Lincoln Electric INVERTEC POWER WAVE 450 SVM112-B manual

SERVICE MANUAL • World's Leader in W elding and Cutting Products • • Sales and Service through Subsidiaries and Distributors Worldwide • Cleveland, Ohio 441 17-1 199 U.S.A. TEL: 216.481.8100 F AX: 216.486.1751 WEB SITE: www .lincolnelectric.com SVM112-B February , 2001 For use with machines having Code Numbers: 10105 thru 10610 INVER T[...]

Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC FOR ENGINE powered equipment. 1.a. T urn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running. ____________________________________________________ 1.b. Operate engines in open, well-ventilated areas or ven[...]

Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ii SAFETY ii ARC RA YS can burn. 4.a. Use a shield with the proper filter and cover plates to protect your eyes from sparks and the rays of the arc when welding or observing open arc welding. Headshield and filter lens should conform to ANSI Z87. I standards. 4.b. U[...]

Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC FOR ELECTRICALL Y powered equipment. 8.a. T urn of f input power using the disconnect switch at the fuse box before working on the equipment. 8.b. Install equipment in accordance with the U.S. National Electrical Code, all local codes and the manufacturer ’s recom[...]

Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC iv SAFETY iv PRÉCAUTIONS DE SÛRETÉ Pour votre propre protection lire et observer toutes les instructions et les précautions de sûreté specifiques qui parraissent dans ce manuel aussi bien que les précautions de sûreté générales suiv- antes: Sûreté Pour [...]

MASTER T ABLE OF CONTENTS FOR ALL SECTIONS v v POWER W A VE 450 Page Safety .................................................................................................................................................i-iv Installation ...............................................................................................................[...]

Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC T ABLE OF CONTENTS - INST ALLA TION SECTION - Section A-1 Section A-1 POWER W A VE 450 Installation T echnical Specifications ....................................................................................................... ......A-2 Safety Precautions .......[...]

Input V oltages: 200 230 400 460 575 Input Currents @ 500A/40 VDC 87 76 44 38 32 @ 450A/38 VDC 75 65 38 32 28 Duty Cycle Amps V olts at Rated Amperes 60% Duty Cycle 500 40 VDC 100% Duty Cycle 450 38 VDC Constant Open Continuous Process Circuit V oltage Current Range Current Ranges 75 V olts 5-540 Amps GMAW 50-540 Amps FCAW 40-540 Amps STICK 30-540 [...]

Read this entire installation section before you start installation. SAFETY PRECAUTIONS ELECTRIC SHOCK can kill. • Only qualified personnel should perform this installation. • T ur n 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 W [...]

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 gr ound- ing methods. S[...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC INST ALLA TION A-5 A-5 POWER W A VE 450 2 3 1 FIGURE A.3 – FRONTP ANEL/BACK P ANEL 1 WORK TERMINAL 2 ELECTRODE TERMINAL 3 REMOTE CONTROL AMPHENOL RECEPT ACLE 4 WA TER COOLING F[...]

NOTES POWER W A VE 450 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC[...]

Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC T ABLE OF CONTENTS - OPERA TION SECTION - Operation ............................................................................................................................... Section B Safety Instructions ........................................................[...]

OPERA TION B-2 B-2 POWER W A VE 450 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC OPERA TING INSTRUCTIONS Read and understand this entire section of operating instructions before operating the machine. SAFETY INSTRUCTIONS EL[...]

QUICK ST ART REFERENCE FOR USING THE PROCESS SELECTION OVERLA Y Read and understand the “Controls and Settings” and “Operating Overlays” sections of this manual before using the following Quick Start Reference pr ocedure to operate the Power W ave. NOTE: Selection of certain options may limit the selection of subsequent options. Step 1: Sel[...]

GENERAL DESCRIPTION The INVERTEC Power W ave power source is a high performance, digitally controlled inverter welding power source capable of complex, high-speed wave- form control. It uses thr ee-phase input power only . The Power W ave is designed to be used as a syner gic welding system in conjunction with a wire feeder . SYNERGIC WELDING The P[...]

CONTROLS AND SETTINGS All operator controls and adjustments ar e located on the case front of the Power W ave. Refer to Figure B.1 and corresponding explanations. FIGURE B.1 – CASE FRONT CONTROLS CASE FRONT CONTROLS Refer to Figure B.1 for the location of the following controls: 1. LCD DISPLA Y : Provides welding procedur e infor- mation and para[...]

OPERA TING OVERLA YS OVERVIEW The Power W ave is controlled by a panel of keys (key- pad) located on the front of the machine. The opera- tor can access controls by placing an overlay over the keys. An OVERLA Y 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 [...]

OVERLA Y TYPES Four types of overlays can be used with the Power W ave. 1. Process Overlays. These overlays are used to create, save and r ecall specific welding proce- dures by selecting and adjusting the various weld- ing settings that have been programmed into the Power W ave at the factory . 2. W eld From Memory Overlays . These overlays (also [...]

1. LCD DISPLA Y WINDOW : Power up the machine with this overlay in place. When the Power W ave is turned on, the following message appears on the display for a few seconds: LINCOLN ELECTRIC VERSION X.X This display is followed by: OVERLA Y ID NUMBER = 1 A welding procedur e is made up of seven compo- nents: process, material type, wir e diameter , [...]

3. ELECTRODE CLASS UP/DOWN: Use the ELEC- TRODE CLASS UP or DOWN keys to select from the material types available for the selected process. Pr ess the ELECTRODE CLASS UP or DOWN key until the desired material type is dis- played. 4. ELECTRODE SIZE UP/DOWN: Use the ELEC- TRODE SIZE UP or DOWN keys to select from the wire diameters available for the [...]

10. RECALL FROM MEMOR Y KEY : This key is used to recall an existing pr ocedure fr om memory . Y ou can recall and use any of the pr eviously created welding procedur es that are stor ed in one of the eight memory locations. Simply press the RECALL FROM MEMOR Y key and then the appropriate MEMOR Y LOCA TION NUMBER key . If you press the RECALL FROM[...]

1. LCD DISPLA Y WINDOW: Power up the machine with this overlay in place. When the Power W ave is turned on, the following message appears in the display window for a few seconds: LINCOLN ELECTRIC V ersion X.X This display is followed by: OVERLA Y ID NUMBER = 2 This message is then replaced by the following message: SELECT A MEMOR Y LOCA TION 2. MEM[...]

1. LCD DISPLA Y WINDOW: Power up the machine with this overlay in place. When the Power W ave is turned on, the following message appears in the display window for a few seconds: LINCOLN ELECTRIC V ersion X.X This display is followed by: OVERLA Y ID NUMBER = 3 This message is then replaced by the following message: SELECT A MEMOR Y LOCA TION 2. MEM[...]

When a pair of welding procedur es are r ecalled from memory , the display window will show the procedur e description, wire feed speed, and the preset voltage or ar c length trim of the LAST pro- cedure welded with. With this overlay in place, the wire feed speed and the preset voltage or ar c length trim can be changed from the wir e feeder . The[...]

1. LCD DISPLA Y WINDOW: Power up the machine with this overlay in place. When the Power W ave 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: OVERLA Y ID NUMBER = 9 2. WIRE FEEDERS MEMOR Y CHART : The active welding procedur e is determined by the active [...]

1. LCD DISPLA Y WINDOW: Power up the machine with this overlay in place. When the Power W ave is turned on, the following message appears in the display window for a few seconds: LINCOLN ELECTRIC V ersion X.X This display is followed by: OVERLA Y ID NUMBER = 4 This message is then replaced by the following message: SELECT A MEMOR Y LOCA TION 2. REC[...]

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 minim[...]

1. LCD DISPLA Y WINDOW: Power up the machine with this overlay in place. When the Power W ave is turned on, the following message appears in the display window for a few seconds: LINCOLN ELECTRIC V ersion X.X This display is followed by: OVERLA Y ID NUMBER = 0 This message is then replaced by the following message: POWER WA VE SETUP 2. WA TER COOLE[...]

When the “WA TER COOLER PRESSURE” light turns on, release the key . If this key has been pressed for 30 seconds and the ‘W A TER COOLER PRESSURE’ light still did not turn on, check the water cooler for adequate fluid level. 5. WIRE FEEDER 1 +/- POLARITY KEY : Press this key to change the present voltage sensing polari- ty of wire feeder 1. [...]

Use the ELECTRODE SENSE LEAD KEY to select either the - output terminal or the electrode sense (67) lead for the positive voltage refer ence. The work sense (21) lead is used only in rare cir cum- stances. For most installations, use the WORK SENSE LEAD KEY to select the - output terminal for negative voltage refer ence. Consult the factory if use [...]

OVERVIEW OF WELDING PROCEDURES FLUX CORED ARC WELDING (FCA W) AND GMA W PROCEDURES For each wire feed speed, a corr esponding voltage has been prepr ogrammed into the machine by welding experts. This prepr ogrammed voltage is the best average voltage for the procedur e at the given wire feed speed. If the wire feed speed is changed on the wire feed[...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC OPERA TION B-21 B-21 POWER W A VE 450 T rigger Position 1 GMAW GMAW STICK 1 GMA W GMAW Pulse FCAW Pulse FCAW WFS DISPLA Y : WFS DISPLA Y : Wire Feed Speed Wire Feed Speed WFS and[...]

In Pulse processes: The wave control adjustment allows the fr equency set- ting to vary . Increasing the wave contr ol allows the fre- quency setting to increase, and decr easing the wave control allows the fr equency setting to decrease. V arying the wave control setting affects the dr oplet transfer and allows fine-tuning for differ ent welding p[...]

