU D6 OUTPUT DIODES ARE MATCHED 5 0 lt gt gt 07 THRU 014 OUTPUT DIODES ARE A MATCHED SET i 1 lt 3 220 230 o i 015 THRU 020 OUTPUT DIODES ARE MATCHED SET PROTECTION BOARD i N C C1 C2 C4 CAPACITORS ARE A MATCHED SET 2 i N D NOT EXIST ON MACHINE WITHOUT WATER COOLER 9 he NOT EXIST ON MACHINE ELECTRICAL SYMBOLS PER E1537 4 1803 1 a gt POWER WAVE P5 5 5 MACHINE SCHEMATIC 5 5 G 2990 NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual LINCOLN ELECTRIC POWER WAVE 450 ELECTRICAL DIAGRAMS SCHEMATIC CONTROL PC BOARD 1 28 512 M
87. WF1 Port Switch WF1 S L Comunication enabled WF1 S L Comunication disabled Open Closed WF2 Port Switch WF2 S L Comunication enabled WF2 S L Comunication disabled Open Closed F TROUBLESHOOTING amp REPAIR FIGURE F 38 SERIAL LOOP WIRING DIAGRAM J22 5R J44 gt 5 gt 5 TxD 5 lt 40mA current supply DISPLAY BOARD BOARD lt lt 7 Y i 7 J26 1 263 J14 gt 3 l lt 6 lt 5 i 4 lt TRN REC DK 126 1 264 J14 gt 4 i 3 lt 14 _ WF M27 1 1114 g i y lt TRN gt 1 1 REC WF J27 112A i gt 4 m lt P8 6 d rper 1 14 WED WF2 pe a IE LL 1174 p lt P82 PET 8244 Vy 4 lt TRN l CON gt i REC 3 118A M 222 1 8A lt 82 1 2810 NE 1 POWER BOARD o eec 422 5W J44 gt 4 gt 4 gt M
88. be careful not to touch these resistors Locate terminals 9 and 12 on the switch boards They can be identified by the Discharge labels which are located on each of the four switch boards See Figure FIGURE 2 RESISTOR LOCATIONS 5 PAIRS OF RESISTORS CHECK VOLTAGES BETWEEN EACH TERMINAL AND FROM EACH RESISTOR TO CASE GROUND POWER WAVE 450 LINCOLN amp Return to Section Return to Master TOC Return to Section TOC Return to Master TOC TROUBLESHOOTING amp REPAIR CAPACITOR DISCHARGE PROCEDURE continued FIGURE DISCHARGE LABEL v v v a 4 mox roo co lt 13086 117 WARNING 25 ELECTRIC SHOCK kill Proceed with caution Be careful not to touch any internal machine components during the discharge procedure o 2 3 Return to Section Return to Master TOC o O gt o E tc 9 Using the insulated needle nose type jumper leads and insulated gloves con nect one jumper lead to one end of the resistor obtained in step 6 Connect the other jumper lead to the other end of the resistor 10 Carefully connect the needle nose end of one of the jumper leads to terminal 9
89. display CAUTION Do not touch the sensors located on the left side of the display board when you handle it for removal or replacement Failure to do so can result in permanent damage to the sen sors 10 Carefully remove the display board from the its mounting pins Remove the display board by lifting up and out 11 12 13 14 Reinstall the display board by carefully pressing it onto its mounting pins Install the LCD display connector the key pad connector and the eight molex plugs that fit along the bottom portion of the display board After you have installed the display board a new one or the old one you must per form the Display Board Sensor Calibration Test and necessary voltage calibration Refer to this test in the test portion of this section of the manual After performing the Display Board Sensor Calibration Test install the machine case sides and top Install the handle and the lift bail rubber gasket POWER WAVE 450 LINCOLN F 181 182 NOTES POWER WAVE 450 LINCOLN 5 F 182 901 Je1Se A 0 uunjeHd 901 4 1 0 uunjeH 901 J91Se N 01 DOL 01 901 uonoes uumeg DOL uonoes uumeg DOL uonoes uumeg DOL uonoes uumeg 183 F 183 TROUBLESHOOTING amp REPAIR MAIN INPUT CONTACTOR CR1 REMOVAL AND REPLACEMENT WARNING Service and repair should be performed by only Lincoln Electric factory trai
90. gt 2 lt WH Lu e gt gt lt VEH gt PRU TP 29 oz m g 21 OL 4 gt 9 s Er lt lt 182 5 8 VIH ue 1 SH o 0 lt 9 lt o t vee 2 2 a E 9 cl A ae lt pm tc 6 3 H VET ASLLOZd gt m lt e 7 gt p gt 686 lt 3 186 108 01 u 901 Je1Se A 0 uunjeH 901 4 1 0 901 J91Se N 01 901 J91Se N 01 UuunjeH DOL uonoes DOL uonoes DOL uonoes DOL uonoes Return to Section Return to Master TOC Return to Section TOC Return to Master TOC o 2 3 Return to Section Return to Master TOC o O gt o gt E tc F 97 F 97 TROUBLESHOOTING amp REPAIR INTERNAL AND AUXILIARY SUPPLY VOLTAGE 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 elec trical shock please observe all safety notes and precautio
91. i ni 1 415 Va i i m i i 4 380 460 8 i INARA EL H 1 4 303 9 air gt E d 8 4 4 307 gt Y 2n gt 226 gt lt 351 gt 1435 gt 0 VAG FROM 1433 RECONNECT PANEL 1 9B i o i i ues ENS m FET BANKA 2VAC SUPPLY FROM PROTECTION DAMES l i if 1 1 i I SE 265 gt 6108 gt Y GT SIGNAL BS 2 3 88 4 Wee H 1 4 41 E 2 205 i gt sns TRIGGER 4 1 3 d ve Exc i i 7 2 go WR il v s SE 8 T 81 L5 snm 404 266 gt 4 DIFFERENTIAL VOLT NEG i 8 RS232 mh ISOLATED i Ghee pt ue t250Hz WHEN CAP BALANCED us amp 12K MAIN CHOKE E CONNECTOR 65 28 sa 5 Va 1 i ene oy CAPRA _ i ER REA NS B au 15 Va ct 226 5 15 Va y ILI i wae eas kad E emme Bl ELECTRODE EIE BE A e SE coumet 224 i nu i 22 ecl 08 n i 8 Ws 5 Sp tit sect 268 gt ame gt 8 205 i o THRU CT i 1 1 TSI O
92. lt 8Ke lt lt 1 gt H tc ger 8601 lt lt 18k9 lt lt lt 1041N09 1 lt 020 s 44 Id j 7 4 00 lt lt lt lt o m a 049 yep HU vso1 oc lt mw lt lt 25 rer 8201 gt 049 pep eed ast z lt lt lt lt lt Xx eir 8 ver 901 IL oF e lt um azot RT LM Z 0 in 9c f eer sjousyduiy Sjoueuduy 5 yee 66 vee ud 19 8 89 z 3 5 i U3 HOJSNVUL 126 901 Je1Se A 0 901 4 1 0 uunjeH 901 J91Se N 01 901 J91Se N 01 DOL uonoes DOL DOL DOL uonoes Return to Section Return to Master TOC Return to Section TOC Return to Master TOC o 2 3 Return to Section Return to Master TOC o O gt o gt E tc F 127 F 127 TROUBLESHOOTING amp REPAIR K941 1 REMOTE CONTROL KIT TEST WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel Unauthorized repairs performed on this equipment m
93. o p 5 F 124 TROUBLESHOOTING amp REPAIR INTERNAL REMOTE CONTROL TEST continued FIGURE F 45 DISPLAY BOARD PLUG LOCATIONS _ oo 417 J16 J15 J14 J13 J12 J11 J10 TEST PROCEDURE WARNING 1 6 Remove main input supply power to the machine With the 3 8 nut driver remove the 4 screws that hold the handle to the machine Remove the rubber gasket cover seal from the lift bail With the 5 16 nut driver remove the sheet metal screws from the case top With the 5 16 nut driver remove the screws holding the right and left case sides Remove the case sides by lifting up and out Perform the Capacitor Discharge Procedure described earlier in this section of the manual Before continuing with the test procedure perform the capacitor discharge proce dure to avoid electric shock After you have completed the capacitor dis charge procedure for all four switch boards remove the PC board cover Use the 5 16 nut driver Remove the 5 leads 3 heavy and 2 small T1 T2 T3 from main input contactor CR1 This is a safety precaution It prevents high voltage from being put on the machine dur ing the test Wrap tape around the lead ends to insulate them and prevent them from touching
94. the manual WARNING Before continuing with the test procedure perform the capaci tor discharge procedure to avoid electric shock the Capacitor Discharge T MAIN TRANSFORMER After you have completed the capacitor dis charge procedure for all four switch boards perform the Refer to the proce dure in this section of the manual After the FET module assembly has been removed the main transformer and chokes are easily accessible With the 3 8 socket wrench remove the four main transformer mounting bolts Disconnect the heavy leads between the main transformer and the choke assembly You will need to cut the cable ties on the insulating sleeve and slide the sleeve for ward to access the connection 10 Lift the main transformer out Remove the 11 background or output chokes if necessary by removing any mounting bolts holding the chokes to the machine frame bottom After reassembly test on high voltage input and reconnect POWER WAVE 450 LINCOLN amp F 198 199 199 TROUBLESHOOTING amp REPAIR PRE POWERUP SWITCH BOARD TEST PROCEDURE FOR REPLACEMENT OF SWITCH ASSEMBLY G2402 2 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 y
95. 11 Turn input power ON Machine output must be OFF Measure the frequency between J23 pin 4 and J23 pin 2 on the control board You should see between 3 2 and 5 3 divi sions per cycle 950 to 1550 Hz If you do see this the test is completed If you do not see this go to the next step Turn the power switch SW1 to the OFF position disconnect input power to the machine and perform the Discharge Procedure A WARNING Before continuing with the test procedure per form the capacitor discharge procedure to avoid electric shock 13 After you have completed the capacitor discharge procedure for all four switch boards with the volt ohmmeter test leads 9J 9K 12J and 12K for continuity between the between the reconnect Switch and the protection board 14 15 16 17 18 19 Test leads 232 and 234 for continuity These leads are between the protection board and the control board Lead 232 is between J39 pin 3 and J23 pin 2 Lead 1234 is between J39 pin 2 and J23 pin 4 These leads must be intact for the fre quency signal to be measured because the transistor side of the optocoupler needs the power from the control board If all the leads tested in step 14 are okay make sure that the molex plugs are all plugged in correctly and pushed far enough into their headers Check the fre quency again on the oscilloscope If the frequency is still incorrect the pro tection board may
96. 122 Female 58053 123 P23 adapter Male connector 518247 6 58053 123 Toggle switch SPST alternate method of testing using an isolated oscilloscope may be used Return to Section TOC Return to Master TOC POWER WAVE 450 LINCOLN B Return to Section Return to Master TOC Return to Section TOC Return to Master TOC O10 515 9 1 EIS 2 Return to Section Return to Master TOC F 200 F 200 TROUBLESHOOTING amp REPAIR PRE POWERUP SWITCH BOARD TEST PROCEDURE FOR REPLACEMENT OF SWITCH ASSEMBLY G2402 2 continued FILTER CAPACITOR POLARITY TEST 1 Perform this procedure with the input power removed Perform the DIS CHARGE Procedure to remove any charge from the input filter capacitors 2 Configure the machine for 230VAC opera tion 3 Attach the ohmmeter set to 1 K ohm range across one of the 7 5K ohm bleeder resistors R9 or R10 See wiring diagram 4 Attach the positive meter probe to wire 9 and the negative meter probe to lead 12 The resistance should slowly increase to a value between 3K ohms and 3 5K ohms 5 Repeat the procedure for the other bleeder 7 5K ohm resistor FIGURE F 76 AC SUPPLY LEADS FUSE INPUT RECTIFIER 1 1 2 i 115 gt VARIABLE INPUT RECTIFIER 0 gt 115 gt 13
97. 30 minutes to perform POWER WAVE 450 LINCOLN F 192 F 192 TROUBLESHOOTING amp REPAIR FET MODULE REMOVAL AND REPLACEMENT continued FIGURE F 73 FET MODULE LOCATION Return to Section TOC Return to Master TOC NaC S p 1 E 2 52 A VS NP o o 2 5 Return to Master TOC s 1 FET MODULE 2 PIEZO ALARM BUZZER 3 FET MODULE LOCKING BAR 27 24 4 RESISTORS PROCEDURE WARNING 5 8 1 Remove main input supply power to the p T machine Before continuing with the 8 2 2 With the 3 8 nut driver remove the 4 test procedure perform the screws that hold the handle to the machine capacitor discharge Z dure to avoid electric shock 8 4 3 Remove the rubber gasket cover seal from the lift bail 512 4 With the 5 16 nut driver remove the sheet 7 After you have completed the capacitor dis metal screws from the case top charge procedure for all four switch boards 4 use the 5 16 nut driver to remove the two 5 With the 5 16 nut driver remove the screws holding the printed circuit board screws holding the right and left case sides cover in place Slide the cover forward and Remove the case sides by lifting up and lift up to remove it out 6 Perform the Capacitor Discharge Proce A CAUTION dure described earlier in
98. 4 IC CONVERTER D A SS X61 X71 X92 515128 18 QUAD OP AMP X63 X64 17900 22 QUAD ANALOG SWITCH SS DZ7 DZ8 DZ9 DZ10 DZ11 DZ12 20 T12702 52 1N4733A 0213 0214 0215 0216 0217 0218 0219 0220 0221 0222 0230 0231 0232 0233 01 02 08 08 011 016 017 54 816668 11 1750 R153 R160 R162 R163 R164 16 519400 10 0 10 1 4W 18 19 20 21 22 23 R165 R166 R225 R260 R305 24 27 28 29 31 32 R306 R307 R309 R312 R313 34 37 40 41 42 43 R316 44 45 48 59 60 61 R299 C68 C69 C73 C77 C79 C81 R159 1 519400 1503 150 1 4W 83 84 95 97 98 100 195 8197 207 8211 212 519400 3321 3 32K 1 4W 105 111 119 155 156 R241 R289 R290 3025026 0 3 516682 47 00 TZ R200 R201 R208 R234 819400 5622 56 2K 174W 22pF 100 1 0735 R286 30 56 90 126 135 5 516668 8 330 100 R215 TT 819400 2671 Z 67K GW 52 53 54 106 108 114 12 516668 7 820 750 R236 R243 R245 3 519400 6192 61 9 87 91 96 101 132 133 15 7022750 0141 0142 0144 0145 0148 150 0151 0152 153 poss 1 51349085 2750 o cc Mee qu R328 R329 R330 R331 R332 519400 2210 221 1 4W 117 123 127 128 136 o O C118 0122 0125 C129 4 15134903 0047400 RE UNDERYOLT SENSING CTR 0 01701 Tee x2 1 M15102 3 UNDERVOLT SENSING CIR SS D2 D17 D18 D19 D20 D21 D22 1N4004 5 517900 13 25 028 027 028 029 030 15101 6 D31 D32 D33 D34 D35 D36 815 fet
99. 74 139 V ADORTI 1113 J24 475 DSP1 ADDRESS BUS ADDR O 11 2 L 0 0 0 15 B 9 3B BUS DECODE DSP 1 NOISE GROUND 10 0 0 0 b 0 1 5 a e oni op 00 10 2 0 0 lt lt s 0 08 Jonis a 7 o s 004 10 00 AD os 0 05 0 06 DATAS n 6 o 0006 AD Em or 2 1007 or AD DATA NOISE GROUND R262 415 42 GND uL 100K CLKOUT AD 8 Xs 545 ge WRITE 0 TEN TOLK2 CLKX AD DATA 9 LATCH READ 4 1 CLKIN TOLKt CLKR a gt CLR iet CLKOUT Ee 3 ant TMS320E14 08 0 08 08 TMS320E14 ac NOISE GROUND 4 4 STROBE AD 0 09 1 0 09 09 3 V 24 475 we oo 10 z 01010 00 2 OUTPUT_ON RESET RS on 5 DSP_REN yy wro RD VOL 45V 45V g L2 013 RD HIGH ag CMPA CAP2 FSX D14 NOISE_GROUND RD LOW cart vest 424 475 lt lt 8 330p 100V ID 740573 AD DATAO 15 PXD CMP5 CAPS FSX E OMP5
100. 777 FRAME CONNECTION D EARTH GROUND CONNECTION FILE 62241 2A1 THE LINCOLN ELECTRIC CO TYPE POWER WAVE CLEVELAND OHIO U S A SUBJECT CONTROL SCHEMATIC scale NONE SHT DATE 11 25 92 SUP S D G G 2241 3 WITH PUBLISHED STANDARDS NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual POWER WAVE 450 ot ELECTRICAL DIAGRAMS SCHEMATIC CONTROL PC BOARD 4 1 4 Return to Section TOC Return to Master TOC ON OFF SWITCH 485 vT 007 pe SHEET 1 X20 CNY17 8 226 SWITCHt TO HCI THERMAL 2 026 00 CNY17 8 LOW NORMAL 58 2K HIGH FAULT HIGH TRIGGER OPEN C128 E HIGH TRIGGER OPEN LOW TRIGGER CLOSED LOW TRIGGER CLOSED 180p mu 50 lt lt gn amp J TURN ON OFF DISPLAY KEYPAD FROM SERIAL LOOP MUST BE ISOLATED FROM MUST BE ISOLATED FROM GROUND ALL OTHER SIGNALS ALL OTHER SIGNALS _ 2N THERMAL OVERLOAD INPUT A 2 3123 INPUT FROM PROTECTION 5V FOR FAULT CONDITION Tes 002 OV FOR NORMAL CONDITION CNY17 3 SHEET 1 X20 1 2 TO DSP2 0127 180p 50V Return to Section TOC Return to Master TOC
101. 833 9353 POWER WAVE 450 LINCOLN Return to Section Return to Master TOC Return to Section TOC Return to Master TOC o 2 3 Return to Section Return to Master TOC o O gt o gt E F 19 F 19 TROUBLESHOOTING amp REPAIR TROUBLESHOOTING GUIDE PROBLEMS SYMPTOMS Machine loses output while weld ing Fans and display are func tioning properly Observe Safety Guidelines detailed in the beginning of this manual POSSIBLE AREAS OF MISADJUSTMENT S WELDING PROBLEMS Check the yellow High Temperature light on the front panel If the light is ON then refer to the Output Problems section in this table relating to this condition Check for proper input volt ages per machine nameplate Check for balanced three phase input supply voltages Check electrode and work cables for loose or poor con nections RECOMMENDED COURSE OF ACTION 1 Perform the Welding Feedback Test 2 Perform the Switch Board 3 Perform the Snubber and Bleeder Resistor Test 4 Perform the Static Capacitor Balance Test 5 Perform the Dynamic Capacitor Test 6 Perform the appropriate Wire Feeder Trigger Circuit Test If a K941 1 Remote Control Kit is used perform the K941 1 CAUTION If for any reason you do not understand the test procedures or are
102. CAPS FSX CMPA CAP2 FSR Vo NOISE_GROUND STROBE_AD 424 475 554 STROBE AD 1 0716 j CLR_CAP OUTPUT_ON FROM HCt1 GND PAL16R4 053 NOISE GROUND 922 ie gt gt 515 9 16 gt 218 5 2 J24 3B DSP 1 FUNCTION GENERATOR 7 922 V GROUND gt gt INDICATES CHANGE FROM VERSION nsew p 20 MAIN FET DRIVE GENERAL INFORMATION LAST NO USED ELECTRICAL SYMBOLS PER E1537 05 d CAPACITORS 022 50V UNLESS OTHERWISE SPECIFIED ou DATA O 15 0 0 0 15 RESISTORS Ohms 1 04 UNLESS OTHERWISE SPECIFIED LABES gt e dior nat ai DSP FUNCTION GENERATOR SHEET 2 RD MATE Sr A T TET Power SUPPLY SOURCE POINT 6B PARALLEL COMMUNICATION COMMON CONNECTION 1777 FRAME CONNECTION EARTH GROUND CONNECTION NOTES FILE G2241 2A1 SINCE COMPONENTS OR CIRCUITRY ON A PRINTED CIRCUIT BOARD MAY CHANGE UNLESS OTHERWISE SPECIFIED TOLERANCE if noise WITHOUT AFFECTING THE INTERCHANGEABILITY OF COMPLETE BOARD THIS DIAGRAM MAY eas THE LINCOLN ELECTRIC CO POWER WAVE NOT SHOW THE EXACT COMPONENTS OR CIRCUITRY OF CONTROLS HAVING A COMMON COD
103. COOLER ON OFF KEY Press this key to toggle the water cooler between being enabled and disabled The present status of the water cooler is indicated by the WATER COOLER ON light 6 WIRE FEEDER 1 ELECTRODE SENSE LEAD KEY 7 WIRE FEEDER 1 WORK SENSE LEAD KEY WATER COOLER PRESSURE LIGHT This light indicates whether or not the coolant flow rate is high enough for normal water cooler operation If the water cooler loses the required flow rate it will shut down within a couple of seconds the water cooler pressure light will turn off and the machine sounds a buzzer PRIME WATER COOLER KEY The water cooler may have to be primed if there is not enough coolant in the system for proper operation Make sure that the water cooler has been turned on before it is primed The WATER COOLER ON light should be turned on Check reservoir for proper coolant level See Water Cooler informa tion in ACCESSORIES section To prime the water cooler hold the PRIME WATER COOLER key down While this key is pressed the display will show PRIME WATER COOLER POWER WAVE 450 LINCOLN B Return to Section Return to Master TOC Return to Section TOC O o e 5 5 9 gt 5 2 Return to Section Return to Master TOC Return to Master TOC B 18 OPERATION When the WATER COOLER PRESSURE light turns on release the key If this key has been pressed for 30 seco
104. DIAGRAMS G9 SCHEMATIC CONTROL PC BOARD 2 08 ADDRESS BUS RAM_SEL DATA O GND 70199 30 ANALOG DIGITAL CONVERTERS DSP1 DATA BUS 16 DATA O 15 x43 x 0 gt vi D ov 144004 D S orm IREN 5320 14 NN 744158 50 100878 7440139 8 Return to Section Return to Master TOC DSP2 MISC 0 BUS CURRENT CONVERSION DATA 0 15 E STROBEAD DSP_REN DSP WE RD DSP2 DSP A0 le Is 10 0K AD DATA DATA 77 AD ND 14 139 DATA 12 DATAS ND ow 20 AD DATA DIRECTION AD n RD LATCH 8 1 PORT STROBEAD 4 MORI x 50301 AD m p RDLATCH _ DSPi PORTI AD RD HIGH PSD301 s OE HIGH D 7440153 Veet 2 AD 0 AD 74 CONTROL DATA FLOW DSP 1 lt gt HC11 Return to Section TOC Return to Master TOC WRITE 0 DIRECTION HIGH HCT1 gt DSP 1 NOISE GROUND ud DIRECTION LOW DSP 1 gt 0 11
105. DOL 01 901 uonoes uumeg DOL uonoes uumeg DOL uonoes uumeg DOL uonoes uumeg F 175 F 175 TROUBLESHOOTING amp REPAIR PRINTED CIRCUIT BOARD REMOVAL AND REPLACEMENT CONTROL BOARD POWER BOARD AND PROTECTION BOARD A 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 elec trical 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 trou bleshooting assistance before you proceed Call 1 800 833 9353 WELD DESCRIPTION The following procedure will aid the technician in removing the control power or protection printed circuit boards for maintenance or replacement Return to Section TOC Return to Master TOC MATERIALS NEEDED 5 16 Nut driver 3 8 Nut driver Machine Wiring Diagram in the Electrical Diagrams section of this manual This procedure takes approximately 30 minutes to perform O o Fle 5 o 9 gt sis 2 Return to Section Return to Ma
106. J12 from the display board 10 Place a jumper wire between pins C and D of wire feeder receptacle 1 Remove the 5 leads 3 heavy and 2 small T1 T2 T3 from main input contactor CR1 This is a safety precaution t prevents high voltage from being put on the machine during the test Wrap tape around the lead ends to insulate them and prevent them from touching POWER WAVE 450 LINCOLN amp F 112 Return to Section Return to Master TOC Return to Section TOC Return to Master TOC 2 3 Return to Section Return to Master TOC 5 113 TROUBLESHOOTING REPAIR WIRE FEEDER 1 TRIGGER CIRCUIT TEST continued WARNING ELECTRIC SHOCK can kill With the input power ON there are high volt ages inside the machine including the protec tion board Do not reach into the machine or touch any internal parts 11 Remove plug J30 from the protection board See Figure F 1 for location of the board and plug J30 WARNING 2 ELECTRIC SHOCK can kill With the input power ON there are high voltages inside the machine Do not reach into the machine or touch any internal parts 12 Turn input power ON 13 With the volt ohmmeter check for 24 VAC between plug J12 pin 2 and pin 4 A If 24 VAC IS present go to step 14 NOTE A voltage of 5 to 10 VDC
107. LINCOLN Return to Section Return to Master TOC Return to Section TOC Return to Master TOC o 2 3 Return to Section Return to Master TOC o p 5 F 32 TROUBLESHOOTING amp REPAIR AUXILIARY TRANSFORMER TEST 2 continued FIGURE F 7 TRANSFORMER 1 AND T2 LOCATION TEST PROCEDURE 6 With the 5 16 Remove main input supply power to the machine With the 3 8 nut driver remove the 4 screws that hold the handle to the machine Remove the rubber gasket cover seal from the lift bail With the 5 16 nut driver remove the sheet metal screws from the case top nut driver remove the screws holding the right and left case sides Remove the case sides by lifting up and out Perform the Capacitor Discharge Proce dure described earlier in this section of the manual A WARNING Before continuing with the test procedure perform the capacitor discharge proce dure to avoid electric shock 10 PLUG J73 2 PLUG J30 3 PROTECTION BOARD After you have completed the capacitor discharge procedure for all four switch boards remove the PC board cover Use the 5 16 nut driver Remove plug J73 from the T1 transformer T2 is connected in parallel with T1 Leaving the t
108. NET SERIAL LOOP PROTECTION INTERFACE SHEET 4 rower surety source pon 87 COMMON CONNECTION FRAME CONNECTION FILE G2241 2A1 CC EARTH GROUND CONNECTION UNLESS OTHERWISE SPECIFIED TOLERANCE nes THE LINCOLN ELECTRIC CO POWER WAVE ONRAEDEOMASS QE I CLEVELAND U S A CONTROL SCHEMATIC ONG PLACE DECIMALS 5 002 X ON ALL ANGLES IS 5 OF A DEGREE SCALE NONE pm MATERIAL TOLERANCE TO AGREE 30 DATE 11 25 92 47506 G 2241 4 MATH PUBLSHED STANDARDS WIRE FEEDER TRANSMIT RECEIVE FOR SERIAL LOOP 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 LINCOL POWER WAVE 450 ELECTRICAL DIAGRAMS PC BOARD ASSEMBLY CONTROL 04 11 25 PART DESCRIPTION PART NO DESCRIPTION Return to Section TOC Return to Master TOC X25 X26 X27 X28 X29 X30 X68 X90 X38 X39 21292 5 IC CMOS MCU DSP SS 515128 4 LM224 519650 5 IC CMOS LATCH 3 STATE SS 21293 3 DSP ASSEMBLY SS 21294 1 IC CMOS PLD GENERIC SS 17900 24 QUAD SCHMITT NAND SS 19650 3 1 OF 4 DECO DEMUX SS 19650 6 1 5 4 1 SS 45 46 15104 11 C CMOS EEPROM FLASH X54 M15105 11 CONVERTER D A SS X56 M14513
109. OGA8 9 FH 9 5 D gt gt gt y3wod 2 20258 gt o Ll gt gt 63 SH oui e gt SINALNO tc gt lt auvog 2 51 81 49 E L gt lt ES Be s 2 4 a lt S SASA 51 Eer Q 96 J lt 1 ps eer ser ia tc Azt D u 9 1 5 1 E lt 82 NOWWOD le omes IC cc CI N N A 8 4 SA AA AAA vs e Lu m E m u3MOd NOLLO3 10Ud og 8 5 8 sss 5 8 SS o OK n 0x gt iL A A h A A AK AR AA 55 8 8 M lt lt lt lt 25 fa pU NOLLO3OHd 3T0VLd303 14 91 884 284 901 Je1Se A 0 901 Je1Se A 0 901 J91Se N 01 901 J91Se N 01 DOL uonoes DOL DOL DOL uonoes F 102 NOTES POWER WAVE 450 LINCOLN 5 F 102 901 Je1Se A 0 901 4 1 0 uunjeH 901 J91Se N 01 DOL 01 901 uonoes uumeg DOL uonoes uumeg DOL uonoes uumeg DOL uonoes uumeg
110. Ohmmeter Multimeter 5 16 Nut driver 3 8 Nut driver Short piece of jumper wire Auxiliary Transformer 1 Secondary Circuit Wiring Diagram Figure 44 This procedure takes approximately 25 minutes to perform O10 e 515 9 1 EIS 2 Return to Section Return to Master TOC POWER WAVE 450 LINCOLN Return to Section Return to Master TOC Return to Section TOC Return to Master TOC o HE 2 3 Return to Section Return to Master TOC o 5 120 PROTECTION BD F 120 TROUBLESHOOTING amp REPAIR TRIGGER CIRCUIT AND WIRING HARNESS TEST continued FIGURE F 43 PROTECTION BOARD PLUG HEADER LOCATIONS 1 1471 1 121 1 MER TU eer 16 74 6 611 14 430 431 432 433 434 485 436 43538 439 3 TEST PROCEDURE C With the volt ohmmeter check for continu 1 6 With the 5 16 Remove main input supply power to the machine With the 3 8 nut driver remove the 4
111. P41 pin 9 P41 pin 10 7 41 pin 7 P41 pin 8 8 P41 pin 1 P41 pin 2 POWER WAVE 450 LINCOLN B F 205 F 205 TROUBLESHOOTING amp REPAIR PRE POWERUP SWITCH BOARD TEST PROCEDURE FOR REPLACEMENT OF SWITCH ASSEMBLY G2402 2 continued FIGURE F 81 FET DRIVE SIGNAL Return to Section TOC Return to Master TOC Tye TT TIT I T T t T 0 V olo 5 8 Oo 9 1 0 a gt g 3 20V Div 20uS Div EIE 2 5 SNUBBER SIGNAL TEST 6 Attach the oscilloscope to each of the follow ojo 1 Adjust the grid for a light load ing eight test points Each test point should 2 Turn ON the variable AC supply applied to the ook like the Oscilloecepe ploture In primary circuit See Figure F 76 3 Slowly increase the voltage until the filter A WARNING capacitor voltage is 25VDC See ALL METERS AND OSCILLOSCOPES MUST 4 Adjust the grid load to get 5 amps output from BE ELECTRICALLY ISOLATED Isolated o 8 the Power Wave DO PULL MORE Transformer Ec THAN 7 8 AMPS OUTPUT FROM THE 5 5 POWER WAVE o 8 5 Set the Oscilloscope for 5 Vidiv cle 20 uS div 2 2 POSITIVE PROBE NEGATIVE PROBE 2 R1 12E or 12L 401 R2 402 9E or 9L R3 12F 403 R4 404 9F R5 405 12G or 12M R6 406 9G or 9M R7 12H 407 R8 408 9H Turn the variable AC primary supply to zero Once the filter capacitor voltage drops to zero volts and then turn it OF
112. PRIMARY THE INTERCHANGEABILITY OF A COMPLETE BOARD 0000 0800080 BOTTOM BOTTOM THIS DIAGRAM MAY NOT SHOW THE EXACT COMPONENTS OR CIRCUITRY HAVING A COMMON CODE NUMBER 4 H 6 5 tL 6 10 TO 80 2 D1 THRU 06 OUTPUT DIODES ARE A MATCHED SET D7 THRU 014 OUTPUT DIODES ARE A MATCHED SET A gue 410 419 430 440 441 460 2 015 THRU 020 OUTPUT DIODES A MATCHED SET C1 C2 03 C4 CAPACITORS ARE MATCHED SET 939292099 E 8 PROTECTIO 2 D THESE ITEMS ARE ONLY USED ON 450 MACHINE m J4 RIGHT SIDE WITH A WATER COOLER WATER COOLER ELECTRODE O mE E TOROID DOES NOT APPEAR ON EARLIER MODELS CONNECTOR CAVITY NUMBERING SEQUENCE RIGHT SIDE OF MACHINE ELECTRICAL SYMBOLS PER E1537 8 28 98B TO J60 FOOT AMPTROL REMOTE CONTROL RECEPTACLE TO SWITCH BD 1 TO SWITCH BD 1 177A 176A 175A 1026 TO SWITCH BD 2 TO SWITCH BD 2 1058 lt 7 1 PIEZO 220 BUZZER 5A T 1 PROTECTION BD SQUARE WAVE CIRCUIT 83 84 CONNECTION BREAKER 453 454 455 456 TO SWITCH BD 2 404 SWITCH BD 2 5 t 1 WATER dpi ot 5 Hm 3 4 455
113. PROTECTION BOARD BOARD ASSEMBLY INPUT CONTACTOR POSITIVE THREE PHASE INPUT POWER Return to Section TOC Return to Master TOC LINE SWITCH NEGATIVE Return to Section TOC Return to Master TOC O o 5 5 9 gt 5 5 Return to Section Return to Master TOC GENERAL DESCRIPTION The Power Wave is an inverter type power source that can support most welding procedures It is modeled after a P C Personal Computer There are no specif ic welding characteristics designed into the power portion of the machine All welding characteristics are programmed into the software package CONTROL BOARD INPUT VOLTAGE The Power Wave can be connected for a variety of three phase voltages The initial input power is applied to the Power Wave through a line switch located on the front of the machine The voltage is connected to the Protection Board where it is current limited before being passed on to the input rectifier and reconnect switches The reconnect panel allows the user to switch to low or high voltage and connect the Auxiliary Transformer to the appropriate input voltage The Auxiliary Transformer supplies power to the fan motors and through the Protection Board to the printed cir cuit boards and wire feeder s NOTE Unshaded areas of Block Logic Diagram are the subject of discussion POWER WAVE 450 LINCOLN B
114. Resistor ojeg ohm Boards Test o 313 2B 9B Less than OK None Continue 100 ohms Greater Open Replace 4 Snubber tio than 1K Switch Resistor cuc ohm Boards Test 9B 2B Greater OK None Continue than 1K ohm Less than Shorted Replace 4 Snubber 100 ohms Switch Resistor boards Test NOTE K ohm ohm reading multiplied by 1000 NOTE Always make sure that all four Switch Boards are changed at the same time Never mix an old style different part number Switch Board with a new style new part number O o Fle 5 9 918 43 POWER WAVE 450 LINCOLN amp Return to Section Return to Master TOC Return to Section TOC Return to Master TOC o 2 3 Return to Section Return to Master TOC o O gt o gt E tc F 68 TABLE SWITCH BOARD 2 RESISTANCE TEST TABLE Continued TROUBLESHOOTING amp REPAIR FIELD EFFECT TRANSISTOR SWITCH BOARD TEST continued F 68 Apply Apply Positive Negative Test Test Probe to Probe to Test Repair Next Terminal Terminal Result Conclusion Action Procedure 12B 1B Less than OK None Continue 100 ohms Greater Open Replace 4 Snubber than 1K Switch Resistor ohm Boards Test 1B 12B Greater OK None Continue than 1K ohm Less than Shorted Replace 4 Snubber 100 o
115. Resistor Test 1 Perform the Auxiliary Transformer Test 1 2 Perform the Internal and Auxiliary Supply Voltage Test 1 Replace the Power P C Board 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 POWER WAVE 450 LINCOLN F 9 F 9 TROUBLESHOOTING amp REPAIR TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginning of this manual Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o o 2 3 Return to Section Return to Master TOC o O gt o gt E PROBLEMS SYMPTOMS Circuit breaker 5 amp trips when gun trigger is pulled fans run POSSIBLE AREAS OF MISADJUSTMENT S OUTPUT PROBLEMS 1 Make sure that not more than 5 amps of auxiliary power are being used Remove the wire feeder s con trol cable s from the Power Wave If the symptoms disap pear replace the wire feeder and cables with known good equipment If the problem is solved the wire feeder or con trol cable is faulty RECOMMENDED COURSE OF ACTION 1 The 5 amp circuit breaker may be faulty Test or replace 2 Perform the Trigger Circuit and Wiri
116. SENSING CIR 55 518395 8 REGULATOR ASSEMBLY 183057 15128 15 ON 518104 5 15128 12 S15128 6 15205 13 515128 7 5151285 1 1 R185 1 1 1 1 1 le IC VOLT REG 5V REG ASB C VOLT REG C VOLT REG 4 CAPACITORS MFD VOLTS RESISTORS OHMS FI THE LINCOLN ELECTRIC CO re INVERTER WELDERS pea CLEVELAND U S A POWER P C BOARD ASSEMBLY SCALE FULL SUBJECT ule a m ELA SUP S D G 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 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 amp ine LINCOLN 5 machine POWER WAVE 450 ou ELECTRICAL DIAGRAMS cu SCHEMATIC PROTECTION PRINTED CIRCUIT BOARD AUXILIARY WIRE FEEDER 1 WIRE FEEDER 2 POWER BD DISPLAY BD AMPTROL IN AN AS AN AN AS INANIS AN SAN 10 7777 quiste FROM CURRENT TRANSF
117. SV 4 8 4228 E 5 8 9 4 gt 48 x x zz a 23 88 1 91 gt 826 gt 1 gt P82 32 B L gt TAR gt t gt 117A EIE 2 E a TON WF2 RECEPTACLE ale SYSTEM GROUND PER 23 gt gg 5 NATIONAL ELECTRICAL CODE 8 8 4 D 27 SE SWITCH BOARD 3 x x 2 55 30 913551 A cc 6 gt 76 4 LI 215 MAIN TRANSFORMER LEFT SIDE E E gt i 7 i da 13888 8 CE LLLI u 5713 222252 7 SERIAL LOOP COMMUNICATION Ga pomu a 3 2 5 FOR WIRE FEEDERS als 5 gt 115VAC FROM 6183 Mine iain p 137 55855 E o k 3T E WF1 RECEPTACLE 11 g 328 1284 gt _ OVAC FROM 1433 8 i 555558565 UP 428 10434 SOFT START H 326 t 1 5 LCD DISPLAY Es z m E 80 se id d 1323 trad P M E Mad lt 1 96 1 i 35 25 55585 55 LLLLLI 2 4 e 2 0 1028 5 2VACFROM i t 88333358 hat P4 E 105 L3144 24VAC WHEN Wet i i 108 88 i Es TRIG
118. See Figure F 5 Connect the needle nose end of the other jumper lead to terminal 12 Terminals 9 and 12 are indicated by the Discharge label Leave the resis tor connected for 10 seconds DO NOT TOUCH TERMINALS RESISTORS OR ANY INTERNAL MACHINE COMPO NENTS DURING THIS PROCEDURE POWER WAVE 450 LINCOLN amp Return to Section Return to Master TOC Return to Section TOC Return to Master TOC o 2 3 Return to Section Return to Master TOC o O gt o gt E tc F 26 TROUBLESHOOTING amp REPAIR CAPACITOR DISCHARGE PROCEDURE continued FIGURE F 4 RESISTOR WITH LEADS CONNECTED 11 Check the voltage across terminals 9 and 12 with the DC voltmeter Terminal 9 has positive polarity and terminal 12 has negative polarity Voltage should be zero If any voltage remains repeat this capaci tor discharge procedure 12 Repeat discharge procedure steps 9 10 and 11 for each of the other three switch boards of the FET or IGBT switch board assembly POWER WAVE 450 LINCOLN amp F 26 Return to Section Return to Master TOC Return to Section TOC Return to Master TOC o 2 3 Return to Section Return to Master TOC o O gt o gt E 27
119. Switch Board Test 1 For Switch Board Marked CAP 1 on the Switch Board Assem bly Connection Decal Figure F 23 A Disconnect all wiring harness leads from switch board 1 Fold the leads up so that they do not interfere with the exposed PC board terminals B With the volt ohmmeter measure the resis tance between terminals according to Table F 2 See Figure F 23 for the locations of the terminals If any test fails replace all four switch boards Refer to the FET Module Assembly Removal and Re placement procedure in this section of the manual If none of the tests fails reconnect the wiring harness leads to switch board 1 and perform switch board test 2 Switch Board Test 2 For Switch Board Marked CAP 2 on the Switch Board Assem bly Connection Decal Figure F 23 A Disconnect all wiring harness leads from switch board 2 Fold the leads up so that they do not interfere with the exposed PC board terminals B With the volt ohmmeter measure the resis tance between terminals according to Table F 3 If any test fails replace all four switch boards Refer to the FET Module Assembly Removal and Replacement pro cedure in this section of the manual If none of the tests fails reconnect the wiring harness leads to switch board 2 and perform switch board test 3 Switch Board Test 3 For Switch Board Marked CAP 3 on the Switch Board Assem bly Connection Decal Figure F 23 A Disconn
120. TOC Return to Section TOC Return to Master TOC o 2 3 Return to Section Return to Master TOC o 5 WELD FROM MEMORY DUAL PROCEDURE OVERLAY The Weld From Memory Dual Procedure Overlay lets an operator recall and use dual welding procedures stored in memory The overlay must be used with a separate dual procedure switch or a gun that has a two position trigger The switch or trigger selects which procedure will be active See Figure B 6 FIGURE B 6 WELD FROM MEMORY DUAL PROCEDURE OVERLAY A PANEL 3 WELD FROM MEMORY DUAL wes mem2 mms PRocEDURE A mem4 O aia C 0 ILECTRIC COMPANY CLEVE BEER POWER WAVE 450 PROCEDURE A OHIO USA e THERMAL PROCEDURE B 1 LCD DISPLAY WINDOW 2 MEMORY RECALL KEYS 3 PROGRAM LIST 1 LCD DISPLAY WINDOW Power up the machine with this overlay in place When the Power Wave is turned on the following message appears in the display window for a few seconds LINCOLN ELECTRIC Version X X This display is followed by OVERLAY ID NUMBER 3 This message is then replaced by the following message SELECT A MEMORY LOCATION 2 MEMORY RECALL KEYS The following four memory pairs ar
121. The control board may be faulty Replace and perform voltage calibration and current calibration The arc is too hot and cannot be adjusted Perform the full voltage cali bration Check plugs J60 J62 and J20 for loose or faulty connections See Wiring Diagram The snubber board may be faulty Replace and perform full voltage calibration The control board may be faulty Replace and perform voltage calibration and current calibration CAUTION If for any reason you do not understand the test procedures or are unable to perform the test repairs safely tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed Call 1 800 833 9353 POWER WAVE 450 LINCOLN jui TROUBLESHOOTING amp REPAIR id TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginning of this manual PROBLEMS POSSIBLE AREAS OF RECOMMENDED SYMPTOMS MISADJUSTMENT S COURSE OF ACTION WELDING PROBLEMS Return to Section TOC Return to Master TOC Machine often noodle welds with The machine may be trying to If problem occurs all the time a particular procedure deliver too much power When change the control board the average output current exceeds a maximum limit the peak current is drastically cut back Lower the welding para meter settings and or increase the stickout length to eliminate this problem Power Wave 450 When the
122. WAVE 450 Return to Section TOC Return to Master TOC Return to Section Return to Master TOC Return to Section TOC Return to Master TOC Q BS 5 2 Return to Section Return to Master TOC 2 0 8 5 ep ELECTRICAL DIAGRAMS G 15 PC BOARD ASSEMBLY PROTECTION L 961 ITEM PART NO IDENTIFICATION C11 C20 C21 C22 C23 C26 11 16668 5 022 50 221 22 33 35 516668 9 50 100 34 36 516668 11 1 50 CRI CR2 515122 4 E ELAY 01 02 03 04 028 12705 34 13 2199 1 1 4936 1 4004 Rm o o o o o gt LR po vom o PROTECTION 035 2 211 0212 213 0214 0215 2 112702 29 1 112702 27 2 112702 40 1 4744 1N4740 1N4735 520351 16 520351 14 520351 6 520351 4 HEADER HEADER HEADER HEADER 31 J34 32 J33 J35 36 J37 J38 J39 1 12 712218 9 9mH OCIS3 OCIA OCI5 2 15000 10 1 515000 11 ISOLATOR 3043 06 09 011 012 014 017 015 016 112704 68 2 712704 73 204401 PKG MOSFET R2 R3 R4 R5 5 519400 1500 519400 1001 519400 3321 150 1 4W 1K 1 4W 3 32K 1 4W R155 R9 R13 R10 R12 R90 2 519400 1000 3 519400 5622 12 194
123. WAVE 450 LINCOLN Return to Section Return to Master TOC Return to Section TOC Return to Master TOC o 2 3 Return to Section Return to Master TOC o p 5 56 TROUBLESHOOTING amp REPAIR PIEZO ELECTRIC ALARM BUZZER TEST FIGURE F 17 ALARM BUZZER LOCATION TEST PROCEDURE 1 6 Remove main input supply power to the machine With the 3 8 nut driver remove the 4 screws that hold the handle to the machine Remove the rubber gasket cover seal from the lift bail With the 5 16 nut driver remove the sheet metal screws from the case top With the 5 16 nut driver remove the screws holding the right and left case sides Remove the case sides by lifting up and out the Capacitor Discharge Perform Procedure described earlier in this section of the manual e WARNING Before continuing with the test procedure perform the capacitor discharge proce dure to avoid electric shock 11 12 13 Iny LEADS 300 301 TO PLUG J15 ON DISPLAY BOARD 2 PIEZO ELECTRIC ALARM BUZZER After you have completed the capacitor discharge procedure for all four switch boards locate and remove plug J15 from the display board See Figure F 17 for location Using lead 300 as positive and lead
124. XX 819650 7 037 038 039 040 041 042 a 521291 5 55 55 043 046 01 14 37 15105 4 IC CMOS CONVERTER A D 59 pu pu ee ques 2 X15 M15104 6 MPU SS D15 D16 D24 D47 o X16 X20 X55 517900 25 5 3 5 55 1N4936 olo X21 519650 1 HEX INVERTER SS 2 T12702 40 1 4735 24 14428 2 CRYSTAL MODULE 25 0MHZ 2 r12702 45 1 4746 4 12702 29 1 4744 ala 2 520351 8 HEADER HEADER HEADER 42 43 ANGLE HEADER 2 HEADER 5 515000 10 ISOLATOR 12704 69 214403 NPN TRANSISTOR 17 T12704 68 244401 11270473 T12704 47 300 VOLT PNP 1 5 112704 73 PKG MOSFET SS 19400 1002 10K 1 4W R3 R7 R68 R70 R142 R154 2 519400 4751 4 75 R161 R214 R216 R302 R310 R314 R336 R337 R338 R339 Q R341 R342 R343 R344 R345 5 21K 1 4W SEG so 22 22 ee 714231 2 1 2W 519 X61 R11 R99 R141 R148 R175 10 519400 1003 100K 1 4W s R209 R223 R263 R266 R277 R15 R36 R38 R39 R40 R64 50 519400 1001 fx a R67 R69 R71 R73 R89 R90 R91 R92 R93 R94 R97 R108 p fm cx 91 515128 10 VOLTAGE REF X93 515128 21 TC COMPARATOR HI SPD 5 V Q2 Q3 Q4 Q5 Q6 Q7 Q8 Q9 Q10 Q13 Q16 Q19 Q20 Q23 Q28 Q33 Q34 ay ays oj gt B 2 1 16665 5 8 0 MHZ 5 E 2 o 4
125. are now easily accessi ble Refer to the Removal and Replacement Procedure in this section of the module Replacement of the FET Module Assembly 27 28 29 Carefully set the assembly into the bottom of the machine The terminal label should face the front toward the main trans former Connect all leads to their appropriate ter minals on the assembly Use the Wiring Diagram for reference Carefully position the subframe on top of the FET module assembly Slide the assembly into place so that the retainer clips snap into their slots top and bottom Fit the locking bar into place on top of the subframe to secure the FET module assembly POWER WAVE 450 LINCOLN F 194 Return to Section Return to Master TOC Return to Section TOC O10 515 9 1 gt EIS 2 Return to Section Return to Master TOC Return to Master TOC F 195 30 31 32 33 34 TROUBLESHOOTING amp REPAIR FET MODULE REMOVAL AND REPLACEMENT continued Install the water cooler assembly Refer to the Water Cooler Removal and Replace in this section of the module With the 7 16 wrench connect the heavy current carrying flat copper strap running from the shunt amplifier to the output rec tifier bridge With a 5 16 wrench install the two sheet metal screws holding the subframe bottom support section Connect the green ground lead on the lef