OVERLOAD PROTECTION THERMAL PROTECTION The Power W ave has thermostatic protection fr om excessive duty cycles, overloads, loss of cooling, and high ambient temperatures. When the power sour ce 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 fr[...]

NOTES POWER W A VE 450 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC[...]

Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC T ABLE OF CONTENTS - ACCESSORIES - Accessories ........................................................................................................................... Section C Options/Accessories..................................................................[...]

OPTIONS/ACCESSORIES • Syner gic 7 wire feeder (K632-1) standar d speed,or (K632-2) high speed • MAGNUM 400 gun (K471-2) or 550 gun (K598) • Internal water cooler • Undercarriages (Single [K961-1]or Dual [K962-1]Gas Cylinders) • Remote control (stick welding) K941-1 • Amptrols (Hand K963-1 or -2, Foot K870) • Limits Overlay K946-4 • [...]

ACCESSORIES C-3 C-3 POWER W A VE 450 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC There are two water connections on the rear of the Power W ave. See Figure C.1. Connect the water lines between these connectors and those on[...]

G3503-[ ] COOLER PERIODIC MAINTENANCE 1. Preparation: • Always switch off the Power W ave machine power . • Always disconnect the Power W ave 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 W ave m[...]

C-5 C-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. • T ighten v-clamp with 15 to 30 in-lbs. of torque. h. Attach coolant lines to QD and reser- voir . i. Wipe dry all areas wetted by coolant. Dispose of to[...]

C-6 C-6 NOTES POWER W A VE 450 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC[...]

D-1 D-1 T ABLE OF CONTENTS -MAINTENANCE- POWER W A VE 450 Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Maintenance ......................................................................................................................... Section D Safety Precautions..............................................[...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC MAINTENANCE D-2 D-2 POWER W A VE 450 W ARNING W ARNING CAUTION SAFETY PRECAUTIONS ELECTRIC SHOCK can kill. • Only Qualified personnel should perform this maintenance. • T ur [...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC MAINTENANCE D-3 D-3 POWER W A VE 450 FIGURE D.1 – RESISTOR LOCA TIONS W ARNING 5. Locate two sets of two resistors on the left side of the machine and three sets of two r esist[...]

6. Locate the #9 and #12 terminals, identified by the “Dischar ge” labels, on each of the four Switch Boards. See Figur e D.2. 7. Using insulated, needle nose-type jumper leads and insulated gloves, connect one jumper lead to one end of the resistor obtained in step 4. Connect the other jumper lead to the other end of the resistor . 8. Carefull[...]

PREVENTIVE MAINTENANCE Perform the following preventive maintenance pr oce- dures at least once every six months. It is good prac- tice to keep a preventive maintenance r ecord; a r ecor d tag attached to the machine works best. 1. Remove the hex head screws fr om the sides and top of the machine. Remove the handle bar and the machine wrap-around c[...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC MAINTENANCE D-6 D-6 POWER W A VE 450 FIGURE D.4 – GENERAL COMPONENT LOCA TIONS 1 DISPLA Y BOARD (BACK OF P ANEL) 2 POWER SWITCH 3 MAIN TRANSFORMER 4 AUXILIAR Y TRANSFORMER 5 IN[...]

Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC T ABLE OF CONTENTS -THEOR Y OF OPERA TION- Theory of Operation ............................................................................................................. Section E General Description ...............................................................[...]

CONTROL BOARD DISPLA Y BOARD PROTECTION BOARD AUX. TRANS POWER BOARD CT CONT ACTOR INPUT INPUT RECTIFIER AND RECONNECT SWITCH BOARD FET ASSEMBL Y SWITCH BOARD FET ASSEMBL Y MAIN TRAMSFORMER OUTPUT RECTIFIER SHUNT CHOKE POSITIVE NEGA TIVE SNUBBER AND LEADS SENSE LCD DISPLA Y KEYP AD OVERLA Y WA TER COOLER PC INTERF ACE INPUT LINE SWITCH FA N WF1 WF2[...]

PRECHARGE (SOFT ST ART) The Protection Boar d contains a “soft Start” circuit, which is powered by the Auxiliary T ransformer . During prechar ge 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 Rec[...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC THEOR Y OF OPERA TION E-4 E-4 POWER W A VE 450 SWITCH BOARDS There ar e four Switch Boards in the Power W ave, each containing an input capacitor . The capacitors on Switch Board[...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC THEOR Y OF OPERA TION E-5 E-5 POWER W A VE 450 MAIN TRANSFORMER Each Switch Board assembly works as a switch pair . Each board feeds curr ent to a primary winding of the Main T r[...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC THEOR Y OF OPERA TION E-6 E-6 POWER W A VE 450 OUTPUT RECTIFIER AND CHOKE The Output Rectifier receives the AC output fr om the Main T ransformer secondary and rectifies it to a [...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC THEOR Y OF OPERA TION E-7 E-7 POWER W A VE 450 CONTROL BOARD The Control Boar d is at the heart of controlling the out- put of the machine. With the information it receives from [...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC THEOR Y OF OPERA TION E-8 E-8 POWER W A VE 450 POWER BOARD The Power Board pr ovides gate drives for the FET s on the Switch Boards. It does so based on the “turn-on” signals[...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC THEOR Y OF OPERA TION E-9 E-9 POWER W A VE 450 DISPLA Y BOARD The Display Board allows the operator to select fr om the procedur es that are pr ogrammed into the machine, and it [...]

THERMAL PROTECTION T wo normally closed (NC) thermostats protect the machine from excessive operating temperatur es. These thermostats are wir ed in series and are con- nected to the Control Boar d. One of the thermostats is located on the heat sink of a switch board, and the other is located on the main choke. Excessive tem- peratures may be cause[...]

An FET is a type of transistor . FET s are semi- conductors well suited for high-frequency switching. Drawing A above shows an FET in a passive mode. There is no gate signal (zer o volts) from the source and, ther efore, no curr ent flow . The drain terminal of the FET may be connected to a voltage supply . But since there is no con- duction, the c[...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC THEOR Y OF OPERA TION E-12 E-12 POWER W A VE 450 The term PULSE WIDTH MODULA TION is used to describe how much time is devoted to conduction in the positive and negative por- tio[...]

Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC T ABLE OF CONTENTS -TROUBLESHOOTING & REP AIR SECTION- T roubleshooting & Repair Section ....................................................................................... Section F How to Use T roubleshooting Guide .....................................[...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-2 F-2 POWER W A VE 450 HOW TO USE TROUBLESHOOTING GUIDE Service and repair should be performed by only Lincoln Electric Factory T rained Personnel[...]

ELECTRIC SHOCK can kill. Have an electrician install and ser- vice this equipment. T ur n the machine OFF before working on equipment. Do not touch electrically hot parts. Sometimes machine failures appear to be due to PC board failur es. These problems can sometimes be traced to poor electrical connections. T o avoid prob- lems when troubleshootin[...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-4 F-4 POWER W A VE 450 PC BOARD REPLACEMENT CALIBRA TION REQUIREMENTS DISPLA Y BOARD REPLACED IF POSSIBLE QUICK VOL T AGE CALIBRA TION CURRENT CAL[...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-5 F-5 POWER W A VE 450 TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginning of this manual. CAUTION If for any reason you do [...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-6 F-6 POWER W A VE 450 TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginning of this manual. CAUTION If for any reason you do [...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-7 F-7 POWER W A VE 450 TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginning of this manual. CAUTION If for any reason you do [...]

TROUBLESHOOTING & REP AIR F-8 F-8 POWER W A VE 450 TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginning of this manual. CAUTION If for any reason you do not understand the test pr ocedures or ar e unable to perform the test/r epairs safely , con- tact the Lincoln Electric Service Department for electrical troubleshooting as[...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-9 F-9 POWER W A VE 450 TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginning of this manual. CAUTION If for any reason you do [...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-10 F-10 POWER W A VE 450 TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginning of this manual. CAUTION If for any reason you d[...]

TROUBLESHOOTING & REP AIR F-11 F-11 POWER W A VE 450 TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginning of this manual. CAUTION If for any reason you do not understand the test pr ocedures or ar e unable to perform the test/r epairs safely , con- tact the Lincoln Electric Service Department for electrical troubleshooting [...]

TROUBLESHOOTING & REP AIR F-12 F-12 POWER W A VE 450 TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginning of this manual. CAUTION If for any reason you do not understand the test pr ocedures or ar e unable to perform the test/r epairs safely , con- tact the Lincoln Electric Service Department for electrical troubleshooting [...]

TROUBLESHOOTING & REP AIR F-13 F-13 POWER W A VE 450 TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginning of this manual. CAUTION If for any reason you do not understand the test pr ocedures or ar e unable to perform the test/r epairs safely , con- tact the Lincoln Electric Service Department for electrical troubleshooting [...]

TROUBLESHOOTING & REP AIR F-14 F-14 POWER W A VE 450 TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginning of this manual. CAUTION If for any reason you do not understand the test pr ocedures or ar e unable to perform the test/r epairs safely , con- tact the Lincoln Electric Service Department for electrical troubleshooting [...]