126. be faulty Replace the protection board and perform the Dynamic Capacitor Balance Test again If the frequency is still incorrect the con trol board may be faulty Replace the con trol board Install the machine case sides and top Install the handle and the lift bail rubber gasket POWER WAVE 450 LINCOLN amp F 95 F 96 quvog 2 b ezr tc 255 o 1N3IBHnSV3W _ 320 AON3QO3UJ 626 2 0847048 18 Guvog a HOLIMS HOLIMS HOLIMS HOLIMS 6m vy lt gt eer Y Yzer 2459 143 4 10140 tc 29 NOLLO310Ud vof eer OEN OEF OEF OEP 16 Ler Ler 09 1 AERAN 1 A A k A 1 1 1 1 i o ASLL 2 60 al M6 ov Q i VIZE Lov p gt 40 Intz a n 3 T 2 DLE lt gt
127. cases the operator may want to change the preprogrammed voltages for example to compensate for cable and fixture voltage drops The preset volt ages can be adjusted on the wire feeder s Voltage dis play When a change is made to the voltage at one wire feed speed this change is applied to all other wire feed speed settings For example if the operator turns up the voltage by 10 percent the machine auto matically increases the preset voltages at all the other wire feed speeds by 10 percent In the GMAW FCAW process the display shows the Procedure Description WFS and Preset Voltage The preset voltage which was programmed at the factory may be changed on the wire feeder voltage display Note that if you change the default preset voltage up or down a respective A or V sign will be displayed after the preset value When the gun trigger is pulled note that the display changes to show WFS Actual Arc Voltage and Actual Arc Current See Table 5 display summary PULSE PROCEDURES In these procedures the actual voltage greatly depends on the waveform used The peak currents background currents rise times fall times and pulse times all affect the actual voltage The actual voltage for a given wire feed speed is not directly predictable unless the waveform is known In this case it is not practical to preset an actual voltage for the procedure Instead an arc length adjustment is provided The machine
128. factory trained personnel Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty For your safety and to avoid elec trical shock please observe all safety notes and precautions detailed throughout this manual 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 trou bleshooting assistance before you proceed Call 1 800 833 9353 WELD DESCRIPTION The following procedure will determine if the four switch boards and their related circuitry are functioning properly This is a resistance test not a voltage test The machine does not have to be powered up to perform the test which is both safer for the technician and less likely to result in accidental damage to the switch boards Return to Section TOC Return to Master TOC MATERIALS NEEDED Analog Volt Ohmmeter Multimeter 5 16 Nut driver 3 8 Nut driver Machine Wiring Diagram in the Electrical Diagrams section of this manual O10 e 515 9 1 EIS 2 Er This procedure takes approximately 60 minutes to perform Return to Section TOC Return to Master TOC POWER WAVE 450 LINCOLN Return to Section Return to Master TOC Return to Section TOC Return to Master TOC
129. gt gt J16 Q21 12 REFERENCE CIRCUIT lt s e 10V 100K TO REMOTE 10K POTENTIOMETERS c82 13 50V src gt WATER COOLER ELECTRICAL DIAGRAMS 1 0011 4 OPB706 SENSE m m y INFRAS lt mn OPTEK OPB706 E SENSE 7 J 0014 iq 0015 OPTEK 706 OPTEK OPB706 B B p SENSE INFRA2 44 4 24VAC ISOLATED TRIGGER CIRCUIT INFRA6 4 00110 OPB706 1 00112 706 pe SENSE Q24 600 40V pe SENSE INFRAB 4 4 103 681K 22 gt 006 OPTEK 706 2 Ue SENSE 027 600mA G 10 1 K OPTEK OPB706 2 NC ANODE vB 7 CATH tleh f GND 0013 NOTES SINCE COMPONENTS OR CIRCUITRY ON A PRINTED CIRCUIT BOARD MAY CHANGE WITHOUT AFFECTING THE INTERCHANGEABILITY OF A COMPLETE BOARD THIS DIAGRAM MAY NOT SHOW THE EXACT COMPONENTS OR CIRCUITRY OF CONTROLS HAVING A COMMON CODE NUM
130. gun When a water cooler is used the water cooler must be enabled by using the Setup Overlay The water cooler contains a flow switch which is closed when there is adequate coolant circulating in the system If this flow rate drops below the switch manufacturer s set point the flow switch opens A cou ple of seconds after the flow switch opens the water cooler shuts down If the water cooler is enabled and the flow switch opens the machine beeps loudly indi cating that there is a problem with the water cooler operation RECOMMENDED COOLANTS 1 The following coolants have been determined to be compatible with the wetted materials used in the G3503 cooler assembly Distilled or deionized water Potable tap water e Sediment free mixtures containing a maxi mum of 50 ethylene glycol or automotive grade antifreeze and the balance of distilled or deionized water 2 Ethylene glycol mixtures should be selected if the cooler may be exposed to a temperature below the freezing point of water 3 Consult gun torch and wire feeder manuals for coolant recommendations and select one from the above list 4 Pure solutions and mixtures of or materials i e towels wetted with ethylene glycol are toxic to humans and animals They must not be haphaz ardly discarded especially by pouring liquids down the drain Contact the local EPA office for responsi ble disposal methods or for recycling information 5 The cooler
131. lead 21 lead of the wire feeder The SETUP Overlay allows you to select between which two places arc voltage will be sensed Once the selection is made it is not necessary to reconfirm the selection every time a new overlay is used or a wire feeder is replaced with another one The selection will remain until it is changed with the SETUP Overlay When welding with a stick procedure the arc volt age is automatically measured between the Power Wave s output studs Select arc voltage sensing polarity first POLARITY KEY A Positive Voltage Sensing Polarity In most welding applications the electrode cable is connected to the output terminal and the work cable is connected to the output terminal of the power source This is the positive voltage sensing polarity illustrated by When the Power Wave and the wire feeder s are connected in this manner the arc voltage can be measured in one of four ways These four ways are shown in Table B 1 Table B 1 Positive Voltage Sensing Options Positive Voltage Reference Negative Voltage Reference Output Terminal Output Terminal Output Terminal Work Sense 21 Lead Electrode Sense 67 Lead Output Terminal Electrode Sense 67 Lead Work Sense 21 Lead Consult the factory before using this option Use the ELECTRODE SENSE LEAD KEY to select either the output terminal or the electrode sense 67 lead for the positive vol
132. much time is devoted to conduction in the positive and negative por tions 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 FET is turned on and off for different dura tions during a cycle The top drawing above shows the minimum output signal possible over a 50 microsecond time period The positive portion of the signal represents one FET group conducting for 1 microsec ond The negative portion is the other FET group The dwell time off time is 48 micro seconds both FET groups off Since only 2 microseconds of the 50 microsecond time period is devoted to conducting the output power is minimized MAXIMUM OUTPUT By holding the gate signals on for 20 micro seconds each and allowing only 10 microsec onds 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 under the curve the more power is present FET group consists of the sets of FET modules grouped onto one switch board POWER WAVE 450 LINCOLN B Section F 1 Section F 1 TABLE OF CONTENTS TROUBLESHOOTING amp REPAIR SECTION E Troubleshooting amp Repair
133. nuts to the motor mounting bolts Carefully slide the fan blade all the way onto the motor shaft The side of the hub with the metal clip goes toward the motor Install the clip so that it grips the rounded side of the D shaped shaft not the flat Swing the back panel back down being careful not to damage the RS232 connector or the wire feeder receptacles Install the lead to the rear positive output termi nal Install the case back lower sides and the lower rear panel with the 5 16 screws Attach the fan motor leads to the terminal strip and replace the tie wraps cut during removal so that the motor leads are held away from the fan blades Install the machine case sides and top Install the handle and the lift bail rubber gasket POWER WAVE 450 LINCOLN amp F 169 170 NOTES POWER WAVE 450 LINCOLN 5 F 170 901 Je1Se A 0 901 4 1 0 uunjeH 901 J91Se N 01 DOL 01 901 uonoes uumeg DOL uonoes uumeg DOL uonoes uumeg DOL uonoes uumeg Return to Section Return to Master TOC Return to Section TOC Return to Master TOC o 2 3 Return to Section Return to Master TOC o O gt o gt E tc F 171 F 171 TROUBLESHOOTING amp REPAIR INPUT RECTIFIER REMOVAL AND REPLACEMENT WARNING Service and repair should be pe
134. obtain and record the calibration number for six different voltage sensing points These points are the following Polarity 67A Polarity 67B Polarity 21A Polarity 21B Polarity Polarity 6 Install the new replacement display board 7 With the L9660 255 overlay installed apply power to the machine Press the Voltage Calibration function 32 Enter the re corded calibration numbers for each of the six voltage sensing points The calibration numbers are entered by selecting the prop er sensing point lead pressing the Enter Key 133 and obtaining the display that reads ADJUST TO 30V CALIBRATION XX The calibration number is changed using the up down Arrow Keys 100 101 Press the Enter Key when the desired number is dis played 8 Repeat the process for all six sensing points leads 9 Perform the Sensor Calibration Test POWER WAVE 450 LINCOLN amp F 144 F 144 TROUBLESHOOTING amp REPAIR e 9 QUICK VOLTAGE CALIBRATION continued 5 5 FIGURE 54 TEST AND CALIBRATION OVERLAY iz ur E 918 LINCOLN G HE _ IWERIEC POWER WAVE J J CJ LJ ir D 22 PROCEDURE 5 Repeat the process by pressing the Voltage Return to Section Return to Master TOC Return to Section TOC O10 e 515 9 1 EIS 2 Er Return to Section TOC Return to Master TOC Return to Master TOC
135. overlay frame and place it in the storage compartment 4 Slide the new overlay into the overlay frame Align the overlay with the two tracks on the sides of the frame Be sure the overlay is seated in the bottom lip of the frame and on the top two locating pins Close the access door securely POWER WAVE 450 LINCOLN B Return to Section Return to Master TOC Return to Section TOC Return to Master TOC o 2 3 Return to Section Return to Master TOC o p 5 OPERATION OVERLAY TYPES Four types of overlays can be used with the Power Wave 1 Process Overlays These overlays used to create save and recall specific welding proce dures by selecting and adjusting the various weld ing settings that have been programmed into the Power Wave at the factory Weld From Memory Overlays These overlays also called Shop Overlays provide a simple way for operators to recall and use any of the welding procedures that have been stored in the memory of the Power Wave Setup Overlays These overlays provide specific machine setup information such as operating lim its for the welding procedures stored in memory Special Purpose Overlays These are custom overlays for specific customer applications Detailed information on how to use currently available Power Wave overlays follows
136. performed by only Lincoln Electric factory trained personnel Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty For your safety and to avoid electri cal shock please observe all safety notes and precautions detailed throughout this manual 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 TEST DESCRIPTION This test will determine if there are any short circuits or other problems in the circuit feeding the primary windings of the auxiliary transformers which would cause the fuse F1 on the recon nect panel to blow Return to Section TOC Return to Master TOC MATERIALS NEEDED Volt Ohmmeter Multimeter 5 16 Nut driver 3 8 Nut driver Input and Auxiliary Circuit Wiring Diagram Figure F 10 Machine Wiring Diagram in the Electrical Diagrams section of this manual Protection PC Board Schematic in the Electrical Diagrams section of this manual o O gt o gt E tc This procedure takes approximately 20 minutes to perform 2 3 Return to Section Return to Master TOC POWER WAVE 450
137. place Slide the cover forward and lift up to remove it POWER WAVE 450 LINCOLN amp F 176 F 177 F 177 TROUBLESHOOTING amp REPAIR 9 9 PRINTED CIRCUIT BOARD REMOVAL AND REPLACEMENT S5 CONTROL BOARD POWER BOARD AND PROTECTION BOARD continued 8 2 10 When reinstalling the PC board make cer A CAUTION tain the tabs at the bottom of the board fit 5 into the slots on the compartment floor tio Be sure to follow the recommended static free When the board is properly seated the cm methods for handling printed circuit boards retainer clips will snap into the locked Failure to do so can result in permanent dam position age rois equipment 11 Install the molex plugs removed earlier Be sure to fit the each plug into its respec 8 Remove the molex plugs from the PC board the Hoard you are removing 12 Perform appropriate calibration procedure NOTE The plugs are numbered in order from por Towel int Figure RET left to right 13 Install the PC board cover tighten the 9 Depress the two PC board retainer clips two screws with the 5 16 nut driver located on the left and right sides of the 14 Install the machine case sides and top board Lift the board by the clips to remove 45 Install the handle and the lift bail rubber x gasket o 2 5 Return to Master FIGURE F 67 PC BOARD REPLACEMENT CALIBRATION REQUIREMENTS
138. possibilities that may contribute to the machine symptom Perform these tests checks in the order listed In general these tests can be con ducted without removing the case wrap around cover Step 3 PERFORM COMPONENT TESTS The last column labeled Recommended Course of Action lists the most likely 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 elec trical wiring diagrams and schematics Refer to the Electrical Diagrams Section Table of Contents to locate the appropriate diagram A 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 POWER WAVE 450 LINCOLN B F 2 F 3 F 3 TROUBLESHOOTING amp REPAIR PC BOARD TROUBLESH
139. processes The wave control adjusts the inductance Inductance is inversely proportional to pinch Increasing the wave control setting decreases the inductance which results in the arc getting colder and pinched tighter Decreasing the wave control setting increases the inductance which results in the arc getting wider In Stick processes The wave control adjusts the arc force Increasing the wave control setting increases the arc force making the arc more harsh but less likely to stick Decreasing the wave control setting decreases the arc force mak ing the arc softer and smoother PULSE WELDING Some people have trouble getting used to the behav ior of the pulsing arc The parameters programmed into the Power Wave have been thoroughly tested for their ability to deliver a sound weld with good appear ance There are however a few things to keep in mind when pulse welding Spatter levels are often very low with the pulse welding process Pulsing is often used to eliminate cleaning operations necessary when using other weld ing processes Fume levels are sometimes lower with the pulsing process Whether or not you will get lower fume lev els depends on the pulsing programs used Certain waveform characteristics are necessary to get low fume levels Unfortunately low fume procedures are harder to weld with than procedures designed to opti mize the welding process The pulsing process is not slower than other proces
140. recommended to reduce the size of the gun and improve parts life The Power Wave comes with a standard internal water cooler However an external cooler may also be used TABLE C 1 RECOMMENDED GUNS FOR USE WITH POWER WAVE 450 Gun Application Cooling Product No MAGNUM 400 GMAW Gas K471 2 MAGNUM 550 GMAW Gas K598 WATER COOLER USAGE The Power Wave is equipped with an optional internal water cooler We recommend using the water cooler when welding above 300 amps with argon blends on a regular basis The gun heating from pulsing above 300 amps average current is often excessive and leads to reduced consumable life reduced gun life and operator discomfort Water cooling greatly increases the durability of the gun and parts at high current Use of the Synergic 7 wire feeder requires appropriate input cable assembly wire stand and drive roll kit Refer to Synergic 7 Operators Manual for available options POWER WAVE 450 LINCOLN B Return to Section Return to Master TOC Return to Section TOC O o e 5 5 0 9 gt 5 2 Return to Section Return to Master TOC Return to Master TOC C 3 C 3 ACCESSORIES There are two water connections on the rear of the Power Wave See Figure 1 the water lines between these connectors and those on the wire feed er The water is fed through the feeder into the
141. rubber To install the water cooler slide the assembly into the machine base Make sure the cooler fits under the retaining clips Connect the water lines to the back panel and connect the plastic strain reliev ers where they hold the water lines to the subframe Connect plugs 3 and 4 behind the water cooler assembly Attach the circuit breaker Use the 9 16 open end wrench Install the two 5 16 sheet metal screws that hold the lower case back panel Install the two 3 8 water cooler assembly mounting screws Connect the water cooler lines to the back panel using the 3 4 and 11 16 wrenches Set the tabs of the water cooler access door in place and secure the door with the two 5 16 screws Install the machine case sides and top gasket POWER WAVE 450 LINCOLN F 159 160 NOTES POWER WAVE 450 LINCOLN 5 F 160 901 Je1Se A 0 uunjeHd 901 4 1 0 901 J91Se N 01 DOL 01 901 uonoes uumeg DOL uonoes uumeg DOL uonoes uumeg DOL uonoes uumeg Return to Section Return to Master TOC Return to Section TOC O10 e 515 9 1 EIS 2 Return to Section Return to Master TOC Return to Master TOC F 161 F 161 TROUBLESHOOTING amp REPAIR WATER COOLER DISASSEMBLY WARNING Service and repair should be performed by only Lincoln Electric factory train
142. switch SW1 to the OFF position To use the machine place the appropriate overlay in position and turn power switch SW1 to the ON position NOTE Turn power switch SW1 to the OFF position and get the overlay that was not recognized by the power wave Replace the TEST overlay with this overlay and turn the machine ON The machine should recognize the overlay now If it does not the overlay is faulty POWER WAVE 450 LINCOLN amp F 142 143 143 TROUBLESHOOTING amp REPAIR QUICK VOLTAGE CALIBRATION 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 elec trical 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 trou bleshooting assistance before you proceed Call 1 800 833 9353 WELD PROCEDURE DESCRIPTION This procedure is a quick way of calibrating the voltage sensing points leads provided that the existing display board is capable of displaying the calibration numbers that are stored in the display board Return to Section TOC Retu
143. terre le chassis du poste conformement au code de l lectricit et aux recommendations du fabricant Le dispositif de montage ou la piece souder doit tre branch une bonne mise la terre Autant que possible l installation et l entretien du poste seront effectu s par un lectricien qualifi Avant de faires des travaux l interieur de poste la debranch er l interrupteur la boite de fusibles Garder tous les couvercles et dispositifs de s ret leur place Mar 93 RETURN MAIN INDEX MASTER TABLE OF CONTENTS FOR ALL SECTIONS Page Safely 25 CDU UL LL i iv Installation eiit er eR Section A X H Section B 5 E Section C Theory of Operation Section E Troubleshooting and Section F How To Use Troubleshooting GUIGO nns F 2 PC Board Troubleshooting Procedures and F 3 Troubleshooting 4244 4 100800 F 5 Test F 27 Removal and Replacement Procedures
144. the Power Wave machine from service input power Do not remove the pump relief valves 3 4 in acorn hex nut or attempt to adjust the relief valve setting 2 Remove the G3503 cooler from the Power Wave machine whenever replacing major cooler components i e pump motor heat exchanger etc replacing hoses and electrical harnesses that are kinked or damaged cut abraded deterio rated or swollen etc investigating suspect coolant leakage 3 Pump replacement a Drain the reservoir of coolant and dispose of it an environmentally responsible manner see Recommended Coolants Remove fan shroud Place absorbent towels underneath pump head and wherever coolant system is opened Carefully pull pump inlet hose and its elbow from reservoir bottom Loosen pump outlet hose clamp at QD then carefully remove from fitting Disconnect v band clamp from motor and remove pump Do not drop or lose drive coupling between pump and motor Do not discard old pump Remove both fit tings Keep v clamp Seal old pump in a waterproof bag Package into protective con tainer and Return to nearest Lincoln Electric FSS center oc POWER WAVE 450 LINCOLN B Return to Section Return to Master TOC Return to Section TOC O10 e 515 9 16 gt EIS 2 Return to Section Return to Master TOC Return to Master TOC
145. the equipment in accordance with the U S National Electrical Code and the manufacturer s recommendations Return to Master TOC Return to Master TOC o 5 8 5 Return to Master SAFETY i PR CAUTIONS DE 0 6 Eloigner les mat riaux inflammables ou les recouvrir afin de Pour votre propre protection lire et observer toutes les instructions et les pr cautions de s ret specifiques qui parraissent dans manuel aussi bien que les pr cautions de s ret g n rales suiv antes Sdret Pour Soudage A L Arc 1 Protegez vous contre la secousse lectrique 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 pa
146. the subframe With the Phillips head screw driver remove the screw that holds the piezo electric alarm buzzer in place Cut the cable tie that holds the wire 17 18 19 20 1 LIFT BAIL 2 LIFT BAIL BAFFLE 3 SUBFRAME STAND With the 3 8 wrench remove the six resistors that are attached to the top of the subframe four on the top right two on the top left Note the physical placement and wiring for reassembly labeling is recom mended Also loosen the bottom resistors closest to the FET module assembly This will allow the capacitors to clear the resis tors when the FET module assembly slides forward for removal With the 5 16 nut driver remove the sheet metal screw holding the ground leads to the right rear of the subframe On the left side unclip the cable tie holding the leads Let the back of the subframe swing out carefully the harness will sup port it With the 5 16 wrench remove the two sheet metal screws holding the subframe bottom support section Note the green ground lead on the left side be sure to reconnect it during reassembly With the 7 16 wrench disconnect the heavy current carrying flat copper strap running from the shunt amplifier to the output rectifier bridge POWER WAVE 450 LINCOLN F 193 Return to Section Return to Master TOC Return to Section TOC O o e 5 9 0 gt 5 2
147. this section of the manual Be sure to follow the recommended static free methods for handling printed circuit boards Failure to do so can result in permanent dam age to the equipment 8 Remove the molex plugs from the PC boards except the display board POWER WAVE 450 LINCOLN amp Return to Section TOC Return to Master TOC Return to Section Return to Master TOC Return to Section TOC O10 e 515 9 1 EIS 2 Return to Section Return to Master TOC Return to Master TOC F 193 10 11 12 13 14 15 16 TROUBLESHOOTING amp REPAIR FET MODULE REMOVAL AND REPLACEMENT continued FIGURE F 74 LIFT BAFFLE BAIL REMOVAL With the wire cutters cut all necessary cable ties Disconnect the leads to the output rectifi er bridge Cut all necessary cable ties Disconnect two plugs from the snubber board Disconnect the output cable strap and pull it through and free from the lift bail baffle eyelet hole Cut any necessary cable ties With the 3 8 nut driver remove the two screws that hold the lift bail baffle See Figure F 74 Remove the baffle With the 1 2 socket wrench remove the four bolts two on each side of the machine from the lift bail See Figure F 74 Slide the lift bail up and free of the machine On the right side of the machine cut any necessary cable ties to free the wiring har ness from
148. to Section Return to Master TOC Return to Section TOC Return to Master TOC o 2 3 Return to Section Return to Master TOC o p 5 F 82 TROUBLESHOOTING amp REPAIR RECONNECT SWITCH TEST 1 FIGURE 26 RECONNECT SWITCH 1 RECONNECT PANEL 2 RECONNECT SWITCH 3 LEAD CONNECTIONS 7 TEST PROCEDURE 6 With the 5 16 Remove main input supply power to the machine With the 3 8 nut driver remove the 4 screws that hold the handle to the machine Remove the rubber gasket cover seal from the lift bail With the 5 16 nut driver remove the sheet metal screws from the case top nut driver remove the screws holding the right and left case sides Remove the case sides by lifting up and out Perform the Capacitor Discharge Procedure described earlier in this section of the manual WARNING Before continuing with the test procedure perform the capacitor discharge proce dure to avoid electric shock 7T Test the reconnect switch for short circuits according to the voltage for which the machine is wired For 230 VAC A C Check that the following leads are con nected together
149. to the scratched off areas only If a large area of the bar code is scratched off the machine either will not recognize the overlay or will mistake the overlay for another one Inspect gun and cables for good condition POWER WAVE 450 LINCOLN B D 6 o S gt 2 z o T o lt gt gt lt Z 9 Z gz lt 2 I cr 2 o lt E 5 g 36 gt lt O gf E d e 20r 50 2 205 IO ZZ OLeWZ gt lt 552 Sube ars lt 5 5 gt 6 a amp zazroorc a 901 Je1Se A 0 901 4 1 0 901 J91Se N 01 901 J91Se N 01 DOL uonoes DOL uonoes DOL DOL uonoes Section E 1 Section E 1 o TABLE OF CONTENTS E THEORY OF OPERATION gt Theory eterne rt Section E General Description 2 5 Voltage esiste i ado npa rS E Draco dup E 2 Precharge i er EAD E 3 72 21 4
150. to the 200 208V terminal To operate at 220 230 VAC 1 Open the reconnect input access door 2 Move the input voltage switch to voltage 220 230V position 3 Move A lead to the 220 230V terminal To operate at 380 415 VAC 1 Open the reconnect input access door 2 Move the input voltage switch to Voltage 380 415V position 3 Move A lead to the 380 415 VAC terminal To operate at 440 460 VAC No setup required The machine is factory connected to operate at 440 volts To verify do the following 1 Open the reconnect input access door 2 Check that the input voltage switch is set to Voltage 440 460V position 3 Check that the A lead is at the 440 460V 4 WATER COOLING FITTINGS ON BACK PANEL 5 WIRE FEEDER CONNECTIONS ON BACK PANEL 6 ELECTRODE TERMINAL OUTPUT CONNECTIONS See Figure A 3 for the location of the work terminal electrode terminal remote control amphenol recepta cle water cooler fittings and wire feeder connections WORK AND ELECTRODE CABLE CONNECTIONS SIZE Use the largest welding electrode and ground cables possible at least 70mm 82 0 copper wire even if the output current does not require it When pulsing the pulse current often exceeds 650 amps with the Power Wave 450 Voltage drops can become exces sive if undersized welding cables are used ROUTING To avoid interference problems with
151. unable to perform the test repairs safely tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed Call 1 800 833 9353 POWER WAVE 450 LINCOLN Return to Section Return to Master TOC Return to Section TOC Return to Master TOC o 2 3 Return to Section Return to Master TOC o O P o 9 gt E F 20 F 20 TROUBLESHOOTING amp REPAIR TROUBLESHOOTING GUIDE PROBLEMS SYMPTOMS For no apparent reason the weld characteristics have changed Observe Safety Guidelines detailed in the beginning of this manual POSSIBLE AREAS OF MISADJUSTMENT S WELDING PROBLEMS Check for proper wire feed speed setting In the MIG MAG and FCAW Modes check for proper voltage set tings In the MIG MAG Pulse Modes check the arc length trim setting These controls are on the wire feeder In the Stick Mode check for proper preset current setting Check for proper shielding gas and gas flow Check for loose or faulty weld ing cables RECOMMENDED COURSE OF ACTION 1 If zero arc voltage is displayed while welding the voltage sense leads may be broken Check the following molex plugs and associated wiring for loose or faulty connections J60 J62 on the snubber board J20 on the control board 2 Perform the Welding Feedback Test
152. wire feeder is NOT connected to the Power Wave the machine may not display output volts 4 Connect the resistance grid load to the machine s output terminals Connect the reference ammeter in series with the grid load See Figure F 57 FIGURE 57 RESISTANCE GRID LOAD CONNECTIONS POWER WAVE VOLT METER AMMETER E RESISTANCE GRID LOAD POWER WAVE 450 LINCOLN amp F 152 Return to Section Return to Master TOC Return to Section TOC O o e 5 5 9 5 2 Return to Section Return to Master TOC Return to Master TOC F 153 F 153 TROUBLESHOOTING amp REPAIR CURRENT CALIBRATION continued FIGURE 58 TEST AND CALIBRATION OVERLAY COPMmGHT 1994 THE LINCOLN ELECTRIC COMPANY CLEVELAND USA 19660 255 _ CALBRATION 8 TEST OVERLAY LINCOLN amp ELECTRIC IWVERTEC POWER WAVE ENTER 00 E E PROCEDURE 1 Install the Test and Calibration Overlay and apply power to the machine See Figure F 58 WARNING The machine s output terminals will be electri cally HOT when the trigger circuit is 2 Press the Manual Procedure Entry Key 64 activated The machine should display the following PROCESS 1 SETUP 5 Adjust the potentiometer until the reference 1 0 external ammeter reads 304 amps 1 0 3 Toggl
153. 00 2673 100 1 4W 56 2K 1 4W 267K 1 4W R44 R72 R101 R45 873 R102 Ej 110812 73 3 519400 5621 519400 1002 2K 1 2W TRIMMER 5 62 1 4W 10K 1 4W R111 R112 R136 519400 3322 819400 2212 33 2K 1 4W 7 22 1K 1 4W 1 519400 8251 819400 1502 8 25K 1 4W 15K 1 4W R95 R96 R153 519400 4752 519400 6812 519400 5111 519400 1503 519400 4750 519400 1333 710812 68 519400 2671 519400 1003 519400 2431 519400 1501 519400 2211 519400 1821 T14900 1 47 5K 1 4W 68 1K 1 4W 5 11K 1 4W 150K 1 4W 475 1 4W 133K 1 4W 1K 1 2W TRIMMER 2 67K 1 4W 100K 1 4W 2 43K 1 4W 1 5K 1 4W 2 21K 1 4W 1 82K 1 4W 200 20W R55 R89 R76 R77 R78 R79 R82 R91 R137 R83 R84 R105 R106 R109 R110 R113 R114 R115 R116 R117 R119 R120 R127 R129 R132 R150 R151 R160 Ec R130 519400 4751 519400 2210 Xx 519400 6811 519400 2000 19400 26R7 112300 79 519400 6810 518380 4 4 75 221 1 4W 6 81K 1 4W 200 1 4W 26 7 1 4W 1 WATT 1 1 RESISTOR 681 1 4W PTC THERMISTOR R134 R135 R140 R158 R159 R162 13640 15 518395 9 515161 27 ON 518104 5 518395 7 515128 4 515128 18 515128 10 515128 15 518104 5 LM224 QUAD OP VOLTAGE REF _ 02140215 _______ ______________ 3 005 _____________ 06 09 011 012 014 017 C Ee CAAT R6 R8 R11 R107 R139 R157 R7 R108 R128 R138 R154 C CHAA R40 R41 R42 R43 R6
154. 021 2145 48 9 021 23 26 28 29 osii Qut ELECTRICAL SYMBOLS PER E1537 ROXS Te CAPACITORS 022 50V UNLESS OTHERWISE SPECIFIED RESISTORS Ohms 4 4W UNLESS OTHERWISE SPECIFIED DIODES 14 400 UNLESS OTHERWISE SPECIFIED osa LABELS 12 SUPPLY VOLTAGE NET Power SUPPLY SOURCE POINT RI 15 83 85 100 107 111 117 122 125 11 139 187 COMMON CONNECTION 139 140 172 176 190 265 267 260 272320 326 47171 FRAME CONNECTION X4 6 9 17 19 22 23 31 36 40 47 49 51 53 57 FILE 02241 EARTH GROUND CONNECTION NOTES 58 60 62 65 67 69 70 72 80 NA SINCE COMPONENTS OR CIRCUITRY ON A PRINTED CIRCUIT BOARD MAY CHANGE LES once GREED TU GE TID WITHOUT AFFECTING THE INTERCHANGEABILITY OF A COMPLETE BOARD THIS DIAGRAM MAY CH HOLES SEFS PER THE LINCOLN ELECTRIC CO PE POWER WAVE CONTROL SCHEMATIC NOT SHOW THE EXACT COMPONENTS OR CIRCUITRY OF CONTROLS HAVING A COMMON CODE 2 PLACE DECIMALS IS 02 UNGER ONS PLAGE DESMALSIS OD gt PERS CLEVELAND OHIO E SUBJECT ON ALL ANGLES 5 OF A DEGREE EET scare _ NONE 6 MATERIAL TOLERANCE 1 TO AGREE 30 25 S D C i 26 JRE DATE 11 25 92 SUP SDG NO 2241 1 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 LINCOLN E ELECTRIC POWER WAVE 450 ELECTRICAL
155. 10 e 515 9 16 gt EIS 2 Return to Section Return to Master TOC Return to Master TOC F 185 TROUBLESHOOTING amp REPAIR MAIN INPUT CONTACTOR CR1 REMOVAL AND REPLACEMENT continued 9 With the slot head screw driver remove 10 11 12 the two small leads 1 and from the output side of the contactor With the slot head screw driver remove the two contactor coil leads 324 and 326 from the contactor With the slot head screw driver and 3 8 wrench loosen the two mounting screws and nuts holding the contactor to the ver tical mounting panel Remove the contactor by lifting up and out 13 14 15 16 For replacement mount the contactor to the vertical mounting panel with the two 3 8 mounting screws and nuts Attach all the contactor leads coil leads 324 and 326 small leads T1 and T3 to the output side three heavy leads to the output side small leads L1A and L3A and three input leads to the input side Tighten all evenly with the slot head screw driver Install the machine case sides and top Install the handle and the lift bail rubber gasket POWER WAVE 450 LINCOLN F 185 186 NOTES POWER WAVE 450 LINCOLN 5 F 186 901 Je1Se A 0 uunjeHd 901 4 1 0 901 J91Se N 01 DOL 01 901 uonoes uumeg DOL uonoes uumeg DOL uonoes uumeg DOL uono
156. 2 Return to Section TOC R98 939 INPUT 39 2K 39 2 FILTER 1 90 39 2 39 2 02 07 EI l A M AFN OL 16100 26 2 TRANSFORMER 4 PRIMARY 1 00K 09 600mA A 40V 2N4403 C2 C3 C4 05 NOT SHOW THE EXACT COMPONENTS OR CIRCUITRY OF CONTROLS HAVING A COMMON CODE WITHOUT AFFECTING THE INTERCHANGEABILITY OF A COMPLETE BOARD THIS DIAGRAM MAY NUMBER 08 i 40V d p 16100 28 o 600mA T e E2 4 E5 SINCE COMPONENTS OR CIRCUITRY ON A PRINTED CIRCUIT BOARD MAY CHANGE 401 405 403 407 Ojo O10 515 gt 218 5 2 1 Bu SNUBBER W RESISTOR M16100 26 NEGATIVE INPUT 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 LINCOLN POWER WAVE 450 ee ELECTRICAL DIAGRAMS G 23 PC BOARD ASSEMBLY SWITCH 1 06 PART NO DESCRIPTION Aa M16100 6 ELECTRONIC MODULE 00 ior ELECTRONIC MODULE SS 11 55 53 So 71907 947 1200 06 07 08 2702 27 pam 025 02602809 1 1 17777171 111473
157. 256 4 7900 1 va 9 w Tee lt 2 284 E tc t eei 4n Z joueuduy m 9er vir m f ger A sjouaydwy sjouayduy 66 FEE 9 8 mc ums 89 z 1 18 1 POWER WAVE 450 1 430334 2830334 901 Je1se N 01 DOL uonoeg LINCOLN amp 119 119 TROUBLESHOOTING amp REPAIR TRIGGER CIRCUIT AND WIRING HARNESS TEST A 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 elec trical 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 trou bleshooting assistance before you proceed Call 1 800 833 9353 WELD TEST DESCRIPTION This test will determine if there are any short circuits or other problems in the trigger circuit wiring or if there are any faulty PC boards which would cause the 5 amp circuit breaker to trip repeatedly Return to Section TOC Return to Master TOC MATERIALS NEEDED Volt
158. 353 WELD DESCRIPTION The following procedure will aid the technician in removing the main transformer for main tenance or replacement MATERIALS NEEDED Slot head screw driver Phillips head screw driver 5 16 Nut driver 3 8 Nut driver 5 16 Open end or box wrench 7 16 Open end or box wrench 3 8 Socket wrench 1 2 Socket wrench Wire cutters Machine Wiring Diagram in the Electrical Diagrams section of this manual This procedure takes approximately 2 hours 30 minutes to perform POWER WAVE 450 LINCOLN Return to Section Return to Master TOC Return to Section TOC Return to Master TOC o 2 3 Return to Section Return to Master TOC o p 5 F 198 TROUBLESHOOTING amp REPAIR MAIN TRANSFORMER CHOKE REMOVAL AND REPLACEMENT continued FIGURE F 75 MAIN TRANSFORMER LOCATION PROCEDURE 1 6 Remove main input supply power to the machine With the 3 8 nut driver remove the 4 screws that hold the handle to the machine Remove the rubber gasket cover seal from the lift bail With the 5 16 nut driver remove the sheet metal screws from the case top With the 5 16 nut driver remove the screws holding the right and left case sides Remove the case sides by lifting up and out Perform Procedure described earlier in this section of
159. 36 40 135 136 19400 7751 i R137 R138 1 1 519400 2212 NL F R7 RTT ATO A34 AICS 19400 1001 R163 R164 10812 52 R9 R22 R23 R24 R25 R29 R31 11 519400 1002 R76 R88 R89 R180 R10 R142 R143 R144 R145 19400 2211 R187 R188 R197 R17 R16 196 19400 2087 26 7 172W 500 1 2W TRIMMER 10K 1 4W 2 21 1 4W 00 80 WATT 0 5 100K 1 4W 1M 1 4W 13 7K 1 4W 12 1K 1 4W 2 67 1 4W 1 3K 1 2W 221K 1 4W 267 1 4 200 1 4W R21 R32 R33 3 19400 1003 827 8177 5 2 519400 1004 19200 1372 195 519400 1212 519400 2671 519400 1301 19400 2213 19400 2670 R63 R64 65 R06 R67 19400 2000 R69 R70 R80 19400 3321 R86 Co 25 3 32 1 4W 4 24 4 24 2 gt 5 519400 2430 243 1 4W H107 R156 2 19400 1500 150 1 4W R109 R110 R192 R193 4 19400 3010 a 1 1 m 301 TW R67 RT68 169 R170 2 519200 2431 1 2 43 1 4W 68 1K 1 4W 47 5 1 4W 475 1 4W TRANSFORMER RANSFORMER TRANSFORMER TRANSFORMER PULSE TRANSFORMER 515 9 16 218 5 2 19400 0812 19200 2752 19400 2750 M16744 1 116741 1 M16744 8 1 Mi67442 75 76 12737 1 TPLTPZTP3 13640 18 160 15458 3 PWM CONTROLLER 15125 11 PIN QUAD COMPARATOR 1415102 3 RESET L C UNDERVOLT
160. 401 402 9 and 12 on switch board 1 Switch Board 2 Switch Board 2 is Marked CAP 2 on the Switch Board Assembly Connection Decal See Figure 24 A B Remove quick connect terminals 403 404 9 and 12 With the volt ohmmeter check for 25 ohms resistance between lead 403 and 12F If the measurement reads between 20 and 30 ohms resistor R3 and leads 403 and 12F are okay Go to step C If the measurement does not read between 20 and 30 ohms check for continuity in leads 403 and 12F Then test for 25 ohms resistance across R3 directly If the measurement does not read between 20 and 30 ohms replace resistor R3 POWER WAVE 450 LINCOLN amp F 77 Return to Section Return to Master TOC Return to Section TOC O o e 5 5 9 5 2 21 Return to Section Return to Master TOC Return to Master TOC F 78 C TROUBLESHOOTING amp REPAIR SNUBBER AND BLEEDER RESISTOR TEST continued With the volt ohmmeter check for 25 ohms resistance between lead 404 and 9F If the measurement reads between 20 and 30 ohms resistor R4 and leads 404 and 9F are okay Go to step D If the measurement does not read between 20 and 30 ohms check for continuity in leads 404 and 9F Then test for 25 ohms resistance across R4 directly If the mea surement does not read between 20 and 30 ohms replace resistor R4 Reconne
161. 450 Wire Feeder 512 Trigger 2 2 Position GMAW GMAW STICK GMAW GMAW Pulse FCAW Pulse FCAW WFS DISPLAY WFS DISPLAY Wire Feed Speed Wire Feed Speed WFS and WFS and Preset VOLTAGE VOLTAGE Open Arc Length Trim Preset Voltage Current DISPLAY DISPLAY Arc Length Trim Preset Voltage WFS WFS WFS DISPLAY WFS DISPLAY Actual Arc Actual Arc Preset Current Wire Feed Speed Wire Feed Speed Closed Voltage Voltage Actual Arc VOLTAGE VOLTAGE Actual Arc Actual Arc Voltage Actual DISPLAY DISPLAY Current Current Arc Current Actual Arc Voltage Actual Arc Voltage In Stick trigger is on Remote Control Kit K941 1 Return to Section TOC Return to Master TOC Current not wire feed speed is displayed if a Remote Control Kit is attached to the wire feeder POWER WAVE 450 LINCOLN B Return to Section Return to Master TOC Return to Section TOC Return to Master TOC O o e 5 9 gt 5 2 Return to Section Return to Master TOC B 22 B 22 OPERATION In Pulse processes The wave control adjustment allows the frequency set ting to vary Increasing the wave control allows the fre quency setting to increase and decreasing the wave control allows the frequency setting to decrease Varying the wave control setting affects the droplet transfer and allows fine tuning for different welding positions In GMAW and FCAW
162. 5 112 __INVERTEC POWER WAVE 450 _ For use with machines having Code Numbers 10105 thru 10610 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 READING THIS MANUAL AND THE SAFETY PRECAUTIONS CONTAINED THROUGHOUT And most importantly think before you act and be careful Return to Master TOC View Safety Info Fg TF 9 5 2 oo z 9 als c SERVICE MANUAL Copyright 2001 Lincoln Global Inc LINCOLN ELECTRIC World s Leader 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 View Safety Info Return to Master Return to Master TOC gt 7 tc Return to Master TOC SAFETY WARNING CALIFORNIA PROPOSITION 65 WARNINGS 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
163. 51 eT A I DNIT _____________ omes 27 22403 E 2210 51500 1080 Return to Section TOC Return to Master TOC CAPACIT INDUCTA RESISTAN Return to Section TOC Return to Master TOC Ojo E 515 9 16 2 2 5 2 539077 400 SWITCH E THE LINCOLN ELECTRIC INVERTER WELDERS CLEVELAND OHIO U S A SWITCH BOARD ASSEMBLY SCALE FULL bn DATE 2 16 24 REF 180821 sUPSD G 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 LINCOLN amp ine LINCOLN 5 machine POWER WAVE 450 Return to Section Return to Master TOC Return to Section TOC Return to Master TOC o 2 3 Return to Section Return to Master TOC o O gt
164. 6 of the protection board Lead 321A Between terminal L1 of the main contactor and plug J30 pin 1 of the protection board Lead T3 Put the power switch SW1 in the OFF position Replace any broken or damaged leads discov ered by these tests 13 Connect any plugs disconnected for the tests Replace the PC board cover with two sheet metal screws 14 Install the machine case sides and top 15 Install the handle and the lift bail rubber gasket POWER WAVE 450 LINCOLN amp F 105 106 auvog 2 2 p lt eer ezr tc 262 02 g 1 _ 25 lt 686 PROHVOH 6 08 704 24 08704 QHVOS AURI HOLIMS HOLIMS HOLIMS HOLIMS tc GP 68 VY gt 2 Yzer a 189 8 OvIVeLLOLdO tc OVAFZ 49 eer cer OEF OEF OEF 0070 17 Ler Ler 8 AAAA L 2 9 i 5 E 9 91 L OL o 5 A AAA
165. 77777777777777777777777777777777777777777777777777777777777777777777777777777777777777 JJ 5 5 X 5 71 Ymmr WORK _ J50 SHUNT AMPLIFIER BOARD MY INMY _SWITCH BOARD 1 2 SNUBBERBD 61 1 soo c 402 12E TO SWITCH BD 1 SE TO SWITCH BD 1 REC SWITCH 42108 10 TO RECT THERM Hs 1 1 ITEE ojo O o FE 5 8 0 9 818 clt 5 5 10 BOTTOM AUXILIARY TRANSFORMER SECONDARY PRIMARY a TOP nm TOPRIMARY 28 2B 1 SWITCH K 9B TO SWITCH BD 1 R4 koa TO SWITCH 12 128 4 2 ar TORS ur 80 415 5 Nh 1 1B e H 483 220 280 STRIP 404 E 404 C BREAKER o p 5 10 200 208 SWITCH BOARD 2 336 6 ul 1159 P70 P73 412 13 18 NOTES 427 428 86 J14428 26 337 338 339 J82 38 85 11420021 SINCE COMPONENTS OR SEU OF A PRINTED 543 450 192 162 193 417 18 426 461 CIRCUIT BOARD MAY CHANGE WITHOUT AFFECTING 1 2 3 1 gt 4 1 5 SECONDARY
166. 8 6 18 we ele 55 d J eo AE 9 5 Sk cer 962 ger a als oo c 2 2 5 a m O vL 01 8 gt gt f ge gu IE RA a 1 E 7142 gt gt als NOWWOD I xp uU NOWWOD v gt gt gt per o0 0 1 2 olo 4 8 293 gt 4 gt 1 pun E 2 5 gt gt 115 m 9 amp gt ge T T tg AEEA om wer gt gt x ape gt gt NOWWOD V 2 9o 8 8 8 Bh JEEE 884 Ls Sz V io olo eg 5 5 S S mS E VAAAAAAAAAAJ T 1 POWER WAVE 450 LINCOLN amp Return to Section Return to Master TOC Return to Section TOC Return to Master TOC o 2 3 Return to Section Return to Master TOC o O gt o gt F 43 F 43 TROUBLESHOOTING amp REPAIR INPUT POWER AND WIRING HARNESS TEST A 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
167. 8 R69 70 871 97 898 R99 R100 872 810 ____ 845 873 8102 _________ R46 R51 R52 R74 R80 R103 47 58 75 R92 R104 R124 R48 R59 R85 R142 R143 R144 R50 R53 R61 R81 R86 R93 S 1282 8106 ____________ 3 8115 11617 __________ R122 R123 R125 H126 R161 C 5135 __________ R141 C C D 5 6 _________ CAPACITORS MFD VOLTS INDUCTANCE HENRIES RESISTORS OHMS THE LINCOLN ELECTRIC CO E INVERTER WELDERS CLEVELAND U S A PROTECTION BOARD ASSEMBLY DATE 2 27 37 OHK DRS 2453 2 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 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 amp ine LINCOLN Y machine POWER WAVE 450 EIS ELECTRICAL DIAGRAMS SCHEMATIC SQUARE WAVE PROTECTION PRINTED CIRCUIT BOARD Return to Section Return to Mast
168. A AAA A A gt ASLL 667 MeL 16 M6 amp Q gt 9 ll oc gt 2 ul 8 1 gt d 1 lt i gt z a gt gt y t Ll 26 986 3 Era 831002 431M OL gt 973 a ET lt lt 190 9 o 5 c veu Cm js lt e o 8 Ew Y m 788 5 9 N 5 ECT yzy T v ve wee T p lt LUE BE qvoN N7 9667 10014 2 gt I e 2 gt gt 73 3 1 lt gt 814 186 108 ay u 901 Je1Se A 0 uunjeH 901 4 1 0 901 J91Se N 01 901 J91Se N 01 UuunjeH DOL uonoes DOL uonoes DOL uonoes DOL uonoes Return to Section Return to Master TOC Return to Section TOC Return to Master TOC o 2 3 Return to Section Return to Master TOC o O gt o gt E tc F 107 F 107 TROUBLESHOOTING amp REPAIR SERIAL LOOP WIRING HARNESS 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 operato
169. AL AND REPLACEMENT continued FIGURE F 70 OUTPUT RECTIFIER BRIDGE LOCATION Return to Section TOC Return to Master TOC 22 22 77 y ssim Ne NS o o 2 5 Return to Master TOC RX 2 1 OUTPUT RECTIFIER BRIDGE 9 515 8 PROCEDURE WARNING 8 1 Remove main input supply power to the 4 E machine Before continuing with the 2 Dle 2 With the 3 8 nut driver remove the 4 test procedure perform the screws that hold the handle to the machine capacitor discharge dure to avoid electric shock 3 Remove the rubber gasket cover seal from the lift bail 4 With the 5 16 nut driver remove the sheet 7 After you have completed the capacitor dis metal screws from the case top charge procedure for all four switch boards a cut all necessary cable ties necessary for 5 With the 5 16 nut driver remove the removal of the output rectifier bridge on the screws holding the right and left case sides left side of the machine Remove the case sides by lifting up and out 8 Disconnect all necessary leads from the left side of the output rectifier bridge two 6 Perform the Capacitor Discharge heavy and two small leads Place the fas Procedure described earlier in this section tener hardware back together to avoid loss of the manual Retu
170. BER GENERAL INFORMATION ELECTRICAL SYMBOLS PER E1537 CAPACITOR MFD 022 50V UNLESS OTHERWISE SPECIFIED RESISTORS Ohms _1 4W_ UNLESS OTHERWISE SPECIFIED DIODES 1A 400V UNLESS OTHERWISE SPECIFIED FILE NAME G2239_1DA SHEET 2 OF 2 THE LINCOLN ELECTRIC CO SUPPLY VOLTAGE NET POWER SUPPLY SOURCE POINT 17 COMMON CONNECTION FRAME CONNECTION EARTH GROUND CONNECTION INVERTEC 400 TYPE DISPLAY KEYPAD PCB SCHEMATIC CLEVELAND OHIO U S A scale 2 DATE 1 17 94 SUP SD G 2239 2 NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual POWER WAVE 450 PC BOARD ASSEMBLY DISPLAY ELECTRICAL DIAGRAMS PEM PART NO ee R67 888 8104 R105 R1 10 319400 1500 R150 R151 R152 R153 R154 RST ATOZ AT26 5100 R134 R135 R140 R174 R175 R178 R180 R181 E ooo R95 Eri 2210 571 1 Le C26 C27 C29 C30 C31 C34 C35 C36 C38 C39 C40 C41 C48 C49 C50 C52 C54 C55 C56 C57 C59 C60 C65 C67 C76 C80 C81 C82 C83 C84 C85 C86 C87 C95 C97 C99 C100 C1 01 C10 11 bes C70 C75 C77 TB 120 BIIJU 130 aI 24 2120 7 7 n 9200 17477 C78 C79 88 C89 C90 C91 8 z 5 R217 R218 R219 R220 R229 C92 C93
171. C94 map 3 s R230 R231 R232 R234 B 8 X ED SOOT OR mez 1 ee 3 Q 1175 S10400 1301 232 253 5155581 2 10 mer R145 9400 2000 61 66 12 513490 73 _ 20 50 16668 7 820 750 Return to Section Return to Master TOC E B EEE 77200 N2004 D11 D12 013 014 015 016 017 018 019 020 021 022 ee SS RES 3 6190025 Ie CMOS LATOR STATES Poze Dero per 7527525 Br OT 2395 HC11 MICROPROCESSORISS 4 ROM ASSEMBLY SS pa 7 1 75 TET JUMPER 8227 R137 eva 02 1814 B a 1 d ol lt S is 1 MO ACUn MOS ACIA OMHZ 68B50P UNDERVO NSIN Her 3 LED7 LED8 LED9 LED10 LED11 5 LED12 LED13 LED14 LED15 MEDNOLTS LED16 LED17 LED18 LED19 RESISTANCE OHMS LED20 LED21 LED22 LED23 LED25 LED26 LED27 LED28 LED29 LED30 LED31 LED32 LED33 LED34 2 TED
172. CBBHC1 1 74 646 74 0646 Return to Section Return to Master TOC DA AD 0 7 DATA BUS DATAQ 1S V GROUND PARALLEL COMMUNICATION je bri AGBSRO BACIK D PORTI DIRECTION DIR AtoB CLK ___ RD LOW DA ADJO A0 oE ___ Low n 2 SHEET 2 x44 DA AD 1 LL DATA DA AD 2 A2 Br DATAS DA AD 3 B2 DATAA DA ADI4 B3 DATA DA ADIOL en DAADIIL foa aps s 599 DA DD pa apr n MODA DA ADISI 148848 Lg y DA ADIA oz X10 DA ADISI 1 DA ADI6 1 DA ADI7I no OUTPUT_ON 8 BioA SRC Veo 065 T ABSRO BACK 2 Be SP1 PORT 002 00019 DIRECTION oR Vpp CTRL THERMAL OE L HIGH 20 SHEET 2 x44 MACHINE CONNECTED IN PARALLEL MODE_SLAVE ud p SWITCH 400 A2 SWITCH2 B2 IRES A5 B4 LATCH_READ Ha A6 B5 1 Lok 7 AT 8 74 0848 22 miso 23 24 5 INPUT COMMAND 25 88 VAL
173. D TEST DESCRIPTION The following procedure will determine whether one of the output rectifier diodes is shorted If one of the diodes is shorted the output rectifier assembly must be replaced MATERIALS NEEDED Analog Volt Ohmmeter Multimeter 5 16 Nut driver 3 8 Nut driver Machine Wiring Diagram in the Electrical Diagrams section of this manual This procedure takes approximately 15 minutes to perform POWER WAVE 450 LINCOLN Return to Section Return to Master TOC Return to Section TOC O10 e 515 9 16 gt EIS 2 Return to Section Return to Master TOC Return to Master TOC F 58 TROUBLESHOOTING amp REPAIR OUTPUT RECTIFIER DIODES TEST FIGURE F 18 SNUBBER BOARD OUTPUT TERMINAL LOCATION PC BOARD FRONT BOTTOM COVER SNUBBER PC BOARD NEGATIVE OUTPUT TERMINAL POSITIVE OUTPUT TERMINAL TEST PROCEDURE 1 6 With the 5 16 Remove main input supply power to the machine With the 3 8 nut driver remove the 4 screws that hold the handle to the machine Remove the rubber gasket cover seal from the lift bail With the 5 16 nut driver remove the sheet metal screws from the case top nut driver remove the screws holding the right and left case sides Remove the case sides by lifting up and out Perform the Capacitor Discharge Procedure described earlier in this section of the
174. E 44 5 5 AUXILIARY TRANSFORMER 1 SECONDARY CIRCUIT WIRING DIAGRAM 518 0 12 9 2 cao 1 gt 9 515 e 986 E 3 OO gt gt 212 29 ppp 186 NOWNOD i am 291 2 gt 191 zm Eg 5 5 58 oz 2 8 55 ez 8 MN EIE TO gt 9 gt gt gt 2 als SB zer 962 ser 2 dE E gt gt gt B d sr s x ak NE 90 gs mU Aer gt y a iL gt gt gt 2 9228 5 5 o 818 4 4 voor 3 1 iz d ASH 4 ah gt gt gt d gt gt 1 NOWWO9 I 5 NOWWO gt gt 12 PAS lt 8 18 8 8 8 8 2 8 8 88 5 2 sa 5 CON z4 oz 8 lt y y do o Sg SG VEN V gt zo z OE lt 3 t N 2 5 WAAAAAAAAAJ c POWER WAVE 450 LINCOLN 122 NOTES POWER WAVE 450 LINCOLN 5 F 122 901 Je1Se A 0 901 Je1se A 0 901 J91Se N 01 DOL 01 901 uonoes uumeg DOL uonoes uumeg DOL uonoes uumeg DOL uonoes uumeg Return to Section Return to Master TOC Return to Section TOC Return to Master TOC o
175. E QNZPLACEDEGMALSIS 000 CLEVELAND OHIO U S A SUBJECT CONTROL SCHEMATIC IMALS 18 EIN MER ONALLANGLES 5 SOFADEGREE 7 SCALE 8 MATERIAL TOLERANCE 7 80 25 S D TOA DATE 11 25 92 SUP S D G G 2241 2 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 LINCOLN amp ea POWER WAVE 450 Return to Section Return to Section TOC Return to Master TOC Q BS 5 2 Return to Section Return to Master TOC Return to Master TOC o 2 0 8 5 9 6 SCHEMATIC CONTROL BOARD 3 LINCOLN amp ELECTRIC 2 CURRENT MODE CONTI os 74AC578 LE EY p507 PORT DSP2_WO ND 74 573 CLR SHUNT 0592 ELECTRICAL DIAGRAMS 54HC4066 54HC4066 e 07545 00018 08 2 DATA BUS GENERATE A REFERENCE LEVEL 1 0K 681K R275 T R276 t 0185 0188 C184 i T SHUNT CONNECTION 15V CURRENT SIGNAL 10 800A OUTPUT 330p 150p FILTER INCOMING SECONDARY CURRENT A CURRE
176. ED SUPPLY VOLTAGE 05 99 8106 ARE NOT ASSIGNED POWER SUPPLY SOURCE POINT 06 57 COMMON CONNECTION a7 FILE NAME G2239_1DA FRAME CONNECTION n SHEET 1 OF 2 EARTH GROUND CONNECTION LE_KEY LE INFRA 50301 GI KEYPAD INTERFACE NOTES THE LINCOLN ELECTRIC CO INVERTEC V400 pcr CLEVELAND OHO 53 DISPLAV KEYPAD PCB SCHEMATIC NOT SHOW THE EXACT COMPONENTS OR CIRCUITRY OF CONTROLS HAVING A COMMON CODE SCALE NONE _ 5 NUMBER DATE _1 26 94 CHK 307506 2239 1 Return to Section Return to Master TOC NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual LINCOLN amp ea POWER WAVE 450 Return to Section Return to Section TOC Return to Master TOC Q BS 5 2 Return to Section Return to Master TOC Return to Master TOC o 2 0 8 5 6 10 SCHEMATIC DISPLAY BOARD SHEET 2 LINCOLN amp ELECTRIC THERMAL 10K J6 200 THERMAL FAN PRESSURE 15V 10K 1 00K J10 5 R213 0728 54V 1w
177. ELATIONSHIP BETWEEN P VOLTAGE TRIM AND PRESET VOLTAGE SELECTED ARC LENGTH TRIM AND PRESET 912 ARC LENGTH AS INDICATED BY ARC LENGTH 9 2 Voltage Trim Relationship to Preset Voltage 0 6 60 of preset voltage Arc Length Trim Preset Arc Length 0 8 80 of preset voltage Biz 0 6 6096 of preset length 2 1 0 change to preset voltage 0 8 80 of preset length 1 2 120 of preset voltage 1 0 no change to preset length 1 4 140 of preset voltage 1 2 120 of preset length Explanation of Table B 3 1 4 140 of preset length for example the minimum voltage trim is set to 0 8 and the maximum voltage trim is set to 1 4 this means that the voltage for a given wire feed speed can be adjusted to be anywhere between 80 and 140 of the preset voltage of that wire feed speed TABLE B 4 ADJUSTABLE PARAMETERS Adjustable GMAW GMAW Parameters Pulse FCAW Wire Feeder Wire Feed Wire Feed WFS Displa Speed Speed Wire Feeder Arc Length Preset Voltage Displa Trim o 2 3 Return to Master TOC Power Wave 450 Display with GMAW Pulse Wave Wave Wave GMAW FCAW Stick Control Control Control olo Process Selection Overlay Frequency Inductance Arc Force JE 5 5 59 TABLE 5 DISPLAYS THE POWER WAVE AND WIRE FEEDERS 2 FOR DIFFERENT PROCESSES IN BOTH TRIGGER POSITIONS 2 8 Power Wave
178. EM MES 1 40 i CONTROL BOARD current path POWER WAVE 450 LINCOLN 110 Return to Section Return to Master TOC Return to Section TOC Return to Master TOC o 2 3 Return to Section Return to Master TOC o O gt o gt 111 111 TROUBLESHOOTING amp REPAIR WIRE FEEDER 1 TRIGGER CIRCUIT 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 elec trical 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 there are any faults in the 24 VAC trigger circuit integral to the Power Wave and the wire feeder 1 amphenol P83 MATERIALS NEEDED Volt Ohmmeter Multimeter 5 16 Nut driver 3 8 Nut driver Short piece of jumper wire Trigger Circuit Wiring Diagram Figure F 40 This procedure takes approximately 30 m
179. EPAIR WATER COOLER REMOVAL AND REPLACEMENT For later model coolers Inlet amp Outlet on lower left of machine back Refer to IM645 A 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 elec trical 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 DESCRIPTION The following procedure will aid the technician in removing the machine water cooler assembly for maintenance or replacement MATERIALS NEEDED 5 16 Nut driver 9 16 Open end or box wrench 3 8 Nut driver or socket wrench 3 4 Open end wrench 11 16 Open end wrench Machine Wiring Diagram in the Electrical Diagrams section of this manual This procedure takes approximately 60 minutes to perform POWER WAVE 450 LINCOLN Return to Section Return to Master TOC Return to Section TOC O10 e 515 9 16 gt EIS 2 Return to Section Return to Master TOC Return to Master TOC F 158 TROUBLE
180. EQ MODULATED i i i 5 3 456 sum 1 CAP DIFFERENTIAL VOLT 71523 lt 234 wd EJS i este i i 232 14 EIE 2 i i Els i H5 X 8 8 GA OUTPUT DISABE 33 lt 233 4d cle TERMINAL STRIP FEEDED E i i 5 o 5 9 1T gt Sle 1 87 19 77 meee i cs zi S 144 144 1 1 THRU CT 8 8 Mods s 2 ale 1 1 5 RECTIFIED CT VOLT une i i i m 2 8 373 i RECTIFIED OT VOLT Tja 371 bwy a WHEN WET OR H2 H2A H3A H4H4A c jd i 8 gt 15 ser FOOT AMPTROL TRIGGER CLOSE L L B oe 4 5808 oo 16Va lt ua 21 21 i i 8 sivas gary AUXILIARY TRANSFORMER 1 L 8 C 47 18 Vb 5 SST 2 24VAC WHEN use el ET 1 55 9 PN 372 5 amr WF2 TRIGGER CLOSE 2 SE s I gt 45 Vb i 15Va lt an 212 BN eri oem i i PROTESTON B0 gt B ae gt 5 i SHUNT CURRENT lt 218 comel ur P 1 PP wm aiu M EHE 4 H 1 gr 444 Lane gt 8Vb ar 400 WELDING CURE i i 5Vb 448 E 208 238 MV euss lt 336 EUY
181. ER 4 This message is then replaced by the following Select another memory location message SET LIMIT KEY SELECT A MEMORY AND LONON LIMIT UP DOWN KEYS The SET LIMIT key and LIMIT UP LIMIT DOWN AND keys are used to set the maximum and minimum MEMORY LOCATION NUMBERS The RECALL FROM MEMORY key is used to recall a welding procedure from memory allowed wire feed speed and voltage trim or arc length trim values of the procedure that was recalled from memory POWER WAVE 450 LINCOLN B Return to Section Return to Master TOC Return to Section TOC O o e 5 5 9 5 2 21 Return to Section Return to Master TOC Return to Master TOC B 16 OPERATION Use the LIMIT UP and LIMIT DOWN keys to change the maximum wire feed speed to the desired value Press the SET LIMIT key again The new maximum and old minimum wire feed speeds will be dis played Use the LIMIT UP and LIMIT DOWN keys to change the minimum wire feed speed to the desired value Press the SET LIMIT key The present maximum and minimum voltage trim or arc length trim will be displayed Refer to Table B 3 to see how voltage trim affects preset voltage Refer to Table B 6 to see how arc length trim affects preset arc length Use the LIMIT UP and LIMIT DOWN keys to change the maximum value The maximum for either type is 1 5 P
182. F See Figure 76 turn the arc start switch OFF See Figure F 79 Return to Section TOC Return to Master TOC POWER WAVE 450 LINCOLN B F 206 F 206 TROUBLESHOOTING amp REPAIR PRE POWERUP SWITCH BOARD TEST PROCEDURE FOR REPLACEMENT OF SWITCH ASSEMBLY G2402 2 continued FIGURE F 82 SNUBBER SIGNAL Return to Section TOC Return to Master TOC Heese fh be a 0v 5 i 5 5 T o ae 010 L gt 8 5V Div 20uS Div EIE az 460VAC RECONNECT ojo 1 Reconfigure the machine for 460VAC operation 4 Slowly increase the voltage until the filter capac 2 Turn ON the variable AC supply applied to the See Figure E77 primary circuit See Figure 76 5 Adjust the grid load to get 5 amps output from the Power Wave DO NOT DRAW MORE 3 Turn on the arc start switch See Are Start 5 PW450 or Figure F 79 rS OUTPUT FROM TH 4 Slowly increase the voltage until filter capacitor voltage is 25VDC NOTE Monitor both capaci 6 Set for 5 8 tor voltages If the two voltages are not within 5 10 uS div to 8 VDC of each other STOP and check wiring 5 5 to the FET switch board assembly and also the 0 gt 5 8 individual switch boards See Figure 277 WARNING olo 5 Adjust the grid load to get 5 amps output from pe the Power Source DO NOT PULL MORE ALL METERS AND OSCILLOSCOPES MUST BE 5 THAN 7 8 A
183. GER CLOSE TO 4437 J i Eg i EV ue i 5 i i 5 4 i 154 8 8 682 lt 1 326 jFEEDED i 22 i 13160 4 221A 15 Va i 5 2 i 1 equate 167 2 i EU 320 554 gt ovac FRoM 1493 8 i THRU CT i E ven KEYPAD oq um 5 meses lt rome p J 8 B PE aim lt 121A 12 su 205 g gt 42VAGEROM 333 E 85 i 67 i 57 15Va a suo cL sw gi 82E alos ouo rou 1103 i E GND aster lt 208 suo J EI 1020 gt ana SNUBBER BOARD i a i Looc INPUT RECTIFIER i moe 202 i i m n oa BVR Os i oo 1 ffffIrlli cane d 39 3 PM 1 pe O i as WEZ ARC VOLT FEEDBAGK 201 i c X 2 7 i i Y yyyy i TD i E Y Tet P 6 1 207 i d ebd KM lt 802 wir 1 cod i i SAS i 2 81 11 806 gt gt 261 1 00 auram i 4 1 1 217 gt 5 Ve 85232 i 01 06
184. H and 67A N located in wire feeder receptacle 1 to the machine s positive output terminal 2 Using the jumper leads connect 21B H and 67B N located in wire feeder receptacle 2 to the machine s positive output terminal 3 Connect the resistive grid load or wire feeder to the machine s output terminals 4 Connect the DC voltmeter to the machine s output terminals Do not connect the volt meter to the load This avoids erroneous readings due to cable drop This procedure takes approximately 45 minutes to perform POWER WAVE 450 LINCOLN F 145 Return to Section Return to Master TOC Return to Section TOC Return to Master TOC o 2 3 Return to Section Return to Master TOC o p 5 F 146 TROUBLESHOOTING amp REPAIR FULL VOLTAGE CALIBRATION continued FIGURE 55 TEST AND CALIBRATION OVERLAY COPREATI9M THELINCOLN ELECTRIC COMPANY CLEVELAND OHIO UBA N 19660 255 CALIBRATION amp TEST OVERLAY LINCOLN B ELECTRIC IWVERTEC POWER WAVE PROCEDURE 1 The voltage calibration numbers are stored in the display board They are program mable from the front panel using the Test and Calibration Overlay 2 Change the PC board in question 3 Install the Test and Calibration Overlay L9660 255 and power up the machine See Figure F 55 4
185. HB Return to Master TOC TO SWITCH BD 3 406 TO SWITCH BD 3 v Return to Section TOC RECONNECT SWITCH 9A TO SWITCH BD 1 gt 98 TOSWITCHED 2 9K TO 31 POS TO INPUT RECT POS TO INPUT RECT 10 121 TO Jo SWITCH 805 12A TO SWITCH BD 1 182 128 TO SWITCH BD 2 4 A 1 TERM STRIP 9 TO SWITCH BD 3 9 9 SWITCH BD 4 430 9J TO J81 TO SWITCH BD 4 H TO SWITCH BD 4 TO CRI 134 A LIA SWITCH 12 TO SWITCH BD 3 T9489 12D TO SWITCH BD 4 12K J81 NEG TO INPUT RECT X NEG TO INPUT RECT 407 SWITCH BD 4 408 SWITCH BD 4 OUTPUT on RECTIFIER V VOLTAGE 200 230V J41 a A E 489 ISWITCH THERM INPUT RECTIFIER HH AFN J42 TO SWITCH BD 3 C BREAKER 211121 22 2 0047 400 SECONDARY PRIMARY TOP TOP 443 we aw LEFT WIRE FEEDER RECEPTACLE 1 TO REC SWITCH E TO SWITCH BD 4 1085 9 ELECTRODE TO REC SWITCH 3B TO R6 J44 AAA TO TERM STRIP o
186. IJLLO3H M E lt A09b 0bb YOLOVLNOD gu oH NIV 2L NOLLOSIOHd ugyy3 sare ug xn X I 2 1819 086 Ya 9126 us yu gf 21 HOLIMS gr 2 lt 68 088 7 u3MOd 2 vee c 1 3 arze gt yep E WEN ae er gt gt gt 7 1351 amp coe e 9 lt 7 3504 2 RENE n ET sc 802 002 802 002 Ld ZH s EET a 4 LZE 1 lt lt 4 40g 080 gt e 091080 F 38 901 49159 OL DOL 49152 0 uunjeg DOL Je1se N DOL Je1se N DOL uonoes o uonoes 0 DOL uonaes 201 uonoes DOL uonoeg F 39 F 39 TROUBLESHOOTING amp REPAIR AUXILIARY TRANSFORMER 1 SECONDARY AND WIRING HARNESS TEST A 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 elec trical 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
187. ING amp REPAIR FIELD EFFECT TRANSISTOR SWITCH BOARD TEST continued FIGURE F 21 DISCHARGE LABEL 4 13086 117 9 Using insulated needle nose type jumper leads and insulated gloves connect one jumper lead to one end of the resistor obtained in step 6 Connect the other jumper lead to the other end of the resistor 10 Carefully connect the needle nose end of 11 one of the jumper leads to terminal 9 See Figure 22 Connect the needle nose end of the other jumper lead to terminal 12 Terminals 9 and 12 are indicated by the Discharge label Leave the resis tor connected for 10 seconds DO NOT TOUCH TERMINALS RESISTORS OR ANY INTERNAL MACHINE COMPO NENTS DURING THIS PROCEDURE Check the voltage across terminals 9 and 12 with the DC voltmeter Terminal 9 has positive polarity and terminal 12 has negative polarity Voltage should be zero If any voltage remains repeat this capaci tor discharge procedure 12 13 14 FIGURE F 22 RESISTOR WITH LEADS CONNECTED F 62 Repeat discharge procedure steps 9 10 and 11 for each of the other three switch boards After you have completed the capacitor discharge procedure for all four switch boards Visually inspect the switch boards If any of them appear burned or overheated replace all four switch boards and input filter capa
188. ION PROCEDURES POWER WAVE PC BOARD REPLACEMENT CALIBRATION PROCEDURES If the display board is replaced the display sensor cal ibration and a voltage calibration must be performed for optimum performance f the calibration is not done the voltage may be accurate only to within 3 volts If the sensor calibration is not done the display board may have some problems sensing the correct overlay on power up WARNING The display is shipped with the water cooler disabled If an internal water cooler is being used with the Power Wave you must use the Setup Overlay L9770 0 to enable the water cooler before using the system If the control board is replaced the voltage calibration and current calibration must be performed for opti mum performance If the calibration is not done the voltage may be accurate only to within 3 volts and the current will be accurate only to within 15 amps POWER WAVE 450 LINCOLN B F 139 140 NOTES POWER WAVE 450 LINCOLN 5 F 140 901 Je1Se A 0 901 Je1se A 0 901 J91Se N 01 DOL 01 901 uonoes uumeg DOL uonoes uumeg DOL uonoes uumeg DOL uonoes uumeg Return to Section Return to Master TOC Return to Section TOC Return to Master TOC o 2 3 Return to Section Return to Master TOC o O gt o gt E
189. ITCH 401 BOARD 25 1 01 12 25W 12L 124 gt RECONNECT SWITCH 75 402 R9 a 9 9L 1984 RECONNECT SWITCH 55 olg g 5 SWITCH 403 olo BOARD 250 2 12F 25W 218 128 212 447 gt TO RECONNECT SWITCH iL 404 _Co 29 498 ______ TO RECONNECT SWITCH 9o SWITCH 405 BOARD 250 5 3 ie 12G 12M 35190 313 120 gt RECONNECT SWITCH olg 7 5 3 60 dun 2 2 6 25W amp lt po 9G 9M 90 RECONNECT SWITCH SWITCH 407 BOARD 5 4 12 25W 1 120 RECONNECT SWITCH E 408 21 nz 250 5 2 25W E 9H 3 490 SWITCH 2 POWER WAVE 450 LINCOLN Return to Section Return to Master TOC Return to Section TOC O10 e 515 9 1 EIS 2 Return to Section Return to Master TOC Return to Master TOC F 93 93 TROUBLESHOOTING amp REPAIR DYNAMIC CAPACITOR BALANCE 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 elec trical shock please observe all safety note
190. If the difference is more than 75 VDC sta tic capacitive balance is not okay Perform the Input Rectifier Test Also visually check input filter capacitors C1 C2 C3 and C4 for any signs of damage replace the FET or IGBT assembly For 220 VAC Input Voltage 12 13 The two resistance measurements should be the same If one or both is less than 175 VDC perform the Main Contactor Test the Input Rectifier Test Also visually check input filter capacitors C1 C2 C3 and C4 for any signs of damage replace the FET or IGBT assembly After the test is completed and the prob lem successfully repaired install the machine case sides and top Install the handle and the lift bail rubber gasket BLEEDER RESISTOR R9 AND R10 VOLTAGE VALUES VAC INPUT VDC ACROSS BLEEDER RESISTORS R9 AND R10 460 VAC 325 VDC 440 VAC 311 VDC 415 VAC 293 VDC 380 VAC 269 VDC 230 VAC 325 VDC 208 VAC 294 VDC POWER WAVE 450 LINCOLN amp F 91 92 TROUBLESHOOTING REPAIR F 92 4 5 Figure 31 SNUBBER AND BLEEDER RESISTOR WIRING DIAGRAM 9 5 5 SNUBBER AND BLEEDER RESISTOR WIRING DIAGRAM 5 ele 5 212 SW
191. LECTRICAL DIAGRAMS G 19 PC BOARD ASSEMBLY SHUNT 20121 516668 5 _____ 022750 _ 516668 11 E ______ 071 07722 EEE ke xu Mi 518248 6 HEADER p O pj 22 252 224 RIRS E E 2 84 5 88 2 51940 8028 SEEK 1 51940056520 52147 1 916296 3 500 1 2W TRIMMER 1 _ 519400 1301 1 3K 1 4 10 811 1__ 15128 13 PRECISION IC Return to Section Return to Master TOC CAPACITORS MFD VOLTS Return to Section TOC Return to Master TOC Z DA 1 lt L NX Co LO 2 A o o Ojo E 515 9 16 2 2 5 2 ____ ______________ THE LINCOLN ELECTRIC 0 80 INVERTER WELDERS a er CLEVELAND OHIO U S A SHUNT AMPLIFIER P C BD ASSEMBLY SUBJECT SCALE FULL c M DR LJB 11 4 97 CHK JJ REF 17150 1 SUP S D G 17150 2 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
192. LIBRATION 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 elec trical 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 trou bleshooting assistance before you proceed Call 1 800 833 9353 WELD PROCEDURE DESCRIPTION This procedure is necessary if the control and or the shunt amplifier boards are replaced The current control is the most critical function in the Power Wave machine MATERIALS NEEDED Test and Calibration Overlay L9660 255 A 300 amp 30 volt resistance grid load A small trimmer screwdriver A calibrated DC ammeter accurate to read 300 0 amps 1 0 amps A machine output triggering device such as the K941 1 Remote Control Kit Return to Section TOC Return to Master TOC SETUP PROCEDURE 1 Remove and install the replacement board in question This procedure takes approximately 45 minutes to perform FIGURE F 56 PC BOARD REMOVED BUT STILL CONNECTED Lay Control Board on top of machine Make sure it is snapped into t
193. LINCOLN Return to Section Return to Master TOC Return to Section TOC O10 515 9 1 EIS 2 Return to Section Return to Master TOC Return to Master TOC F 24 TROUBLESHOOTING amp REPAIR CAPACITOR DISCHARGE PROCEDURE continued TEST PROCEDURE 1 Remove main input supply power to the machine With the 3 8 nut driver remove the screws that hold the handle to the machine Remove the rubber gasket cover seal from the lift bail With the 5 16 nut driver remove the sheet metal screws from the case top With the 5 16 nut driver remove the screws holding the right and left case sides Remove the case sides by lifting up and out Obtain a high resistance and high wattage resistor 25 1000 ohms 25 watts mini mum This resistor is not supplied with the machine Secure this resistor to a piece of insulating material such as a glastic board See Figure F 4 NEVER USE A SHORTING STRAP FOR THIS PROCEDURE 7 Locate the two sets of two resistors on the left side of the machine and three sets of two resistors on the right side of the machine See Figure 2 Do not touch the resistors or any other internal machine component Using a DC voltmeter check for any DC voltage that may be present across the terminals of each resistor and from each resistor to case ground 20 mea surements in all If a voltage is present
194. LN 13 13 TROUBLESHOOTING REPAIR TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginning of this manual PROBLEMS POSSIBLE AREAS OF RECOMMENDED SYMPTOMS MISADJUSTMENT S COURSE OF ACTION FUNCTION PROBLEMS The display cannot be seen clear 1 Adjust the viewing angle of the 1 Perform the L CD Display Test ly or cannot be seen at all display Follow the instructions provided in the Operation Section of this manual Look under the LCD DISPLAY ADJUSTMENTS in the CON TROLS AND SETTINGS sub section of the Operation Section Return to Section TOC Return to Master TOC Machine does not respond to Each time an overlay is Using the test and calibration keys being pressed or the changed make certain that the overlay L9660 255 perform machine has improper displays machine is powered up with the keyboard LED test See the new overlay in place overlay Make certain that the correct 2 Perform the Serial Loop overlay ID number is displayed Wiring Harness Test Or power up Hele to Replace the control board and SACO OF thig perform voltage calibration and manual for the overlay descrip tion Return to Section TOC Return to Master TOC current calibration Replace the display board and In some cases some of the perform voltage calibration keys on the overlay may be locked out Refer to the Replace the power board Section of this manual
195. MPS OUTPUT FROM THE ELECTRICALLY ISOLATED Qu POWER WAVE 6 Repeat the previous Snubber Signal Test by 7 Connect the positive oscilloscope probe to the checking the eight test points Power Wave positive welding output terminal and the negative probe to the negative welding output terminal The output should look like the OUTPUT SIGNAL TEST oscilloscope picture in Figure F 83 1 Make certain the machine is configured for 9 460 operation 2 Turn ON the variable AC supply applied to the primary circuit See Figure 76 3 Turn ON the arc start switch See Arc Start PW450 or Figure F 79 Return to Section TOC Return to Master TOC POWER WAVE 450 LINCOLN B Return to Section Return to Master TOC Return to Section TOC Return to Master TOC o 2 3 Return to Section Return to Master TOC o O gt o 9 E F 207 F 207 TROUBLESHOOTING amp REPAIR PRE POWERUP SWITCH BOARD TEST PROCEDURE FOR REPLACEMENT OF SWITCH ASSEMBLY G2402 2 continued FIGURE F 83 OUTPUT SIGNAL HHH 5V Div 8 Turn the variable AC primary supply to zero volts and then turn it OFF See Figure 76 9 Once the filter capacitor voltage drops to zero turn the arc start switch OFF See Arc Start PW450 or Figure F 79 PREPARE MACHINE FOR NO
196. Master TOC Return to Section TOC O o e 5 0 9 5 2 Return to Section Return to Master TOC Return to Master TOC 1 LCD DISPLAY WINDOW 2 WIRE FEEDERS MEMORY CHART 3 DISPLAY RECALL KEY 4 HIGH TEMPERATURE LIGHT 5 MEMORY LIGHTS OPERATION DUAL WIRE FEEDERS DUAL PROCEDURE OVERLAY OPTIONAL The Dual Wire Feeders Dual Procedures Overlay is used when the Power Wave is equipped with two wire feed ers and two guns with two position switches Any welding procedure stored in memory locations 1 2 3 or 4 can be automatically recalled and used See Figure B 7 FIGURE 7 DUAL WIRE FEEDERS DUAL PROCEDURE OVERLAY LINCOLN 9 ELECTRIC e vivi 1 o 2 ojo 35 ELECTRIC COMPANY CLEVELAND USA COPYRIGHT 1994 POWER WAVE 450 PROCEDURE PROCEDURE 1 LCD DISPLAY WINDOW Power up the machine with this overlay in place When the Power Wave is turned on the following message appears in the display window for a few seconds LINCOLN ELECTRIC VERSION X X This display is followed by OVERLAY ID NUMBER 9 WIRE FEEDERS MEMORY CHART The active welding procedure is determined by the active wire feeder and its gun switch position The weld ing procedure recall from memory is as follows Active Gun Trigger Memory Location Wire Feeder Position of
197. NI TVNHSLX3 LNAWdINOF HQ3MOd c duy lt a 1777 d i T 7 1044409 9 0 DIL 5 01 X0 77 642 lt p 2 OL 1162 pe 2 17921 8 8 u our 262 zi vezi o z D 0 lt 18k9 lt lt 5 lt _ ___ LE gt TOH1NOO ag Av 1dsid NOLLO310Ud b 30r 0201 5 lt 42 9 tc tc Id pA A 00 p lt p lt lt T 5 24 208 1 430334 9 LL 2 lt psexs me ver 820 o gt l lt 1 lt 4 08 884 EN E oer 192 Joueudui Ast 2 2 4 122 IP lt Ps 7901 283034 ous lt p L y lt lt KE lt lt 1201 992 ov ver 5 ls um eir 849 zer Z 0 age eer eer A sjouayduy sjoueyduiy 5 udp 8 o 995 i vs H3 HOJSNVUL i se sjouayduiy F 129 901 Je1Se A 0 901 4 1 0 uunjeH 901 J91Se N 01 901 J91Se N 01 DOL uonoes DOL DOL DOL uonoes 130 NOTES POWER WAVE 450 LINCOLN 5 F 130 901 Je1Se A 0 901 4 1 0 uunjeH 901 J91Se N 01
198. NOWWOD gt z gt 2981 NEC 2 gt S1NdLNO tc 11 gt auvog s aasa 51 5 8 Sh L 1 oc 5 ES Bg S 2 o a SA SASA SA 966 gt nra E t cor ger gt 5 ose 1 1 E lt 82 lt gt gt C lt o SZ 5 2 NOWWOO ise i TEE M SLNANI SESI FN 8 ES A A AA 10 auvog 43MOd se isla isis s 8 E t5 2 A 5 A Ah A AK AAA RA ss 8 8 5 gt 6 05 lt lt 5 lt lt E ox lt 505 55 gt 5 5 2 2 NOLLDFLOUd 319143099 14 3120303 911 8d 284 901 Je1Se A 0 901 Je1Se A 0 uunjeH 901 J91Se N 01 901 J91Se N 01 DOL uonoes DOL 0 DOL DOL uonoes Return to Section Return to Master TOC Return to Section TOC Return to Master TOC o 2 3 Return to Section Return to Master TOC o O gt o v E tc F 139 TROUBLESHOOTING amp REPAIR CALIBRAT
199. NT FEEDBACK CLEARING NETWORK CLR SHEET 2 X39 CURRENT MODE CONTROL DISABLE THE FETS AS SOON AS SECONDARY CURRENT IS GREATER THAN A REFERENCE LEVEL P gt CLA_SHUNT 0892 CLEARING NETWORK SECONDARY CURRENT REGULATION LAD CURRENT A D VMT CURRENT FEEDBACK INTERGATOR CURRENT FEEDBACK AMPLIFIER GAIN 5 0 to 6 9 LAD 5 0V 8 800A OUTPUT 5 v 20 SECONDARY CURRENT SENSE 2D CURRENT FEEDBACK ov En KELVIN VOLTAGE FEEDBACK SWITCH MATRIX VOLTAGE IDEALLY EQUAL TO 10 210 80V 3 81V ADDRVDATA BUS 3 POLE FILTER FIRST STAGE CUTOFF FREQ THIRD STAGE CUTOFF FREQ 15 J20 lt i geen v lt s 12 V NOISE GROUND 0218 9 CONTROLED BY SHEET 1 X16 Ww PLEXING THE V INPUFS PRECISION RECTIFIER GAIN 2 x92 C100 101 33074A MC1408 TRIM DAC REFERENCE VOLTAGE FEEDBACK MC1408 3 74AC573 CURRENT A D REFERENCE VOLTAGE A D
200. O MEMORY KEY 3 ELECTRODE CLASS UP DOWN KEYS 9 MEMORY LOCATION NUMBER KEYS 4 ELECTRODE SIZE UP DOWN KEYS 10 RECALL FROM MEMORY KEY 5 ELECTRODE GAS TYPE UP DOWN KEYS 11 HIGH TEMPERATURE LIGHT 6 WAVE CONTROL UP DOWN KEYS 1 LCD DISPLAY WINDOW Power up the machine NOTE The following four selections should with this overlay in place When the Power Wave always be performed in this order process elec is turned on the following message appears on trode class electrode size electrode gas type the display for a few seconds Selecting a setting for one component narrows LINCOLN ELECTRIC your choice of available settings in remaining com ponents This is why the order of performing the VERSION X X steps is important However if you make compo This display is followed by nent selections out of order the machine will OVERLAY ID m new selection for any set NUMBER 1 9 PRY 2 PROCESS SELECT KEY Use the PROCESS A welding procedure is made up of seven compo nente Dn s material type wire diameter Droaram SELECT key to select from the processes avail 2 Program able in the machine Press the PROCESS wire feed speed voltage or arc length trim and wave SELECT key until the light by the desired process control new welding procedure is created by S is lit selecting a combination of these components from the ones that have been programmed into the Power Wave See Figure B 4 for key locati
201. OC O o e 5 9 gt 5 5 Return to Section Return to Master TOC E 8 E 8 THEORY OF OPERATION FIGURE E 8 POWER BOARD OUTPUT INPUT MAIN RECTIFIER AND TRAMSFORMER RECTIFIER INPUT CONTACTOR RECONNECT THREE PHASE INPUT FET POWER ASSEMBLY aml POSITIVE ARI 1 2 T 5 SWITCH Ea SWITCH PROTECTION BOARD BOARD FET ASSEMBLY 4 SHUNT SNUBBER AND SENSE LEADS WATER LCD POWER BOARD The Power Board provides gate drives for the FETs on the Switch Boards It does so based on the turn on signals it receives from the Control Board One func tion of the Power Board is to isolate the Control Board from the Switch Boards The Power Board also pro vides the other printed circuit boards with the DC volt age supply they require NOTE Unshaded areas of Block Logic Diagram are the subject of discussion POWER WAVE 450 LINCOLN B 9 9 THEORY OPERATION FIGURE E 9 DISPLAY BOARD MAIN OUTPUT TRAMSFORMER RECTIFIER INPUT RECTIFIER INPUT AND CONTACTOR RECONNECT POSITIVE THREE PHASE INPUT POWER Return to Section TOC Return to Master TOC INPUT LINE SWITCH SWITCH BOARD FET ASSEMBLY NEGATIVE SHUNT CONTROL BOARD Return to Section TOC Return to Master TOC PC IN
202. OOTING PROCEDURES AND REPLACEMENT e 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 sta tic shielding bag A WARNING e ELECTRIC SHOCK can kill Have an electrician install and ser vice this equipment Turn the machine OFF before working on equipment Do not touch electrically hot parts Return to Section TOC Return to Master TOC e f the PC Board uses protective shorting jumpers don t remove them until installation is complete e f you return a PC Board to The Lincoln Electric Company for credit it must be in the static shield ing bag This will prevent further damage and allow roper failure analysis 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 5 please use the following procedure 4 Perform any necessary PC Board calibration pro cedures See the flow chart on the next page Test the machine to determine if the failure symp tom has been corrected by the replacement PC board NOTE Allow the machine to heat up so that all elec trical components can reach their operating temperature 1 Determine to the best of your techni
203. ORMER J36 lt lt TO CONTROL BD J36 Return to Section TOC Return to Master TOC SECONDARY 4000V ISOLATION FROM PRIMARY CIRCUITS TO LOAD SIDE OF CONTACTOR JIJE 77 1 g 200 20w ENABLE CAP1 FAULT SOFT START E DISABLE PRIMARY 25004 ISOLATION 4 UPPER CAP FAULT SOFT START F VOLTAGE MONITOR SOFT START DISABLE FROM ALL CIRCUITS NO FAULT 09 5 Vupcap gt VOLTAGE 2 di 1 026 GAIN 016 V V v 01144 UNDER VOLTAGE amp 10 12 13 14 15 Vv VERIFY CHARGE 4 d gt 170 VOC E 1 18181818 TO LOAD SIDE OF INPUT SWITCH 5 5 lt 1700 DISABLE RM V 1707 ENABLE RM Return to Section TOC Return to Master TOC Ei 4 V START A 1 CONTACTOR COIL Vupcap or OV ENABLE Uu J32 RUN MODE 22 6 V VOLTAGE 2 DISABLE 432 489 MONITOR 2 FAULT RUN MODE gt gt gt gt GAIN 016 V V RUN MODE DISABLE S a E 012 p Vlowcap gt TO CONTROL BD LOWER CAP 8 VOLTAGE MONITOR 50V 2 CNYI7 3 NO FAULT DISABLE OUTPUT Vupcap Vlowcap cas OR Vlowcap 5 150 50V SECONDARY 4000V ISOLATION FROM PRIMARY
204. PAIR FAN MOTOR REMOVAL AND REPLACEMENT continued FIGURE F 63 FAN MOTOR LOCATION PROCEDURE 6 With the 5 16 Remove main input supply power to the machine With the 3 8 nut driver remove the 4 screws that hold the handle to the machine Remove the rubber gasket cover seal from the lift bail With the 5 16 nut driver remove the sheet metal screws from the case top nut driver remove the screws holding the right and left case sides Remove the case sides by lifting up and out Perform the Capacitor Discharge Procedure described earlier in this section of the manual 1 2 TERMINAL STRIP WARNING 8 Before continuing with the test procedure perform the capacitor discharge proce dure to avoid electric shock After you have completed the capacitor dis charge procedure for all four switch boards use the wire cutters to cut any necessary cable ties necessary for removal of the fan motor holding the fan motor leads togeth er Note the location of these cable ties for reassembly Remove the fan motor leads from the ter minal strip With the 5 16 nut driver remove the water cooler access door Then remove the four screws from the lower rear panel POWER WAVE 450 LINCOLN amp F 168 3 FAN MOTOR AND MOUNTING BRACKET Return to Section Retu
205. PAIR OUTPUT SHUNT WELDING FEEDBACK TEST continued FIGURE F 16 SHUNT AMPLIFIER BOARD LOCATION TEST PROCEDURE 1 6 Remove main input supply power to the machine With the 3 8 nut driver remove the 4 screws that hold the handle to the machine Remove the rubber gasket cover seal from the lift bail With the 5 16 nut driver remove the sheet metal screws from the case top With the 5 16 nut driver remove the screws holding the right and left case sides Remove the case sides by lifting up and out Perform the Capacitor Discharge Procedure described earlier in this section of the manual WARNING Before continuing with the test procedure perform the capacitor discharge proce dure to avoid electric shock 7 After you have completed the capacitor dis charge procedure for all four switch boards locate plug J50 at the shunt amplifier board Locate the plug and insert your voltmeter positive probe into pin 3 and negative probe into pin 1 Right angle probes are recommended 8 Turn supply power to the machine ON POWER WAVE 450 LINCOLN amp F 53 Return to Section Return to Master TOC Return to Section TOC O o 5 5 9 5 2 Return to Section Return to Master TOC Return to Master TOC F 54 TROUBLESHOOTING amp REPAIR OU