TROUBLESHOOTING & REP AIR F-15 F-15 POWER W A VE 450 TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginning of this manual. CAUTION If for any reason you do not understand the test pr ocedures or ar e unable to perform the test/r epairs safely , con- tact the Lincoln Electric Service Department for electrical troubleshooting [...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-16 F-16 POWER W A VE 450 TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginning of this manual. CAUTION If for any reason you d[...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-17 F-17 POWER W A VE 450 TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginning of this manual. CAUTION If for any reason you d[...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-18 F-18 POWER W A VE 450 TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginning of this manual. CAUTION If for any reason you d[...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-19 F-19 POWER W A VE 450 TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginning of this manual. CAUTION If for any reason you d[...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-20 F-20 POWER W A VE 450 TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginning of this manual. CAUTION If for any reason you d[...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-21 F-21 POWER W A VE 450 TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginning of this manual. CAUTION If for any reason you d[...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-22 F-22 POWER W A VE 450 POW ER B D PRO TECTI ON BD G R OU ND PL ANE CONTROL BD J20 J21 J22 J23 J24 J25 J26 J27 J28 J30 J31 J32 J33 J34 J35 J36 J3[...]

CAP ACITOR DISCHARGE PROCEDURE Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may r esult 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 [...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC POWER W A VE 450 F-24 F-24 CAP ACITOR DISCHARGE PROCEDURE (continued) TROUBLESHOOTING & REP AIR TEST PROCEDURE 1. Remove main input supply power to the machine. 2. With the 3[...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC POWER W A VE 450 F-25 F-25 CAP ACITOR DISCHARGE PROCEDURE (continued) FIGURE F .3 – DISCHARGE LABEL D I S C H A R G E D I S C H A R G E D I S C H A R G E D I S C H A R G E D I [...]

F-26 F-26 CAP ACITOR DISCHARGE PROCEDURE (continued) FIGURE F .4 - RESISTOR WITH LEADS CONNECTED. TROUBLESHOOTING & REP AIR 11. Check the voltage across terminals #9 and #12 with the DC voltmeter . T erminal #9 has positive polarity and terminal #12 has negative polarity . V oltage should be zero. If any voltage remains, r epeat this capaci- to[...]

AUXILIAR Y TRANSFORMER TEST #1 Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may r esult 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 [...]

F-28 F-28 AUXILIAR Y TRANSFORMER TEST #1 (continued) FIGURE F .5 - TRANSFORMER T1 AND T2 LOCA TION 3 2 4 1 TROUBLESHOOTING & REP AIR 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 b[...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC POWER W A VE 450 F-29 F-29 AUXILIAR Y TRANSFORMER TEST #1 (continued) TROUBLESHOOTING & REP AIR 11. Remove plugs J32 and J33 fr om the pro- tection board. 12. T urn the main [...]

POWER W A VE 450 FIGURE F .6 – INPUT AND AUXILIAR Y CIRCUIT WIRING DIAGRAM TROUBLESHOOTING & REP AIR F-30 F-30 (L1A) (L3A) 4 2 3 1 F1 FUSE P OWER SWITCH SWI (321B) (HIB) 321A MAIN CON T ACT OR (L1) (L2) (L3) (T1) (T2) (T3) U V W G (324) (326) 24V A C CR1 I NPU T R ECTIFIER AC 1 AC 2 AC 3 POS NEG JUMP ER "A" (H4) (H3) 200- 208 (H2) ([...]

AUXILIAR Y TRANSFORMER TEST #2 Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may r esult 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 [...]

F-32 F-32 AUXILIAR Y TRANSFORMER TEST #2 (continued) FIGURE F .7 - TRANSFORMER T1 AND T2 LOCA TION 3 1 2 TROUBLESHOOTING & REP AIR 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 bai[...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC POWER W A VE 450 F-33 F-33 TROUBLESHOOTING & REP AIR 11. T o conduct this test, you will be measuring the voltage between pin 2 and pin 5 of plug J4. The plug is located in t[...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC POWER W A VE 450 F-34 F-34 TROUBLESHOOTING & REP AIR FIGURE F .8 – INPUT AND AUXILIAR Y CIRCUIT WIRING DIAGRAM (L1A) (L3A) 4 2 3 1 F1 FUSE P OWER SWITCH SWI (321B) (HIB) 32[...]

AUXILIAR Y TRANSFORMER PRIMAR Y WIRING HARNESS TEST Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may r esult in danger to the technician or machine operator and will invalidate your factory warranty . For your safety and to avoid electri- cal shock, pleas[...]

F-36 F-36 AUXILIAR Y TRANSFORMER PRIMAR Y WIRING HARNESS TEST (continued) FIGURE F .9 - RECONNECT P ANEL/TERMINAL STRIP LOCA TION 1 3 2 4 TROUBLESHOOTING & REP AIR 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 gask[...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC POWER W A VE 450 F-37 F-37 AUXILIAR Y TRANSFORMER PRIMAR Y WIRING HARNESS TEST (continued) TROUBLESHOOTING & REP AIR 10. Check the wires that run fr om the r econ- nect panel[...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC POWER W A VE 450 F-38 F-38 TROUBLESHOOTING & REP AIR FIGURE F .10 – INPUT AND AUXILIAR Y CIRCUIT WIRING DIAGRAM (L1A) (L3A) 4 2 3 1 F1 FUSE P OWER SWITCH SWI (321B) (HIB) 3[...]

POWER W A VE 450 AUXILIAR Y TRANSFORMER #1 SECONDAR Y AND WIRING HARNESS TEST Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may r esult in danger to the technician or machine operator and will invalidate your factory warranty . For your safety and to avoid[...]

F-40 F-40 AUXILIAR Y TRANSFORMER #1 SECONDAR Y AND WIRING HARNESS TEST (continued) FIGURE F .11 - PLUG AND RECEPT ACLE INSPECTION POINTS 2 3 4 5 6 1 TROUBLESHOOTING & REP AIR 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 [...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC POWER W A VE 450 F-41 F-41 TROUBLESHOOTING & REP AIR 10. Check for shorts at plugs J33, J34, J35, J37, and J38 on the protection boar d. Inspect the board for evidence of ar [...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC POWER W A VE 450 F-42 F-42 2 5 3 6 W U N R 5A C.B. 33 32A 333 334 *336 42V 24V 115V COMMON A UXILIA R Y TRANSF ORM ER 1 PRO TECTION B OA RD A I K C J D COMMON COMMON 42V 24V 115V[...]

INPUT POWER AND WIRING HARNESS TEST Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may r esult 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 sa[...]

F-44 F-44 INPUT POWER AND WIRING HARNESS TEST FIGURE F .13 - INPUT POWER INSPECTION POINTS 1 2 3 TROUBLESHOOTING & REP AIR 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. Wi[...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC POWER W A VE 450 F-45 F-45 INPUT POWER AND WIRING HARNESS TEST (continued) TROUBLESHOOTING & REP AIR 9. Check for shorts or fusing at the input (top) leads to the main contac[...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC F-46 F-46 FIGURE F .14 – INPUT AND AUXILIAR Y CIRCUIT WIRING DIAGRAM TROUBLESHOOTING & REP AIR POWER W A VE 450 (L1A) (L3A) 4 2 3 1 F1 FUSE P OWER SWITCH SWI (321B) (HIB) 3[...]

INPUT RECTIFIER RESIST ANCE TEST Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may r esult 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 safet[...]

F-48 F-48 INPUT RECTIFIER RESIST ANCE TEST (continued) FIGURE F .15 - RECONNECT SWITCH LOCA TION 1 2 3 TROUBLESHOOTING & REP AIR 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.[...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC POWER W A VE 450 F-49 F-49 INPUT RECTIFIER RESIST ANCE TEST (continued) TROUBLESHOOTING & REP AIR 9. Check all leads connected to the input rectifier . Check for looseness or[...]

F-50 F-50 NOTES POWER W A VE 450 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC[...]

OUTPUT SHUNT/WELDING FEEDBACK TEST Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may r esult 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 saf[...]

TEST PROCEDURE 1. Remove main input supply power to the Power W ave 450. 2. Disconnect the Output leads from the machine. 3. If a wire feeder is connected to the Power W ave 450, release the drive r oll tension so the unit will not feed wire when the trigger is activated. 4. T ur n on the Power W ave 450 and activate the gun trigger and hold for se[...]

F-53 F-53 OUTPUT SHUNT/WELDING FEEDBACK TEST (continued) FIGURE F .16 - SHUNT AMPLIFIER BOARD LOCA TION 1 TROUBLESHOOTING & REP AIR 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 ba[...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC F-54 F-54 OUTPUT SHUNT/WELDING FEEDBACK TEST (continued) TROUBLESHOOTING & REP AIR ELECTRIC SHOCK can kill. Proceed with caution. Be careful not to touch any inter- nal machi[...]

PIEZO-ELECTRIC ALARM BUZZER TEST Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may r esult 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 safet[...]

F-56 F-56 PIEZO-ELECTRIC ALARM BUZZER TEST FIGURE F .17 - ALARM BUZZER LOCA TION 1 2 TROUBLESHOOTING & REP AIR 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&[...]

OUTPUT RECTIFIER DIODES TEST Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may r esult 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 no[...]

F-58 F-58 OUTPUT RECTIFIER DIODES TEST FIGURE F .18 - SNUBBER BOARD, OUTPUT TERMINAL LOCA TION 3 4 1 2 TROUBLESHOOTING & REP AIR 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.[...]

FIELD EFFECT TRANSISTOR/SWITCH BOARD TEST OR IGBT/SWITCH BOARD TEST Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may r esult in danger to the technician or machine operator and will invalidate your factory warranty . For your safety and to avoid elec- tri[...]

F-60 F-60 FIELD EFFECT TRANSISTOR/SWITCH BOARD TEST FIGURE F .19 – F .E.T . SWITCH BOARD LOCA TION 1 TROUBLESHOOTING & REP AIR TEST PROCEDURE 1. Remove main input supply power to the machine. 2. With the 3/8" nut driver , r emove the screws that hold the handle to the machine. 3. Remove the rubber gasket (cover seal) from the lift bail. [...]

F-61 F-61 FIELD EFFECT TRANSISTOR/SWITCH BOARD TEST (continued) FIGURE F .20 - RESISTOR LOCA TIONS TROUBLESHOOTING & REP AIR 7. Locate the two sets of two resistors on the left side of the machine and three sets of two resistors on the right side of the machine. See Figure F .20. Do not touch the resistors or any other internal machine componen[...]

F-62 F-62 FIELD EFFECT TRANSISTOR/SWITCH BOARD TEST (continued) D I S C H A R G E D I S C H A R G E D I S C H A R G E D I S C H A R G E D I S C H A R G E TROUBLESHOOTING & REP AIR 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 jumpe[...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC POWER W A VE 450 F-63 F-63 FIELD EFFECT TRANSISTOR/SWITCH BOARD TEST (continued) FIGURE F .23 - SWITCH BOARD ASSEMBL Y CONNECTION DECAL 3W 3R 2W 2R 406 401 3T 2T 12C 9A 9C 12A 4T[...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC POWER W A VE 450 F-64 F-64 FIELD EFFECT TRANSISTOR/SWITCH BOARD TEST (continued) TROUBLESHOOTING & REP AIR Switch Board T est 1: (For Switch Board Marked CAP 1 on the Switch [...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC POWER W A VE 450 F-65 F-65 FIELD EFFECT TRANSISTOR/SWITCH BOARD TEST (continued) T ABLE F .2 – SWITCH BOARD 1 RESIST ANCE TEST T ABLE TROUBLESHOOTING & REP AIR Apply Apply [...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC POWER W A VE 450 F-66 F-66 TROUBLESHOOTING & REP AIR FIELD EFFECT TRANSISTOR/SWITCH BOARD TEST (continued) T ABLE F .2 – SWITCH BOARD 1 RESIST ANCE TEST T ABLE (Continued) [...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC POWER W A VE 450 F-67 F-67 TROUBLESHOOTING & REP AIR FIELD EFFECT TRANSISTOR/SWITCH BOARD TEST (continued) T ABLE F .3 – SWITCH BOARD 2 RESIST ANCE TEST T ABLE Apply Apply [...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC POWER W A VE 450 F-68 F-68 TROUBLESHOOTING & REP AIR FIELD EFFECT TRANSISTOR/SWITCH BOARD TEST (continued) T ABLE F .3 – SWITCH BOARD 2 RESIST ANCE TEST T ABLE (Continued) [...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC POWER W A VE 450 F-69 F-69 TROUBLESHOOTING & REP AIR FIELD EFFECT TRANSISTOR/SWITCH BOARD TEST (continued) T ABLE F .4 – SWITCH BOARD 3 RESIST ANCE TEST T ABLE Apply Apply [...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC POWER W A VE 450 F-70 F-70 TROUBLESHOOTING & REP AIR FIELD EFFECT TRANSISTOR/SWITCH BOARD TEST (continued) T ABLE F .4 – SWITCH BOARD 3 RESIST ANCE TEST T ABLE (Continued) [...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC POWER W A VE 450 F-71 F-71 TROUBLESHOOTING & REP AIR FIELD EFFECT TRANSISTOR/SWITCH BOARD TEST (continued) T ABLE F .5 – SWITCH BOARD 4 RESIST ANCE TEST T ABLE Apply Apply [...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC POWER W A VE 450 F-72 F-72 TROUBLESHOOTING & REP AIR FIELD EFFECT TRANSISTOR/SWITCH BOARD TEST (continued) T ABLE F .5 – SWITCH BOARD 4 RESIST ANCE TEST T ABLE (Continued) [...]

F-73 F-73 IGBT/SWITCH BOARD TEST (G3165-1) T ABLE F .6 – NOTE: This test will NOT determine if an individual IGBT device is open. TROUBLESHOOTING & REP AIR POWER W A VE 450 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC[...]

F-74 F-74 IGBT/SWITCH BOARD TEST (Continued) T ABLE F .6 (Continued) TROUBLESHOOTING & REP AIR POWER W A VE 450 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Apply Apply Positive Negative T est T est Probe to Pr obe to T[...]

SNUBBER AND BLEEDER RESISTOR TEST Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may r esult 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 safe[...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC POWER W A VE 450 F-76 F-76 SNUBBER AND BLEEDER RESIST OR TEST FIGURE F .24 - SWITCH BOARD ASSEMBL Y CONNECTION DECAL 3W 3R 2W 2R 406 401 3T 2T 12C 9A 9C 12A 4T 1T 405 402 4R 1R 4[...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC F-77 F-77 SNUBBER AND BLEEDER RESIST OR TEST (continued) TROUBLESHOOTING & REP AIR TEST PROCEDURE 1. Remove main input supply power to the machine. 2. With the 3/8" nut [...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC F-78 F-78 SNUBBER AND BLEEDER RESIST OR TEST (continued) TROUBLESHOOTING & REP AIR C. With the volt/ohmmeter , check for 25 ohms resistance between lead #404 and #9F . If the[...]

F-79 F-79 FIGURE F .25 – SNUBBER AND BLEEDER RESISTOR WIRING DIAGRAM ( ) ( ) SWITCH BOARD #3 405 12C 406 9C C 3 (405) (12G) (12C) (406) (9G) (9C) R5 ( ) 25 Ω 25W ( ) 25 Ω 25W R6 T O R ECONNECT SWITCH 7.5K Ω 25W R10 T O R ECONNECT SWITCH (12M) (9M) SWITCH BOARD #4 407 12D 408 9D C 4 (407) (12H) (12D) (408) (9H) (9D) R7 ( ) 25 Ω 25W ( ) 25 [...]

F-80 F-80 NOTES POWER W A VE 450 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC[...]

RECONNECT SWITCH TEST 1 Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may r esult 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 a[...]

F-82 F-82 RECONNECT SWITCH TEST 1 FIGURE F .26 - RECONNECT SWITCH 1 2 3 TROUBLESHOOTING & REP AIR 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 dri[...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC F-83 F-83 RECONNECT SWITCH TEST 1 (continued) TROUBLESHOOTING & REP AIR For 380 or 460 V AC: A. Check that the following leads are connect- ed together at the reconnect switc[...]

F-84 F-84 FIGURE F .27 – INPUT AND RECONNECT WIRING DIAGRAM 6 R9 U V W G L1 L2 L3 CR1 T1 T2 T3 (326) (324) AC 1 AC 2 AC 3 - + POS NEG 12A 9A C1 C2 C3 C4 SWITCH BOARD # 1 SWITCH BOARD # 2 SWITCH BO AR D #3 SWITCH BOARD # 4 R10 12C 9C 12B 9B 12D 9D (329) (326) 4 CONTROL BOARD 2 4 J23 J23 234 232 3 2 FR EQU ENCY ME ASU RE ME N T J39 J39 RC R 1 R CR2[...]

RECONNECT SWITCH TEST 2 Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may r esult 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 a[...]

F-86 F-86 RECONNECT SWITCH TEST 2 (continued) FIGURE F .28 - RECONNECT SWITCH 1 2 3 TROUBLESHOOTING & REP AIR 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&q[...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC F-87 F-87 RECONNECT SWITCH TEST 2 (continued) TROUBLESHOOTING & REP AIR • Lead #9A between the reconnect switch and switch board #1. • Lead #9B between the reconnect swit[...]

F-88 F-88 FIGURE F .29 – INPUT AND RECONNECT WIRING DIAGRAM 6 R9 U V W G L1 L2 L3 CR1 T1 T2 T3 (326) (324) AC 1 AC 2 AC 3 - + POS NEG 12A 9A C1 C2 C3 C4 SWITCH BO AR D #1 SWITCH BO AR D #2 SWITCH BO AR D #3 SWITCH BO AR D #4 R10 12C 9C 12B 9B 12D 9D (329) (326) 4 CONTROL BOARD 2 4 J23 J23 234 232 3 2 FR EQU ENCY ME ASU RE ME N T J39 J39 RC R 1 R [...]

ST A TIC CAP ACITOR BALANCE TEST Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may r esult 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 safet[...]

F-90 F-90 ST A TIC CAP ACIT OR BALANCE TEST (continued) FIGURE F .30 - BLEEDER RESISTORS R9 AND R10 LOCA TION 1 TROUBLESHOOTING & REP AIR 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 l[...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC F-91 F-91 ST A TIC CAP ACIT OR BALANCE TEST (continued) TROUBLESHOOTING & REP AIR ELECTRIC SHOCK can kill. With input supply power ON, there ar e high voltages inside the mac[...]

F-92 F-92 Figure F .31 – SNUBBER AND BLEEDER RESISTOR WIRING DIAGRAM ( ) ( ) SWITCH BOARD #3 405 12C 406 9C C 3 (405) (12G) (12C) (406) (9G) (9C) R5 ( ) 25 Ω 25W ( ) 25 Ω 25W R6 T O R ECONNECT SWITCH 7.5K Ω 25W R10 T O R ECONNECT SWITCH (12M) (9M) SNUB BER A ND BLEED ER R ESI ST OR WI RI NG DI A GRAM SWITCH BOARD #4 407 12D 408 9D C 4 (407)[...]

DYNAMIC CAP ACITOR BALANCE TEST Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may r esult 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[...]