206. Procedure 1 1 1 B 2 2 A 3 2 B 4 Pull the trigger on either wire feeder Depending on the gun switch position the corre sponding memory location is automatically recalled The wire feeders memory chart has no keys it is simply a chart The display window will show the procedure description wire feed speed and the preset volt age or arc length trim of the last active welding procedure With this overlay in place the wire feed speed and the preset voltage or arc length trim can be changed from the wire feeder The new values replace the previous values and become a perma nent part of the procedure If limits have been set on the wire feed speed volt age or arc length trim of the selected procedures these limits will be active when this overlay is in place They cannot be overridden from this over lay DISPLAY RECALL KEY To view other information about the active welding procedure press the DISPLAY RECALL key The display window will show the procedure description and gas type of the last active procedure for as long as the key is held depressed When the key is released the wire size material type and process descriptions will be displayed for a few seconds HIGH TEMPERATURE LIGHT The high tempera ture light comes on when the internal machine temperature exceeds the allowed limit Output is disabled until the machine cools down and the high temperature light goes out MEMORY LIGHTS A memory light is o
207. R AUXILIARY TRANSFORMER TEST 1 continued FIGURE F 5 TRANSFORMER 1 AND T2 LOCATION TEST PROCEDURE 6 With the 5 16 Remove main input supply power to the machine With the 3 8 nut driver remove the 4 screws that hold the handle to the machine Remove the rubber gasket cover seal from the lift bail With the 5 16 nut driver remove the sheet metal screws from the case top nut driver remove the screws holding the right and left case sides Remove the case sides by lifting up and out Perform the Capacitor Discharge Proce dure described earlier in this section of the manual A WARNING Before continuing with the test procedure perform the capacitor discharge proce dure to avoid electric shock T 10 J5 LOCATED IN BASE 2 PROTECTION BOARD 3 PLUG J30 4 AUXILIARY TRANSFORMER 1 After you have completed the capacitor discharge procedure for all four switch boards remove the PC board cover Use the 5 16 nut driver Remove plug J5 from the T2 transformer located in the machine base assembly This is a 6 pin molex plug with 5 wires see Figure F 5 for location T2 is con nected in parallel with T1 Leaving the two transformers connected in parallel for the test might result in incorrect readings therefore plug J5 should be disconnected Remove plug J30 from the protection board See Figure 1 loc
208. RESISTANCE TEST TABLE Continued F 72 Apply Apply Positive Negative Test Test Probe to Probe to Test Repair Next Terminal Terminal Result Conclusion Action Procedure 12D 3B Less than OK None Continue 100 ohms Greater Open Replace 4 Snubber than 1K Switch Resistor ohm Boards Test 3B 12D Greater OK None Continue than 1K ohm Less than Shorted Replace 4 Snubber 100 ohms Switch Resistor Boards Test 12D 407 Greater OK None Continue than 1K ohm Less than Shorted Replace 4 Snubber 100 ohms Switch Resistor Boards Test 407 12D Less than OK None Continue 100 ohms Greater Open Replace 4 Snubber than 1K Switch Resistor ohm Boards Test 9D 408 Less than OK None Continue 100 ohms Greater Open Replace 4 Snubber than 1K Switch Resistor ohm Boards Test 408 9D Greater OK None Continue than 1K ohm Less than Shorted Replace 4 Snubber 100 ohms Switch Resistor boards Test NOTE ohm ohm reading multiplied by 1000 NOTE Always make sure that all four Switch Boards are changed at the same time Never mix an old style different part number Switch Board with a new style new part number POWER WAVE 450 LINCOLN amp F 73 F 73 TROUBLESHOOTING amp REPAIR olo o IGBT SWITCH BOARD TEST G3165 1 5 5 TABLE F 6 NOTE This test will NOT determine if an individual IGBT device is open PT o 9 1 22 Positive Negative z Test Te
209. RMAL OPERATION 1 Turn OFF the 115VAC pretest power circuit See Figure 78 2 Make certain the filter capacitors are completely discharged Remove the variable AC primary supply Figure F 76 3 Remove the 115VAC pretest power circuit See Figure F 78 4 Reconnect plug P70 5 Remove the in P23 See Figure F 80 6 Reconnect P23 7 Reconnect P73 jumper plug 10uS Div OUTPUT TESTS SETUP The filter capacitors must be discharged before continuing Make sure the Power Wave is configured for 460VAC operation 1 Connect a power input cable to CR1 DO NOT APPLY INPUT VOLTAGE AT THIS TIME 2 Connect the grid load to the Power Wave out put terminals Make sure the grid load is OFF PRIMARY OVER CURRENT TEST 1 Connect a current probe to the oscilloscope and set it for 10 mV div should be equal 10 mA div 10 uS div 2 Put the current probe on lead 221 at J21 pin 1 See Wiring Diagram 3 Loosely assemble the sheet metal case to the Power Wave 4 Apply input power to the machine and turn the Power Wave power switch ON POWER WAVE 450 LINCOLN B Return to Section Return to Master TOC Return to Section TOC Return to Master TOC o HE 2 3 Return to Section Return to Master TOC o 5 F 208 F 208 TROUBLESHOOTING amp REPAIR PRE POWERUP SWITCH BOARD
210. RMAL PROTECTION The Power Wave has thermostatic protection from excessive duty cycles overloads loss of cooling and high ambient temperatures When the power source is subjected to any of these conditions or any of the con ditions mentioned above a thermostat will open The yellow high temperature light on the case front comes on See Figure 1 location Machine output is disabled and welding is not possible until the machine is allowed to cool and the High Temperature Light goes out OVER CURRENT PROTECTION The Power Wave 450 is limited to producing 750 amps peak current If the average current exceeds 540 amps then the peak current will be limited to 100 amps until the average current decreases to under 50 amps POWER WAVE 450 LINCOLN B NOTES POWER WAVE 450 LINCOLN 901 Je1Se A 0 uunjeHd 901 4 1 0 901 J91Se N 01 901 J91Se N 01 901 uonoes uumeg DOL uonoes uumeg DOL uonoes uumeg DOL uonoes Section 1 Section C 1 TABLE OF CONTENTS ACCESSORIES 2 Accessories MC eee eee plata dea vee Section C gt 0191 6181 77 16 0 1 1 1011 2 Wire Feeder C 2 E Guns and Cables C 2 Water Cooler Usage reise denen endi s c nte eret eL i 2 Recommended Coolants C 3 Priming the Cooler RR C 3 Cooler Periodic Maint
211. Return to Master TOC 5 PAIRS OF RESISTORS CHECK VOLTAGES BETWEEN EACH TERMINAL AND FROM EACH RESISTOR TO CASE GROUND Return to Section TOC Return to Master TOC 8 Locate terminals 9 and 12 on the switch boards They can be identified by the 7 Locate the two sets of two resistors on the left side of the machine and three sets of O o 5 5 9 gt 5 2 Return to Section Return to Master TOC two resistors on the right side of the machine See Figure F 20 Do not touch the resistors or any other internal machine component Using a DC voltmeter check for any DC voltage that may be present across the terminals of each resistor and from each resistor to case ground 20 mea surements in all If a voltage is present be careful not to touch these resistors A WARNING e ELECTRIC SHOCK can kill Proceed with caution Be careful not to touch any internal machine components during the dis charge procedure Discharge labels which are located on each of the four switch boards See Figure POWER WAVE 450 LINCOLN amp Return to Section Return to Master TOC Return to Section TOC Return to Master TOC o 2 3 Return to Section Return to Master TOC o O gt o E tc F 62 TROUBLESHOOT
212. Return to Master TOC F 167 F 167 TROUBLESHOOTING amp REPAIR FAN MOTOR 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 elec trical 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 DESCRIPTION The following procedure will aid the technician in removing the machine fan motor for main tenance or replacement MATERIALS NEEDED 5 16 Nut driver 3 8 Nut driver 3 4 Open or box end wrench Wire cutters Slot head screw driver Machine Wiring Diagram in the Electrical Diagrams section of this manual This procedure takes approximately 30 minutes to perform POWER WAVE 450 LINCOLN Return to Section Return to Master TOC Return to Section TOC Return to Master TOC o 2 3 Return to Section Return to Master TOC o p 5 168 TROUBLESHOOTING amp RE
213. Return to Section TOC Return to Master TOC If limits have been set on the wire feed speed volt age or arc length trim of the selected procedures these limits will be active when this overlay is in place They cannot be overridden from this over lay 3 THE PROGRAM LIST The PROGRAM LIST block in the center of this overlay provides a convenient place to record a brief description of each welding procedure stored in memory A Dry Erase mark er should be used for this purpose 4 DISPLAY RECALL KEY To view other information about the active procedure press the DISPLAY RECALL key The display window will show the procedure description and gas type of the active procedure for as long as the key is held depressed When the key is released the wire size material type and process descriptions dis play for a few seconds 5 HIGH TEMPERATURE LIGHT The high tempera ture light comes on when the internal machine temperature exceeds the allowed limit Output is disabled until the machine cools down and the high temperature light goes out 6 MEMORY LIGHTS A memory light is on when its corresponding memory is selected This tells you what memory location is active at any given time Return to Section TOC Return to Master TOC O o e 5 5 9 5 2 Return to Section Return to Master TOC POWER WAVE 450 LINCOLN B Return to Section Return to
214. SHOOTING amp REPAIR F 76 901 Je1Se A 0 901 4 1 0 uunjeH 901 J91Se N 01 901 J91Se N 01 DOL uonoes DOL DOL DOL uonoes Return to Section Return to Master TOC Return to Section TOC O o 5 5 0 9 5 2 Return to Section Return to Master TOC Return to Master TOC F 77 TROUBLESHOOTING amp REPAIR SNUBBER AND BLEEDER RESISTOR TEST continued TEST PROCEDURE 1 6 With the 5 16 Remove main input supply power to the machine With the 3 8 nut driver remove the 4 screws that hold the handle to the machine Remove the rubber gasket cover seal from the lift bail With the 5 16 nut driver remove the sheet metal screws from the case top nut driver remove the screws holding the right and left case sides Remove the case sides by lifting up and out Perform the Capacitor Discharge Proce dure Hescribed earlier in this section of the manual 7 e WARNING Before continuing with the test procedure perform the capacitor discharge proce dure to avoid electric shock Perform the following tests on the four switch boards Switch Board 1 Switch Board 1 is Marked CAP 1 on the Switch Board Assembly Connection Decal See Figure F 24 A B Remo
215. SHOOTING amp REPAIR WATER COOLER REMOVAL AND REPLACEMENT continued FIGURE F 60 WATER COOLER LOCATION PROCEDURE NOTE These instructions may vary slightly 6 with later model coolers See instruc tions included with cooler kit Remove main input supply power to the machine With the 3 8 nut driver remove the 4 screws that hold the handle to the machine Remove the rubber gasket cover seal from the lift bail With the 5 16 nut driver remove the sheet metal screws from the case top With the 5 16 nut driver remove the screws holding the right and left case sides Remove the case sides by lifting up and out Perform the Capacitor Discharge Proce dure described earlier in this section of the manual BACK PANEL 2 WATER COOLING FITTINGS 3 CIRCUIT BREAKER WARNING 7 9 Before continuing with the test procedure perform the capacitor discharge proce dure to avoid electric shock After you have completed the capacitor dis charge procedure for all four switch boards use the 5 16 nut driver to remove the water cooler access door See Figure F 60 for location With the 3 8 open end or socket wrench remove the two water cooler assembly mounting screws Slide the assembly to the left to better access the circuit breaker which will be removed in a moment With the 5 16 nut driver remove the two sheet metal s
216. ST A 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 elec trical 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 eight snubber resistors and two bleeder resistors are of the proper value and their associated leads intact MATERIALS NEEDED Volt Ohmmeter Multimeter 5 16 Nut driver 3 8 Nut driver Snubber and Bleeder Resistor Wiring Diagram Figure F 25 This procedure takes approximately 30 minutes to perform POWER WAVE 450 LINCOLN F 76 4 98 io lt lt e m m m tn x 8 N 9 9 N N 9 w 2 L dvo e lt Ni 5 dvo dvo gt 5 m 9 9 m 9 m 5 co co co co co o SNUBBER AND BLEEDER RESISTOR TEST FIGURE F 24 SWITCH BOARD ASSEMBLY CONNECTION DECAL TROUBLE
217. Service Department for electrical troubleshooting assistance before you proceed Call 1 800 833 9353 POWER WAVE 450 LINCOLN Return to Section Return to Master TOC Return to Section TOC Return to Master TOC o 2 3 Return to Section Return to Master TOC o O P o 9 gt E 11 11 TROUBLESHOOTING REPAIR TROUBLESHOOTING GUIDE PROBLEMS SYMPTOMS Machine regularly overheats yel low light LED on the front panel glows indicating a thermal over load The display is on Machine does not appear to over heat but yellow light turns on and off intermittently Output is dis abled whenever yellow light is on POSSIBLE AREAS OF MISADJUSTMENT S OUTPUT PROBLEMS 1 Welding application may exceed recommended duty cycle Dirt and dust may have clogged the cooling channels inside the machine Refer to the Maintenance Section of this manual Air intake and exhaust louvers may be blocked due to inade quate clearance around machine Make sure both fans are func tioning correctly Observe Safety Guidelines detailed in the beginning of this manual RECOMMENDED COURSE OF ACTION 1 One of the thermostats located on the output rectifier or FET heat sink may be faulty Test or replace Check thermostats on output rectifier and switch board 1 These thermos
218. Switch Board pairs occurs during halves of a 50 microsecond interval creating two constant 20 kHz square waves on the pri mary side of the transformer The current flow through the Main Transformer primaries induces a 20 kHz AC square wave output signal at the secondary of the Main Transformer NOTE Unshaded areas of Block Logic Diagram are the subject of discussion POWER WAVE 450 LINCOLN B SHUNT E 5 POSITIVE NEGATIVE Return to Section Return to Master TOC Return to Section TOC Return to Master TOC O o e 5 9 gt 5 5 Return to Section Return to Master TOC E 6 E 6 THEORY OF OPERATION FIGURE E 6 OUTPUT RECTIFIER AND CHOKE TPUT INPUT MAIN OU RECTIFIER TRAMSFORMER RECTIFIER INPUT CONTACTOR RECONNECT THREE PHASE INPUT FET POWER ASSEMBLY mE I POSITIVE ARI SWITCH SS SWITCH PROTECTION BOARD BOARD FET ASSEMBLY NEGATIVE SHUNT 2 SNUBBER AND SENSE LEADS WATER LCD OUTPUT RECTIFIER AND CHOKE The Output Rectifier receives the AC output from the Main Transformer secondary and rectifies it to a DC level with a 40 kHz ripple Since the Output Choke is in series with the positive leg of the Output Rectifier and also in series with the welding load a filtered DC output is applied to the machine output terminals
219. T RECTIFIER RESISTANCE VALUES Step Place Place See Lead Lead Note Test for on on If Then A 1K Ohms POS AC1 gt 1K Ohms Go to step B lt 100 Ohms Tested failed B 1K Ohms POS AC2 gt 1K Ohms Go to step C lt 100 Ohms Tested failed 1K Ohms POS AC3 gt 1K Ohms Go to step D lt 100 Ohms Tested failed D 1K Ohms AC1 NEG gt 1K Ohms Go to step E lt 100 Ohms Tested failed E 1K Ohms AC2 NEG gt 1K Ohms Go to step F lt 100 Ohms Tested failed F 1K Ohms AC3 NEG gt 1K Ohms Go to step G lt 100 Ohms Tested failed G lt 100 Ohms AC1 POS lt 100 Ohms Go to step H gt 1K Ohms Test failed H lt 100 Ohms AC2 POS lt 100 Ohms Go to step gt 1K Ohms Test failed lt 100 Ohms AC3 POS lt 100 Ohms Go to step J gt 1K Ohms Test failed J lt 100 Ohms NEG AC1 lt 100 Ohms Go to step K gt 1K Ohms Test failed K lt 100 Ohms NEG AC2 lt 100 Ohms Go to step L gt 1K Ohms Test failed L lt 100 Ohms NEG AC3 lt 100 Ohms Input Rectifier OK gt 1K Ohms Test failed POWER WAVE 450 LINCOLN amp F 49 50 NOTES POWER WAVE 450 LINCOLN 5 F 50 901 Je1Se A 0 uunjeHd 901 4 1 0 uunjeH 901 J91Se N 01 DOL 01 901 uonoes uumeg DOL uonoes uumeg DOL uonoes uumeg DOL uonoes uumeg Return to Section Return to Master TOC Return to Section TOC Return to Master TOC o
220. TERFACE DISPLAY BOARD The Display Board allows the operator to select from the procedures that are programmed into the machine and it lets the Control Board know which procedure was selected These procedures are pro grammed into the machine s software package The Display Board is used to communicate with the oper ator It determines what Overlay is installed in the machine and which buttons are active on the keypad It also controls the LCD display the lights on the front of the machine the Piezo Buzzer and the water cool er Through the use of a current serial loop the Display Board and Control Board communicate or talk to the wire feeder s The Display Board can also communicate with a computer through the RS232 interface o e 5 5 9 gt 5 5 r C NOTE Unshaded areas of Block Logic Diagram are the subject of discussion Return to Section TOC Return to Master TOC POWER WAVE 450 LINCOLN B Return to Section Return to Master TOC Return to Section TOC Return to Master TOC O o e 5 5 9 gt 5 2 Return to Section Return to Master TOC E 10 THEORY OF OPERATION THERMAL PROTECTION Two normally closed NC thermostats protect the machine from excessive operating temperatures These thermostats are wired in series and are con nected to the Control Board One of the t
221. TEST PROCEDURE FOR REPLACEMENT OF SWITCH ASSEMBLY G2402 2 continued FIGURE F 84 PRIMARY CURRENT SIGNAL 10V Div Press the MANUAL PROCEDURE ENTRY Key on the Calibration and Test Overlay and change the Power Wave to Process 1 Setup 1 8 mode Turn the arc start switch ON See Start PW450 or Figure F 79 Adjust the output grid load to get 400 amps at 36VDC The oscilloscope picture should look like Figure F 84 ALTERNATE TEST without current probe 1 Check the capacitor voltages Connect a transformer isolated oscilloscope as follows Set oscilloscope for 2v div and 10us div Probe 421 1 wire 211 Common 21 5 wire 215 Observe a waveform similar to Figure F 84 Equal amplitude and symmetry of the pulses is important The capacitor voltages must be within eight volts of each other Turn the arc start switch OFF Arc Start PW450 or Figure F 79 Turn OFF the Power Wave and remove the input power Make sure the filter capacitors are completely discharged Figure 77 10uS Div PREPARE MACHINE FOR NORMAL OPERATION 1 Turn the power switch OFF and remove input power to the machine The input capacitors must be discharged before continuing Remove the capacitor voltage monitoring leads See Figure F 77 Remove the power input cable from CR1 Remove the output cables
222. TPUT SHUNT WELDING FEEDBACK TEST continued WARNING ELECTRIC SHOCK can kill Proceed with caution Be careful not to touch any inter nal machine components during the remainder of the test procedure 9 Check for 15 VDC between plug J50 10 11 pin 3 and J50 pin 1 Carefully move the probes placing the negative probe at plug J50 pin 6 and the positive probe at J50 pin 1 Check for 15 VDC If the voltage readings are NOT correct check the associated wiring to the control board If the wiring is okay the control board may be faulty Replace the control board Refer to the Printed Circuit Board Removal and Replacement Procedure in this section of the manual 12 If the supply voltage readings are correct load the machine to 400 amps A CAUTION Do not run the machine under load for more than 15 sec with case removed 13 14 15 17 Use current probe to check for 5 ma of current through lead 218 plug J50 pin 4 This also reads approximately 1 VDC if you use a voltmeter If the current reading is NOT correct the shunt amplifier board may be faulty Replace the shunt amplifier assembly and perform current calibration If the current reading IS correct the con trol board may be faulty Replace the con trol board Refer to the Printed Circuit Board Removal and Replacement proce dure in this section of the manual After the test is co
223. UBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginning of this manual PROBLEMS POSSIBLE AREAS OF RECOMMENDED SYMPTOMS MISADJUSTMENT S COURSE OF ACTION OUTPUT PROBLEMS Return to Section TOC Return to Master TOC Major physical or electrical dam Contact your local authorized age is evident when the sheet Lincoln Electric Field Service metal cover s are removed Facility for technical assis tance Machine is dead no output no Check the main input fuses If 1 If fuse F1 quickly fails per fans no displays open replace form the Auxiliary Transformer Primary Wiring Make certain that the input power switch S1 is in the ON position 2 f fuse F1 does not fail per form the Auxiliary Check for proper input voltage Transformer Test must match the rating on the machine nameplate Make certain the reconnect panel is configured properly for the applied voltage Return to Section TOC Return to Master TOC Check fuse F1 in the recon nect panel If faulty replace with 5 amp slow blow fuse O o e 9 gt 5 2 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 Retur
224. UTPUT DISABLE i 2 8 264 gt nm i 233 m 8 i sk NOISE D 5 D i COUPLED TO 1427 i yvy i ERE rA i oft i i gt meme 2 i COUPLED 326 4 su lt 1 1 gt sits 40mA CURRENT 80080 i poem FROM 4J28 au 1 5W au 5 9 OND i RECONNECT PANEL 77 i sERALLOO y SHUNT BOARD WORK i CURRENT i i i i i i i 200 208V 5 EL 6 soy wren 5 i X 4 2 5 my i 1 8 i _ 220 280V ane gt i i 3 4 gt CETE i FET BANKB Le ARS i 380 415V 23 26 gt 810 WIPER i DRYER lt 1 227 eL 130 dod Sta 275 pm i GATE SIGNAL 8 GL 944 440 460V 28 2 3 POT MAX 294 15 V aw 7 wT DET ej 215 has gt IN id L4 POT WIPER 201 15 eno WIPER i t 15441120 i i H 8886 POTMIN 292 mo 5 361 ns gt i wo E 5 Lomein o 8 1 58 gt i se m 2 5 poas 454 gt 015 0 i a Du 1 i i i 455 gt gt PRESSURE FR
225. ________ ___________________ Return to Section Return to Master TOC CAPACITORS MFD VOLTS C oS mO M Or Z lt m Return to Section TOC Return to Master TOC C5 M16062 D Q Ojo 515 9 16 218 5 2 Q RO o o o o LINCOLN ELECTRIC _ SQUAREWAVE TIG 300 amp 350 a CLEVELAND OHIO U S A PROTECTION P C BOARD ASSEMBLY SCALE DOUBLE 0 00000 M 16062 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 amp ine machine POWER WAVE 450 Return to Section TOC Return to Master TOC Return to Section Return to Master TOC Return to Section TOC 515 9 16 218 5 2
226. and Outershield and stick proce dures OPERATIONAL FEATURES AND CONTROLS The Power Wave through use of a keypad overlay system provides various options and controls such as Multiple Process Procedure Selection Memory Storage of Procedures Weld from Memory Only oper ation Dual Process Dual Feeder capability DESIGN FEATURES AND ADVANTAGES e Designed to NEMA Standards Multiple process output ranges 5 540 amps e 2 line LCD display e Easy access for input connections Connections are simple strip and clamp no lugs required Modular construction for easy servicing e Thermostatically protected e Electronic overcurrent protection Overvoltage protection Digital signal processor and microprocessor control e RS232 interface for future welding application updates Simple reliable reconnection for various input volt ages New accessories and wire feeders communicate using a digital current loop to transfer information Auto device recognition simplifies accessory cable connections Direct support of two wire feeders Auto configurable for either metric or English mode Multi process control Stick short arc GMAW spray GMAW pulse and flux cored arc welding FCAW Simple control through use of overlays that limit access to only those keys required for a given appli cation WELDING CAPABILITY The Power Wave 450 is rated at 500 amps 40 volts at 6096 duty cycl
227. and gas combination to produce a Spray Arc For example 0 035 1 50 wire with 90 Argon and 10 CO blend of gas SETUP PROCEDURE 1 Connect a DC voltmeter to the machine s negative output terminal and the conductor block of the wire feeder 2 Connect the Synergic 7 wire feeder to the Wire Feeder 1 amphenol on the back of the Power Wave This procedure takes approximately 45 minutes to perform POWER WAVE 450 LINCOLN F 148 F 148 TROUBLESHOOTING amp REPAIR FULL VOLTAGE CALIBRATION continued FIGURE F 55a TEST AND CALIBRATION OVERLAY THE LNCOLN ELECTRIC COMPANY CLEVELAND OHIO USA N L9660 255 CALIBRATION 8 TEST OVERLAY LINCOLN E ELECTRIC INVERIEC POWER WAVE Return to Section TOC Return to Master TOC Return to Section TOC O o e 5 5 9 5 2 21 Return to Section Return to Master TOC Return to Master TOC PROCEDURE 1 The voltage calibration numbers are stored in the display board They are programma ble from the front panel using the Test and Calibration Overlay 2 Change the display board in question 3 Install the Test and Calibration overlay L9660 255 or do not insert any overlay into the machine and power up the machine See Figure F 55a If the 255 overlay is not available use Figure F 55a as a guide to see which keys to press 4 Press the Voltage Calibration fu
228. and the lift bail rubber gasket POWER WAVE 450 LINCOLN amp F 78 Return to Section Return to Master TOC Return to Section TOC O10 e 515 9 1 EIS 2 Return to Section Return to Master TOC Return to Master TOC F 79 FIGURE F 25 SNUBBER AND BLEEDER RESISTOR WIRING DIAGRAM TROUBLESHOOTING amp REPAIR 401 POWER WAVE 450 LINCOLN SWITCH BOARD R1 250 H a 12E 25W 12L 12 ______ TO RECONNECT SWITCH 402 101 250 R2 49 6 59 9 484 __ TO RECONNECT SWITCH SWITCH BOARD R3 250 2 403 12F 25W L 12B 028 RECONNECT SWITCH 4 404 Co 2 88 ______ RECONNECT SWITCH SWITCH BOARD 5 250 3 126 12 120 RECONNECT SWITCH 406 rio 250 406 H6 25W 96 9M BC _ TO RECONNECT SWITCH SWITCH ay BOARD 250 4 407 12H 29W 12D 020 TO RECONNECT SWITCH 408 250 9 OD _ TO RECONNECT SWITCH F 79 7 5 9 25W 7 5KQ 25W 80 NOTES POWER WAVE 450 LINCOLN 5 F 80 901 Je1Se A 0 901 4 1 0 uunjeH 901 J91Se N 01
229. and to avoid elec trical 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 there are any short circuits or other problems on the input power circuit that would cause the input fuses to repeatedly blow MATERIALS NEEDED Volt Ohmmeter Multimeter 5 16 Nut driver 3 8 Nut driver Input and Auxiliary Circuit Wiring Diagram Figure 14 This procedure takes approximately 20 minutes to perform POWER WAVE 450 LINCOLN Return to Section Return to Master TOC Return to Section TOC Return to Master TOC o 2 3 Return to Section Return to Master TOC o p 5 F 44 TROUBLESHOOTING amp REPAIR INPUT POWER AND WIRING HARNESS TEST FIGURE F 13 INPUT POWER INSPECTION POINTS TEST PROCEDURE 1 6 With the 5 16 Remove main input supply power to the machine With the 3 8 nut driver remove the 4 screws that hold the handle to the machine Remove the rubber gasket cover seal from the lift bail With the 5 16 nut driver remov
230. ant 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 contre les chutes dans le cas ou on recoit un choc Ne jamais LES MACHINES SOUDER enrouler le c ble lectrode autour de n importe quelle partie du TRANSFORMATEU R ET 2 Dans le cas de travail au dessus du niveau du sol se prot ger corps REDRESSEUR Un coup 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 1 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 LINCOLN Relier la
231. assembly Install the machine case sides and top Install the handle and the lift bail rubber gasket Prior to applying full input power perform the Pre Power Up Switch Board Test POWER WAVE 450 LINCOLN F 195 196 NOTES POWER WAVE 450 LINCOLN 5 F 196 901 Je1Se A 0 901 Je1se A 0 901 J91Se N 01 DOL 01 901 uonoes uumeg DOL uonoes uumeg DOL uonoes uumeg DOL uonoes uumeg Return to Section Return to Master TOC Return to Section TOC Return to Master TOC o 2 3 Return to Section Return to Master TOC o O gt o gt E tc F 197 F 197 TROUBLESHOOTING amp REPAIR MAIN TRANSFORMER REMOVAL AND REPLACEMENT A 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 elec trical 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 9
232. at hold the handle to the machine Remove the rubber gasket cover seal from the lift bail With the 5 16 nut driver remove the sheet metal screws from the case top With the 5 16 nut driver remove the screws holding the right and left case sides Remove the case sides by lifting up and out Perform the Capacitor Discharge Procedure described earlier in this section of the manual WARNING Before continuing with the test procedure perform the capacitor discharge proce dure to avoid electric shock e 7 After you have completed the capacitor dis charge procedure for all four switch boards remove the PC board cover Use the 5 16 nut driver Perform the following test for faults on the serial loop circuitry between wire feeder 1 amphenol P83 and the control board Disconnect the wire feeder from the wire feeder 1 amphenol P83 POWER WAVE 450 LINCOLN amp F 108 Return to Section Return to Master TOC Return to Section TOC Return to Master TOC o 2 3 Return to Section Return to Master TOC o p 5 109 10 11 TROUBLESHOOTING REPAIR SERIAL LOOP WIRING HARNESS TEST continued Check for loose or broken leads between the following pins P83 pin L and J27 pin 1 on the control
233. at the reconnect switch 9A 9B 9C 90 9J and POS Check that the following leads are con nected together at the reconnect switch 12A 12B 12C 12D 12K 12J and NEG With the volt ohmmeter check that there is no continuity between the two groups of leads in A and B above POWER WAVE 450 LINCOLN amp F 82 Return to Section Return to Master TOC Return to Section TOC O o 5 5 9 0 5 2 Return to Section Return to Master TOC Return to Master TOC F 83 TROUBLESHOOTING amp REPAIR RECONNECT SWITCH TEST 1 continued For 380 or 460 VAC A Check that the following leads are connect ed together at the reconnect switch 9A 9B 9K and POS Check that the following leads are con nected together at the reconnect switch 90 9 12A 12B and 12 Check that the following leads are con nected together at the reconnect switch 12C 12D 12K and NEG With the volt ohmmeter check that there is no continuity between the three groups of leads in A B and C above If any of the leads tested above are short ed go to step 9 If none of the leads are shorted the test is complete Install the machine case sides top handle and the lift bail rubber gasket Perform the following steps With the 5 16 nut driver remove the screws that hold the PC board cover Remove the cover
234. ated in the display window Select another memory loca tion It is not necessary to save a procedure back to memory after it is recalled from memory When a procedure is saved into a memory location it can be recalled from there until another procedure is stored in that location or the location is cleared The RECALL FROM MEMORY and SAVE TO MEMORY keys can be used to clear a memory location Return to Section TOC Return to Master TOC Press the SAVE TO MEMORY and then the RECALL FROM MEMORY key Do not press both keys at the same time A message in the display window will ask you to press the MEM ORY LOCATION NUMBER key of the memory location you want to clear If you press the SAVE TO MEMORY and RECALL FROM MEMORY keys and then change your mind you can exit this function by pressing the DISPLAY RECALL key 11 HIGH TEMPERATURE LIGHT The high tempera ture light comes on when the internal machine temperature exceeds the allowed limit Output is disabled until the machine cools down and the high temperature light goes out Return to Section TOC Return to Master TOC O10 e 515 0 gt EIS 2 Return to Section Return to Master TOC POWER WAVE 450 LINCOLN B Return to Section Return to Master TOC Return to Section TOC Return to Master TOC o 2 3 Return to Section Retur
235. ation of the board and plug J30 Remove the 5 leads 3 heavy and 2 small T1 T2 T3 from main input contactor CR1 This is a safety precaution t prevents high voltage from being put on the machine during the test Wrap tape around the lead ends to insulate them and prevent them from touching POWER WAVE 450 LINCOLN amp F 28 AUXILIARY TRANSFORMER T1 PLUG Return to Section Return to Master TOC Return to Section TOC Return to Master TOC o 2 3 Return to Section Return to Master TOC o p 5 F 29 TROUBLESHOOTING amp REPAIR AUXILIARY TRANSFORMER TEST 1 continued 11 Remove plugs J32 and J33 from the pro tection board 12 Turn the main input supply power to the machine back ON A WARNING ELECTRIC SHOCK can kill e Proceed with caution careful not to touch any internal machine compo nents during the remainder of the test proce dure 13 Check for the correct AC voltage at plugs J32 and J33 as follows DO NOT CHECK THE VOLTAGE ON THE PROTECTION BOARD Test A J33 pin 1 lead 32A to J33 pin 3 lead 333 42 Test B J33 1 82A to J33 4 334 24 VAC Test C J32 1 321 to J32 3 323 24 VAC Test D 33 1 leads 32A to J33 6 lead 336 115VAC If the voltage checks are good then Auxiliary Transformer 1 is good
236. ay result in danger to the technician or machine operator and will invalidate your factory warranty For your safety and to avoid elec trical shock please observe all safety notes and precautions detailed throughout this manual 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 K941 1 Remote Control Kit is faulty MATERIALS NEEDED Volt Ohmmeter Multimeter Trigger Circuit Wiring Diagram Figure F 48 This procedure takes approximately 20 minutes to perform POWER WAVE 450 LINCOLN Return to Section Return to Master TOC Return to Section TOC Return to Master TOC o 2 3 Return to Section Return to Master TOC o p 5 F 128 TROUBLESHOOTING amp REPAIR K941 1 REMOTE CONTROL KIT TEST continued FIGURE F 47 6 PIN AMPHENOL LOCATION 1 1 MACHINE FRONT PANEL 2 REMOTE CONTROL AMPHENOL RECEPTACLE 6 PIN TEST PROCEDURE 1 Remove the Remote Control Kit from the power source Perform the following tests If any test fails the Remote Control Kit is faulty and should be replaced With the volt ohmmeter check the conti nuity b
237. ay section of this manual for instructions RECOMMENDED COURSE OF ACTION 1 Perform the Transformer 2 Test 2 The water cooler may be defective Replace Check the continuity of lead 453 454 455 amp 456 from plug J3 to J11 See wiring dia gram The display board may be faulty Replace A 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 POWER WAVE 450 LINCOLN 17 17 TROUBLESHOOTING REPAIR TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginning of this manual PROBLEMS POSSIBLE AREAS OF RECOMMENDED SYMPTOMS MISADJUSTMENT S COURSE OF ACTION FUNCTION PROBLEMS Foreign characters are shown on Contact your local Lincoln Make sure molex plug J19 is the Power Wave display Authorized Field Service Facility plugged into the Display board Return to Section TOC Return to Master TOC securely and the pins are secure in the plug body The display board may be faulty Replace and perform voltage calibration Return to Section TOC Return to Master TOC O o e 5 9 cic 5 5 CAUTION If for any reason you do not understand the test procedures or are unable to perform the test re
238. bar and the wrap around machine cover 3 Remove the two case sides There are hex head screws on each side A CAUTION TO PREVENT DAMAGE TO MACHINE AVOID UNNECESSARY MOVEMENT OF FRONT PANEL O o Fle 5 o 9 515 2 4 Obtain high resistance and high wattage resistor 25 1000 ohms and 25 watts minimum This resistor is not supplied with the machine Secure this resistor to a piece of insulating material such as a glastic board See Figure D 3 NEVER USE A SHORTING STRAP FOR THIS PROCEDURE Return to Section TOC Return to Master TOC POWER WAVE 450 LINCOLN B Return to Section Return to Master TOC Return to Section TOC Return to Master TOC O10 e 515 9 1 EIS 2 Return to Section Return to Master TOC MAINTENANCE FIGURE D 1 RESISTOR LOCATIONS 5 PAIRS OF RESISTORS CHECK VOLTAGES BETWEEN EACH TERMINAL AND FROM EACH RESISTOR TO CASE GROUND Locate two sets of two resistors on the left side of the machine and three sets of two resistors on the right side of the machine See Figure D 1 Do not touch the resistors or any other internal machine component Using a DC voltmeter check for any DC voltage that may be present across the termi nals of each resistor and from each resistor to case ground 20 measurements in all If a voltage is present be careful not t
239. board lead 111A P83 pin M and J27 pin 4 on the control board lead 112A Make sure that plug J27 is plugged into the control board securely and that none of its pins are loose Reconnect the wire feeder to the wire feeder 1 amphenol P83 Perform the following test for faults on the serial loop circuitry between wire feeder 2 amphenol P82 and the control board Disconnect the wire feeder from the wire feeder 2 amphenol P82 Check for loose or broken leads between the following pins P82 pin L and J28 pin 1 on the control board lead 117A P82 pin M and J28 pin 4 on the control board lead 118A Make sure that plug J28 is plugged into the control board securely and that none of its pins are loose Reconnect the wire feeder to the wire feeder 2 amphenol P82 Perform the following test for faults on the serial loop circuitry between the display board and the control board Check for loose or broken leads between the following pins J26 pin 3 on the control board and J14 pin 6 on the display board lead 263 J26 pin 4 on the control board and J14 pin 3 on the display board lead 264 Make sure that plug J26 is plugged into the control board securely and that none of its pins are loose Also make sure that plug J14 is securely plugged into the dis play board and that none of its pins are loose Perform the following test for faults on the serial loop circuitry 40 mA curr
240. burn skin Always be sure coolant is not hot before Tm doing any work on cooler parts POWER WAVE 450 LINCOLN B Return to Section Return to Master TOC Return to Section TOC Return to Master TOC o 2 3 Return to Section Return to Master TOC o p 5 OPERATION QUICK START REFERENCE FOR USING THE PROCESS SELECTION OVERLAY Read and understand the Controls and Settings and Operating Overlays sections of this manual before using the following Quick Start Reference procedure to operate the Power Wave NOTE Selection of certain options may limit the selection of subsequent options Step 1 Select your process information Install the desired PROCESS OVERLAY b Turn the machine ON c Select the desired welding PROCESS 1 PULSE at GMAW stick e SELECT PROCESS olo ELECTRODE CLASS d Select ELECTRODE CLASS ELECTRODE SIZE MM IN e Select ELECTRODE SIZE ELECTRODE GAS TYPE f Select ELECTRODE GAS TYPE JP g Press the WAVE CONTROL UP or DOWN keys to see the present setting Press the WAVE CONTROL UP or WAVE CONTROL DOWN keys to adjust WAVE CONTROL EG Step 2 Adjust the wire feed to speed WFS and voltage or arc length if
241. cal ability that the PC board is the most likely component causing the failure symptom Return to Master TOC 2 Check for loose connections at the PC board to assure that the PC board is properly connected Return to Section TOC 6 Remove the replacement PC board and substitute it with the original PC board to recreate the original problem Recalibrate if required 3 If the problem persists replace the suspect PC board using standard practices to avoid static elec trical damage and electrical shock Read the warn ing inside the static resistant bag and perform the following procedures 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 termi nal strips PC Board can be damaged by static electricity e Remove your body s static O o e 5 9 gt 5 2 Return to Section Return to Master TOC Static Sensitive Devices Handle only at Static Safe Workstations Reusable Container Do Not Destroy charge before opening the stat ic 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 If you don t have a wrist strap touch an unpainted grounded par
242. cer birth defects and other reproductive 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 249 1 from the American Welding Society 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 FOR ENGINE powered equipment 1 a Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running 3 SX 1 h To avoid scalding do not remove the radiator pressure cap when the engine is hot 1 b Operate engines in open well ventilated areas or vent the engine exhaust fumes outdoors ELECTRIC AND 3 MAGNETIC FIELDS may be dangerous 1 c Do not add the fuel near an open flame weld ing arc or when the engine is runn
243. charge e Before continuing with the test procedure perform the capacitor discharge proce dure to avoid electric shock After you have completed the capacitor discharge procedure for all four switch boards remove the PC board cover Use the 5 16 nut driver 8 Remove plug J12 from the display board 9 Place a jumper wire between pins D and E 10 of the six pin amphenol Remove the 5 leads 3 heavy and 2 small T1 T2 T3 from main input contactor CR1 This is a safety precaution t prevents high voltage from being put on the machine during the test Wrap tape around the lead ends to insulate them and prevent them from touching POWER WAVE 450 LINCOLN amp F 132 Return to Section Return to Master TOC Return to Section TOC Return to Master TOC o 2 3 Return to Section Return to Master TOC o p 5 133 TROUBLESHOOTING REPAIR K941 1 REMOTE CONTROL KIT TRIGGER CIRCUIT TEST continued 11 Remove plug J30 from the protection board See Figure for location of the board and plug J30 WARNING ELECTRIC SHOCK can kill With the input power ON there are high volt ages inside the machine Do not reach into the machine or touch any internal parts 12 Turn input power ON 13 With the volt ohmmeter check for 24 VAC between plug J12 pin 2 a
244. checked in step 11 were cor rect go to step 14 If any of the voltages in step 11 were not cor rect go to step 13 13 14 15 16 Perform the following tests to locate the problem Auxiliary Transformer 1 Test and and Auxiliary Voltage Supply Test If these tests show no com ponent failures go to step 14 Make sure plug J19 is plugged into the display board securely and that none of its pins are loose or broken If the pins are all okay replace the LCD display If the problem persists after replacing the LCD display replace the display board After the problem has be repaired install the machine case sides and top Install the handle and the lift bail rubber gasket POWER WAVE 450 LINCOLN F 137 138 NOWNOD 21 gt Szi gt gt gt amod 01 gt gt 01 TOHLNOO lt gt 9 92 gt 9 tc 5 JOULNOD lt INVHOVIG ONIYIM Alddns TVNSH3 LLNI c 9 NoWwoo a fi 2 gt 20188 gt gt 1 8rr 4 gt 01 gt 0 I ae a AY IdSIG c 9 308 9 gt 777 L9 2 gt r B 25258
245. citors C1 C2 C3 and C4 Refer to Module Assembly Removal and Replacement Procedure in this section of the manual If none of the switch boards shows physi cal damage test each switch board according to the procedures given below If any test shows that one of the switch boards is damaged replace all four switch boards and input filter capacitors C1 C2 and Refer to the FET Module Procedure this section of the manual POWER WAVE 450 LINCOLN amp F 63 4 98 5 5 5 5 g 8 EF a5 8 8 8 8 g dvo 2 8 lt m 5 5 dvo dvo gt 5 8 9 m m S e TROUBLESHOOTING amp REPAIR FIELD EFFECT TRANSISTOR SWITCH BOARD TEST continued FIGURE F 23 SWITCH BOARD ASSEMBLY CONNECTION DECAL F 63 901 Je1Se A 0 901 4 1 0 uunjeH 901 J91Se N 01 DOL J91Se N 01 DOL uonoes DOL DOL DOL uonoes Return to Section Return to Master TOC Return to Section TOC O10 515 9 16 gt EIS Return to Section Return to Master TOC Return to Master TOC F 64 TROUBLESHOOTING amp REPAIR FIELD EFFECT TRANSISTOR SWITCH BOARD TEST continued
246. contac tor Connect all molex plugs to the PC boards and replace the cover with two sheet metal screws Install the machine case sides top handle and lift bail rubber gasket POWER WAVE 450 LINCOLN TROUBLESHOOTING 8 REPAIR du F 118 901 Je1Se A 0 DOL uonoes DOL 4 18 DOL uonoeg DOL Je1se N uunjeH DOL uonoeg TIVNHAQLLNI IVNHALX3 lt LNINdINOF tc 5 HQ3MOd o sjousyduiy er ud g 10 ff 084 E 08 4 01 2 062 lt 6 lt lt 2 2 WIZI d OL 57 24 162 lt lt lt 1911 8 8 11 8 2 iz lt lt lt 262 5 mm 2 rc Jm g a lt t1Bikga lt g TOULNOD 08 14810 1 Marc 5 8 ge 0000 3 5 z rc 14 5 e v lt ur PECORA 222 2 gt lt 2 lt lt 1 lt Ser 8201 3 2 0 lt 9 gt lt 84 7 v ui Pp 1 Jouauduiy N y i z lt 2 1 NM tt a SP ETT 5
247. crews holding the lower case back panel POWER WAVE 450 LINCOLN amp 1 WATER COOLER ACCESS DOOR ON F 158 Return to Section Return to Master TOC Return to Section TOC O10 e 515 gt EIS 2 Return to Section Return to Master TOC Return to Master TOC F 159 10 11 12 13 14 TROUBLESHOOTING amp REPAIR WATER COOLER REMOVAL AND REPLACEMENT continued With the 9 16 open end wrench remove the circuit breaker Locate and disconnect plug J4 behind the water cooler Plug J 4 a large molex plug has two leads H1A Double check that these are the leads feeding the plug there is another large molex plug in the same area that is not connected to the water cooler Disconnect Plug 3 a small molex plug with four leads This plug is also located behind the water cooler Slide out the water cooler assembly Take care not to damage the reservoir tank and cooling coils If complete removal is required with the 3 4 and 11 16 open end wrenches dis connect the water cooler lines from the machine back panel Disconnect the plastic strain relievers that hold the water lines to the subframe If disassembly of the water cooler is required refer to the Water Cooler Disassembly Procedurelin this section of the manual 15 16 17 18 19 20 21 22 Install the handle and the lift bail
248. ct input power to the machine Perform the Capacitor Discharge Proce dure Hescribed earlier in this section of the manual WARNING Before continuing with the test procedure per form the capacitor discharge procedure to avoid electric shock 14 Remove plug 410 from the display board Check for continuity between the following pins J10 pin 10 and A of the remote amphenol J10 pin 6 and P1 pin B of the remote amphenol J10 pin 7 and P1 pin C of the remote amphenol If you find no continuity between any of these pins do the following A 18 19 No continuity between J10 pin 10 and P1 pin A of the remote amphenol Check lead 177A between the remote amphenol and the square wave TIG pro tection board for continuity e Check lead 294 between the square wave TIG protection board and the dis play board for continuity Check plugs J10 J92 and J93 to make sure the pins are seated properly and not opened up or loose Replace the square wave TIG protection board No continuity between J10 pin 6 and P1 pin B of the remote amphenol Check lead 176A between the remote amphenol and the square wave TIG pro tection board for continuity e Check lead 291 between the square wave TIG protection board and the dis play board for continuity Check plugs J10 J92 and J93 to make sure the pins are seated properly and not opened up or loos
249. ct quick connect terminals 403 404 9 and 12 on switch board 2 Switch Board 3 Switch Board 3 is Marked CAP 1 on the Switch Board Assembly Connection Decal See Figure F 24 A B Remove quick connect terminals 405 406 9 and 12 from switch board 3 With the volt ohmmeter check for 25 ohms resistance between lead 405 and 12G If the measurement reads between 20 and 30 ohms resistor R5 and leads 405 and 12G are okay Go to step C If the measurement does not read between 20 and 30 ohms check for continuity in leads 405 and 12G Then test for 25 ohms resistance across R5 directly If the measurement does not read between 20 and 30 ohms replace resistor R5 With the volt ohmmeter check for 25 ohms resistance between lead 406 and 9G If the measurement reads between 20 and 30 ohms resistor R6 and leads 406 and 9G are okay Go to step D If the measurement does not read between 20 and 30 ohms check for continuity in leads 406 9G Then test for 25 ohms resistance across R5 directly If the measurement does not read between 20 and 30 ohms replace resistor R5 With the volt ohmmeter check for 7 5 K ohms resistance between lead 12G 12M and 9G 9M If the measurement reads between 6 75 and 8 25 K ohms resistor R10 and leads 12G 12M 9G 9M are okay Go to step E If the measurement does not read between 6 75 and 30 K ohms check for continuity in leads 129
250. ction Return to Master TOC Return to Section TOC Return to Master TOC o 2 3 Return to Section Return to Master TOC o O gt o gt E 191 191 TROUBLESHOOTING amp REPAIR FET MODULE 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 elec trical 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 DESCRIPTION The following procedure will aid the technician in removing the FET modules and main transformer for maintenance or replacement MATERIALS NEEDED Slot head screw driver Phillips head screw driver 5 16 Nut driver 3 8 Nut driver 5 16 Open end or box wrench 7 16 Open end or box wrench 3 8 Socket wrench 1 2 Socket wrench Wire cutters Machine Wiring Diagram in the Electrical Diagrams section of this manual This procedure takes approximately 3 hours
251. d FIGURE F 53 SENSOR LOCATION BEHIND OVERLAY LINCOLN amp ELECTRIC 1994 THE LINCOLN ELECTRIC COMPANY CLEVELAND USA 1 19660 255 CALIBRATION 8 TEST OVERLAY INWVERTEC POWER WAVE PROCEDURE 1 Turn the machine ON with no overlay in place The overlay ID number displayed should be 255 2 When the display reads SELECT A FUNC TION place the TEST overlay on the machine 3 Press key 34 OVERLAY CALIBRATE The OVERLAY CALIBRATE light turns on and for a few seconds the display reads OVERLAY SENSOR CALIBRATION Then the display changes to read INSERT REF OVRLY PRESS ENTER Insert set up overlay 4 Press key 133 ENTER The machine will begin to calibrate the eight overlay sensors 5 If one of the sensors could not be calibrat ed the display reads SENSOR X FAILED ENTER TO RETRY Make sure the overlay is lined up properly and press key 133 ENTER This will cause the machine to try to calibrate the sensor again If a particular sensor continues to fail Clean sensor or replace display board 6 If the calibration procedure is successful the display reads CALIBRATION SUCCESSFUL After a few seconds the display changes to read INSERT CAL OVRLY PRESS ENTER 7 Press key 133 ENTER the OVERLAY CALIBRATE LED turns off the machine exits the OVERLAY CALIBRATE function and the display reads SELECT A FUNCTION 8 Turn the power
252. driver to remove the two screws holding the PC board cover Remove the cover If possible set the machine up for 380 VAC or above by setting the reconnect switch and Jumper A to 380 VAC If only 220 VAC is available perform the test that way Turn the machine on but have no output POWER WAVE 450 LINCOLN amp Return to Section Return to Master TOC Return to Section TOC Return to Master TOC o 2 3 Return to Section Return to Master TOC o O gt o v z o gt E tc F 91 TROUBLESHOOTING amp REPAIR STATIC CAPACITOR BALANCE TEST continued inside the machine WARNING ELECTRIC SHOCK can kill With input supply power ON there are high voltages Do not reach into the machine or touch any internal part of the machine including resistors R9 and R10 Use insulated gloves to measure the resistance across these resistors 9 Turn input supply power to the machine 10 11 ON Machine output must be OFF Measure and record the DC voltage across bleeder resistors R9 and R10 Compare the voltage recorded to the desired values in Table F 7 depending on the input supply voltage setup Determine the difference between the two bleeder resistor voltages TABLE F 7 For 380 VAC Input Voltage or Higher If the difference is less than 75 VDC static capacitive balance is okay
253. dust or any foreign material that can be drawn into the welder should be kept at a minimum Using filters on the air intake to prevent dirt from building up restricts air flow Do not use such fil ters Failure to observe these precautions can result in excessive operating temperatures and nuisance shut downs The Power Wave may be used outdoors Power Wave power sources carry an IP23 enclosure rating They are rated for use in damp dirty environments subject to occasional falling water such as rain However the best practice is to keep the machine in a dry sheltered area since a wet environment speeds corrosion of parts Do not place the machine in puddles or other wise submerge parts of the machine in water This may cause improper operation and is a possible safe ty hazard STACKING Power Wave machines cannot be stacked TILTING Each machine must be placed on a secure level sur face The machine may topple over if this procedure is not followed LIFTING Lift the machine by the lift bail only Do not attempt to lift the machine by the push handle HIGH FREQUENCY PRECAUTIONS If possible locate the Power Wave away from radio controlled machinery The normal operation of the Power Wave may adversely affect the operation of RF controlled equipment which may result in bodily injury or damage to the equipment INPUT CONNECTIONS Be sure the voltage phase and frequency of the input power is as specified on the ratin
254. e Replace the square wave TIG protection board No continuity between J10 pin 7 and P1 pin C of the remote amphenol e Check lead 175A between the remote amphenol and the square wave TIG pro tection board for continuity e Check lead 292 between the square wave TIG protection board and the dis play board for continuity Check plugs J10 J92 and J93 to make sure the pins are seated properly and not opened up or loose Replace the square wave TIG protection board Connect all the plugs disconnected for the tests above Connect plug J30 into the protection board and replace the PC board cover with two sheet metal screws Connect the five leads to the main con tactor Install the machine case sides and top Install the handle and the lift bail rubber gasket POWER WAVE 450 LINCOLN F 125 126 TVNHALNI TVNHSLX3 lt LNANdINO A tc HQMOd lt d 5 1777 04 02 1084 tc 8 201 062 lt 6 lt lt 0 wn OL 57 24 Ph or 162 Peet 2 1911 gt 62 NEC lt z
255. e 21 lead is used only in rare circum stances For most installations use the WORK SENSE LEAD KEY to select the output terminal for negative voltage reference Consult the factory if use of the work sense 21 lead is desired Return to Section TOC Return to Master TOC FIGURE B 10 POSITIVE VOLTAGE SENSING POLARITY Wire Feeder Block Return to Section Return to Master TOC Electrode Cable Work Cable FIGURE B 11 NEGATIVE VOLTAGE SENSING POLARITY Control Cable includes 67 lead O o Fle 5 o 9 515 2 Electrode Sense Lead CN Wire Feeder E Block Cable Work Cable Return to Section TOC Return to Master TOC POWER WAVE 450 LINCOLN B Return to Section Return to Master TOC Return to Section TOC O10 515 9 1 gt EIS Return to Section Return to Master TOC Return to Master TOC B 20 B 20 OPERATION OVERVIEW OF WELDING PROCEDURES FLUX CORED ARC WELDING FCAW AND GMAW PROCEDURES For each wire feed speed a corresponding voltage has been preprogrammed into the machine by welding experts This preprogrammed voltage is the best average voltage for the procedure at the given wire feed speed If the wire feed speed is changed on the wire feeder the voltage automatically changes with it In some
256. e available on this overlay Memory 1 and Memory 2 Memory 3 and Memory 4 Memory 5 and Memory 6 Memory 7 and Memory 8 4 DISPLAY RECALL KEY 5 HIGH TEMPERATURE LIGHT 6 MEMORY LIGHTS Select a memory location PAIR for the two desired welding procedures by pressing either of the two cor responding MEMORY RECALL NUMBER keys If no procedure was saved to one of the memory pair locations the following message appears MEMORY LOCATION IS EMPTY In this case select another memory pair Set the dual procedure switch or gun trigger to the position for PROCEDURE A or PROCEDURE B Position A activates the welding procedure from the odd numbered memory locations 1 3 5 or 7 Position B activates the welding procedure from the corresponding even numbered memory locations 2 4 6 or 8 For example if memory location 3 was selected Position A activates the procedure from memory location 3 Position B activates the proce dure from memory location 4 POWER WAVE 450 LINCOLN B 13 OPERATION When a pair of welding procedures are recalled from memory the display window will show the procedure description wire feed speed and the preset voltage or arc length trim of the LAST pro cedure welded with With this overlay in place the wire feed speed and the preset voltage or arc length trim can be changed from the wire feeder The new values will replace the previous values and become a perma nent part of the procedure
257. e based on a ten minute time period It is capable of higher duty cycles at lower output cur rents If the duty cycles are exceeded a thermostat will shut off the output until the machine cools to a rea sonable operating temperature LIMITATIONS The Power Wave is not recommended for process es other than those specified by available overlays e The Power Wave is not recommended for pipe thawing POWER WAVE 450 LINCOLN B Return to Section Return to Master TOC Return to Section TOC Return to Master TOC o 2 3 Return to Section Return to Master TOC o p 5 OPERATION CONTROLS AND SETTINGS All operator controls and adjustments are located on the case front of the Power Wave Refer to Figure B 1 and corresponding explanations FIGURE B 1 CASE FRONT CONTROLS OF a D BO LCD DISPLAY POWER SWITCH HIGH TEMPERATURE LIGHT REMOTE CONTROL AMPHENOL RECEPTACLE 5 AMP CIRCUIT BREAKER LCD DISPLAY ADJUSTMENT CASE FRONT CONTROLS Refer to Figure B 1 for the location of the following controls 1 LCD DISPLAY Provides welding procedure infor mation and parameters such as wire type gas type WFS trim etc POWER SWITCH Controls inpu
258. e in Ground Wire in Super Lag Voltage Rating on Conduit Conduit or Breaker Nameplate Size Amps Sizes MM Sizes MM 200 50 60 4 120 230 50 60 4 100 400 50 60 8 50 460 50 60 8 50 575 50 60 8 50 200 50 60 4 100 230 50 60 4 25 100 400 50 60 8 10 50 460 50 60 8 10 50 575 50 60 8 10 40 PHYSICAL DIMENSION Height Width Depth Weight 905 mm 515 mm 1010 mm 137 9 kg 35 6 in 20 3 in 39 8 in 303 5 Ibs OPERATING TEMPERATURE RANGE STORAGE TEMPERATURE RANGE 0 to 40 C 50 to 85 C POWER WAVE 450 LINCOLN B Return to Section Return to Master TOC Return to Section TOC O o e 5 9 gt 5 2 r C Return to Section TOC Return to Master TOC Return to Master TOC A 3 INSTALLATION Read this entire installation section before you start installation SAFETY PRECAUTIONS A WARNING ELECTRIC SHOCK can kill Only qualified personnel should perform this installation Turn the input power OFF at the disconnect switch or fuse box before working on this equipment Do not touch electrically hot parts Always connect the Power Wave grounding terminal located inside the reconnect input access doors SELECT SUITABLE LOCATION Place the welder where clean cooling air can circulate in through the rear louvers and out through the side and front louvers Dirt
259. e the Arrow Keys 100 and 101 until amps The load voltage should be greater the display reads than 15 volts but less than 35 volts PROCESS 1 SETUP 6 Remove power to the machine 1 6 7 If necessary re install the control board 4 Activate the external trigger device Replace the machine case parts K941 1 and load the machine POWER WAVE 450 LINCOLN amp 154 NOTES POWER WAVE 450 LINCOLN 5 F 154 901 Je1Se A 0 901 4 1 0 uunjeH 901 J91Se N 01 DOL 01 901 uonoes uumeg DOL uonoes uumeg DOL uonoes uumeg DOL uonoes uumeg Return to Section Return to Master TOC Return to Section TOC Return to Master TOC o 2 3 Return to Section Return to Master TOC o O gt o v E tc F 155 F 155 TROUBLESHOOTING amp REPAIR T1 AUXILIARY TRANSFORMER 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 elec trical 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 pe
260. e the sheet metal screws from the case top nut driver remove the screws holding the right and left case sides Remove the case sides by lifting up and out Perform the Capacitor Discharge Pro cedure described earlier in this section of the manual 9 WARNING Before continuing with the test procedure perform the capacitor discharge proce dure to avoid electric shock S 1 POWER SWITCH 51 44 2 MAIN CONTACTOR INPUT LEADS 3 PROTECTION BOARD 7 After you have completed the capacitor dis charge procedure for all four switch boards remove the PC board cover Use the 5 16 nut driver Manually check the power switch S1 for proper operation by turning it back and forth At the back of the front panel where the switch is mounted make visual inspection Be sure the input and output leads are not shorted together Make sure the switch contacts are not fused together or shorted to another phase Because of the high input voltage involved you should be able to see physical evidence if any of these problems exist Remove the tape covering the switch and check the switch with an ohmmeter High resistance should be present POWER WAVE 450 LINCOLN amp F 45 F 45 TROUBLESHOOTING amp REPAIR INPUT POWER AND WIRING HARNESS TEST continued 9 Check for shorts or fusing at the input
261. ect all wiring harness leads from switch board 3 Fold the leads up so that they do not interfere with the exposed PC board terminals B With the volt ohmmeter measure the resis tance between terminals according to Table F 4 If any test fails replace all four switch boards Refer to the FET Module Assembly Removal and Replacement pro cedure in this section of the manual If none of the tests fails reconnect the wiring harness leads to switch board 3 and perform switch board test 4 Switch Board Test 4 For Switch Board Marked CAP 4 on the Switch Board Assem bly Connection Decal See Figure F 23 A Disconnect all wiring harness leads from switch board 4 Fold the leads up so that they do not interfere with the exposed PC board terminals B With the volt ohmmeter measure the resis tance between terminals according to Table F 5 If any test fails replace all four switch boards Refer to the FET Module Assembly Removal and Replacement pro cedure in this section of the manual If none of the tests fails reconnect the wiring harness leads to switch board 4 IGBT Switch Board Test G3165 1 Table A Disconnect all wiring harness leads from the switch boards Fold the leads up so that they do not interfere with the exposed PC board terminals B With the Volt Ohmmeter measure the resistance between terminals according to If any test fails replace all four switch boards Refer to the FET Module Ass
262. ection Return to Master TOC Return to Section TOC Return to Master TOC o 2 3 Return to Section Return to Master TOC o O gt o tc F 16 F 16 TROUBLESHOOTING amp REPAIR TROUBLESHOOTING GUIDE PROBLEMS SYMPTOMS The machine beeps without the keys being pressed Observe Safety Guidelines detailed in the beginning of this manual POSSIBLE AREAS OF MISADJUSTMENT S FUNCTION PROBLEMS If the water cooler is enabled and the flow switch inside the water cooler opens due to inadequate coolant flow rate the machine indicates this by beeping This happens regardless of the overlay placed on the machine In this case do the following 1 Turn the machine off and on a couple of times and see if the beeping continues If the flow rate dropped momentarily then turning the machine off and on eliminates the beeping A momentary drop in flow rate could be due to a temporary restriction in the water cooler hose Check the water cooler and accessory hoses for kinks internal obstructions or block age or ruptures If such prob lems were found then correct them Turn the machine Off and On to check if the beeping has been eliminated Check the water cooler fluid level Low coolant level could cause the flow rate to drop Prime the water cooler Refer to the Setup Overl
263. ed personnel Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty For your safety and to avoid elec trical shock please observe all safety notes and precautions detailed throughout this manual 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 DESCRIPTION The following procedure will aid the technician in disassembly of the machine water cooler assembly for maintenance or part replacement for early model coolers MATERIALS NEEDED Phillips head screw driver Pliers 3 4 Open end wrench 5 16 Box wrench This procedure takes approximately 60 minutes to perform POWER WAVE 450 LINCOLN Return to Section Return to Master TOC Return to Section TOC Return to Master TOC o 2 3 Return to Section Return to Master TOC o O gt o E tc F 162 F 162 TROUBLESHOOTING amp REPAIR WATER COOLER DISASSEMBLY continued FIGURE F 61 WATER COOLER DISASSEMBLY EARLY MODEL PROCEDURE T 6 Remove main input supply power to the machine With the 3 8 nut driver remove the 4 screws that hold the handle to
264. embly Removal and Replacement pro cedure in this section of the manual If none of the tests fail reconnect the wiring harness leads to the switch boards 15 After the test is completed and the prob lem successfully repaired install the machine case sides and top 16 Install the handle and the lift bail rubber gasket POWER WAVE 450 LINCOLN amp F 64 65 65 TROUBLESHOOTING amp REPAIR e FIELD EFFECT TRANSISTOR SWITCH BOARD TEST continued 5 5 TABLE F 2 SWITCH BOARD 1 RESISTANCE TEST TABLE Ola 818 Positive Negative 1 6 Test Test Probe to Probe to Test Repair Next Terminal Terminal Result Conclusion Action Procedure 2T 12A Greater OK None Continue than 1K ohm Less than Replace 4 Snubber 100 ohms Shorted Switch Resistor olo Boards Test O o jn pul 12A 2T Less than OK None Continue 100 ohms o 8 Greater Open Replace 4 Snubber than 1K Switch Resistor Test 5 5 2 9A 1T Greater OK None Continue than 1K ohm Less than Shorted Replace 4 Snubber 100 ohms Switch Resistor Boards Test 1T 9A Less than OK None Continue 100 ohms 5 8 Greater Open Replace 4 Snubber p E than 1K Switch Resistor ojeg ohm Boards Test o 8 2 9A Less than OK None Continue 100 ohms Greater Open Replace 4 Snubber tio than 1K Switch Resistor Test 9A 2T Greate
265. enance ccceccceeeseeeeeeeeeeeseeeeeeeeeeaeeeeaeeeeeaeeeeaeeesaaeessaaeeseeeeseaeeeeenaeees C 4 Return to Master TOC o 5 Return to Master TOC POWER WAVE 450 LINCOLN B Return to Section Return to Master TOC Return to Section TOC O o e 5 5 0 9 gt 815 5 2 Return to Section Return to Master TOC Return to Master TOC C 2 ACCESSORIES OPTIONS ACCESSORIES Synergic 7 wire feeder K632 1 standard speed or K632 2 high speed e MAGNUM 400 gun 471 2 or 550 gun K598 e Internal water cooler e Undercarriages Single K961 1 or Dual K962 1 Gas Cylinders e Remote control stick welding K941 1 e Amptrols Hand K963 1 or 2 Foot K870 e Limits Overlay K946 4 e Dual Wire Feeders Dual Procedures Overlay K946 9 e Dual Feeder Dual Procedure Memory Selection Overlay K946 12 e Test and Calibration Overlay WIRE FEEDER SETUP The Power Wave must be used with wire feeders list ed above Mount the feeder in a location suitable to your needs For most applications connect the electrode cable between the feeder and the positive connection of the power source When negative electrode polarity is required such as in some Innershield applications connect the electrode cable between the feeder and the negative connection of the power source See Figure C 1
266. ent supply A Check for loose or broken leads between the following pins J22 pin 5 on the control board and J44 pin 5 on the power board lead 5R J22 pin 4 on the control board and J44 pin 4 on the power board lead 5W Make sure that plug J22 is plugged into the control board securely and that none of its pins are loose Also make sure that plug J44 is securely plugged into the power board and that none of its pins are loose With the DC voltmeter check for at least 30 VDC between plug J44 pin 5 and pin 4 on the power board This is the voltage source for the 40 mA current for the serial loop If the voltage is low or not present the power board may be faulty Replace the power board 12 13 14 After the test is completed and the prob lem successfully repaired replace the PC board cover with two sheet metal screws Install the machine case sides and top Install the handle and the lift bail rubber gasket POWER WAVE 450 LINCOLIN REP F 109 Return to Section Return to Master TOC Return to Section TOC Return to Master TOC o 2 3 Return to Section Return to Master TOC O gt o gt E tc F 110 Serial Loop Master Transmit amp Receive Lines Display Board Port Switch Open DK Board S L Comunication enabled Closed DK Board S L Comunication disabled
267. er and Shunt printed circuit boards e Power Switch e Main Transformer e Auxiliary Transformers e Input Rectifier e Heat Sink Fins e Input Filter Capacitors e Output Terminals e Terminal Strip Examine the capacitors for leakage or oozing Replace if needed Examine the wrap around and side covers for dents and breakage Repair them as needed The covers must be kept in good condition to assure that high voltage parts are protected and that cor rect spacings are maintained Remove welding cables and check the electrical ground continuity Use an ohmmeter to measure the resistance between each output terminal and an unpainted surface of the machine case The meter reading should be 500 000 ohms or more If the meter reading is less than 500 000 ohms check for electrical components that are not prop erly insulated from the case Correct component insulation if needed 8 Reconnect the shunt and wire 467 to the nega 10 11 12 tive output terminal Make sure the connection is tight Replace and secure the machine covers and han dle bar Remove the overlay from the front panel of the machine Clean the plastic case with a low pres sure airstream Wipe the sensors Fig D 4 Item 8 with a clean soft cloth Make sure the sensors are not scratched in the process Check the back of the overlays If the bar code black square s on the back of the overlay is scratched apply a dull black spray finish
268. er TOC Return to Master TOC Return to Section TOC FRANCE CANADA AUSTRALIA E 515 9 16 2 2 5 2 GENERAL INFORMATION LAST NO USED ELECTRICAL SYMBOLS PER E1537 CAPACITORS MFD 022 50V UNLESS OTHERWISE SPECIFIED RESISTORS Ohms 1 4W UNLESS OTHERWISE SPECIFIED LABELS DIODES 1A 400V UNLESS OTHERWISE SPECIFIED SUPPLY VOLTAGE NET NOTES POWER SUPPLY SOURCE POINT N A SINCE COMPONENTS OR CIRCUITRY ON A PRINTED CIRCUIT BOARD MAY CHANGE 5 COMMON CONNECTIO WITHOUT AFFECTING THE INTERCHANGEABILITY OF A COMPLETE BOARD THIS DIAGRAM MAY 1 7 FRAME CONNECTION in STONE THE EXACT COMPONENTS OR CIRCUITRY OF CONTROLS HAVING A COMMON CODE oe THE LINCOLN ELECTRIC CO Swe SQUARE WAVE TIG 350 CLEVELAND OHIO U S A PROTECTION BOARD SCHEMATIC SCALE NONE M MK DRS DATE_1 12 90 GM BS REF SUPS DG X 1 61 1 5 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 LINCOLN POWER WAVE 450 e ELECTRICAL DIAGRAMS Git PC BOARD ASSEMBLY SQUARE WAVE PROTECTION 1 2909 LIN C2 C4 C5 CO 111577 58 NETT 111 12 13 14 16 16 6 112218 9 J22 1 518248 6 HEADER P23 _________ 1 1 518248 8 HEADER ______
269. er TOC POWER WAVE 450 LINCOLN B Return to Section Return to Master TOC Return to Section TOC Return to Master TOC O o 5 9 gt 5 5 Return to Section Return to Master TOC E 5 THEORY OF OPERATION FIGURE E 5 MAIN TRANSFORMER MAIN OUTPUT TRAMSFORMER RECTIFIER INPUT CONTACTOR RECONNECT FET ASSEMBLY 1 1 T 5 SWITCH SWITCH PROTECTION BOARD BOARD FET ASSEMBLY THREE PHASE INPUT POWER RIGHT SENSE LEADS CONTROL BOARD WATER LCD BOARD z INTERFACE MAIN TRANSFORMER Each Switch Board assembly works as a switch pair Each board feeds current to a primary winding of the Main Transformer These primary currents are moni tored by the Current Transformer CT The CT sends a signal through the Protection Board to the Control Board If the primary currents become abnormally high the Control Board will shut off the FETs thus dis abling machine output The right and left sides of the transformer are isolated from each other The right side of the transformer is supplied from Switch Boards 1 and 2 while the left side of the transformer is sup plied from Switch Boards 3 and 4 The DC current flow through each primary winding is clamped back to each respective input capacitor when the FETs are turned off The firing of the four
270. es uumeg 187 187 TROUBLESHOOTING amp REPAIR OUTPUT RECTIFIER BRIDGE 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 elec trical 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 trou bleshooting assistance before you proceed Call 1 800 833 9353 WELD DESCRIPTION The following procedure will aid the technician in removing the output rectifier bridge for maintenance or replacement Return to Section TOC Return to Master TOC MATERIALS NEEDED Slot head screw driver 5 16 Nut driver 3 8 Nut driver 7 16 Open end wrench Wire cutters Machine Wiring Diagram in the Electrical Diagrams section of this manual This procedure takes approximately 1 hour 30 minutes to perform O o 5 5 o 9 515 2 Er Return to Section TOC Return to Master TOC POWER WAVE 450 LINCOLN 188 188 TROUBLESHOOTING REPAIR OUTPUT RECTIFIER BRIDGE REMOV
271. es approximately 30 minutes to perform POWER WAVE 450 LINCOLN Return to Section Return to Master TOC Return to Section TOC Return to Master TOC o HE 2 3 Return to Section Return to Master TOC o 5 F 132 TROUBLESHOOTING amp REPAIR K941 1 REMOTE CONTROL KIT TRIGGER CIRCUIT TEST continued FIGURE F 49 DISPLAY BOARD PLUG LOCATIONS a pe eo J17 J16 J15 J14 J13 J12 J11 J10 TEST PROCEDURE A WARNING NOTE Before troubleshooting the remote con 6 trol trigger circuit troubleshoot the remote control kit itself Refer to the in this section of the manual If that test is successful perform the trigger circuit test below Remove main input supply power to the machine With the 3 8 nut driver remove the 4 screws that hold the handle to the machine Remove the rubber gasket cover seal from the lift bail With the 5 16 nut driver remove the sheet metal screws from the case top With the 5 16 nut driver remove the screws holding the right and left case sides Remove the case sides by lifting up and out Perform the Procedure described earlier in this section of the manual Capacitor Dis
272. ess door and related connection diagram INPUT POWER CONNECTIONS Connect 11 12 according to the Input Supply Connection Diagram decal located on the reconnect input access door See Figure A 2 INPUT FUSE AND SUPPLY WIRE CONSIDERATIONS Refer to the Technical Specifications at the beginning of this Installation section for recommended fuse and wire sizes Fuse the input circuit with the recom mended super lag fuses or delay type circuit breakers Choose an input and grounding wire size according to local or national electrical codes Using fuses or cir cuit breakers smaller than recommended may result in nuisance shut offs from welder inrush currents even if the machine is not being used at high currents INPUT VOLTAGE RECONNECT PROCEDURE Welders are shipped connected for the highest input voltage listed on the rating plate To change this con nection for a different input voltage refer to reconnect instructions in Figure A 2 and proceed according to the steps that follow for the appropriate voltage FIGURE A 2 CONNECTION DIAGRAM ON RECONNECT INPUT ACCESS DOOR NOTE Turn main input power to NOTE MACHINES ARE SHIPPED FROM FACTORY Disconnect power mthe machine OFF before perform CONNECTED FOR 440 OR 460 VOLTS 2 ing reconnect procedure Failure to 1 CONNECT Lt 12 amp L3 INPUT INPUT LINES oet aly do so will result in damage to the SUPPLY LINES TO THE INPUT
273. eturn to Master TOC POWER WAVE 450 LINCOLN B Return to Section Return to Master TOC Return to Section TOC Return to Master TOC o 2 3 Return to Section Return to Master TOC o O gt o gt E TROUBLESHOOTING amp REPAIR TROUBLESHOOTING GUIDE PROBLEMS SYMPTOMS Fans run slow or intermittently display is very dim no weld out put Machine has no output no dis play fans run circuit breaker 5 amp repeatedly trips Observe Safety Guidelines detailed in the beginning of this manual POSSIBLE AREAS OF MISADJUSTMENT S OUTPUT PROBLEMS 1 Make certain the reconnect panel and fuse F1 jumper A is configured properly for the input voltage being applied Make sure that not more than 5 amps of auxiliary power are being drawn Remove the wire feeder control cable from the Power Wave If the symptom disappears the wire feeder or control cable is faulty RECOMMENDED COURSE OF ACTION 1 Perform the Auxiliary Transformer Test 1 1 The circuit breaker 5 amp may be faulty Test or replace 2 Perform the Auxiliary Transformer 1 Secondary and Wiring Harness Test A CAUTION If for any reason you do not understand the test procedures are unable to perform the test repairs safely con tact the Lincoln Electric Service Departmen
274. etween pin F of the 6 pin amphenol and the case of the Remote Control Kit The reading should be zero ohms With the volt ohmmeter check the conti nuity between pin F and the other five pins of the 6 pin amphenol The reading should be open no continuity Set the Output Terminals switch to the ON position With the volt ohmmeter check the continuity between pins D and E of the amphenol There SHOULD BE continuity zero ohms Set the Output Terminals switch to the OFF position With the volt ohmmeter check the continuity between pins D and E of the amphenol There should be NO continuity With the volt ohmmeter check the resis tance between pins A and C of the amphe nol There should be 10 Kohm 10 resistance between these pins at all times Turn the knob of the Remote Control Kit all the way counterclockwise With the volt ohmmeter check the resistance between pins A and B of the amphenol There should be 10 Kohm 10 resis tance between these pins now Turn the knob clockwise The resistance between pins A and B should smoothly decrease to zero ohms 10 POWER WAVE 450 LINCOLN amp F 128 129 TVNHAQL
275. f the heat sink The input rectifier bridge can now be removed You may have to bend the bot tom tab slightly in order to get it past the main transformer FIGURE F 71 HEAT SINK REMOVAL GLASTIC INSULATED ANGLE MOUNTING PIECE TOP BOTTOM TAB CONNECTION GLASTIC INSULATED ANGLE MOUNTING PIECE BOTTOM HEAT SINK POWER WAVE 450 LINCOLN F 189 Return to Section Return to Master TOC Return to Section TOC Return to Master TOC O10 e 515 9 1 EIS 2 Return to Section Return to Master TOC F 190 TROUBLESHOOTING amp REPAIR OUTPUT RECTIFIER BRIDGE REMOVAL AND REPLACEMENT continued 13 14 FIGURE 72 CABLE TIE LOCATIONS PRIMARY HARNESS ASSEMBLY BLACK SECONDARY HARNESS ASSEMBLY WHITE For reassembly attach the glastic insulat 15 Install the machine case sides and top ed angle mounting pieces to the heat sink 46 install the handle and the lift bail rubber first Slide the bridge into position and ket then fasten the bottom tab to the sub ae frame with the bolt split ring lock washer and nut Then attach and tighten down the top and bottom bolts that hold the heat sink on both sides of the machine Reconnect the leads on both sides of the bridge Install new cable ties according to Figure F 72 POWER WAVE 450 LINCOLN F 190 Return to Se
276. for the overlay descrip tions O O Fle 5 9 515 2 CAUTION If for any reason you do not understand the test procedures or are unable to perform the test repairs safely tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed Call 1 800 833 9353 Return to Section TOC Return to Master TOC POWER WAVE 450 LINCOLN F 14 F 14 TROUBLESHOOTING amp REPAIR TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginning of this manual PROBLEMS POSSIBLE AREAS OF RECOMMENDED SYMPTOMS MISADJUSTMENT S COURSE OF ACTION FUNCTION PROBLEMS Return to Section TOC Return to Master TOC Machine display reads Error 1 Make certain the overlay is 1 Perform the Invalid Overlay or it displays an installed properly Calibration Test invalid ID number on power up Inspect the infrared sensors on the front panel If they are dirty blow them out with low pressure air and clean with a soft cloth Inspect for damage to the Bar Code s black squares on the back of the overlay Also check for dirt build up on back of overlay Wipe off with a soft rag Return to Section TOC Return to Master TOC Machine displays ERROR S L Contact your local Lincoln 1 Perform the Serial Loop NOT INITIALIZED on power up Authorized Field Service Facility for technica
277. from the Power Wave Remove the arc start switch circuit Enable the water cooler if it was enabled at the start of this test POWER WAVE 450 LINCOLN B Return to Master Return to Master TOC o 0 2 5 Return to Master TOC TABLE OF CONTENTS ELECTRICAL DIAGRAMS Electrical Diagrams SeCtion Secti WIIG PAG FANN Schematic Complete 9 Control PC Board Schematic 1 Control PC Board Schematic 2 2 Control PC Board Schematic 3 4 2 Control PC Board Schematic 4 of 4 nennen nennen nnn Control PG Board Assembly t dia i ne ide etre Display PC Board Schematic 1 gt nennen nnne nennen Display PC Board Schematic 2 gt ener Display PG Board Assembly xn exe Ren xa E ik en Eva ee XE Rep ERE Eee Ea ba Power PC Board iiic cese tense depart rad ES Power PG 5 epa rip ensi Protection PC Board Protection PC Board Assembly eee hie x Square Wave Protection PC Board 100000
278. fting up and out 6 Perform the Capacitor Discharge Procedure described earlier in this section of the manual WARNING Before continuing with the test procedure per form the capacitor discharge procedure to avoid electric shock 7 After you have completed the capacitor dis charge procedure for all four switch boards remove the PC board cover Use the 5 16 nut driver 8 Remove the 5 leads 3 heavy and 2 small T1 T2 T3 from main input contactor CR1 This is a safety precaution It prevents high voltage from being put on the machine dur ing the test Wrap tape around the lead ends to insulate them and prevent them from touching 9 Remove plug 430 from the protection board See Figure F 1 for location of the board and plug J30 10 Make sure that none of the pins are loose or open on the following molex plugs J33 434 435 J37 438 on the protection board J12 J13 J16 on the display board J22 on the control board J42 43 and J44 on the power board See the Internal Auxiliary Supply Wiring Diagram Figure 4 WARNING ELECTRIC SHOCK can kill With input power ON there are high voltages inside the machine including plug J30 and the protection board Do not reach into the machine or touch any internal part of the machine while power is ON 11 Turn input power ON Machine output must be OFF 12 Verify the following voltage measure ments A Protec