F-94 F-94 DYNAMIC CAP ACITOR BALANCE TEST (continued) FIGURE F .32- CONTROL BOARD PLUG LOCA TIONS PRO TECTION B D G RO UND PL ANE CONTROL BD J20 J21 J22 J23 J24 J25 J26 J27 J28 J30 J31 J32 J33 J34 J35 J36 J37 J38 J39 1 16 1 14 1 6 1 6 1 14 1 6 111 1 4 4 4 4 1 8 1 8 1 12 6 1 1 14 1 10 1 6 1 4 1 4 DI SPLA Y 2 3 4 2 TROUBLESHOOTING & REP AIR TEST [...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC F-95 F-95 DYNAMIC CAP ACITOR BALANCE TEST (continued) TROUBLESHOOTING & REP AIR ELECTRIC SHOCK can kill. With input power ON, there are high voltages inside the machine, incl[...]

F-96 F-96 FIGURE F .33 – INPUT AND RECONNECT WIRING DIAGRAM 6 R9 U V W G L1 L2 L3 CR1 T1 T2 T3 (326) (324) AC 1 AC 2 AC 3 - + POS NEG 12A 9A C1 C2 C3 C4 SWITCH BOARD # 1 SWITCH BO AR D #2 SWITCH BO AR D #3 SWITCH BO AR D #4 R10 12C 9C 12B 9B 12D 9D (329) (326) 4 CONTROL BOARD 2 4 J23 J23 234 232 3 2 FR EQU ENCY ME ASU RE ME N T J39 J39 RC R 1 R C[...]

INTERNAL AND AUXILIAR Y SUPPL Y VOL T AGE TEST Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may r esult in danger to the technician or machine operator and will invalidate your factory warranty . For your safety and to avoid elec- trical shock, please obs[...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC F-98 F-98 INTERNAL AND AUXILIAR Y SUPPL Y VOL T AGE TEST (continued) TROUBLESHOOTING & REP AIR TEST PROCEDURE 1. Remove main input supply power to the machine. 2. With the 3/[...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC F-99 F-99 INTERNAL AND AUXILIAR Y SUPPL Y VOL T AGE TEST (continued) TROUBLESHOOTING & REP AIR C. Protection Boar d: 115 V AC Between J34 - pin 8 and J34 - pin 12 (Power W av[...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC F-100 F-100 INTERNAL AND AUXILIAR Y SUPPL Y VOL T AGE TEST (continued) TROUBLESHOOTING & REP AIR 13. With the V olt/ohmmeter , check the follow- ing leads for continuity: A. [...]

F-101 F-101 FIGURE F .34 – INTERNAL AUXILIAR Y SUPPL Y WIRING DIAGRAM P82 WF2 R ECEPT ACLE 2 5 3 6 P83 WF1 R ECEPT ACLE SQU ARE W A VE TIG PRO TECTI ON BD 24V TRIG 1 J92 J92 6 3 P83 A I K C J D COMMON COMMON 42V 24V 115V TRIG 1 P82 A I K C J D COMMON COMMON 42V 24V 115V TRIG 2 32D 32E 42C 102D 31C 106A 32B 32C 42B 102B 31B 105A 296 293 W U N R 5A[...]

F-102 F-102 NOTES POWER W A VE 450 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC[...]

MAIN CONT ACTOR TEST Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may r esult 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 [...]

F-104 F-104 MAIN CONT ACTOR TEST (continued) FIGURE F .35 - MAIN CONT ACTOR CR1 L 1 A L1 L2 L3 T1 T2 T3 L 3 A TROUBLESHOOTING & REP AIR 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 lif[...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC F-105 F-105 MAIN CONT ACTOR TEST (continued) TROUBLESHOOTING & REP AIR A. With the power switch SW1 OFF , check to see if leads L1A and L3A are shorted together . If they are[...]

F-106 F-106 FIGURE F .36 – INPUT AND RECONNECT WIRING DIAGRAM 6 R9 U V W G L1 L2 L3 CR1 T1 T2 T3 (326) (324) AC 1 AC 2 AC 3 - + POS NEG 12A 9A C1 C2 C3 C4 SWITCH BO AR D #1 SWITCH BO AR D #2 SWITCH BOARD # 3 SWITCH BOARD # 4 R10 12C 9C 12B 9B 12D 9D (329) (326) 4 CONTROL BOARD 2 4 J23 J23 234 232 3 2 FR EQU ENCY ME ASU RE ME N T J39 J39 RC R 1 R [...]

SERIAL LOOP WIRING HARNESS TEST Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may r esult 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[...]

F-108 F-108 SERIAL LOOP WIRING HARNESS TEST (continued) FIGURE F .37 - WIRE FEEDER AMPHENOL LOCA TIONS 1 TROUBLESHOOTING & REP AIR 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 bai[...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC F-109 F-109 SERIAL LOOP WIRING HARNESS TEST (continued) TROUBLESHOOTING & REP AIR B. Check for loose or br oken leads between the following pins: P83 - pin L and J27 - pin 1 [...]

F-110 F-110 FIGURE F .38 – SERIAL LOOP WIRING DIAGRAM 40mA cu rrent supply J22 J26 J26 J27 J27 J28 J28 J22 5 3 4 1 4 1 4 4 (263) (264) (111A) (112A) (117A) (118A) (5R) (5W) 5 J44 40mA cu rrent path 4 J44 P OWER BOARD Seria l Loop M aster T ra nsm it & Re ceiv e Lines TxD RxD Displa y Boa rd Por t S wi tch Open: DK Boa r d S.L. Comu nicat ion [...]

WIRE FEEDER 1 TRIGGER CIRCUIT TEST Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may r esult 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 saf[...]

F-112 F-112 WIRE FEEDER 1 TRIGGER CIRCUIT TEST (continued) FIGURE F .39 - DISPLA Y BOARD PLUG LOCA TIONS J17 J16 J15 J14 J13 J12 J11 J10 TROUBLESHOOTING & REP AIR 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 gaske[...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC F-113 F-113 WIRE FEEDER 1 TRIGGER CIRCUIT TEST (continued) TROUBLESHOOTING & REP AIR 11. Remove plug J30 fr om the protection board. See Figure F .1 for location of the board[...]

F-114 F-114 FIGURE F .40 – TRIGGER CIRCUIT WIRING DIAGRAM (2) (4) 8-pin Amphenols 14 -pin Amphenols (2) (4) C D C D C D C D F E D C B A R (2) (4) (75) (76) (77) A Remo te Co ntrol Kit K941 - 1 6- pin Amphenols A UXILI AR Y EQU I PMENT EXTERNAL I NTERNAL 2 3 4 7 5 9 1 2 3 6 SQU AR E W A VE TIG PRO TECTI ON BD POW ER W A VE (292) (291) (294) (293) [...]

WIRE FEEDER 2 TRIGGER CIRCUIT TEST Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may r esult 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 saf[...]

F-116 F-116 WIRE FEEDER 2 TRIGGER CIRCUIT TEST (continued) FIGURE F .41 - DISPLA Y BOARD PLUG LOCA TIONS J17 J16 J15 J14 J13 J12 J11 J10 TROUBLESHOOTING & REP AIR 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 gaske[...]

F-117 F-117 WIRE FEEDER 2 TRIGGER CIRCUIT TEST (continued) TROUBLESHOOTING & REP AIR 11. Remove plug J30 fr om the protection board. See Figure F .1 for location of the board and plug J30. ELECTRIC SHOCK can kill. With the input power ON, there ar e high voltages inside the machine. Do not reach into the machine or touch any internal parts. 12.[...]

F-118 F-118 FIGURE F .42 – TRIGGER CIRCUIT WIRING DIAGRAM (2) (4) 8-pin Amphenols 14 -pin Amphenols (2) (4) C D C D C D C D F E D C B A R (2) (4) (75) (76) (77) A Remo te Co ntrol Kit K941 - 1 6- pin Amphenols A UXILI AR Y EQU I PMENT EXTERNAL I NTERNAL 2 3 4 7 5 9 1 2 3 6 SQU AR E W A VE TIG PRO TECTI ON BD POW ER W A VE (292) (291) (294) (293) [...]

TRIGGER CIRCUIT AND WIRING HARNESS TEST Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may r esult 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 al[...]

F-120 F-120 TRIGGER CIRCUIT AND WIRING HARNESS TEST (continued) FIGURE F .43 - PROTECTION BOARD PLUG/HEADER LOCA TIONS 3 1 16 1 14 1 6 1 6 1 14 1 6 1 1 1 1 4 4 4 4 11 4 7 2 PRO TECTION B D J30 J31 J32 J33 J34 J35 J36 J37 J38 J39 TROUBLESHOOTING & REP AIR TEST PROCEDURE 1. Remove main input supply power to the machine. 2. With the 3/8" nut [...]

F-121 F-121 FIGURE F .44 AUXILIAR Y TRANSFORMER #1 SECONDAR Y CIRCUIT WIRING DIAGRAM 2 5 3 6 W U N R 5A C.B. 33 32A 333 334 *336 42V 24V 115V COMMON A UXILIA R Y TRANSF ORM ER 1 PRO TECTION B OA RD A I K C J D COMMON COMMON 42V 24V 115V TRIG 2 32D 32E 42C 102D 31C 106A 5 6 3 4 1 7 (P82) WF2 R ECEPT A CLE (P83) WF1 R ECEPT A CLE SQU ARE W A VE TIG P[...]

F-122 F-122 NOTES POWER W A VE 450 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC[...]

INTERNAL REMOTE CONTROL TEST Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may r esult 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 no[...]