279. g Diagram Figure F 31 This procedure takes approximately 30 minutes to perform POWER WAVE 450 LINCOLN Return to Section Return to Master TOC Return to Section TOC Return to Master TOC o 2 3 Return to Section Return to Master TOC o p 5 90 TROUBLESHOOTING REPAIR STATIC CAPACITOR BALANCE TEST continued FIGURE F 30 BLEEDER RESISTORS R9 AND R10 LOCATION S TEST PROCEDURE 1 Remove main input supply power to the machine With the 3 8 nut driver remove the 4 screws that hold the handle to the machine Remove the rubber gasket cover seal from the lift bail With the 5 16 nut driver remove the sheet metal screws from the case top With the 5 16 nut driver remove the screws holding the right and left case sides Remove the case sides by lifting up and out Perform the Capacitor Discharge Procedure described earlier in this section of the manual PY ACC NN SS K NAS NS 17 22 1 RESISTORS R9 AND R10 BLEEDER RESISTORS WARNING A Before continuing with the test procedure perform the capacitor discharge proce dure to avoid electric shock After you have completed the capacitor discharge procedure for all four switch boards use the 5 16 nut
280. g plate located on the rear of the machine See Figure A 1 for the loca tion of the rating plate FIGURE A 1 RATING PLATE LOCATION 1 0 7 8 1 RATING PLATE 2 RECONNECT INPUT ACCESS DOOR 3 INPUT CORD ACCESS HOLE A WARNING Only a qualified electrician should connect the input leads to the Power Wave Connections should be made in accordance with all local and national electri cal codes and the connection diagram located on the inside of the reconnect input access door of the machine Failure to do so may result in bodily injury or death Use a three phase supply line The Power Wave has a 1 375 85mm access hole for the input cord but the input cord is not supplied POWER WAVE 450 LINCOLN B Return to Section Return to Master TOC Return to Section TOC O o Fle 5 o 9 515 2 Return to Section Return to Master TOC Return to Master TOC A 4 A 4 INSTALLATION A CAUTION Failure to follow these instructions can cause immedi ate failure of components within the welder GROUND CONNECTIONS The frame of the welder must be grounded A ground terminal marked with the symbol is located inside the reconnect input access door for this purpose See your local and national electrical codes for proper ground ing methods See Figure A 2 for the location of the reconnect input acc
281. he ground plane assembly and insulated from the case and other components O o e 5 5 9 5 2 Return to Section Return to Master TOC POWER WAVE 450 LINCOLN Return to Section Return to Master TOC Return to Section TOC Return to Master TOC o 2 3 Return to Section Return to Master TOC o O gt o gt E tc TROUBLESHOOTING amp REPAIR CURRENT CALIBRATION continued 2 Locate the 10 turn trimmer potentiometer located on the control board It is the only trimmer on the board If the trimmer is not accessible with the control board installed then the board must be removed and laid on the top of the PC board compartment Be sure the control board is insulated from the other boards and the case parts All wiring plugs must be connected to the con trol board See Figure F 56 WARNING WHEN THE MACHINE CASE IS REMOVED HIGH VOLTAGE POINTS ARE EXPOSED STAND DIRECTLY IN FRONT OF MACHINE UNDER TEST EXPLODING PARTS CAN CAUSE INJURY FAILED PARTS CAN EXPLODE OR CAUSE OTHER PARTS TO EXPLODE WHEN POWER IS APPLIED ALWAYS WEAR A FACE SHIELD AND LONG SLEEVES WHEN SERVICING A CAUTION WHEN LOADING THE MACHINE WITH THE CASE PARTS REMOVED BE CAREFUL NOT TO OVER HEAT THE MACHINE 3 NOTE
282. hermostats is located on the heat sink of a switch board and the other is located on the main choke Excessive tem peratures may be caused by a lack of cooling air or operating the machine beyond the duty cycle or out put rating If excessive operating temperatures should occur the thermostats will prevent output from the machine The displays will remain on during this time and the yellow Thermal light located of the front of the machine will be illuminated The thermostats are self resetting once the machine cools sufficiently If the thermostat shutdown was caused by excessive output or duty cycle and the fans are operating normally the Power Switch SW1 may be left on and the reset should occur within a 15 minute period If one or both of the fans are not turning or the air intake louvers are obstructed then the power must be removed from the machine and the fan problem air obstruction must be corrected PROTECTIVE CIRCUITS Protective circuits are designed into the Power Wave 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 520 amps then the peak current will be limited to 100 amps until the aver age current decreases to under 50 amps OVER VOLTAGE PROTECTION A protective circuit is included on the Protection Board to monitor the voltage across the input capacitors In the event that a capacitor voltage is to
283. hms Switch Resistor Boards Test 12B 403 Greater OK None Continue than 1K ohm Less than Shorted Replace 4 Snubber 100 ohms Switch Resistor Boards Test 403 12B Less than OK None Continue 100 ohms Greater Open Replace 4 Snubber than 1K Switch Resistor ohm Boards Test 9B 404 Less than OK None Continue 100 ohms Greater Open Replace 4 Snubber than 1K Switch Resistor ohm Boards Test 404 9B Greater OK None Continue than 1K ohm Less than Shorted Replace 4 Snubber 100 ohms Switch Resistor boards Test NOTE K ohm ohm reading multiplied by 1000 NOTE Always make sure that all four Switch Boards are changed at the same time Never mix an old style different part number Switch Board with a new style new part number POWER WAVE 450 LINCOLN amp F 69 F 69 TROUBLESHOOTING amp REPAIR e o FIELD EFFECT TRANSISTOR SWITCH BOARD TEST continued 5 5 TABLE 4 SWITCH BOARD RESISTANCE TEST TABLE PEN 814 5 Positive Negative lo Test Test cc Probe to Probe to Test Repair Next Terminal Terminal Result Conclusion Action Procedure AT 12C Greater OK None Continue than 1K ohm Less than Replace 4 Snubber 100 ohms Shorted Switch Resistor 3 e Boards Test O o jd Ls 12C 4T Less than OK None Continue 2 2 100 ohms 9 Greater Open Replace 4 Snubber than 1K Switch Resistor cjg ohm Boards Test 5 5 2 9C 3T Greater OK None Conti
284. horted now the protection board is faulty Replace the protection board C Visually inspect leads T1 T2 and between the main contactor and the input rectifier and between the main contactor and the protection board If these leads are not damaged or exposed then the input rectifier may be faulty and should be checked Perform the Test described in this section of the man ual 11 With the volt ohmmeter check for conti nuity between the following terminals of the main contactor L1 and T1 L2 and T2 L3 and T3 If any of these measurements shows continu ity replace the main contactor If no continuity is shown go to step 12 12 Visually check the following leads for damage then check for continuity as described Lead 324 Between the main contactor and plug 32 pin 4 of the protection board Lead 326 Between the main contactor and plug 32 pin 6 of the protection board Lead 321 Between plug J71 pin 1 of auxiliary Transformer 1 and plug J32 pin 1 of the protec tion board Lead 323 Between plug 71 pin 4 of auxiliary Transformer 1 and plug J32 pin 3 of the protec tion board Lead T1 Between the main contactor and the protection board plug J30 pin 11 Between the main contactor and the protection board plug J30 pin 16 Put the power switch SW1 in the ON position for the next two continuity tests Lead H1B Between terminal L3 of the main contactor and plug J30 pin
285. ht hand corner of the Power Wave Display Panel it should be OFF O o FIle 5 5 0 9 9g 43 a POWER WAVE 450 LINCOLN B Return to Section Return to Master TOC Return to Section TOC Return to Master TOC O o e 5 5 0 9 0 gt 5 2 Return to Section Return to Master TOC F 204 F 204 TROUBLESHOOTING amp REPAIR PRE POWERUP SWITCH BOARD TEST PROCEDURE FOR REPLACEMENT OF SWITCH ASSEMBLY G2402 2 continued FIGURE F 80 PC BOARD RECEPTACLE P 23 2 gt 3 Unplug P23 and insert jumper plug into PC 5 Turn ON the arc start switch See Start board receptacle See Figure F 80 PW450 with wire Feeder or Figure 79 Turn ON the preset power switch See 6 Attach the oscilloscope probes to each of the Figure 78 following eight test points Each test point Press the MANUAL PROCEDURE ENTRY Figure S 64 key on the Calibration 4 Test overlay and the Power Wave to Process 1 Setup 1 1 the Power Wave to Process 1 Setup 1 1 WARNING made ALL METERS AND OSCILLOSCOPES MUST Set the Oscilloscope for BE ELECTRICALLY ISOLATED isolation trans 20 Vidiv former 20 uS div POSITIVE PROBE NEGATIVE PROBE 1 P40 pin 14 P40 pin 16 2 P40 pin 9 P40 pin 11 3 P40 pin 6 P40 pin 8 4 P40 pin 1 P40 pin 3 5 P41 pin 15 P41 pin 16 6
286. ides by lifting up and out 6 Perform the Capacitor Discharge Proce dure described earlier in this section of the manual WARNING Before continuing with the test procedure per form the capacitor discharge procedure to avoid electric shock 7 After you have completed the capacitor discharge procedure for all four switch boards proceed to remove the T2 auxil iary transformer First you will have to remove the water cooler follow the Water Cooler Removal and Replacement Procedure this section of the manual 8 Disconnect the single molex plug attached to the transformer See Figure F 62 for location 9 The 3 8 nut driver or socket wrench remove the two screws that mount the trans former to the machine base Remove the T2 auxiliary transformer 10 To install the T2 auxiliary transformer carefully position it onto the machine base and tighten the two mounting screws Connect the molex plug to its receptacle on the transformer 11 Install the water cooler Refer to the Water Cooler Removal and Replacement Procedure this section of the manual 12 Install the machine case sides and top 13 Install the handle and the lift bail rubber gasket POWER WAVE 450 LINCOLN 5 Return to Section Return to Master TOC Return to Section TOC O o Fle 5 o 9 515 2 Return to Section Return to Master TOC
287. inal block Attach the two coolant hoses to the motor pump assembly using the 3 4 open end wrench Install the reservoir according to the direc tions in the Reservoir Removal procedure Install the water cooler assembly according to the Water Cooler Removal and Replace ment procedure in this section of the man ual 8 Install the machine case sides and top 9 Install the handle and the lift bail rubber gasket POWER WAVE 450 LINCOLN 164 NOTES POWER WAVE 450 LINCOLN 5 F 164 901 Je1Se A 0 901 4 1 0 uunjeH 901 J91Se N 01 DOL 01 901 uonoes uumeg DOL uonoes uumeg DOL uonoes uumeg DOL uonoes uumeg Return to Section Return to Master TOC Return to Section TOC Return to Master TOC o 2 3 Return to Section Return to Master TOC o O gt o v E tc F 165 F 165 TROUBLESHOOTING amp REPAIR T2 AUXILIARY TRANSFORMER 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 elec trical shock please observe all safety notes and precautions detailed throughout this ma
288. ing 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 2 a Electric current flowing through any conductor causes localized Electric and Magnetic Fields EMF Welding current creates EMF fields around welding cables and welding machines EMF fields may interfere with some pacemakers and welders having a pacemaker should consult their physician before welding 1 d Keep all equipment safety guards covers and devices in posi tion and in good repair Keep hands hair clothing and tools away from V belts gears fans and all other moving parts when starting operating or repairing equipment Exposure to EMF fields in welding may have other health effects which are now not known All welders should use the following procedures in order to 1 6 In some cases it may be necessary to remove safety dd o 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 4 2 Never coi
289. inutes to perform POWER WAVE 450 LINCOLN Return to Section Return to Master TOC Return to Section TOC Return to Master TOC o 2 3 Return to Section Return to Master TOC o O gt o E tc F 112 TROUBLESHOOTING amp REPAIR WIRE FEEDER 1 TRIGGER CIRCUIT TEST continued FIGURE F 39 DISPLAY BOARD PLUG LOCATIONS COO 1 2 J17 J16 J15 J14 J13 J12 J11 J10 TEST PROCEDURE WARNING 1 Perform Remove main input supply power to the machine With the 3 8 nut driver remove the 4 screws that hold the handle to the machine Remove the rubber gasket cover seal from the lift bail With the 5 16 nut driver remove the sheet metal screws from the case top With the 5 16 nut driver remove the screws holding the right and left case sides Remove the case sides by lifting up and out the Capacitor Discharge Procedure described earlier in this section of the manual Before continuing with the test procedure perform the capacitor discharge proce dure to avoid electric shock After you have completed the capacitor discharge procedure for all four switch boards remove the PC board cover Use the 5 16 nut driver 8 Remove plug
290. is normal between these pins without the C to D jumper installed in the wirefeeder recepta cle B If 24 VAC is NOT present check for 24 VAC between plug J33 pin 4 and pin 1 See the Trigger Circuit Wiring Diagram Figure F 40 C If 24 VAC IS present between plug 433 pin 4 and pin 1 check the continuity and integrity of leads 8371 374 1028 and 105A and their associated pin connectors See the Trigger Circuit Wiring Diagram the continuity checks are good the pro tection board may be faulty Replace the protection board D If 24 VAC is NOT present between plug J33 pin 4 and pin 1 check Auxiliary Transformer 1 the 5 amp circuit breaker and the associated wiring See the Trigger Circuit Wiring Diagram Figure 40 14 Turn input power to the machine OFF and perform the Capacitor Discharge 15 Remove plug J26 from the control board Attach a 150 ohm resistor between plug J26 pin 1 and J26 pin 2 the J26 plug not the header on the control board 16 Replace plug J12 into the display board 17 18 19 20 21 Turn input power ON The LCD display will read ERROR S L NOT INITIALIZED Disregard this the test can still be per formed Remove the jumper between pins C and D of wire feeder 1 receptacle With the volt ohmmeter measure the volt age drop across the 150 ohm resistor between J26 pins 1 and 2 With the jumper removed the reading should be zero volts NO voltage dr
291. ith the 3 8 nut driver remove the 4 screws that hold the handle to the machine Remove the rubber gasket cover seal from the lift bail With the 5 16 nut driver remove the sheet metal screws from the case top nut driver remove the screws holding the right and left case sides Remove the case sides by lifting up and out Perform the Capacitor Discharge Proce earlier in this section of the manual A WARNING Before continuing with the X e test procedure perform the capacitor discharge proce dure to avoid electric shock 9 WIRE FEEDER RECEPTACLES SQUARE WAVE TIG PROTECTION BOARD DISPLAY BOARD PROTECTION BOARD CONTROL BOARD POWER BOARD After you have completed the capacitor dis charge procedure for all four switch boards remove the PC board cover Use the 5 16 nut driver Disconnect all plugs and wirefeeder recep tacles associated with the auxiliary trans former secondary This is done to isolate the machine electrically Inspect all the dis connected plugs and receptacles looking for shorted pins and wires See the Auxiliary Transformer 1 Secondary Circuit Wiring Diagram Figure F 12 for the specif ic plugs and receptacles to check which include e WF2 Receptacle WF1 Receptacle Square Wave Protection Board Display Board Power Board Protectio
292. itions in damp locations or while wearing wet clothing on metal structures such as floors gratings or scaffolds 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 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 6 c and 8 LINCOLN 8 ARC RAYS can burn 4 a Use a shield with the proper filter and cover plates to p
293. jumper between J34 pin 4 and J34 pin 7 of header J34 on the protection board This simulates the closing of the trigger on wire feeder 2 With the volt ohmmeter check for continu ity again between 37 pin 2 and J37 pin 3 of header J37 There should be continu ity now Remove the jumper and connect plugs J34 J37 and J38 back into the pro tection board If the continuity tests above detect a fault replace the protection board 9 10 12 13 Remove plug 437 from the protection board and inspect its pins and leads Make sure that the TRIG 1 TRIG 2 and COMMON pins of plug J37 are not short ed together pins 1 2 3 4 respectively Make sure that leads 371 372 373 and 374 are not exposed See the Auxiliary Transformer 1 Secondary Circuit Wiring Diagram Figure F 44 Connect plug J37 to the Protection board If you found no problem with plug J37 pins and leads replace the display board After the tests are completed and the problem successfully repaired reconnect all plugs to their respective boards Replace the PC board cover with the two sheet metal screws Install the machine case sides and top Install the handle and the lift bail rubber gasket POWER WAVE 450 LINCOLN amp F 121 121 TROUBLESHOOTING REPAIR olo FIGUR
294. k to see if the Limits or Setup overlay is installed on the front panel These two overlays cannot be used for welding Check for proper input voltage per machine nameplate Make certain the reconnect panel is configured properly Check to see that when the trigger is pulled on the wire feeder the wire feeder s voltage display changes to indicate arc voltage If this does not hap pen the feeder or control cable may be faulty Check wire feeder control cable for loose or faulty con nections If the machine is connected for 380VAC or higher and has not been used for a long period of time the capacitors may require conditioning Let the Power Wave run at an idle state for 30 minutes RECOMMENDED COURSE OF ACTION 1 Perform the Wire Feeder Trigger Circuit Test 1 pr 42 for the appropriate wire feeder receptacle amphenol K941 1 Remote Control Kit is attached to the Power Wave then perform the 941 1 Remote Control Kit Trigger Circuit Test 3 Perform the Reconnect Switch Test 1 4 Perform the Output Rectifier Diodes Test 5 Perform the Switch Board 6 Perform the Snubber and Bleeder Resistor Test Perform the Static Capacitor Balance Test 7 8 Perform the Dynamic Capacitor Balance Test CAUTION If for any reason you do not understand the test procedures or are unable to perform the test repairs safely tact the Lincoln Electric
295. knows what the best arc length is at the given wire feed speed but allows the operator to change it The arc length can be adjusted between 0 5 and 1 5 on the wire feeder s Voltage display An arc length trim of 1 0 means that no adjustments will be made to the preset arc lengths An arc length trim greater than 1 0 increases the preset arc lengths An arc length trim less than 1 0 decreases the preset arc lengths The arc length adjustment is factored in at all wire feed speed settings Refer to Table 6 summary of arc length trim Increasing the arc length by 10 percent at a given wire feed speed also increases all the other arc length set tings of the procedure by 10 percent In the GMAW Pulse process the display shows the Procedure Description WFS and Arc Length Trim Arc length trim is programmed to a default at the factory and may be adjusted on the wire feeder When the trigger is pulled the WFS Actual Arc Voltage and Actual Arc Current are displayed STICK TIG PROCEDURES Stick welding can be performed with the Power Wave by attaching a remote control kit to the 6 pin amphe nol on the front of the machine The K941 1 remote control kit is recommended Select the stick process from either the GMAW Pulse GMAW FCAW stick process selection overlay or recall it from a previously stored memory location with a Weld From Memory overlay When this process is selected the Power Wave reads the current amps setting f
296. l When the Limits Overlay or the Setup Overlay is installed in the Power Wave the machine and wire feeder displays do not match These overlays cannot be used for welding If two wire feeders nected to the Power Wave only one of the feeder s set tings can be displayed on the Power Wave at one tme Pull the trigger of the wire feeder whose settings you want dis played on the Power Wave Check for proper installation of the Dual Procedure overlay Check the Dual Procedure Gun Trigger or separate dual proce dure switch RECOMMENDED COURSE OF ACTION Try the other wire feeder receptacle If the problem is solved the initial receptacle or associated wiring is faulty If the problem persists with both wire feeder receptacles check or replace the wire feed er and control cable If the wire feeder and control cable are OK then perform the Serial Loop Wiring Harness 4 The display board may be faulty Replace and perform voltage calibration The control board may be faulty Replace and perform voltage calibration and current calibration 1 Perform the Serial Loop Wiring Harness Test CAUTION If for any reason you do not understand the test procedures or are unable to perform the test repairs safely tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed Call 1 800 833 9353 POWER WAVE 450 LINCO
297. l POWER WAVE 450 LINCOLN amp Return to Section Return to Master TOC Return to Section TOC O o e 5 5 9 5 2 21 Return to Section Return to Master TOC Return to Master TOC TROUBLESHOOTING amp REPAIR RECONNECT SWITCH TEST 2 continued e Lead 9A between the reconnect switch and switch board 1 e Lead 9B between the reconnect switch and switch board 2 e Lead 9C between the reconnect switch and switch board 3 e Lead 9D between the reconnect switch and switch board 4 Lead 9J between the reconnect switch and plug J31 pin 10 of the protection board e Lead 9K between the reconnect switch and plug J31 pin 14 of the protection board e Lead 12A between the reconnect switch and switch board 1 e Lead 12B between the reconnect switch and switch board 2 e Lead 12C between the reconnect switch and switch board 3 e Lead 12D between the reconnect switch and switch board 4 e Lead 12J between the reconnect switch and plug J31 pin 12 of the protection board e ead 12K between the reconnect switch and plug J31 pin 1 of the protection board Lead POS between the reconnect switch the input rectifier e Lead NEG between the reconnect switch and the input rectifier 8 With the volt ohmmeter test THAT THERE IS CONTINUITY between the leads in the following groups according to the v
298. l assis tance The control board may be faulty Replace and perform voltage calibration and current calibration The display board may be faulty Replace and perform voltage calibration The power board may be faulty Replace O o Fle S 9 gt 515 2 CAUTION If for any reason you do not understand the test procedures or are unable to perform the test repairs safely tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed Call 1 800 833 9353 Return to Section TOC Return to Master TOC POWER WAVE 450 LINCOLN Return to Section Return to Master TOC Return to Section TOC Return to Master TOC o HE 2 3 Return to Section Return to Master TOC o O 4 o tc F 15 F 15 TROUBLESHOOTING amp REPAIR TROUBLESHOOTING GUIDE PROBLEMS SYMPTOMS The Beeper Piezoelectric Buzzer cannot be heard machine oper ating normally The welding parameters that were saved in memory are different when recalled The water cooler does not turn on POSSIBLE AREAS OF MISADJUSTMENT S FUNCTION PROBLEMS 1 Background noise may be too loud for user to hear beeper Make certain that a remote control unit is NOT connected When remote contr
299. l the electrode lead around your body 1 f Do not put your hands near the engine fan Do not attempt to override the governor or idler by pushing on the throttle control rods while the engine is running 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 close as possible to the area being welded 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 2 d 5 Do not work next to welding power source Mar 95 LINCOLN 8 Return to Master Return to Master TOC o 5 8 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 cond
300. lay board F Control Board 15 VDC Between J22 10 and J22 pin 12 15 VDC Between J22 pin 6 and J22 pin 12 5 VDC Between J22 pin 11 and J22 pin 12 If any of these voltages are not present and the voltages in part D above were present disconnect plug J42 from the power board and check the following voltages at header J42 on the power board 15 VDC Between 42 10 and J42 pin 12 15VDC Between J42 6 and J42 pin 12 5 VDC Between J42 pin 11 and J42 pin 12 If any of these voltages are NOT present replace the power board If these voltages ARE present check the wiring Then replace the control board POWER WAVE 450 LINCOLN amp F 99 F 100 F 100 TROUBLESHOOTING amp REPAIR olo e o INTERNAL AND AUXILIARY SUPPLY VOLTAGE TEST continued 5 3 510 13 With the Volt ohmmeter check the follow C Between the protection board and the 918 ing leads for continuity square wave TIG protection board Between the Protection Board and Wire Lead 296 Between J38 pin 3 and J92 a 2 Feeder 2 Receptacle pin 6 Lead 320 Between J34 5 and P82 14 After the test is completed and the prob lem successfully repaired disconnect Lead 32E Between J34 pin 6 and P82 15 Connect the five leads to main input con tactor CR1 and insert plug J30 into the Lead 42C Between J34 pin 3 and P82 protection board
301. llowing test points POWER WAVE 450 LINCOLN amp F 149 F 149 TROUBLESHOOTING amp REPAIR o o 9 FULL VOLTAGE CALIBRATION continued 5 5 5 9 POLARITY 21A H 2 POLARITY 8 8 POLARITY 518 ec NOTE Do not attempt to weld for Polarity 421A Set the number to the same as recorded for Polarity 4 674 Also for Polarity and Polarity move the volt meter sense lead from the conductor block of the wire feeder to the positive output terminal on the front of the machine 8 o 9 Turn the machine off Connect the Synergic 7 to the Wire feeder 2 amphenol 5 5 on the back of the Power Wave machine 9 8 10 Put the voltmeter sense lead back on the z 8 wire feeder conductor block and repeat je the calibration process steps 5 6 and 7 EIS for the following test points tio POLARITY 678 POLARITY 218 NOTE Do not attempt to weld for Polarity 21B Set the number to the same as recorded for Polarity 67B O o e 5 5 9 gt 5 2 Return to Section Return to Master TOC POWER WAVE 450 LINCOLN amp 150 NOTES POWER WAVE 450 LINCOLN 5 F 150 901 Je1Se A 0 901 Je1se A 0 901 J91Se N 01 DOL 01 901 uonoes uumeg DOL uonoes uumeg DOL uonoes uumeg DOL uonoes uumeg 151 151 TROUBLESHOOTING amp REPAIR CURRENT CA
302. ltage With this overlay in place the wire feed speed and the preset voltage or arc length trim can be changed from the wire feeder The new values will replace the previous values and become a perma nent part of the procedure If limits have been set on the wire feed speed volt age or arc length trim of the selected procedure these limits will be active when this overlay is in place They cannot be overridden from this over lay PROGRAM LIST The PROGRAM LIST block in the center of this overlay provides a convenient place to record a brief description of each welding procedure stored in memory A Dry Erase mark er should be used for this purpose DISPLAY RECALL KEY To view other information about the selected procedure press the DISPLAY RECALL key The display window will show the procedure description and gas type of the se lected procedure for as long as the key is held depressed When the key is released material type wire size and process descriptions will be displayed for a few seconds HIGH TEMPERATURE LIGHT The high tempera ture light comes on when the internal machine temperature exceeds the allowed limit Output is disabled until the machine cools down and the high temperature light goes out MEMORY LIGHTS A memory light is on when its corresponding memory is selected This tells you what memory is active at any given time POWER WAVE 450 LINCOLN B Return to Section Return to Master
303. m stickout The adaptive behavior is pro grammed to support a stickout range from 0 5 to 1 25 1 3 to 3 2 cm In the low and high end of the wire feed speed ranges of most processes the adap tive behavior may be restricted This is a physical restriction due to reaching the edge of the operating range for the process It is possible to achieve adap tive behavior for longer stickout lengths However shielding gas is often lost when the stickout is too long A longer electrical stickout is often used with the pulsing process at higher deposition rates A long stickout will increase the melt off rate of the wire In pulse welding like other wire welding processes the arc length is determined by the voltage setting This voltage is programmed at the factory for each process and wire feed speed It may be changed using the Voltage setting on the wire feeder When adaptive processes are used the voltage will vary with stickout The machine must change the voltage to keep a stable arc It is very important to recognize this Actual arc voltage when welding will vary because the stickout will seldom be held at the nominal 1 9 cm value POWER WAVE 450 LINCOLN B Return to Section Return to Master TOC Return to Section TOC O10 515 9 1 gt EIS 2 Return to Section Return to Master TOC Return to Master TOC B 23 B 23 OPERATION OVERLOAD PROTECTION THE
304. m main input contactor CR1 This is a safety precaution It prevents high voltage from being put on the machine during the test Wrap tape around the lead ends to insulate them and prevent them from touching 9 Remove plug 430 from the protection board location of the board and plug J30 NOTE If removing plug J30 solves the prob lem check for a short circuit or a fault in the 24 VAC circuit plug P71 and the main contactor coil See the Input and Auxiliary Circuit Wiring Diagram Figure F 10 POWER WAVE 450 LINCOLN amp F 36 Return to Section Return to Master TOC Return to Section TOC O10 515 9 1 gt EIS 2 Return to Section Return to Master TOC Return to Master TOC F 37 10 11 TROUBLESHOOTING amp REPAIR AUXILIARY TRANSFORMER PRIMARY WIRING HARNESS TEST continued Check the wires that run from the recon nect panel to the terminal strip Look for shorts between wires caused by broken or burned insulation See the Input and Auxiliary Circuit Wiring Diagram Check for shorts in the wires that run from the terminal strip to the auxiliary trans formers and to the fan motors The fan motors or the auxiliary transformer may be faulty Disconnect these compo nents one at a time and see if fuse F1 blows when input power is applied The internal resistance of the fan motors should be about 16 oh
305. m the Sensor Calibration POWER WAVE 450 LINCOLN amp F 146 Return to Section Return to Master TOC Return to Section TOC Return to Master TOC o 2 3 Return to Section Return to Master TOC o O gt o gt E tc F 147 F 147 TROUBLESHOOTING amp REPAIR FULL VOLTAGE CALIBRATION USING A WELDING ARC 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 elec trical 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 PROCEDURE DESCRIPTION This procedure is necessary if the display board is replaced and the Quick Voltage Calibration or the Normal Full Voltage Calibration is NOT possible MATERIALS NEEDED A Test and Calibration overlay L9660 255 the test procedure can be done within this A Synergic 7 wire feeder A calibrated DC voltmeter accurate to 0 1 volts at 30 0 volts The proper welding wire
306. manual A WARNING Before continuing with the test procedure perform the capacitor discharge proce dure to avoid electric shock Replacement Procedure After have completed the capacitor discharge procedure for all four switch boards disconnect plug J62 from the snubber board See Figure F 18 for loca tion Remove any output load that may be con nected to the machine With the volt ohmmeter measure the resistance between the positive and neg ative output terminals IMPORTANT The positive probe must be attached to the positive output terminal and the negative probe must be attached to the negative output terminal If the reading is 40 ohms the output recti fier diodes are good If the reading is less than 40 ohms replace the output rectifier Refer to the Output Rectifier in this section of the manual After the test is completed and the prob lem successfully repaired reconnect plug J62 to the snubber board Install the machine case sides and top Install the handle and the lift bail rubber gasket POWER WAVE 450 LINCOLN amp F 58 59 59 TROUBLESHOOTING amp REPAIR FIELD EFFECT TRANSISTOR SWITCH BOARD TEST OR IGBT SWITCH BOARD TEST A WARNING Service and repair should be performed by only Lincoln Electric
307. mpleted and the prob lem successfully repaired install the machine case sides and top Install the handle and the lift bail rubber gasket LINCOLN amp F 54 55 55 TROUBLESHOOTING amp REPAIR PIEZO ELECTRIC ALARM BUZZER 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 elec trical 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 trou bleshooting assistance before you proceed Call 1 800 833 9353 WELD oio 912 DESCRIPTION 9 0 D The following procedure will determine whether the piezo electric alarm buzzer is function 918 ing properly EIE 5 5 Pc MATERIALS NEEDED Volt Ohmmeter Multimeter 5 16 Nut driver 3 8 Nut driver Machine Wiring Diagram in the Electrical Diagrams section of this manual This procedure takes approximately 30 minutes to perform O10 e 515 9 16 gt EIS 2 Return to Section Return to Master TOC POWER
308. ms Remove plug P70 from the transformer If this solves the problem check for a short in the secondary circuit See the machine Wiring Diagram and the Protection PC Board Schematic in the Electrical Diagrams section of this manual 14 16 17 18 19 After the test is completed and the prob lem successfully repaired reconnect plug J30 to the protection board Reconnect plugs P70 and P71 to the 1 transformer Reconnect the 5 leads to the main con tactor CR1 Install the PC board cover Install the machine case sides and top Install the handle and the lift bail rubber gasket POWER WAVE 450 LINCOLN amp F 37 2 LL z lt O lt s L 08 qe lt lt Z JNVUL _ 27 926 pze 202 02 022 ra VEH 1 802 002 lt g lt p lt 5 5 qct vize Men i j 207 lt d o E 21 27 LL c1 cov 28 amp VY Veeromy Voer oer GU 61 8 79 Hu 9 9 lt 9 gt 2 gt 504 tov 4 gt ASL UY VHN or 11 11 n 2 U3
309. n 10 and J34 pin 12 24 VAC Between J34 pin 11 and J34 pin 12 If any of these voltages are not present on the protection board and the voltages in part A above were present replace the protection board D Power Board 42 VAC Between J43 pin 1 and 43 pin 3 If this voltage is not present and the voltages in part A above were present disconnect plug J35 from the protection board and check for 42 VAC at header J35 between pin 1 and pin 6 If this voltage is NOT present replace the protection board If this voltage IS present check the wiring between the boards Then replace the power board E Display Board 5 VDC Between J16 pin 2 and J16 3 15 VDC Between J16 pin 10 and J16 pin 7 5 VDC Between J16 pin 1 and J16 pin 7 5 VDC Between J16 pin 9 and J16 pin 7 8 VDC Between 16 pin 6 and 16 pin 7 If any of these voltages are not present and the voltages in part D above were present disconnect plug J44 from the power board and check the following voltages at header J44 on the power board 5 VDC Between J44 pin 3 and J44 pin 2 15 VDC Between J44 10 and J44 pin 12 5 VDC Between J44 pin 11 and J44 pin 12 5 VDC Between J44 pin 9 and J44 pin 12 8 VDC Between J44 pin 6 and J44 pin 12 If any of these voltages are NOT present replace the power board If these voltages ARE present check the wiring first Then replace the disp
310. n Board Check for shorts on the associated PC boards See the Auxiliary Transformer 1 Secondary Circuit Wiring Diagram Figure POWER WAVE 450 LINCOLN amp F 41 F 41 TROUBLESHOOTING amp REPAIR AUXILIARY TRANSFORMER 1 SECONDARY AND WIRING HARNESS TEST continued 10 Check for shorts at plugs J33 J34 J35 J37 and J38 on the protection board Inspect the board for evidence of arcing Return to Section TOC Return to Master TOC 11 After the test is completed and the prob lem successfully repaired reconnect plugs disconnected for the test 12 Install the PC board cover 13 Install the machine case sides and top 14 Install the handle and the lift bail rubber gasket Return to Section TOC Return to Master TOC O10 515 9 16 gt EIS 2 Return to Section Return to Master TOC POWER WAVE 450 LINCOLN amp F 42 F 42 TROUBLESHOOTING amp REPAIR 12 AUXILIARY TRANSFORMER 1 SECONDARY CIRCUIT WIRING DIAGRAM o 4 8 T o 0 a 0 12 r gt b gt gt 9 gt 5 5 55 2 Bie 5 QR eer 166 amp c ser NOWNWOD gt gt xp T ae ir E zo IE ut 9
311. n pul 12D 4B Less than OK None Continue 100 91 8 9 gt Greater Open Replace 4 Snubber than 1K Switch Resistor ohm Boards Test 5 9 9D 3B Greater OK None Continue s than 1K ohm Less than Shorted Replace 4 Snubber 100 ohms Switch Resistor Boards Test 3B 9D Less than OK None Continue 100 ohms Olo Greater Open Replace 4 Snubber e than 1K Switch Resistor 2 8 Test amp gt 4B 9D Less than OK None Continue 158 100 ohms Greater Open Replace 4 Snubber gt 9 than 1K Switch Resistor Boards Test 9D 4B Greater OK None Continue than 1K ohm Less than Shorted Replace 4 Snubber 100 ohms Switch Resistor boards Test NOTE ohm ohm reading multiplied by 1000 NOTE Always make sure that all four Switch Boards are changed at the same time Never mix an old style different part number Switch Board with a new style new part number O o Fle 5 9 9g 43 POWER WAVE 450 LINCOLN amp Return to Section Return to Master TOC Return to Section TOC Return to Master TOC o 2 3 Return to Section Return to Master TOC o O gt o gt E tc F 72 TROUBLESHOOTING amp REPAIR FIELD EFFECT TRANSISTOR SWITCH BOARD TEST continued TABLE F 5 SWITCH BOARD 4
312. n to Master TOC Return to Master TOC F 23 F 23 TROUBLESHOOTING amp REPAIR 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 elec trical 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 PURPOSE FOR THE PROCEDURE This procedure will drain off any charge stored in the four large capacitors that are part of the FET or IGBT 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 internal components of the machine MATERIALS NEEDED Volt Ohmmeter Multimeter 5 16 Nut driver 3 8 Nut driver Insulated gloves Jumper wire with insulated leads and needle nose ends High wattage resistor 25 to 1000 ohms 25 watts minimum Piece of glastic board or similar insulating materials on which to secure the resistor This procedure takes approximately 25 minutes to perform POWER WAVE 450
313. n to Master TOC o p 5 11 OPERATION WELD FROM MEMORY OVERLAY The Weld From Memory Overlay lets an operator recall and use any welding procedure stored in one of eight mem ory locations See Figure B 5 FIGURE B 5 WELD FROM MEMORY OVERLAY PANEL 2 WELD FROM MEMORY THELINCOLN ELECTRIC COMPANY CLEVELANC LINCOLN G ELECTRIC LEVELAND COPYRIOHT 1994 POWER WAVE 450 LCD DISPLAY WINDOW MEMORY RECALL KEYS PROGRAM LIST DISPLAY RECALL KEY HIGH TEMPERATURE LIGHT MEMORY LIGHTS e e mms LCD DISPLAY WINDOW Power up the machine with this overlay in place When the Power Wave is turned on the following message appears in the display window for a few seconds LINCOLN ELECTRIC Version X X This display is followed by OVERLAY ID NUMBER 2 This message is then replaced by the following message SELECT A MEMORY LOCATION MEMORY RECALL NUMBERS Select the mem ory location of the desired welding procedure by pressing the appropriate MEMORY RECALL NUMBER key If no procedure was saved in the selected memo ry location the following message appears MEMORY LOCATION IS EMPTY Select another memory location When a welding procedure is recalled from mem ory the display window will show the procedure description wire feed speed and arc length trim or preset vo
314. n to Section TOC Return to Master TOC POWER WAVE 450 LINCOLN B F 6 F 6 TROUBLESHOOTING amp REPAIR TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginning of this manual PROBLEMS POSSIBLE AREAS OF RECOMMENDED SYMPTOMS MISADJUSTMENT S COURSE OF ACTION OUTPUT PROBLEMS Machine has no output fans are 1 Turn power OFF immediately 1 Perform the running display is on a click Transformer Test 1 2 Check for proper input voltage heard Gong per machine nameplate 2 Perform the Main Contactor Test Return to Section TOC Return to Master TOC 3 Make certain the reconnect panel is configured properly for 3 Perform the Reconnect the applied voltage Switch Test 1 4 Perform the Reconnect Switch Test 2 5 Perform the nput Rectifier 6 Perform the Switch Board 7T Perform the Snubber and Bleeder Resistor Test 8 The protection board may be faulty Replace Return to Section TOC Return to Master TOC 9 The input filter capacitors may be faulty Replace olo o e 5 5 9 gt 5 2 CAUTION If for any reason you do not understand the test procedures or are unable to perform the test repairs safely tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed Call 1 800 833 9353 Return to Section TOC R