F-124 F-124 INTERNAL REMOTE CONTROL TEST (continued) FIGURE F .45 - DISPLA Y BOARD PLUG LOCA TIONS J17 J16 J15 J14 J13 J12 J11 J10 TROUBLESHOOTING & REP AIR 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 (cov[...]

F-125 F-125 INTERNAL REMOTE CONTROL TEST (continued) TROUBLESHOOTING & REP AIR ELECTRIC SHOCK can kill. With input power ON, there are high voltages inside the machine, including the pro- tection board. Do not r each into the machine or touch any internal part. 10. T ur n input power ON. 11. T ur n the knob on the Remote Control Kit all the way[...]

F-126 F-126 FIGURE F .46 – TRIGGER CIRCUIT WIRING DIAGRAM (2) (4) 8-pin Amphenols 14 -pin Amphenols (2) (4) C D C D C D C D F E D C B A R (2) (4) (75) (76) (77) A Remo te Co ntrol Kit K941 - 1 6- pin Amphenols A UXILIA R Y EQU I PMENT EXTERNAL I NTERNAL 2 3 4 7 5 9 1 2 3 6 SQU AR E W A VE TIG PRO TECTI ON BD POW ER W A VE (292) (291) (294) (293) [...]

K941-1 REMOTE CONTROL KIT TEST Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may r esult 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 [...]

F-128 F-128 K941-1 REMOTE CONTROL KIT TEST (continued) FIGURE F .47 - 6-PIN AMPHENOL LOCA TION 1 2 TROUBLESHOOTING & REP AIR TEST PROCEDURE 1. Remove the Remote Control Kit fr om the power source. 2. Perform the following tests. If any test fails, the Remote Control Kit is faulty and should be replaced. A. With the volt/ohmmeter , check the con[...]

F-129 F-129 FIGURE F .48 – TRIGGER CIRCUIT WIRING DIAGRAM (2) (4) 8-pin Amphenols 14 -pin Amphenols (2) (4) C D C D C D C D F E D C B A R (2) (4) (75) (76) (77) A Remo te Co ntrol Kit K941 - 1 6- pin Amphenols A UXILIA R Y EQU I PMENT EXTERNAL I NTERNAL 2 3 4 7 5 9 1 2 3 6 SQU AR E W A VE TIG PRO TECTI ON BD POW ER W A VE (292) (291) (294) (293) [...]

F-130 F-130 NOTES POWER W A VE 450 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC[...]

K941-1 REMOTE CONTROL KIT TRIGGER CIRCUIT TEST Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may r esult in danger to the technician or machine operator and will invalidate your factory warranty . For your safety and to avoid elec- trical shock, please obs[...]

F-132 F-132 K941-1 REMOTE CONTROL KIT TRIGGER CIRCUIT TEST (continued) FIGURE F .49 - DISPLA Y BOARD PLUG LOCA TIONS J17 J16 J15 J14 J13 J12 J11 J10 TROUBLESHOOTING & REP AIR TEST PROCEDURE NOTE: Before tr oubleshooting the remote con- trol trigger cir cuit, troubleshoot the remote contr ol kit itself. Refer to the K941-1 Remote Control Kit T e[...]

F-133 F-133 K941-1 REMOTE CONTROL KIT TRIGGER CIRCUIT TEST (continued) TROUBLESHOOTING & REP AIR 11. Remove plug J30 fr om the protection board. See Figure F .1 for location of the board and plug J30. ELECTRIC SHOCK can kill. With the input power ON, there ar e high volt- ages inside the machine. Do not reach into the machine or touch any inter[...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC F-134 F-134 FIGURE F .50 – TRIGGER CIRCUIT WIRING DIAGRAM TROUBLESHOOTING & REP AIR POWER W A VE 450 (2) (4) 8-pin Amphenols 14 -pin Amphenols (2) (4) C D C D C D C D F E D[...]

LCD DISPLA Y TEST Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may r esult 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 pre[...]

F-136 F-136 LCD DISPLA Y TEST (continued) FIGURE F .51 - DISPLA Y BOARD PLUG LOCA TIONS J17 J16 J15 J14 J13 J12 J11 J10 TROUBLESHOOTING & REP AIR 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) fr[...]

F-137 F-137 LCD DISPLA Y TEST (continued) TROUBLESHOOTING & REP AIR ELECTRIC SHOCK can kill. With input power ON, there are high voltages inside the machine. Do not reach into the machine or touch any internal part. 10. T ur n input power ON. 11. With the volt/ohmmeter , check the follow- ing voltages between plug J16 pins at the display board [...]

F-138 F-138 FIGURE F .52 – INTERNAL AUXILIAR Y SUPPL Y WIRING DIAGRAM P82 WF2 R ECEPT ACLE 2 5 3 6 P83 WF1 R ECEPT ACLE SQU ARE W A VE TIG PRO TECTI ON BD 24V TRIG 1 J92 J92 6 3 P83 A I K C J D COMMON COMMON 42V 24V 115V TRIG 1 P82 A I K C J D COMMON COMMON 42V 24V 115V TRIG 2 32D 32E 42C 102D 31C 106A 32B 32C 42B 102B 31B 105A 296 293 W U N R 5A[...]

CALIBRA TION PROCEDURES POWER W A VE PC BOARD REPLACEMENT CALIBRA TION PROCEDURES If the display board is r eplaced, the display sensor cal- ibration and a voltage calibration must be performed for optimum performance. If the calibration is not done the voltage may be accurate only to within 3 volts. If the sensor calibration is not done, the displ[...]

F-140 F-140 NOTES POWER W A VE 450 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC[...]

SENSOR CALIBRA TION TEST (FOR DISPLA Y BOARD) Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may r esult in danger to the technician or machine operator and will invalidate your factory warranty . For your safety and to avoid elec- trical shock, please obse[...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC F-142 F-142 SENSOR CALIBRA TION TEST (FOR DISPLA Y BOARD) (continued) FIGURE F .53 - SENSOR LOCA TION BEHIND OVERLA Y TROUBLESHOOTING & REP AIR PROCEDURE 1. T urn the machine[...]

QUICK VOL T AGE CALIBRA TION Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may r esult 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 no[...]

F-144 F-144 QUICK VOL T AGE CALIBRA TION (continued) FIGURE F .54 - TEST AND CALIBRA TION OVERLA Y TROUBLESHOOTING & REP AIR PROCEDURE 1. Before changing or disturbing the display board, power up the machine with the L9660-255 T est and Calibration overlay in place. See Figure F .54. 2. Press the V oltage Calibration function (32). The machine [...]

FULL VOL T AGE CALIBRA TION Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may r esult 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 not[...]

F-146 F-146 FULL VOL T AGE CALIBRA TION (continued) FIGURE F .55 - TEST AND CALIBRA TION OVERLA Y TROUBLESHOOTING & REP AIR PROCEDURE 1. The voltage calibration numbers are stored in the display board. They ar e program- mable from the fr ont panel using the T est and Calibration Overlay . 2. Change the PC board in question. 3. Install the T es[...]

FULL VOL T AGE CALIBRA TION USING A WELDING ARC Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may r esult in danger to the technician or machine operator and will invalidate your factory warranty . For your safety and to avoid elec- trical shock, please ob[...]

F-148 F-148 FULL VOL T AGE CALIBRA TION (continued) FIGURE F .55a - TEST AND CALIBRA TION OVERLA Y TROUBLESHOOTING & REP AIR PROCEDURE 1. The voltage calibration numbers are stored in the display board. They ar e programma- ble from the fr ont panel using the T est and Calibration Overlay . 2. Change the display board in question. 3. Install th[...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC F-149 F-149 FULL VOL T AGE CALIBRA TION (continued) TROUBLESHOOTING & REP AIR – POLARITY (+21A) + POLARITY – POLARITY NOTE: Do not attempt to weld for –Polarity (+21A).[...]

F-150 F-150 NOTES POWER W A VE 450 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC[...]

CURRENT CALIBRA TION Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may r esult 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 [...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC F-152 F-152 CURRENT CALIBRA TION (continued) TROUBLESHOOTING & REP AIR 2. Locate the 10 tur n trimmer potentiometer located on the control boar d. It is the only trimmer on t[...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC F-153 F-153 CURRENT CALIBRA TION (continued) TROUBLESHOOTING & REP AIR PROCEDURE 1. Install the T est and Calibration Overlay and apply power to the machine. See Figure F .58[...]

F-154 F-154 NOTES POWER W A VE 450 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC[...]

T1 AUXILIAR Y TRANSFORMER REMOV AL AND REPLACEMENT Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may r esult in danger to the technician or machine operator and will invalidate your factory warranty . For your safety and to avoid elec- trical shock, please[...]

F-156 F-156 T1 AUXILIAR Y TRANSFORMER REMOV AL AND REPLACEMENT (continued) FIGURE F .59 - T1 AUXILIARY TRANSFORMER LOCA TION 1 2 TROUBLESHOOTING & REP AIR 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[...]

W A TER COOLER REMOV AL AND REPLACEMENT For later model coolers (Inlet & Outlet on lower left of machine back) Refer to IM645-A Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may r esult in danger to the technician or machine operator and will invalidat[...]

F-158 F-158 W A TER COOLER REMOV AL AND REPLACEMENT (continued) FIGURE F .60 - WA TER COOLER LOCA TION 1 3 2 TROUBLESHOOTING & REP AIR PROCEDURE NOTE: These instructions may vary slightly with later model coolers. See instruc- tions included with cooler kit. 1. Remove main input supply power to the machine. 2. With the 3/8" nut driver , re[...]

F-159 F-159 W A TER COOLER REMOV AL AND REPLACEMENT (continued) TROUBLESHOOTING & REP AIR 10. With the 9/16" open end wrench, r emove the circuit br eaker . 11. Locate and disconnect plug J4, behind the water cooler . Plug J 4, a large molex plug, has two leads (H1A and H3A). Double-check that these are the leads feeding the plug; there is[...]

F-160 F-160 NOTES POWER W A VE 450 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC[...]

W A TER COOLER DISASSEMBL Y Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may r esult 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 not[...]

F-162 F-162 W A TER COOLER DISASSEMBL Y (continued) FIGURE F .61 - WA TER COOLER DISASSEMBL Y (EARL Y MODEL) 1 2 3 TROUBLESHOOTING & REP AIR 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 lif[...]

F-163 F-163 W A TER COOLER DISASSEMBL Y (continued) TROUBLESHOOTING & REP AIR Reservoir Removal A. After you have completed the capacitor dischar ge procedur e for all four switch boards, r emove the water cooler assembly . Refer to the W ater Cooler Removal and Replacement Procedure in this section of the manual. B. Empty the coolant fr om the[...]

F-164 F-164 NOTES POWER W A VE 450 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC[...]

T2 AUXILIAR Y TRANSFORMER REMOV AL AND REPLACEMENT Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may r esult in danger to the technician or machine operator and will invalidate your factory warranty . For your safety and to avoid elec- trical shock, please[...]

F-166 F-166 T2 AUXILIAR Y TRANSFORMER REMOV AL AND REPLACEMENT (continued) FIGURE F .62 - T2 AUXILIARY TRANSFORMER LOCA TION 1 2 3 TROUBLESHOOTING & REP AIR 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 se[...]

F AN MOTOR REMOV AL AND REPLACEMENT Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may r esult 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 sa[...]

F-168 F-168 F AN MOTOR REMOV AL AND REPLACEMENT (continued) FIGURE F .63 - F AN MOTOR LOCA TION 1 2 3 TROUBLESHOOTING & REP AIR 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. Wi[...]

F-169 F-169 F AN MOTOR REMOV AL AND REPLACEMENT (continued) FIGURE F .64 - MACHINE BACK SECURED TO LIFT BAIL. 1 2 TROUBLESHOOTING & REP AIR 11. With the 3/4" wrench, r emove the lead connected to the rear positive (+) output terminal. 12. Swing the back panel up and secur e it to the lift bail. See Figure F .64. Use heavy string or wire. B[...]

F-170 F-170 NOTES POWER W A VE 450 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC[...]

INPUT RECTIFIER REMOV AL AND REPLACEMENT Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may r esult 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 a[...]

F-172 F-172 INPUT RECTIFIER REMOV AL AND REPLACEMENT (continued) FIGURE F .65 - INPUT RECTIFIER LOCA TION CR1 1 2 3 4 5 6 TROUBLESHOOTING & REP AIR 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 [...]

F-173 F-173 INPUT RECTIFIER REMOV AL AND REPLACEMENT (continued) TROUBLESHOOTING & REP AIR 10. With the 5 mm Allen wrench and the 10 mm open end wrench, r emove the two screws mounting the input r ectifier to the heat sink panel. 11. When r eplacing the input r ectifier , apply a thin, even coating of Dow Corning 340 Joint Compound (Lincoln T12[...]

F-174 F-174 NOTES POWER W A VE 450 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC[...]

PRINTED CIRCUIT BOARD REMOV AL AND REPLACEMENT (CONTROL BOARD, POWER BOARD, AND PROTECTION BOARD) Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may r esult in danger to the technician or machine operator and will invalidate your factory warranty . For your[...]

F-176 F-176 PRINTED CIRCUIT BOARD REMOV AL AND REPLACEMENT (CONTROL BOARD, POWER BOARD, AND PROTECTION BOARD) (continued) FIGURE F .66 - PC BOARD REMOV AL 1 3 2 TROUBLESHOOTING & REP AIR 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. Remo[...]

F-177 F-177 PRINTED CIRCUIT BOARD REMOV AL AND REPLACEMENT (CONTROL BOARD, POWER BOARD, AND PROTECTION BOARD) (continued) TROUBLESHOOTING & REP AIR Be sure to follow the r ecommended static-free methods for handling printed circuit boar ds. Failure to do so can r esult in permanent dam- age to the equipment. 8. Remove the molex plugs from the P[...]

F-178 F-178 NOTES POWER W A VE 450 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC[...]

DISPLA Y BOARD REMOV AL AND REPLACEMENT Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may r esult 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 al[...]

F-180 F-180 DISPLA Y BOARD REMOV AL AND REPLACEMENT (continued) FIGURE F .68 - DISPLA Y BOARD REMOV AL 3 4 5 2 1 TROUBLESHOOTING & REP AIR NOTE: Before changing or disturbing the dis- play board follow the procedure outlined under QUICK VOL T AGE CALIBRA TION (Fig. F .54) in this section. PROCEDURE 1. Remove main input supply power to the machi[...]

F-181 F-181 DISPLA Y BOARD REMOV AL AND REPLACEMENT (continued) TROUBLESHOOTING & REP AIR 8. Carefully remove the key pad ribbon con- nector from the right side of the display board. 9. Car efully remove the connector to the LCD display . Do not touch the sensors located on the left side of the display board when you handle it for removal or r [...]

F-182 F-182 NOTES POWER W A VE 450 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC[...]

MAIN INPUT CONT ACTOR (CR1) REMOV AL AND REPLACEMENT Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may r esult in danger to the technician or machine operator and will invalidate your factory warranty . For your safety and to avoid elec- trical shock, plea[...]

F-184 F-184 MAIN INPUT CONT ACTOR (CR1) REMOV AL AND REPLACEMENT (continued) FIGURE F .69 - MAIN CONT ACTOR CR1 L 1 A L1 L2 L3 T1 T2 T3 3 2 4 3 2 6 T1 T3 L 3 A TROUBLESHOOTING & REP AIR 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. Remov[...]

F-185 F-185 MAIN INPUT CONT ACTOR (CR1) REMOV AL AND REPLACEMENT (continued) TROUBLESHOOTING & REP AIR 9. With the slot head screw driver , remove the two small leads (T1 and T3) from the output side of the contactor . 10. With the slot head screw driver , remove the two contactor coil leads (#324 and #326) from the contactor . 11. With the slo[...]

F-186 F-186 NOTES POWER W A VE 450 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC[...]

OUTPUT RECTIFIER BRIDGE REMOV AL AND REPLACEMENT Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may r esult in danger to the technician or machine operator and will invalidate your factory warranty . For your safety and to avoid elec- trical shock, please o[...]

F-188 F-188 OUTPUT RECTIFIER BRIDGE REMOV AL AND REPLACEMENT (continued) FIGURE F .70 - OUTPUT RECTIFIER BRIDGE LOCA TION 1 TROUBLESHOOTING & REP AIR 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) fro[...]

F-189 F-189 OUTPUT RECTIFIER BRIDGE REMOV AL AND REPLACEMENT (continued) TROUBLESHOOTING & REP AIR 9. Cut all necessary cable ties on the right side of the machine and disconnect all necessary leads (two heavy and two small leads) from the right side of the output rectifier bridge. Place the fastener har d- ware back together onto the lead ends[...]

F-190 F-190 OUTPUT RECTIFIER BRIDGE REMOV AL AND REPLACEMENT (continued) TROUBLESHOOTING & REP AIR 13. For r eassembly , attach the glastic insulat- ed angle mounting pieces to the heat sink first. Slide the bridge into position and then fasten the bottom tab to the sub- frame with the bolt, split-ring lock washer and nut. Then attach and tight[...]

FET MODULE REMOV AL AND REPLACEMENT Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may r esult 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 sa[...]

F-192 F-192 FET MODULE REMOV AL AND REPLACEMENT (continued) FIGURE F .73 - FET MODULE LOCA TION 1 4 3 2 TROUBLESHOOTING & REP AIR 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. [...]

F-193 F-193 FET MODULE REMOV AL AND REPLACEMENT (continued) FIGURE F .74 - LIFT BAFFLE/BAIL REMOV AL TROUBLESHOOTING & REP AIR 9. With the wire cutters, cut all necessary cable ties. 10. Disconnect the leads to the output rectifi- er bridge. Cut all necessary cable ties. 11. Disconnect two plugs from the snubber board. 12. Disconnect the output[...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC F-194 F-194 TROUBLESHOOTING & REP AIR 21. Remove the water cooler assembly in order to access the r etainer clips that hold the bottom of the FET module assembly in place. (C[...]

F-195 F-195 FET MODULE REMOV AL AND REPLACEMENT (continued) TROUBLESHOOTING & REP AIR 30. Install the water cooler assembly . Refer to the W ater Cooler Removal and Replace- ment Procedure in this section of the module. 31. With the 7/16" wrench, connect the heavy current-carrying flat copper strap running from the shunt amplifier to the o[...]

F-196 F-196 NOTES POWER W A VE 450 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC[...]

MAIN TRANSFORMER REMOV AL AND REPLACEMENT Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may r esult 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 [...]

F-198 F-198 MAIN TRANSFORMER/CHOKE REMOV AL AND REPLACEMENT (continued) FIGURE F .75 - MAIN TRANSFORMER LOCA TION 1 TROUBLESHOOTING & REP AIR 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 li[...]

TROUBLESHOOTING & REP AIR F-199 F-199 POWER W A VE 450 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC PRE-POWERUP SWITCH BOARD TEST PROCEDURE FOR REPLACEMENT OF SWITCH ASSEMBL Y G2402-2 Service and repair should be perfor[...]