315. n when its corresponding memory is selected This tells you what memory location is active at any given time POWER WAVE 450 LINCOLN B 15 15 OPERATION LIMITS OVERLAY OPTIONAL The Limits Overlay is used to set the maximum and minimum limits of the wire feed speed and voltage or arc length trim for any welding procedure stored in memory See Figure B 8 FIGURE B 8 LIMITS OVERLAY Return to Section TOC Return to Master TOC POWER WAVE 450 LINCOLN E ELECTRIC WELDING PROCEDURE LIMITS o 2 5 Return to Master TOC 1 LCD DISPLAY WINDOW 2 RECALL FROM MEMORY KEY 3 MEMORY LOCATION NUMBER KEYS 4 SET LIMIT KEY LIMIT UP DOWN KEYS SAVE TO MEMORY KEY DISPLAY RECALL KEY MEMORY LIGHTS 01 Return to Section Return to Master TOC LCD DISPLAY WINDOW Power up the machine Determine the memory location number of the 5 6 with this overlay place When the Power Wave is welding procedure for which you want to set lim 5 turned on the following message appears the its Then press the RECALL FROM MEMORY key display window for few seconds followed by the MEMORY LOCATION NUM 2 LINCOLN ELECTRIC BER key for the selected procedure 512 If no procedure was saved the selected memo E a This display is followed by ry location the following message appears OVERLAY ID a a NUMB
316. nction 32 The machine should display the following VOLTAGE WIRE POLARITY 67A 5 Press the Enter Key 133 on the lower right side of the overlay The machine should display the following ADJUST TO 30V CALIBRATION XX NOTE Here xx indicates a particular cali bration number for a given voltage sense point WARNING The machine s output terminals will be electri cally HOT when the Enter Key is pressed 6 Adjust the wire feed speed on the Synergic 7 to 500 IPM some wire feed speed to get into the spray range NOTE When the Enter Key is pressed it will clear the wire feed speed to 200 IPM The wire feed speed must be adjusted after pressing the Enter Key but before starting to weld 7 Pull the trigger on the torch and start to weld Hold along stick out This is not nor mally a welding technique The starting will be poor The welding may be poor Main tain a long steady welding arc While weld ing monitor the reference voltage only external voltmeter It is the only important reading Adjust the voltage using the Arrow Keys 100 and 101 until the reference volt meter reads 30 0 volts Record the number on the display xx Press the Enter Key Release the trigger on the torch 8 Repeat the process by pressing the Voltage Calibration function 32 again The next voltage sensing point may be selected by pressing the down Arrow Key 101 Repeat steps 5 6 and 7 for the fo
317. nd pin 4 A 24 VAC IS present go to step 14 NOTE A voltage of 5 to 10 VDC is normal between these pins without the D to E jumper installed in the six pin amphenol receptacle B If 24 VAC is NOT present check for 24 VAC between plug J33 pin 4 and pin 1 See the Trigger Circuit Wiring Diagram Figure F 50 C If 24 VAC IS present between plug J33 pin 4 and pin 1 check the continuity and integrity of leads 371 374 102C 105B 296 and 293 and their associated pin con nectors See the Trigger Circuit Wiring Diagram If the continuity checks are good check the square wave TIG protec tion board by checking the continuity through the following pins See the Trigger Circuit Wiring Diagram Figure F 50 Plug J92 pin 6 to plug J93 pin 5 Normal resistance is 4 ohms Plug J92 pin 3 to plug J93 7 Normal resistance is 4 ohms If the square wave TIG protection board is good then the protection board may be faulty Replace the protection board D If 24 VAC is NOT present between plug J33 pin 4 and pin 1 check Auxiliary Transformer 1 the 5 amp circuit breaker and the associated wiring See the Trigger Circuit Wiring Diagram Figure F 50 14 Turn input power to the machine OFF and perform the capacitor discharge proce dure 15 Remove plug J26 from the protection board Attach a 150 ohm resistor between plug J26 pin 1 and J26 pin 2 the J26 plug not the header on the control board
318. nder Undercarriage Designed for quick installation in the field Consists of a front caster assembly a dual bottle rear platform assembly a handle and a dual bottle upper cylinder support POWER WAVE 450 LINCOLN B Return to Section Return to Master TOC Return to Section TOC O10 e 515 9 16 gt EIS 2 Return to Section Return to Master TOC Return to Master TOC 4 64 ACCESSORIES G3503 COOLER PERIODIC MAINTENANCE 1 Preparation Always switch off the Power Wave machine power Always disconnect the Power Wave machine from service input power e Do not remove the pump relief valves 3 4 in acorn hex nut or attempt to adjust the relief valve setting 2 Remove the G3503 cooler from the Power Wave machine 3 Clean the pump s inlet strainer Drain the reservoir of coolant and dispose of it in an environmentally responsible manner see Recommended Coolants Place absorbent towels underneath pump head Hold pump head to apply countertorque when loosening strainer s 7 8 acorn nut Do not con fuse with 3 4 acorn nut Remove nut and slide inlet strainer down and out from pump head Gently rinse strainer under running water to thoroughly clean it Use the mirror to inspect inside of pump for contamination Carefully remove hardened debris with dental pick if necessary without scratching inside of the pump
319. nds and the WATER COOLER PRESSURE light still did not turn on check the water cooler for adequate fluid level WIRE FEEDER 1 POLARITY KEY Press this key to change the present voltage sensing polari ty of wire feeder 1 The present polarity of wire feeder 1 is indicated by the WIRE FEEDER 1 POLARITY light If wire feeder 1 is set for positive voltage sensing polarity this light is turned on WIRE FEEDER 1 ELECTRODE SENSE LEAD KEY Press this key to enable or disable the elec trode sense lead lead 67 of wire feeder 1 When enabled voltage sensing is done by the electrode sense lead When disabled voltage sensing is done at the Power Wave output terminal When enabled the WIRE FEEDER 1 ELECTRODE SENSE LEAD ENABLED light will be illuminated WIRE FEEDER 1 WORK SENSE LEAD KEY Press this key to enable or disable the work sense lead lead 21 of wire feeder 1 When enabled voltage sensing is done by the work sense lead When disabled voltage sensing is done at the Power Wave output terminal When enabled the WIRE FEEDER 1 WORK SENSE LEAD ENABLED light will be illuminated WIRE FEEDER SETUP DESCRIPTION The Power Wave may be set up for either positive or negative arc voltage sensing using any two of the following places 1 the positive output terminal of the Power Wave 2 the negative output terminal of the Power Wave 3 the electrode sense lead 67 lead of the wire feeder 4 the work sense
320. necessary a Press the DISPLAY RECALL key view additional procedure information DISPLAY RECALL to b Adjust wire feed speed and voltage or arc length trim through the controls on your wire feeder The new values appear on both the wire feeder and the Power Wave display Step 3 Save process information if desired oN a Press the SAVE TO MEMORY key save Press one of the MEMORY LOCATION keys 1 8 You can recall your procedure later by pressing the RECALL FROM MEMORY key and the appro priate MEMORY LOCATION key electrode class electrode size and electrode gas type you can select for your process will be limited to the machine s programmed recommenda tions Therefore selecting certain options may limit other option selections 2 The wave control scale displayed shows the default setting The higher the setting the softer the arc If you change the setting your new setting will be dis played POWER WAVE 450 LINCOLN B Return to Section Return to Master TOC Return to Section TOC O o 5 5 0 9 gt 5 2 Return to Section Return to Master TOC Return to Master TOC B 4 OPERATION GENERAL DESCRIPTION The INVERTEC Power Wave power source is a high performance digitally controlled inverter welding power source capable of complex high speed wave form control It uses three phase input po
321. nect Switch Test 1 81 Reconnect Switch Test Roe 85 t Static Capacitor Balance 2 F 89 5 Dynamic Capacitor Balance nnne F 93 2 Internal and Auxiliary Supply Voltage F 97 Main Contactor Test 103 Serial Loop Wiring Harness 0 42 0 TRAA F 107 Wire Feeder 1 Trigger Circuit Test 111 Wire Feeder 2 Trigger Circuit 8 08 0 0 0 F 115 Trigger Circuit and Wiring Harness 00 F 119 Internal Remote Control F 123 K941 1 Remote Control Kit 2 4 000000 127 K941 1 Remote Control Kit Trigger Circuit F 131 S cle 135 Calibration 2 corii eruere eter F 139 2 Sensor Calibration Test For Display Board F 141 Quick Voltage Calibration 143 Voltage ER 145 Full Voltage Calibration Using A Weldi
322. ned personnel Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty For your safety and to avoid elec trical shock please observe all safety notes and precautions detailed throughout this manual 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 trou bleshooting assistance before you proceed Call 1 800 833 9353 WELD DESCRIPTION The following procedure will aid the technician in removing the main input contactor for maintenance or replacement Return to Section TOC Return to Master TOC MATERIALS NEEDED Slot head screw driver 5 16 Nut driver 3 8 Open end wrench Machine Wiring Diagram in the Electrical Diagrams section of this manual This procedure takes approximately 45 minutes to perform O o Fle 5 o 9 515 2 Return to Section Return to Master TOC POWER WAVE 450 LINCOLN Return to Section Return to Master TOC o 2 3 Return to Section Return to Master TOC o p 5
323. ng F 147 5 Current Calibration 151 2 Replacement 155 T1 Auxiliary Transformer Removal and Replacement F 155 Water Cooler Removal and Replacement 00 157 Water Cooler Disassembly 161 T2 Auxiliary Transformer Removal and Replacement F 165 Fan Motor Removal and F 167 Input Rectifier Removal and 00 171 Printed Circuit Board Removal and Replacement F 175 Display Board Removal and 179 Main Input Contactor CR1 Removal and F 183 Output Rectifier Bridge Removal and 00 F 187 8 FET Module Removal F 191 Main Transformer Removal and 197 Pre P
324. ng Harness Test The machine intermittently loses output The wire feeder still feeds wire If after a few seconds the con tactor pulls back in then check for high input line voltage 1 Perform the Static Capacitor Balance Test 2 Perform the Welding Feedback Test The control board may be faulty Replace The shunt board assembly may be faulty Replace 5 Perform the Switch Board CAUTION If for any reason you do not understand the test procedures or are unable to perform the test repairs safely tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed Call 1 800 833 9353 POWER WAVE 450 LINCOLN Return to Section Return to Master TOC Return to Section TOC O O Fle 5 9 515 2 Return to Section Return to Master TOC Return to Master TOC F 10 TROUBLESHOOTING amp REPAIR TROUBLESHOOTING GUIDE PROBLEMS SYMPTOMS Machine has no welding output fans run display is on Observe Safety Guidelines detailed in the beginning of this manual POSSIBLE AREAS OF MISADJUSTMENT S OUTPUT PROBLEMS 1 Make sure that the machine was powered up with a proper ly installed overlay Without an overlay installed in the Power Wave or an invalid overlay installed the machine will not have welding output Chec
325. ns 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 proper voltages are present at the protection board the power board the control board and the display board MATERIALS NEEDED Volt Ohmmeter Multimeter 5 16 Nut driver 3 8 Nut driver Internal Auxiliary Supply Wiring Diagram Figure F 34 This procedure takes approximately 45 minutes to perform POWER WAVE 450 LINCOLN Return to Section Return to Master TOC Return to Section TOC Return to Master TOC o 2 3 Return to Section Return to Master TOC o p 5 98 TROUBLESHOOTING amp REPAIR INTERNAL AND AUXILIARY SUPPLY VOLTAGE TEST continued TEST PROCEDURE 1 Remove main input supply power to the machine 2 With the 3 8 nut driver remove the 4 screws that hold the handle to the machine 3 Remove the rubber gasket cover seal from the lift bail 4 With the 5 16 nut driver remove the sheet metal screws from the case top 5 With the 5 16 nut driver remove the screws holding the right and left case sides Remove the case sides by li
326. nual 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 DESCRIPTION The following procedure will aid the technician in removing the T2 auxiliary transformer for maintenance or replacement MATERIALS NEEDED 5 16 Nut driver 3 8 Nut driver or socket wrench Machine Wiring Diagram in the Electrical Diagrams section of this manual This procedure takes approximately 30 minutes to perform POWER WAVE 450 LINCOLN Return to Section Return to Master TOC Return to Section TOC O o 5 5 9 gt 5 2 Return to Section Return to Master TOC Return to Master TOC TROUBLESHOOTING amp REPAIR T2 AUXILIARY TRANSFORMER REMOVAL AND REPLACEMENT continued FIGURE F 62 T2 AUXILIARY TRANSFORMER LOCATION 1 BASE 2 AUXILIARY TRANSFORMER T2 3 MOUNTING SCREW 2 PROCEDURE 1 Remove main input supply power to the machine 2 With the 3 8 nut driver remove the 4 screws that hold the handle to the machine 3 Remove the rubber gasket cover seal from the lift bail 4 With the 5 16 nut driver remove the sheet metal screws from the case top 5 With the 5 16 nut driver remove the screws holding the right and left case sides Remove the case s
327. nue c c than 1K ohm Less than Shorted Replace 4 Snubber 100 ohms Switch Resistor Boards Test 3T 9C Less than OK None Continue 100 ohms olo 010 Greater Open Replace 4 Snubber p E than 1K Switch Resistor 2 8 Boards Test 9 AT 9C Less than OK None Continue 8 100 ohms Greater Open Replace 4 Snubber t E than 1K Switch Resistor E ohm Boards Test 9C AT Greater OK None Continue than 1K ohm Less than Shorted Replace 4 Snubber 100 ohms Switch Resistor boards Test NOTE K ohm ohm reading multiplied by 1000 NOTE Always make sure that all four Switch Boards are changed at the same time Never mix an old style different part number Switch Board with a new style new part number O o Fle 5 9 9g 43 POWER WAVE 450 LINCOLN amp Return to Section Return to Master TOC Return to Section TOC Return to Master TOC o 2 3 Return to Section Return to Master TOC o O gt o gt E tc F 70 TROUBLESHOOTING amp REPAIR FIELD EFFECT TRANSISTOR SWITCH BOARD TEST continued TABLE F 4 SWITCH BOARD 3 RESISTANCE TEST TABLE Continued F 70 Apply Apply Positive Negative Test Test Probe to Probe to Test Repair Next Terminal Terminal Result Conclusion Action Procedure 12C 3T Less than OK N
328. o gt E 9 24 9 24 ELECTRICAL DIAGRAMS POWER WAVE RS 232 CONNECTIONS DCD RD TD DTR GND DSR RTS CTS RI 9 PIN RS 232 J17 MOLEX FROM PC NULL POWER WAVE MOS CONNECTOR TERNAL WINING DISPLAY BOARD 302 NOTE Lincoln Electric assumes no responsibility for liabilities resulting from board level troubleshooting PC Board repairs will invalidate your factory warranty This Printed Circuit Board schematic is provided for reference only It may not be totally applicable to your machine s specific PC board version This dia gram is intended to provide general information regarding PC board function Lincoln Electric discour ages 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 WAVE 450 LINCOLN B Return to Section Return to Master TOC Return to Section TOC O10 e 515 9 1 gt 815 5 2 EE C Return to Section TOC Return to Master 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 tr
329. o high the pro tection circuit will prevent output Also in the event that a capacitor voltage is too low the machine output is disabled and the soft start mode is repeated The protection circuit may prevent output if any of the fol lowing circumstances occur 1 Capacitor condition is required Required if machine has been off for a long period of time and is connected for high input voltage operation 2 Voltage across a capacitor exceeds 370 volts High line surges or improper input voltage connec tions 3 Voltage across a capacitor is under 170 volts Due to improper input voltage connections 4 Internal component damage POWER WAVE 450 LINCOLN B Return to Section Return to Master TOC Return to Section TOC O o e 5 5 9 5 2 Return to Section Return to Master TOC Return to Master TOC THEORY OF OPERATION FIELD EFFECT TRANSISTOR FET OPERATION FIGURE E 10 FIELD EFFECT TRANSISTOR OPERATION GATE SOURCE TERMINAL TERMINAL 0 VOLTS i m DRAIN TERMINAL SOURCE N p dii a DRAIN N N CHANNEL SUBSTRATE P A PASSIVE GATE TERMINAL 6 VOLTS SOURCE N DRAIN N e e 9522255 5 5 8 2 5 ae ELECTRONS B ACTIVE An FET is a type of transistor FETs are semi conductors well suited for high frequency switching D
330. o touch these resistors A WARNING e ELECTRIC SHOCK can kill Proceed with caution being care ful not to touch any internal machine components during the discharge procedure POWER WAVE 450 LINCOLN B D 3 Return to Section Return to Master TOC Return to Section TOC Return to Master TOC o 2 3 Return to Section Return to Master TOC o O gt o v E tc 6 MAINTENANCE Locate the 9 and 12 terminals identified by the Discharge labels on each of the four Switch Boards See Figure D 2 Using insulated needle nose type jumper leads and insulated gloves connect one jumper lead to one end of the resistor obtained in step 4 Connect the other jumper lead to the other end of the resistor Carefully connect the needle nose end of one of the jumper leads to terminal 49 See Figure D 3 Connect the needle nose end of the other jumper lead to terminal 12 Terminals 9 and 12 are indicated by the Discharge label Leave resistor connected for 10 seconds DO NOT TOUCH TER MINALS RESISTORS OR ANY INTERNAL MACHINE COMPONENT DURING THIS PROCE DURE FIGURE D 2 DISCHARGE LABEL lt 0 13086 117 FIGURE D 3 RESISTORS WITH LEADS CONNECTED
331. ocedures 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 DESCRIPTION The following procedure will aid the technician in removing the display board for mainte nance or replacement MATERIALS NEEDED 5 16 Nut driver 3 8 Nut driver This procedure takes approximately 45 minutes to perform POWER WAVE 450 LINCOLN Return to Section Return to Master TOC Return to Section Return to Master TOC o 2 3 Return to Section Return to Master TOC o O gt o gt E 180 TROUBLESHOOTING amp REPAIR DISPLAY BOARD REMOVAL AND REPLACEMENT continued FIGURE 68 DISPLAY BOARD REMOVAL A Oa EC 5 5 LCD CONNECTOR MOUNTING PIN HOLE NOTE Before changing or disturbing the dis play board follow the procedure outlined under QUICK VOLTAGE CALIBRATION Fig F 54 in this section PROCEDURE 1 6 Remove main input supply power to the machine With the 3 8 nut driver remove the 4 screws that hold the handle to the machine Remove the rubber gasket c
332. ol unit is used the weld parameters are set by the remote control potentiometers Make sure that the water cool er has been installed and also enabled Refer to the Setup Overlay description in the Section of the manual If the water cooler is enabled but there is insufficient flow rate in the water cooler hose the Power Wave will beep loudly and the water cooler will shut down Prime the water cooler Refer to the Setup Overlay description in the Operation Section of this manual The coolers circuit breaker may have tripped Reset if necessary Observe Safety Guidelines detailed in the beginning of this manual RECOMMENDED COURSE OF ACTION 1 Perform the 2 The display board may be faulty Replace and perform voltage calibration Check the continuity of wire 445 8J44 to 8J16 The power board may be faulty Replace The display board may be faulty Replace Perform the Transformer 2 Test Check the continuity of leads 453 454 455 amp 456 From plug J3 to J11 See wiring dia gram The display board may be faulty Replace The water cooler may be faulty A 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 POWER WAVE 450 LINCOLN Return to S
333. oltage for which the machine is wired For 200 230 VAC A Test for continuity between leads 9A 9B 9C 9D 9K 9J and POS con nected together at the reconnect switch B Test for continuity between leads 12A 12B 12C 120 12K 12 and NEG connected together at the reconnect switch For 380 460 VAC A Test for continuity between leads 9A 9B 9K and POS connected together at the reconnect switch B Test for continuity between leads 9C 9D 9J 12A 12B and 12J connect ed together at the reconnect switch C Test for continuity between leads 12C 12D 12K and NEG connected together at the reconnect switch 9 If there is continuity within the groups of leads tested the test is complete Install the machine case sides top handle and the lift bail rubber gasket POWER WAVE 450 LINCOLN amp F 88 auvog 70H1NOO 2 b lt eer zez 2 g LNaWaunsvaN
334. on TOC O10 e 515 9 16 gt EIS 2 Return to Section Return to Master TOC Return to Master TOC F 173 10 11 12 TROUBLESHOOTING amp REPAIR INPUT RECTIFIER REMOVAL AND REPLACEMENT continued With the 5 mm Allen wrench and the 10 mm open end wrench remove the two screws mounting the input rectifier to the heat sink panel When replacing the input rectifier apply a thin even coating of Dow Corning 340 Joint Compound Lincoln T12837 to the mating surfaces between the input rectifi er and the heat sink panel Avoid applying the compound to either the mounting holes or the mounting hardware Mount the input rectifier to the heat sink panel and tighten the two mounting screws with the 5 mm Allen wrench and the 10 mm open end wrench Be sure to tighten the screws evenly 13 14 15 16 With the Phillips head screw driver attach the positive and negative leads to the input rectifier Attach the three heavy leads and the M O V assembly to the input rectifier Replace the M O V assem bly if it appears damaged Apply silicone sealant to the M O V assembly connections Install the machine case sides and top Install the handle and the lift bail rubber gasket POWER WAVE 450 LINCOLN F 173 174 NOTES POWER WAVE 450 LINCOLN 5 F 174 901 Je1Se A 0 901 4 1 0 uunjeH 901 J91Se N 01
335. one Continue 100 ohms Greater Open Replace 4 Snubber than 1K Switch Resistor ohm Boards Test 3T 12C Greater OK None Continue than 1K ohm Less than Shorted Replace 4 Snubber 100 ohms Switch Resistor Boards Test 12C 405 Greater OK None Continue than 1K ohm Less than Shorted Replace 4 Snubber 100 ohms Switch Resistor Boards Test 405 12C Less than OK None Continue 100 ohms Greater Open Replace 4 Snubber than 1K Switch Resistor ohm Boards Test 9C 406 Less than OK None Continue 100 ohms Greater Open Replace 4 Snubber than 1K Switch Resistor ohm Boards Test 406 9C Greater OK None Continue than 1K ohm Less than Shorted Replace 4 Snubber 100 ohms Switch Resistor boards Test NOTE K ohm ohm reading multiplied by 1000 NOTE Always make sure that all four Switch Boards are changed at the same time Never mix an old style different part number Switch Board with a new style new part number POWER WAVE 450 LINCOLN amp 71 71 TROUBLESHOOTING amp REPAIR olo e e FIELD EFFECT TRANSISTOR SWITCH BOARD TEST continued ed 2 2 TABLE 5 SWITCH BOARD 4 RESISTANCE TEST TABLE 9 1 ae Apply Apply 515 Positive Negative 9 Test Test Probe to Probe to Test Repair Next Terminal Terminal Result Conclusion Action Procedure 4B 12D Greater OK None Continue than 1K ohm Less than Replace 4 Snubber 100 ohms Shorted Switch Resistor Test j
336. ons POWER WAVE 450 LINCOLN B Return to Section Return to Master TOC Return to Section TOC Return to Master TOC o 2 3 Return to Section Return to Master TOC o p 5 OPERATION ELECTRODE CLASS UP DOWN Use the ELEC TRODE CLASS UP or DOWN keys to select from the material types available for the selected process Press the ELECTRODE CLASS UP or DOWN key until the desired material type is dis played ELECTRODE SIZE UP DOWN Use the ELEC TRODE SIZE UP or DOWN keys to select from the wire diameters available for the selected process and material type Press the ELECTRODE SIZE UP or DOWN key until the desired wire diameter is displayed ELECTRODE GAS TYPE UP DOWN KEYS Use the ELECTRODE GAS TYPE UP or DOWN keys to select from the programs available for the select ed process material type and wire diameter Press the ELECTRODE GAS TYPE UP or DOWN Key until the desired program is displayed WAVE CONTROL UP DOWN KEYS Press one of the two WAVE CONTROL keys to display the pre sent wave control This is shown on a scale from LO to HI Use the WAVE CONTROL UP or WAVE CONTROL DOWN key to change the wave control to the desired level When this scale is shown the WAVE CONTROL setting can also be changed while welding on the fly Press the DISPLAY RECALL key to exit the wave control function For a de
337. ontaining the correct shielding gas for the process used and properly operating regulators designed for the gas and pressure used 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 Cylinders 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 on compressed gas cylinders associated equipment and CGA publication Precautions for Safe Handling of Compressed Gases in Cylinders 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
338. op Replace the jumper between pins C and D of wire feeder 1 receptacle Measure the voltage drop with the jumper installed The reading should be about 2 VDC across the resistor If 2 VDC is NOT present check the conti nuity and integrity of leads 262 and 261 and their associated pins and connectors The display board may be faulty replace the display board If 2 VDC IS present across the resistor the control board may be faulty replace the control board Turn input power to the machine OFF and connect the five leads to the main contac tor Connect all molex plugs to the PC boards and replace the cover with two sheet metal screws Install the machine case sides top handle and lift bail rubber gasket POWER WAVE 450 LINCOLN amp 114 TVNYSLNI TVNH3LX3 z LNANdINOA lt tc J3AvM HQ3MOd tc lt di o Y p 2 2 NOLLO310Ud t 3uvnos Y NOH 2 062 2 2 7771 2 B 5 OL 42 07 162 2 7921 8 8 9 8 S 2m 262 ape eer 7771 5 2 lt z lt 8K lt lt 1 gt oc ger asot a 7 lt lt 8
339. other equipment and to achieve the best possible operation route all cables directly Avoid excessive lengths bundle the electrode and ground cables together where practical and do not coil excess cable WATER COOLER CONNECTIONS The water cooler fittings are a quick connect type Refer to the Accessories section of this manual for water cooler operation and antifreeze mixtures WIRE FEEDER CONNECTIONS Refer to the Accessories section for Wire Feeder Con nections Refer to Setup overlay in section for Wire Feeder Configuration POWER WAVE 450 LINCOLN B NOTES POWER WAVE 450 LINCOLN 901 Je1Se A 0 uunjeHd 901 4 1 0 901 J91Se N 01 901 J91Se N 01 901 uonoes uumeg DOL uonoes uumeg DOL uonoes uumeg DOL uonoes Section B 1 Section B 1 TABLE OF CONTENTS OPERATION SECTION 8 Section gt riis 2 Quick Start Reference for Process Selection Overlay eese B 3 E General DESCriPtlON e B 4 synergie WOIGING B 4 Recommended 4 Operational Features and B 4 Design Features and
340. oubleshooting 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 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
341. our safety and to avoid elec trical 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 trou bleshooting assistance before you proceed Call 1 800 833 9353 WELD DESCRIPTION The following tests and procedures must be performed if the main power FET module has been replaced in the Power Wave These tests are necessary to ensure that the FET module has been installed and connected properly This procedure takes approximately 2 hours to perform BEWARE ISOLATED POWER SUPPLIES AND METERING MUST BE USED CATASTROPHIC PC BOARD DAMAGE WILL OCCUR IF THE VOLTAGE SUPPLIES AND METERING ARE NOT COMPLETELY ELECTRICALLY ISOLATED o o 2 5 Return to Master 5 8 MATERIALS NEEDED s Calibration and Test Overlay L9660 255 Isolation transformer for oscilloscope 8 gt Isolation transformer 115 3 amps min circuit of figure 1 Isolation transformer 115 2 amps min circuit of figure 3 p Variable transformer 3 amps min Ble Oscilloscope 2 Current probe Tektronic P6201 or equivalent Voltmeters Fuse 5 amps 2 P70 adapter Female connector 18247 6 Male connector 18249 6 Male pin 58053
342. over seal from the lift bail With the 5 16 nut driver remove the sheet metal screws from the case top With the 5 16 nut driver remove the screws holding the right and left case sides Remove the case sides by lifting up and out Perform the Capacitor Discharge Procedure described earlier in this section of the manual MOLEX PLUG HEADERS 8 KEY PAD RIBBON CONNECTOR LCD DISPLAY WINDOW WARNING Before continuing with the test procedure perform the capacitor discharge proce dure to avoid electric shock CAUTION Be sure to follow the recommended static free methods for handling printed circuit boards Failure to do so can result in permanent dam age to the equipment 7 After you have completed the capacitor dis charge procedure for all four switch boards carefully remove the eight molex plugs from the lower portion of the display board POWER WAVE 450 LINCOLN amp F 180 Return to Section Return to Master TOC Return to Section TOC Return to Master TOC o 2 3 Return to Section Return to Master TOC o O gt o E tc F 181 TROUBLESHOOTING amp REPAIR DISPLAY BOARD REMOVAL AND REPLACEMENT continued 8 Carefully remove the key pad ribbon con nector from the right side of the display board 9 Carefully remove the connector to the LCD
343. owerup Switch Board Test F 199 2 POWER WAVE 450 LINCOLN B Return to Section Return to Master TOC Return to Section TOC O o e 5 5 9 5 2 Return to Section Return to Master TOC Return to Master TOC F 2 TROUBLESHOOTING amp REPAIR HOW TO USE TROUBLESHOOTING GUIDE 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 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 malfunc tions Simply follow the three step procedure listed below Step 1 LOCATE PROBLEM SYMPTOM Look under the column labeled PROBLEM SYMP TOMS This column describes possible symp toms that the machine may exhibit Find the list ing that best describes the symptom that the machine is exhibiting Symptoms are grouped into three main categories Output Problems Function Problems and Welding Problems Step 2 PERFORM EXTERNAL TESTS The second column labeled POSSIBLE AREAS OF MISADJUSTMENT S lists the obvious external
344. pairs safely tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed Call 1 800 833 9353 Return to Section TOC Return to Master TOC POWER WAVE 450 LINCOLN Return to Section Return to Master TOC Return to Section TOC Return to Master TOC o 2 3 Return to Section Return to Master TOC o O gt o gt E tc F 18 F 18 TROUBLESHOOTING amp REPAIR TROUBLESHOOTING GUIDE PROBLEMS SYMPTOMS The control knob on the Remote Control Kit K941 1 does not change the preset current on the Power Wave display Observe Safety Guidelines detailed in the beginning of this manual POSSIBLE AREAS OF MISADJUSTMENT S FUNCTION PROBLEMS 1 Make sure that a stick welding procedure is selected on the Power Wave Make certain that the K941 1 remote control is securely plugged into the Power Wave 6 pin amphenol receptacle RECOMMENDED COURSE OF ACTION 1 Perform 941 1 Remote Control Kit Test install a new 941 1 2 Perform the Internal Remote Control Test CAUTION If for any reason you do not understand the test procedures or are unable to perform the test repairs safely tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed Call 1 800
345. pen Replace 4 Snubber than 1K Switch Resistor ohm Boards Test 9A 402 Less than OK None Continue 100 ohms Greater Open Replace 4 Snubber than 1K Switch Resistor ohm Boards Test 402 9A Greater OK None Continue than 1K ohm Less than Shorted Replace 4 Snubber 100 ohms Switch Resistor boards Test NOTE K ohm ohm reading multiplied by 1000 NOTE Always make sure that all four Switch Boards are changed at the same time Never mix an old style different part number Switch Board with a new style new part number POWER WAVE 450 LINCOLN amp 67 67 TROUBLESHOOTING amp REPAIR e o FIELD EFFECT TRANSISTOR SWITCH BOARD TEST continued 5 5 TABLE SWITCH BOARD 2 RESISTANCE TEST TABLE 518 818 5 Positive Negative lo Test Test Probe to Probe to Test Repair Next Terminal Terminal Result Conclusion Action Procedure 2B 12B Greater OK None Continue than 1K ohm Less than Replace 4 Snubber 100 ohms Shorted Switch Resistor Test O o jn E 12B 2B Less than OK None Continue 2 2 100 ohms Oo 8 Greater Open Replace 4 Snubber than 1K Switch Resistor Test 5 5 213 9B 1B Greater OK None Continue than 1K ohm Less than Shorted Replace 4 Snubber 100 ohms Switch Resistor Boards Test 1B 9B Less than OK None Continue 100 ohms 5 8 Greater Open Replace 4 Snubber p E than 1K Switch
346. power to the machine OFF and perform the Capacitor Discharge 15 Remove plug J26 from the Protection Control board Attach a 150 ohm resistor between plug J26 pin 5 and J26 pin 6 the J26 plug not the header on the con trol board 16 Replace plug J13 into the display board WARNING ELECTRIC SHOCK can kill With the input power ON there are high volt ages inside the machine including the protec tion board Do not reach into the machine or touch any internal parts 17 Turn input power ON The LCD display will read ERROR S L NOT INITIALIZED Disregard this the test can still be per formed 18 Remove the jumper between pins C and D of wire feeder 2 receptacle 19 With the volt ohmmeter measure the volt age drop across the 150 ohm resistor between J26 pins 1 and 2 With the jumper removed the reading should be zero volts NO voltage drop 20 Replace the jumper between pins C and D of wire feeder 2 receptacle Measure the voltage drop with the jumper installed The reading should be about 2 VDC across the resistor A If 2 VDC is NOT present check the conti nuity and integrity of leads 265 and 266 and their associated pins and connectors The display board may be faulty replace the display board B If 2 VDC IS present across the resistor the control board may be faulty replace the control board 21 Turn input power to the machine OFF and connect the five leads to the main
347. r OK None Continue than 1K ohm Less than Shorted Replace 4 Snubber 100 ohms Switch Resistor boards Test NOTE ohm ohm reading multiplied by 1000 NOTE Always make sure that all four Switch Boards are changed at the same time Never mix an old style different part number Switch Board with a new style new part number O o Fle 5 9 9g 43 POWER WAVE 450 LINCOLN amp Return to Section Return to Master TOC Return to Section TOC Return to Master TOC o 2 3 Return to Section Return to Master TOC o O gt o gt E tc TROUBLESHOOTING amp REPAIR FIELD EFFECT TRANSISTOR SWITCH BOARD TEST continued TABLE F 2 SWITCH BOARD 1 RESISTANCE TEST TABLE Continued F 66 Apply Apply Positive Negative Test Test Probe to Probe to Test Repair Next Terminal Terminal Result Conclusion Action Procedure 12A 1T Less than OK None Continue 100 ohms Greater Open Replace 4 Snubber than 1K Switch Resistor ohm Boards Test 1T 12A Greater OK None Continue than 1K ohm Less than Shorted Replace 4 Snubber 100 ohms Switch Resistor Boards Test 12A 401 Greater OK None Continue than 1K ohm Less than Shorted Replace 4 Snubber 100 ohms Switch Resistor Boards Test 401 12A Less than OK None Continue 100 ohms Greater O
348. r and will invalidate your factory warranty For your safety and to avoid elec trical shock please observe all safety notes and precautions detailed throughout this manual 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 there are any short circuits or other problems in the serial loop wiring between the power board the control board the display board wire feeder 1 amphenol P83 and wire feeder 2 amphenol P82 MATERIALS NEEDED Volt Ohmmeter Multimeter 5 16 Nut driver 3 8 Nut driver Serial Loop Wiring Diagram Figure F 38 This procedure takes approximately 30 minutes to perform POWER WAVE 450 LINCOLN Return to Section Return to Master TOC Return to Section TOC Return to Master TOC o 2 3 Return to Section Return to Master TOC o p 5 108 1 WIRE FEEDER CONNECTIONS ON BACK PANEL TROUBLESHOOTING amp REPAIR SERIAL LOOP WIRING HARNESS TEST continued FIGURE F 37 WIRE FEEDER AMPHENOL LOCATIONS TEST PROCEDURE 1 6 Remove main input supply power to the machine With the 3 8 nut driver remove the 4 screws th
349. rawing A above shows an FET in a passive mode There is no gate signal zero volts from the source and therefore no current flow The drain terminal of the FET may be connected to a voltage supply But since there is no con duction the circuit will not supply current to downstream components connected to the source The circuit is turned off like a light switch in the OFF position Drawing B above shows the FET in an active mode When the gate signal a positive DC voltage relative to the source is applied to the gate terminal of the FET it can t conduct cur rent A voltage supply connected to the drain terminal will allow the FET to conduct and henceforth supply current to downstream components Current will flow through the conducting FET to downstream components as long as the gate signal is present This is similar to turning on a light switch POWER WAVE 450 LINCOLN B Return to Section Return to Master TOC Return to Section TOC Return to Master TOC o 2 3 Return to Section Return to Master TOC o p 5 THEORY OPERATION PULSE WIDTH MODULATION FIGURE E 11 TYPICAL FET OUTPUTS 48 usec 50 usec 1 usec 1 usec MINIMUM OUTPUT 20 usec 20 usec 10 usec 50 usec MAXIMUM OUTPUT The term PULSE WIDTH MODULATION is used to describe how
350. re 13 Check for the correct AC voltage between plug J4 pin 2 and J4 pin 5 It should be 220 230 VAC If the voltage is correct then Auxiliary Transformer 2 is good If the voltage is wrong or missing check the associated wiring to the transformer primary See the Input and Auxiliary Circuit Wiring Diagram Figure 8 These voltages are most easily checked at the terminal strip The cor rect voltages are as follows H1A to H3A 220 230 VAC If this voltage is wrong or missing check the associated wiring to the transformer primary If the correct voltage IS applied to the primary but the voltage at H1A to H3A is not correct the transformer may be faulty Replace the transformer Refer to the T2 Auxiliary Trans former Removal Replacement Procedure in this section of the manual 14 After the test is completed and the prob lem successfully repaired reconnect plug J30 to the protection board 15 Reconnect plug J73 to the T1 transformer 16 Reconnect the 5 leads to the main con tactor CR1 17 Install the PC board cover 18 Install the machine case sides and top 19 Install the handle and the lift bail rubber gasket POWER WAVE 450 LINCOLN amp F 33 F 34
351. ress the SET LIMIT key The new maximum and old minimum voltage trim or arc length trim will be displayed Use the LIMIT UP and LIMIT DOWN keys to change the minimum value The minimum for either type is 0 5 SAVE TO MEMORY KEY The SAVE TO MEMO RY KEY is used to save the procedure with the newly set limits to memory Press the SAVE TO MEMORY key followed by the MEMORY LOCATION NUMBER key of the desired memory location This does not have to be the original location from which the procedure was recalled Step 6 can be performed any time during the limit setting process You do not have to set all the available limits When you have set all the desired limits save the procedure to memory To clear any previously set limits recall the proce dure from memory and change the limits to the maximum range available Then save the proce dure to memory DISPLAY RECALL KEY To view other information about the active welding procedure press the DISPLAY RECALL key The display window will show the procedure description and gas type of the last active procedure for as long as the key is held depressed When the key is released the wire size material type and process descriptions will be displayed for a few seconds MEMORY LIGHTS A memory light is on when its corresponding memory is selected This tells you what memory is active at any given time POWER WAVE 450 LINCOLN B Return to Section Return to Master TOC Return
352. rform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 1 800 833 9353 WELD DESCRIPTION The following procedure will aid the technician in removing the T1 auxiliary transformer for maintenance or replacement MATERIALS NEEDED 5 16 Nut driver 3 8 Nut driver or socket wrench Wire cutters Machine Wiring Diagram in the Electrical Diagrams section of this manual This procedure takes approximately 35 minutes to perform POWER WAVE 450 LINCOLN Return to Section Return to Master TOC Return to Section TOC Return to Master TOC o 2 3 Return to Section Return to Master TOC o p 5 156 1 AUXILIARY TRANSFORMER 1 2 MOUNTING SCREW 2 TROUBLESHOOTING amp REPAIR T1 AUXILIARY TRANSFORMER REMOVAL AND REPLACEMENT continued FIGURE 59 1 AUXILIARY TRANSFORMER LOCATION PROCEDURE 1 6 Remove main input supply power to the machine With the 3 8 nut driver remove the 4 screws that hold the handle to the machine Remove the rubber gasket cover seal from the lift bail With the 5 16 nut driver remove the sheet metal screws from the case top With the 5 16 nut driver remove the screws holding the right and left case sides Remove the case side
353. rformed by only Lincoln Electric factory trained personnel Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty For your safety and to avoid elec trical shock please observe all safety notes and precautions detailed throughout this manual 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 DESCRIPTION The following procedure will aid the technician in removing the input rectifier for mainte nance or replacement MATERIALS NEEDED 5 mm Allen wrench Phillips head screw driver 10 mm Open end wrench RTV Silicone sealant Lincoln E2861 Dow Corning 340 Joint Compound Lincoln E1868 518491 M O V Assembly if necessary Machine Wiring Diagram in the Electrical Diagrams section of this manual This procedure takes approximately 45 minutes to perform POWER WAVE 450 LINCOLN Return to Section Return to Master TOC Return to Section TOC O o e 5 5 9 5 2 Return to Section Return to Master TOC Return to Master TOC F 172 TROUBLESHOOTING amp REPAIR INPUT RECTIFIER REMOVAL AND REPLACEMENT continued FIGURE F 65 INPUT RECTIFIER LOCATION
354. rheating and create a fire hazard Do not heat cut or weld tanks drums or containers 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 SAFETY LINCOLN 8 CYLINDER may explode if damaged 7 a Use only compressed gas cylinders c
355. rn to Master TOC MATERIALS NEEDED A known good replacement display board A Test and Calibration overlay L9660 255 This procedure takes approximately 15 minutes to perform O10 e 515 9 1 EIS 2 Er Return to Section TOC Return to Master TOC POWER WAVE 450 LINCOLN Return to Section Return to Master TOC o 2 3 Return to Section Return to Master TOC o p 5 1 Before changing or disturbing the display board power up the machine with the L9660 255 Test and Calibration overlay in place See Figure F 54 2 Press the Voltage Calibration function 32 The machine should display the following VOLTAGE WIRE POLARITY 67A 3 Press the Enter Key 133 on the lower right side of the overlay The machine should display the following ADJUST TO 30V CALIBRATION XX NOTE Here XX indicates a particular cali bration number for a given voltage sensing point WARNING The machine s output terminals will be electri cally HOT when the Enter Key is pressed 4 Record the number displayed for the 67 wire and press the Enter Key 133 again Calibration function again The next sens ing lead may be selected by pressing the down Arrow Key 101 The above proce dure must be repeated six times to
356. rn to Master TOC Return to Section TOC Return to Master TOC o o 2 3 Return to Section Return to Master TOC o p 5 169 11 12 13 14 15 16 TROUBLESHOOTING amp REPAIR FAN MOTOR REMOVAL AND REPLACEMENT continued FIGURE F 64 MACHINE BACK SECURED TO LIFT BAIL With the 3 4 wrench remove the lead connected to the rear positive output terminal Swing the back panel up and secure it to the lift bail See Figure 64 Use heavy string or wire BE CAREFUL NOT TO DAMAGE THE RS232 CONNECTOR OR THE WIREFEEDER RECEPTACLES With the slot head screw driver remove the clip holding the fan blade onto the motor shaft Remove the fan blade by carefully sliding it off the motor shaft With the 11 32 nut driver or socket wrench remove the two fan motor mount ing nuts Remove the split ring lock washers and flat washers Remove the fan motor by sliding it out of the mounting bracket and free of the machine NOTE Repeat this procedure to remove the second fan motor if necessary 17 18 19 1 MACHINE BACK 2 LIFT BAIL To install the fan motor do the following Carefully position the fan motor into place on the mounting bracket with the leads toward the terminal strip Install the flat washers split ring lock washers and
357. rn to Section TOC Return to Master TOC POWER WAVE 450 LINCOLN amp Return to Section Return to Master TOC Return to Section TOC Return to Master TOC o o 2 3 Return to Section Return to Master TOC o p 5 189 TROUBLESHOOTING REPAIR OUTPUT RECTIFIER BRIDGE REMOVAL AND REPLACEMENT continued 9 Cut all necessary cable ties on the right 10 side of the machine and disconnect all necessary leads two heavy and two small leads from the right side of the output rectifier bridge Place the fastener hard ware back together onto the lead ends to avoid loss On the right side of the machine use the 7 16 open end wrench to remove the bolt that connects the heat sink at the top to the glastic insulated angle mounting piece Then remove the carriage bolt that holds the glastic insulated angle mounting piece at the bottom to the subframe Repeat the same procedure on the left side of the machine Save the shake proof washers and nuts for reassembly 11 With the 7 16 wrench remove the bolts top and bottom that connect the heat sink and glastic insulated angle mounting piece at the middle With the side bolts already removed it is easier to access the middle bolts 12 With the 7 16 wrench remove the bolt nut and split ring lock washer from the tab connection at the bottom o
358. rols by placing an overlay over the keys An OVERLAY is a special plastic sheet with a number of keys and symbols printed on one side and a bar code printed on the other See Figure B 2 The print ed keys allow the operator to communicate with the machine for a specific set of functions The bar code allows the machine to identify the overlay FIGURE B 2 TYPICAL POWER WAVE OVERLAY Screw THELNGOL LINCOLN INVERTEC POWER WAVE ELECTRIC PROGRAM LIST 7 Before the Power Wave is turned ON the operator selects the desired overlay and mounts it in the over lay frame on the front of the machine Then when the machine is turned ON it reads the overlay bar code and configures the machine accordingly allowing the operator to access only certain keys The machine must be powered up each time an overlay is changed INSTALLING AN OVERLAY 1 Open the ACCESS DOOR by grasping the provid ed indent on the door and pulling the door for ward See Figure B 3 for door location FIGURE B 3 OVERLAY ACCESS DOOR 1 OVERLAY ACCESS DOOR 2 OVERLAY FRAME 3 ACCESS DOOR INDENT 4 TRACKS 5 LOCATING PINS 2 Select the desired overlay from the storage com partment located behind the access door 3 Remove any overlay already in the
359. rom the remote control kit It also controls the output of the machine based on the position of the Output Terminals switch which is also located on the remote control kit When this switch is in the ON position the output terminals of the Power Wave are electrically hot When the switch is in the OFF position the output terminals of the Power Wave are electrically cold and the machine cannot produce an output In the stick process the LCD display shows Procedure Description and Preset Current SET The Current Trim is always equal to 1 1 00 When the trigger is pulled the Preset Current Actual Arc Voltage and Actual Arc Current are dis played See Tables through B 6 for a summary of the information discussed above WAVE CONTROL The wave control settings of all procedures can be changed on the Power Wave GMAW Pulse GMAW FCAW Stick Process Selection Overlay The wave control is a setup parameter that may be adjusted when the welding procedures are set This feature provides an easy way to change the arc behavior with out creating a new procedure The wave control set ting of a procedure limits the speed at which the cur rent waveform of that procedure can change Typically each procedure is programmed to have average wave control at the center of the scale POWER WAVE 450 LINCOLN B 21 21 OPERATION 9 9 TABLE RELATIONSHIP BETWEEN TABLE B 6 R
360. rotect your eyes from sparks and the rays of the arc when welding or observing open arc welding Headshield and filter lens should conform to ANSI 287 standards 4 b 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 23 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 vapo
361. rs to form phosgene a highly toxic gas and other irritating prod ucts Shielding gases used for arc welding can displace air and 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 5 e Also see item 1 b Mar 95 Return to Master TOC Return to Master TOC Return to Master TOC 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 7491 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 ove
362. rties sous tension des porte lectrodes connect s deux machines souder parce que la tension entre les 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 pr venir tout risque d incendie d aux tincelles Quand on ne soude pas poser la pince 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 solv
363. s 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 with no machine output the control board is receiving the correct frequency signal from the protection board NOTE Conduct this test after the Static Capacitor Balance Test has been performed suc cessfully The reconnect switch and Jumper A must be set for 380 VAC input voltage or higher The selected input voltage must be the actual voltage applied MATERIALS NEEDED Volt Ohmmeter Multimeter Oscilloscope 5 16 Nut driver 3 8 Nut driver Input and Reconnect Wiring Diagram Figure F 33 This procedure takes approximately 45 minutes to perform POWER WAVE 450 LINCOLN O o e 5 5 9 gt 5 2
364. s by lifting up and out Perform the Capacitor Discharge Proce dure described earlier in this section of the manual WARNING Before continuing with the test procedure perform the capacitor discharge proce dure to avoid electric shock 10 11 12 After you have completed the capacitor discharge procedure for all four switch boards disconnect plugs P70 P71 and P73 that attach to the transformer See Figure F 59 for location With the wire cutters cut any necessary cable ties necessary for removal of the transformer Note the location of these cable ties for reassembly With the 3 8 nut driver or socket wrench remove the two screws that mount the transformer to the machine base Remove the T1 auxiliary transformer To install the T1 auxiliary transformer carefully position it onto the machine base and tighten the two mounting screws Connect plugs P70 P71 and P73 to their respective receptacles on the transformer Install the machine case sides and top Install the handle and the lift bail rubber gasket POWER WAVE 450 LINCOLN amp Return to Section Return to Master TOC Return to Section TOC Return to Master TOC o 2 3 Return to Section Return to Master TOC o O gt o gt E tc F 157 F 157 TROUBLESHOOTING amp R
365. screws holding the reservoir to the floor of the assembly With the pliers carefully remove the two coolant hoses from the reservoir Carefully slide out and lift the reservoir free from the motor and fan blade After repair install the reservoir by careful ly setting it in place around the motor and fan blade With the pliers install the two coolant hoses to the reservoir With the Phillips head screw driver install the four screws holding the reservoir to the floor of the assembly and the two screws that hold it to the cooling tube support bracket Replace the old coolant with fresh coolant and install the water cooler assembly into the machine according to the Cooler Removal and Replacement in this section of the manual Motor Pump Fan Assembly Removal A B Perform the Reservoir Removal procedure With the 3 4 open end wrench remove the two coolant hoses attached to the motor pump assembly Remove the four wires leading from the motor to the terminal block Note the lead numbers and locations for reassembly With the Phillips head screw driver and the 5 16 box wrench remove the four screws and nuts mounting the motor pump fan assembly to the mounting platform Carefully lift out the motor pump fan assembly Install the motor pump fan assembly by carefully setting in onto the mounting plat form and attaching it with the four screws and nuts Connect the four wire leads from the motor to the term
366. scription of how the wave control setting affects the welding procedure refer to the Overview of Welding Procedures sub section of the Operation section of this manual The wire feed speed and voltage or arc length trim desired for the new procedure can be changed from the wire feeder 7 DISPLAY RECALL KEY Since not all the informa tion about the procedure can be seen on the 2 line LCD display window at the same time use the DISPLAY RECALL key to display and verify all of the selected procedure information The normal default display window shows the Procedure Description WFS and preset voltage or arc length trim values Press and hold the DISPLAY RECALL key and the window shows the procedure de scription and gas type for as long as the key is held depressed Release the DISPLAY RECALL key and the window shows wire size material type and process description After a few sec onds the window changes back to the default dis play SAVE TO MEMORY KEY This key is used to save a newly created welding procedure The Power Wave has eight memory locations which can be used to store all the settings of up to eight welding procedures Once stored in a memory location a procedure can be recalled for later use with the RECALL FROM MEMORY key To save a newly created welding procedure Press the SAVE MEMORY key 4YE_ and then one of the MEMORY LOCATION NUMBER keys Keep a record of this number for future reference
367. ses The process is sometimes less forgiving when the arc gets on or ahead of the puddle More attention must be paid to the weld to avoid losing the puddle Speed is a matter of deposition rate things being equal regarding the joint being welded the speed will depend on the wire feed speed The travel speed is maximized by maintaining a very short arc Often the process is trimmed down until the arc crackles The spatter increases slightly but many of the advantages of pulsing are retained When welding steel the Power Wave is designed to run well in this region between pulse and short arc The pulsing process greatly affects the heat input to the workpiece This can be a valuable tool for either increasing or decreasing the heat input with a given process For instance it is possible to greatly increase the heat input when welding steel at high deposition rates On the other hand it is possible to reduce the heat input using the pulsing process For example heat input is reduced greatly with some of the low current stainless steel procedures using the processes programmed into the Power Wave In all cases the Power Wave procedures have been checked for their ability to deliver a sound weld However the fusion of the weld metal into the work piece may be affected It is the responsibility of the user to determine if the welds produced are suitable and sound The Power Wave 450 is optimized for use with a 0 75 1 9 c
368. st Probe to Probe to Test Repair Next Terminal Terminal Result Conclusion Action Procedure 2 4 12 Greater Continue 1k ohms Less Shorted Replace Snubber than 1K Switch Resistor ohms Boards Test e 8 9 1 3 Greater OK None Continue e than 1K 5 5 ohms o 8 Less than Shorted Replace Snubber 1k ohms Switch Resistor Test 2 2 4 9 Less OK None Continue cc than 100 ohms Greater than Open Replace Snubber 1k ohms Switch Resistor Boards Test 9 2 4 Greater than OK None Continue 1k ohms Less Shorted Replace Snubber than 1K Switch Resistor ohms Boards Test O10 e 515 9 1 EIS 2 Er NOTE ohm ohm reading multiplied by 1000 NOTE Always make sure that all four Switch Boards are changed at the same time Never mix an old style different part number Switch Board with a new style new part number Return to Section TOC Return to Master TOC POWER WAVE 450 LINCOLN Return to Section Return to Master TOC Return to Section TOC Return to Master TOC o 2 3 Return to Section Return to Master TOC o O gt o gt E tc F 74 TROUBLESHOOTING amp REPAIR IGBT SWITCH BOARD TEST Continued TABLE F 6 Continued F 74 Apply Apply Positive Negative Te
369. st Test Probe to Probe to Test Repair Next Terminal Terminal Result Conclusion Action Procedure 12 1 3 Less than OK None Continue 100 ohms Greater Open Replace Snubber than 1K Switch Resistor ohms Boards Test 1 3 12 Greater OK None Continue than 1K ohms Less than Shorted Replace Snubber 1k ohms Switch Resistor Boards Test 12 401 403 Greater OK None Continue 405 407 than 1K ohms Less than Shorted Replace Snubber 1k ohms Switch Resistor Boards Test 401 403 12 Less than OK None Continue 405 407 100 ohms Greater Open Replace Snubber than 1K Switch Resistor ohms Boards Test 9 402 404 Less than OK None Continue 406 408 100 ohms Greater Open Replace Snubber than 1K Switch Resistor ohms Boards Test 402 404 9 Greater OK None Continue 406 408 than 1K ohms Less than Shorted Replace Snubber 1k ohms Switch Resistor boards Test NOTE K ohm ohm reading multiplied by 1000 NOTE Always make sure that all four Switch Boards are changed at the same time Never mix an old style different part number Switch Board with a new style new part number POWER WAVE 450 LINCOLN Return to Section Return to Master TOC Return to Section TOC Return to Master TOC o 2 3 Return to Section Return to Master TOC o O gt o v E tc F 75 F 75 TROUBLESHOOTING amp REPAIR SNUBBER AND BLEEDER RESISTOR TE
370. ster TOC POWER WAVE 450 LINCOLN Return to Section Return to Master TOC Return to Section TOC Return to Master TOC o 2 3 Return to Section Return to Master TOC o p 5 176 TROUBLESHOOTING amp REPAIR PRINTED CIRCUIT BOARD REMOVAL AND REPLACEMENT CONTROL BOARD POWER BOARD AND PROTECTION BOARD continued FIGURE F 66 PC BOARD REMOVAL PROCEDURE 1 6 Remove main input supply power to the machine With the 3 8 nut driver remove the 4 screws that hold the handle to the machine Remove the rubber gasket cover seal from the lift bail With the 5 16 nut driver remove the sheet metal screws from the case top With the 5 16 nut driver remove the screws holding the right and left case sides Remove the case sides by lifting up and out Perform the Procedure described earlier in this section of the manual Capacitor Discharge 1 PC BOARD COVER 2 PC BOARD ASSEMBLY 3 RETAINER CLIPS A WARNING e Before continuing with the test procedure perform the capacitor discharge proce dure to avoid electric shock 7 After you have completed the capacitor dis charge procedure for all four switch boards use the 5 16 nut driver to remove the two screws holding the printed circuit board cover in
371. t side Swing the back of the subframe into place With the 5 16 nut driver install the sheet metal screw holding the ground leads to the right rear of the subframe On the left side clip the cable tie to hold the leads With the 3 8 wrench install the six resis tors that are attached to the top of the subframe four on the top right two on the top left according to the markings you made during disassembly Also tighten the bottom resistors closest to the FET module assembly With the Phillips head screw driver install the screw that holds the piezo electric alarm buzzer in place Replace the cable tie that holds the wire 35 36 37 38 39 40 41 42 43 Slide the lift bail into place With the 1 2 socket wrench install the four bolts two on each side of the machine to secure the lift bail With the 3 8 nut driver install the two screws to secure the lift bail baffle Feed the output cable strap through the lift bail baffle eyelet hole Replace any necessary cable ties Connect the two plugs to the snubber board Connect the leads to the output rectifier bridge Replace all necessary cable ties Install the molex plugs to the PC boards Refer to Figure Board Connector Locations in this section of the manual Install the printed circuit board cover with two 5 16 screws Replace any necessary cable ties for the wiring harness and other leads that were cut during dis
372. t for electrical troubleshooting assistance before you proceed Call 1 800 833 9353 POWER WAVE 450 LINCOLN B Return to Section Return to Master TOC Return to Section TOC Return to Master TOC o 2 3 Return to Section Return to Master TOC o O gt o gt E 8 8 TROUBLESHOOTING 4 REPAIR TROUBLESHOOTING GUIDE PROBLEMS SYMPTOMS Machine has no output no fans no display Main input fuses are open indicating excessive input current draw Machine has no output no dis play fans run Machine has no output fans run Display flashes On and Off repeatedly Observe Safety Guidelines detailed in the beginning of this manual POSSIBLE AREAS OF MISADJUSTMENT S OUTPUT PROBLEMS 1 Check for proper input voltage connections Make certain the reconnect panel is configured properly for the applied voltage Replace the input fuses with proper size and ratings Check circuit breaker 5 amp located on the front panel Reset if necessary Check for loose or faulty con nections at the Power Board See Wiring Diagram RECOMMENDED COURSE OF ACTION 1 Perform the Input Power and Wiring Harness Test 2 Perform the Input Rectifier 3 Perform the Reconnect Switch Test t1 4 Perform the Switch Board 5 Perform the Snubber and Bleeder
373. t of the equipment frame Keep touching the frame to pre vent static build up Be sure not to touch any electrically live parts at the same time e Tools which come in contact with the PC Board must be either conductive anti static or static dis sipative 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 recalibrate required and test the machine 7 Always indicate that this procedure was followed when warranty reports are to be submitted NOTE Following this procedure and write on the war ranty report INSTALLED AND SWITCHED PC BOARDS TO VERIFY PROBLEM will help avoid denial of legitimate PC board warranty claims POWER WAVE 450 LINCOLN B F 4 TROUBLESHOOTING amp REPAIR olo BOARD REPLACEMENT 5 5 CALIBRATION REQUIREMENTS 140 2 2 515 212 DISPLAY SNUBBER CONTROL BOARD BOARD BOARD BOARD REPLACED REPLACED REPLACED REPLACED 8 515 o 9 1 8 2 2 2 EIE IF POSSIBLE CURRENT 215 QUICK CALIBRATION oc cc VOLTAGE CALIBRATION ale S5 9 FULL 8 gt VOLTAGE o ole CALIBRATION 818 eic Return to Section TOC Return to Master TOC POWER WAVE 450 LINCOLN B TROUBLESHOOTING amp REPAIR TRO
374. t power to the Power Wave When the switch is turned to the ON position the connected wire feeder meters light up and the LCD display on the Power Wave shows the following LINCOLN ELECTRIC Version X X This display is shown for a few seconds followed by another display that depends on the overlay placed on the machine At this point the machine is ready for operation HIGH TEMPERATURE LIGHT thermal overload A yellow light that comes on when an over tempera ture situation occurs Output is disabled until the machine cools down At that point the light goes out and output is enabled again REMOTE CONTROL AMPHENOL RECEPTACLE Allows remote current control during stick welding via a hand or foot Amptrol accessory 5 AMP CIRCUIT BREAKER Protects two auxiliary power circuits the 24V supply used by the trigger circuits and the 42V supply used by the internal machine circuits and the wire feeders LCD DISPLAY ADJUSTMENT Use a small flat blade screw driver to adjust the viewing angle of the LCD display POWER WAVE 450 LINCOLN B Return to Section Return to Master TOC Return to Section TOC O10 515 gt EIS 2 r C Return to Section TOC Return to Master TOC Return to Master TOC B 6 OPERATION OPERATING OVERLAYS OVERVIEW The Power Wave is controlled by a panel of keys key pad located on the front of the machine The opera tor can access cont
375. tage reference The work sense 21 lead is used only in rare cir cumstances For most installations use the WORK SENSE LEAD KEY 10 select the output terminal for negative voltage reference Consult the factory if use of the work sense 21 lead is desired B Negative Voltage Sensing Polarity In some welding applications such shield the electrode cable is connected to the output terminal and the work cable is connected to the output terminal of the power source This is the negative voltage sensing polarity illustrated by Figure B 11 When the Power Wave and the wire feeder s are connected in this manner the arc voltage can be measured in one of four ways These four ways are shown in Table B 2 Table B 2 Negative Voltage Sensing Options Positive Voltage Reference Negative Voltage Reference Output Terminal Output Terminal Output Terminal Work Sense 21 Lead Electrode Sense 67 Lead Output Terminal Electrode Sense 67 Lead Work Sense 21 Lead Consult the factory before using this option POWER WAVE 450 LINCOLN B 11 96 19 19 OPERATION Use the ELECTRODE SENSE LEAD KEY to select either the output terminal or the electrode sense 67 lead for the positive voltage reference The two wire feeders can only be connected in the same manner either by the Positive Polarity or the Negative Polarity setup The work sens
376. tats are normal ly closed Check leads from thermal switches to molex plug J23 on the control board for loose or faulty connections The control board may be faulty Replace and perform voltage calibration and current calibration procedures A 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 POWER WAVE 450 LINCOLN Return to Section Return to Master TOC Return to Section TOC O O Fle 5 9 515 2 Return to Section Return to Master TOC Return to Master TOC F 12 TROUBLESHOOTING amp REPAIR TROUBLESHOOTING GUIDE PROBLEMS SYMPTOMS The voltage and or wire feed speed will not adjust to user satis faction The voltage and or wire feed speed can be adjusted on the wire feeder but the changes are not shown on the Power Wave display The Dual Procedure overlay is installed and the user cannot change from procedure A to procedure B or vice versa Observe Safety Guidelines detailed in the beginning of this manual POSSIBLE AREAS OF MISADJUSTMENT S FUNCTION PROBLEMS Certain limits may have been imposed on the welding para meters Refer to the Limits Overlay section of this manua
377. tc F 141 F 141 TROUBLESHOOTING amp REPAIR SENSOR CALIBRATION TEST FOR DISPLAY BOARD 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 elec trical 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 procedure recalibrates the eight overlay sensors of the Power Wave MATERIALS NEEDED Power Wave Test and Calibration Overlay L9660 255 Set Up Overlay 19660 This procedure takes approximately 15 minutes to perform POWER WAVE 450 LINCOLN Return to Section Return to Master TOC Return to Section TOC Return to Master TOC o 2 3 Return to Section Return to Master TOC o p 5 142 1 LEADS 300 301 TO PLUG J15 DISPLAY BOARD 2 PIEZO ELECTRIC ALARM BUZZER TROUBLESHOOTING amp REPAIR SENSOR CALIBRATION TEST FOR DISPLAY BOARD continue
378. tely 40 minutes to perform POWER WAVE 450 LINCOLN F 86 F 86 TROUBLESHOOTING amp REPAIR RECONNECT SWITCH TEST 2 continued FIGURE 28 RECONNECT SWITCH 1 RECONNECT PANEL 2 RECONNECT SWITCH 3 LEAD CONNECTIONS Return to Section TOC Return to Master TOC Return to Section Return to Master TOC TEST PROCEDURE 1 Remove main input supply power to the machine 2 With the 3 8 nut driver remove the 4 screws that hold the handle to the machine A WARNING e Before continuing with the test procedure perform the capacitor discharge proce dure to avoid electric shock 3 Remove the rubber gasket cover seal from the lift bail O o e 5 5 9 gt 5 2 Return to Section Return to Master TOC 4 With the 5 16 nut driver remove the sheet metal screws from the case top Visually check that the following leads are not damaged or exposed With the 5 With the 5 16 nut driver remove the volt ohmmeter also test the leads for con screws holding the right and left case tinuity sides Remove the case sides by lifting up and out 6 Perform the Capacitor Discharge Procedure described earlier in this section of the manua
379. the machine Remove the rubber gasket cover seal from the lift bail With the 5 16 nut driver remove the sheet metal screws from the case top With the 5 16 nut driver remove the screws holding the right and left case sides Remove the case sides by lifting up and out Perform the Capacitor Discharge Proce dure described earlier in this section of the manual 1 RESERVOIR 2 TUBE SUPPORT BRACKET 3 ASSEMBLY FLOOR WARNING e POWER WAVE 450 LINCOLN amp Before continuing with the test procedure perform the capacitor discharge proce dure to avoid electric shock Return to Section Return to Master TOC Return to Section TOC O o 5 5 9 gt 5 2 Return to Section Return to Master TOC Return to Master TOC F 163 TROUBLESHOOTING amp REPAIR WATER COOLER DISASSEMBLY continued Reservoir Removal A After you have completed the capacitor discharge procedure for all four switch boards remove the water cooler assembly Refer to the Water Cooler Removal and Replacement Procedure this section of the manual Empty the coolant from the reservoir Dispose of the coolant in a proper and approved manner With the Phillips head screw driver remove the two screws holding the reservoir to the cooling tube support bracket With the Phillips head screw driver remove the four
380. tion Board 115 VAC Between J33 pin 6 and J33 pin 1 Power Wave 450 only 42 VAC Between J33 pin 3 and J33 pin 1 24 VAC Between J33 pin 4 and J33 pin 1 If any of these voltages are not present on the protection board and the Auxiliary Transformer 1 Test has been completed successfully do the following Turn the power switch SW1 OFF and disconnect input power to the machine Check the pins of plug J33 to be sure they are not loose or broken Since Auxiliary Transformer 1 Test determined that voltages are present at plug J33 the fault must be that these signals are not getting to header J33 B Protection Board 115 VAC Between J34 pin 1 and J34 pin 5 Power Wave 450 only 42 VAC Between J34 pin 3 and J34 pin 5 24 VAC Between J34 pin 4 and J34 pin 5 If any of these voltages are not present on the protection board and the voltages in part A above were present replace the protection board POWER WAVE 450 LINCOLN amp F 98 Return to Section Return to Master TOC Return to Section TOC Return to Master TOC o 2 3 Return to Section Return to Master TOC o p 5 TROUBLESHOOTING amp REPAIR INTERNAL AND AUXILIARY SUPPLY VOLTAGE TEST continued C Protection Board 115 VAC Between J34 pin 8 and J34 pin 12 Power Wave 450 only 42 VAC Between J34 pi
381. to Section Return to Master TOC o O gt o gt E tc F 47 F 47 TROUBLESHOOTING amp REPAIR INPUT RECTIFIER RESISTANCE 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 elec trical 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 any of the internal diodes in the three phase rectifier are shorted or open MATERIALS NEEDED Analog Volt Ohmmeter Multimeter 5 16 Nut driver 3 8 Nut driver Machine Wiring Diagram in the Electrical Diagrams section of this manual This procedure takes approximately 35 minutes to perform POWER WAVE 450 LINCOLN Return to Section Return to Master TOC Return to Section TOC Return to Master TOC o 2 3 Return to Section Return to Master TOC o p 5
382. to Section TOC O o e 5 9 5 2 Return to Section Return to Master TOC Return to Master TOC OPERATION SETUP OVERLAY The Setup Overlay is used to control the water cooler operation on off and prime the water cooler and to set up the voltage sensing configuration of the machine and wire feeder s connected to the Power Wave See Figure 1994 THE COMPANY CLEVELAND OHIO USA o N INVERTEC POWER WAVE LINCOLNI 350 450 500 ELECTRIC 4 WARNING PoLarity O SENSE LEAD COLEAD ENABLED WATER COOLER ENABLED 5 WATER COOLER PRESSURE 6 2 POLARITY ENABLE ENSE SENSE 2 2 7 WATER COOLER ONLY 4 wor WORK PRIMED WHEN IT IS ENABLED SENSE UNTIL WATER COOLER PRESSURE LIGHT TURNS ON WATER COOLER SETUP WIRE WIRE FEEDER 1 FEEDER 2 1 LCD DISPLAY WINDOW 5 WIRE FEEDER 1 POLARITY KEY 2 WATER COOLER ON OFF KEY 3 WATER COOLER PRESSURE LIGHT 4 PRIME WATER COOLER KEY 1 LCD DISPLAY WINDOW Power up the machine with this overlay in place When the Power Wave is turned on the following message appears in the display window for a few seconds LINCOLN ELECTRIC Version X X This display is followed by OVERLAY ID NUMBER 0 This message is then replaced by the following message POWER WAVE SETUP 2 WATER
383. trained personnel Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty For your safety and to avoid elec trical shock please observe all safety notes and precautions detailed throughout this manual 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 there are any faults in the 24 VAC trigger circuit integral to the Power Wave and the wire feeder 2 amphenol P82 MATERIALS NEEDED Volt Ohmmeter Multimeter 5 16 Nut driver 3 8 Nut driver Short piece of jumper wire Trigger Circuit Wiring Diagram Figure F 42 This procedure takes approximately 30 minutes to perform POWER WAVE 450 LINCOLN Return to Section Return to Master TOC Return to Section TOC Return to Master TOC o 2 3 Return to Section Return to Master TOC o O gt o v gt E tc F 116 TROUBLESHOOTING amp REPAIR WIRE FEEDER 2 TRIGGER CIRCUIT TEST continued FIGURE F 41 DISPLAY BOARD PLUG LOCATIONS
384. tric 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 amp ine LINCOLN machine POWER WAVE 450 6 12 ELECTRICAL DIAGRAMS G 12 SCHEMATIC POWER PRINTED CIRCUIT BOARD INVERTER POWER SUPPLIES PRIMARY SWITCHING CIRCUIT VOLTAGE USE TRANS 18 FET DRIVER WELD 8 CURRENT CONTROL 15Va__ WELD 8 CURRENT CONTROL Vectis 5 __ WELD 8 CURRENT CONTROL DISPLAY KEYPAD DISPLAY KEYPAD DISPLAY KEYPAD Return to Section TOC Return to Master TOC DISPLAY KEYPAD c sve RS 232 e CURRENT SOURCE Voo 18 SWITCH GND 600 Q2 15V 3 iW 1 A 1 2901 i 4 12 7 25 inos 1 1 Tl gt Veo 18 Vocis DISPLAY KEYPAD E 9 IW 2 43 2 43K 2 43 2 43K 17 3 gt
385. turn to Master TOC Return to Section TOC Return to Master TOC o 2 3 Return to Section Return to Master TOC o O gt o gt E tc F 136 TROUBLESHOOTING amp REPAIR LCD DISPLAY TEST continued FIGURE 51 DISPLAY BOARD PLUG LOCATIONS 417 J16 J15 TEST PROCEDURE 1 6 Remove main input supply power to the machine With the 3 8 nut driver remove the 4 screws that hold the handle to the machine Remove the rubber gasket cover seal from the lift bail With the 5 16 nut driver remove the sheet metal screws from the case top With the 5 16 nut driver remove the screws holding the right and left case sides Remove the case sides by lifting up and out Perform the Capacitor Discharge Procedure described earlier in this section of the manual Poy TX S 414 J13 J12 J11 J10 WARNING Before continuing with the test procedure perform the capacitor discharge proce dure to avoid electric shock After you have completed the capacitor dis charge procedure for all four switch boards remove the PC board cover Use the 5 16 nut driver Remove the 5 leads 3 heavy and 2 small T1 T2 T3 from main input contactor CR1 This is a safet
386. ty Individual Printed Circuit Board Components are not available from Lincoln Electric This information is 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 amp ine TET machine POWER WAVE 450 ELECTRICAL DIAGRAMS SCHEMATIC SWITCH PRINTED CIRCUIT BOARD LAST NO USED A SUPPLY VOLTAGE NET POWER SUPPLY SOURCE POINT 57 COMMON CONNECTION EARTH GROUND CONNECTION A FRAME CONNECTION INVERTER WELDERS Return to Section TOC Return to Master TOC IRFD110 SWITCH P C BOARD SCHEMATIC EQUIP TYPE DRS POSITIVE INPUT UNLESS OTHERWISE SPECIFIED 1 4W UNLESS OTHERWISE SPECIFIED UNLESS OTHERWISE SPECIFIED C1 C2 C3 C4 C5 01 SNUBBER RESISTOR 10 28 96 NONE M16100 23 O4 NO et M16100 23 55 2 E4 E5 40V 2N4401 OHIO U S A MFD 022 50V Ohms SCALE DATE AA 400V 406 408 THE LINCOLN ELECTRIC CO CLEVELAND GENERAL INFORMATION ELECTRICAL SYMBOLS PER E1537 CAPACITORS RESISTORS FILE L10611_1AA DIODES JP FM DR 21 TRANSFORMER 3 PRIMARY Return to Master TOC C2 A M16100 23 A
387. 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 there are any short circuits or other problems in the load circuits fed by the secondary windings of the auxiliary transformer which would cause the trans former to overheat or the fuse F1 primary side on the reconnect panel to blow Return to Section TOC Return to Master TOC MATERIALS NEEDED Volt Ohmmeter Multimeter 5 16 Nut driver 3 8 Nut driver Auxiliary Transformer 1 Secondary Circuit Wiring Diagram Figure F 12 This procedure takes approximately 30 minutes to perform O10 e 515 9 1 EIS 2 Er Return to Section TOC Return to Master TOC POWER WAVE 450 LINCOLN Return to Section Return to Master TOC Return to Section TOC Return to Master TOC o 2 3 Return to Section Return to Master TOC o p 5 F 40 F 40 TROUBLESHOOTING amp REPAIR AUXILIARY TRANSFORMER 1 SECONDARY AND WIRING HARNESS TEST continued FIGURE F 11 PLUG AND RECEPTACLE INSPECTION POINTS TEST PROCEDURE 1 6 With the 5 16 Remove main input supply power to the machine W
388. ve quick connect terminals 401 402 9 and 12 from switch board 1 With the volt ohmmeter check for 25 ohms resistance between lead 401 and 12 If the measurement reads between 20 and 30 ohms resistor R1 and leads 401 and 12E are okay Go to step C If the measurement does not read between 20 and 30 ohms check for continuity in leads 401 and 12E Then test for 25 ohms resistance across R1 directly If the measurement does not read between 20 and 30 ohms replace resistor R1 C E With the volt ohmmeter check for 25 ohms resistance between lead 402 and 9E If the measurement reads between 20 and 30 ohms resistor R2 and leads 402 and 9E are okay Go to step D If the measurement does not read between 20 and 30 ohms check for continuity in leads 402 and 9E Then test for 25 ohms resistance across R2 directly If the measurement does not read between 20 and 30 ohms replace resistor R2 With the volt ohmmeter check for 7 5 K ohms resistance between lead 12L 12E and 9L 9E If the measurement reads between 6 75 and 8 25 K ohms resistor R9 and leads 12L 12E and 9L 9E are okay Go to step E If the measurement does not read between 6 75 and 30 K ohms check for continuity in leads 121 12E 9L 9E Then test for 7 5 K ohms resistance across R9 directly If the measurement does not read between 6 75 and 8 25 K ohms replace resistor R9 Reconnect quick connect terminals
389. wer only The Power Wave is designed to be used as a synergic welding system in conjunction with a wire feeder SYNERGIC WELDING The Power Wave system is designed primarily as a synergic welding system The word synergic comes from the word synergism which means two or more things working together to achieve an effect which nei ther can achieve individually The Power Wave and wire feeder operate as a team Each knows what the other is doing at all times They each also know what process wire type wire size and gas combination are being used In a syner gic system the wire feeder and power source must talk together This means that only certain wire feed ers can work in a synergic setup A synergic feeder has special circuitry to talk with and listen to the Power Wave power source Welding experts have preprogrammed the system for the best range of process settings according to wire type wire size and gas combination When the wire feed speed is changed the system automatically adjusts the current and voltage waveforms to give the best weld characteristics This improves the sound ness appearance and repeatability of welds Refer to the Accessories section of this manual for available wire feeders RECOMMENDED PROCESSES The Power Wave is designed to be used as a multiple process machine It comes preprogrammed with GMAW pulse GMAW short arc and spray FCAW Innershield
390. wo transformers connected in parallel for the test might result in incor rect readings therefore plug J73 should be disconnected Remove plug J30 from the protection board See Figure location of the board and plug J30 Remove the 5 leads 3 heavy and 2 small T1 T2 T3 from main input contactor CR1 This is a safety precaution It prevents high voltage from being put on the machine during the test Wrap tape around the lead ends to insulate them and prevent them from touching POWER WAVE 450 LINCOLN amp AUXILIARY TRANSFORMER T1 WITH Return to Section Return to Master TOC Return to Section TOC O o 5 5 9 gt 5 2 Return to Section Return to Master TOC Return to Master TOC TROUBLESHOOTING amp REPAIR AUXILIARY TRANSFORMER TEST 2 continued 11 To conduct this test you will be measuring the voltage between pin 2 and pin 5 of plug J4 The plug is located in the machine undercarriage and is somewhat difficult to reach It is probably easiest to disconnect the plug and insert the probes of your voltmeter alongside pins 2 and 5 before turning on input power which is the next step 12 Turn the main input supply power to the machine back ON A WARNING e ELECTRIC SHOCK can kill Proceed with caution Be careful not to touch any internal machine components during the remainder of the test procedu
391. y precaution It prevents high voltage from being put on the machine dur ing the test Wrap tape around the lead ends to insulate them and prevent them from touching Remove plug J30 from the protection board See Figure F 1 for location of the board and plug J30 POWER WAVE 450 LINCOLN amp F 136 Return to Section Return to Master TOC Return to Section TOC Return to Master TOC o 2 3 Return to Section Return to Master TOC o p 5 137 TROUBLESHOOTING REPAIR LCD DISPLAY TEST continued machine WARNING ELECTRIC SHOCK can kill With input power ON there are high voltages inside the Do not reach into the machine or touch any internal part 10 11 12 Turn input power ON With the volt ohmmeter check the follow ing voltages between plug J16 pins at the display board without removing plug J16 from the display board 5 VDC Between J16 pin 2 and J16 3 15 VDC Between J16 pin 10 and J16 pin 7 5 VDC Between J16 pin 1 and J16 pin 7 5 VDC Between J16 pin 9 and J16 pin 7 8 VDC Between J16 pin 6 and J16 pin 7 Turn power switch SW1 to the OFF posi tion and disconnect input power to the machine Connect plug J30 into the pro tection board Connect the five leads to the main contactor If the voltages

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