SETUP THE POWER W A VE FOR PRETEST 1. T urn the input power switch to the OFF position. 2. Unplug P73. See wiring diagram. 3. Install the L9660-255 Calibration & T est over- lay into the Power W ave. 4. Construct an isolated variable AC supply circuit as shown in Figure F .76 using the following equipment: Isolation transformer 1 15vac @ 3 amps[...]

MAKE SURE FIL TER CAP ACITORS ARE DISCHARGED 1. Construct a 1 15V AC pretest power supply as per Figure F .78 using the following: Switch (SPST) Fuse (5 amp max) P70 adapter ALL AC SUPPLIES MUST BE ELECTRICAL- L Y ISOLA TED (isolation transformers). THE PRINTED CIRCUIT BOARDS WILL BE DAMAGED IF THE AC SUPPLIES ARE NOT ISOLA TED. W ARNING TROUBLESHO[...]

Connect the pretest power supply to plug P70 as per Figure F .78. See wiring diagram. ARC ST ART PW450 WITH WIREFEEDER The arc start may be initiated by any of the follow- ing methods: 1. Release wire tension and pull gun trigger . 2. Jumper pins C and D on wire feeder input con- nector . 3. Jumper pins D and E on front panel amphenol connector nea[...]

ARC ST ART FOR PW450 ROBOTIC 1. Construct and connect an arc start circuit as per Figure F .79. 2. Install leads and an arc start switch into plug J103 pin 10 to pin 1 1 on the interface PC board. Make sure the arc start switch leads are long enough to reach outside of the machine case. 3. Leave plug J103 connected to the interface board. TROUBLESH[...]

TROUBLESHOOTING & REP AIR F-204 F-204 POWER W A VE 450 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC PRE-POWERUP SWITCH BOARD TEST PROCEDURE FOR REPLACEMENT OF SWITCH ASSEMBL Y G2402-2 (continued) 1. Unplug P23 and inser[...]

TROUBLESHOOTING & REP AIR F-205 F-205 POWER W A VE 450 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC PRE-POWERUP SWITCH BOARD TEST PROCEDURE FOR REPLACEMENT OF SWITCH ASSEMBL Y G2402-2 (continued) SNUBBER SIGNAL TEST 1. [...]

TROUBLESHOOTING & REP AIR F-206 F-206 POWER W A VE 450 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC PRE-POWERUP SWITCH BOARD TEST PROCEDURE FOR REPLACEMENT OF SWITCH ASSEMBL Y G2402-2 (continued) 460V AC RECONNECT 1. Re[...]

TROUBLESHOOTING & REP AIR F-207 F-207 POWER W A VE 450 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC PRE-POWERUP SWITCH BOARD TEST PROCEDURE FOR REPLACEMENT OF SWITCH ASSEMBL Y G2402-2 (continued) 8. T urn the variable A[...]

TROUBLESHOOTING & REP AIR F-208 F-208 POWER W A VE 450 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC PRE-POWERUP SWITCH BOARD TEST PROCEDURE FOR REPLACEMENT OF SWITCH ASSEMBL Y G2402-2 (continued) 5. Press the MANUAL PRO[...]

Electrical Diagrams Section ................................................................................................ Section G Wiring Diagram ...........................................................................................................................G-2 Schematic Complete Machine ..............................................[...]

ELECTRICAL DIAGRAMS G-2 POWER W A VE 450 WIRING DIAGRAM - POWER W A VE 450 KEYPAD RS232 CONNECTOR 1 2 3 4 5 6 7 8 20 LCD DISPLAY RECEPTACLE 5A CIRCUIT BREAKER + - + - + - + - CURRENT TRANSFORMER B C D E F A G H I J K L M N 102D 106A 275 276 277 2 3 4 5 6 7 8 9 10 11 12 42C 303 31C 32D 221A 32E 302 306 33 B C D E F A G H I J K L M N 32B 102B 105A 77[...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ELECTRICAL DIAGRAMS G-3 POWER W A VE 450 SCHEMA TIC - COMPLETE MACHINE 7-21-95E G 380-415V 440-460V W G CR1 TP4 TP5 TP6 POS + NEG NEG 2 W 3 5 N U R (24V) (42V) (115V) H1 H2 H3 H4[...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ELECTRICAL DIAGRAMS G-4 POWER W A VE 450 SCHEMA TIC - CONTROL PC BOARD #1 1W 6.2V DZ2 267 R22 1W 15V DZ6 J25 7 J25 6 J25 5 267 R29 50V 0.1 C11 100 R28 J25 9 1.00K R40 J22 9 J22 3[...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ELECTRICAL DIAGRAMS G-5 POWER W A VE 450 SCHEMA TIC - CONTROL PC BOARD #2 4 .7 5K R342 4 .7 5K R344 4 .7 5K R343 4 .7 5K R341 4 .7 5K R339 4 .7 5K R345 4 .7 5K R337 28 14 CY7C199[...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ELECTRICAL DIAGRAMS G-6 POWER W A VE 450 SCHEMA TIC - CONTROL PC BOARD #3 1.00K R191 200 R282 825 R283 50V 820p C138 50V 820p C137 FETS AS SOON AS SECONDARY CURRENT X63 13 1 2 33[...]

ELECTRICAL DIAGRAMS G-7 POWER W A VE 450 SCHEMA TIC - CONTROL PC BOARD #4 5.11K R2 06 10.0 R225 221K R219 CNY17-3 OCI4 4 2 1 6 5 10K R257 221K R254 CNY17-3 OCI8 4 2 1 6 5 D42 150 R256 J26 6 10K R255 D22 J26 2 150 R220 DIS2 SWITCH2 +5V DIS1 1N4936 D23 J26 1 +5V J23 6 J26 5 SWITCH1 +5V LOW = TRIGGER CLOSED (TO HC11) HIGH = TRIGGER OPEN +5.5V LOW = TR[...]

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 troub[...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ELECTRICAL DIAGRAMS G-9 POWER W A VE 450 SCHEMA TIC - DISPLA Y PC BOARD (SHEET 1) J17 7 Tx GRS232 GD +5V 22.1K R51 50V 330p C45 H11L2 OCI8 4 6 1 25 267 R57 /PB7 /PB4 +5V TRANSMIT[...]

ELECTRICAL DIAGRAMS G-10 POWER W A VE 450 SCHEMA TIC - DISPLA Y PC BOARD (SHEET 2) PRESSURE 50V 150p C71 6.81K R103 TO REMOTE 10K POTENTIOMETE RS 22.1K R 102 40V 600mA Q9 +15V THERMAL +15V +15V GD TRIM1 TRIM3 TRIM2 TRIM4 GD +5V +5V SENSE +5V GD INFRA6 GD INFRA5 +5V SENSE J11 5 10.0K R1 57 33.2K R 13 9 OPTEK OPB706 OCI11 2 4 3 1 ( RESISTORS = Ohms ([...]

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 troub[...]

ELECTRICAL DIAGRAMS G-12 POWER W A VE 450 SCHEMA TIC - POWER PRINTED CIRCUIT BOARD GND IN OUT X9 301 R192 1mH L116 1A 100V Q111 GND IN OUT X10 -8Vb e 1W 5.1V DZ115 1N4936 D43 CURRENT SOURCE 18.2K R105 18.2K R108 18.2K R104 40mAe +5Vc c FILE: G2240_1D2 Ch’ge.Sht.No. CHK. THE LINCOLN ELECTRIC CO. DATE SUPPLY COMMON CONNECTION FRAME CONNECTION LAST [...]

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 troub[...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ELECTRICAL DIAGRAMS G-14 POWER W A VE 450 SCHEMA TIC - PROTECTION PRINTED CIRCUIT BOARD +10Vp 2.43K R117 X8 8 9 10 2.43K R116 CNY17-3 OCI3 4 2 1 6 5 50V 0.27 C18 LM224 X6 4 11 10[...]

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 troub[...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ELECTRICAL DIAGRAMS G-16 POWER W A VE 450 SCHEMA TIC -SQUARE W A VE PROTECTION PRINTED CIRCUIT BOARD SUPPLY VOLTAGE NET FRAME CONNECTION COMMON CONNECTION 3000V .0047 C4 J23 1 J2[...]

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 troub[...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ELECTRICAL DIAGRAMS G-18 POWER W A VE 450 SCHEMA TIC - SHUNT PRINTED CIRCUIT BOARD NEGATIVE OUTPUT STUD TO GENERAL INFORMATION A PRINTED Iout = A NOTES : N.A. LABELS G G (R7 + 39[...]

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 troub[...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ELECTRICAL DIAGRAMS G-20 POWER W A VE 450 SCHEMA TIC - SNUBBER PRINTED CIRCUIT BOARD +15V .5W 100K R4 10.0K R21 +OUTPUT J60 13 J60 8 D1 .5W 100K R11 .5W 100K R17 .5W 100K R14 J60[...]

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 troub[...]

ELECTRICAL DIAGRAMS G-22 POWER W A VE 450 SCHEMA TIC-SWITCH PRINTED CIRCUIT BOARD 600mA 40V Q8 600mA 40V Q9 1/2W 1 R28 1W 10V DZ10 100V 1A Q10 1N4936 D10 50V 2700p C8 15.0K R32 1W 6.2V DZ9 47.5 R36 1W 10V DZ2 1N4936 D7 1/2W 1 R22 100V 1A Q1 1W 15V DZ7 C6 10.0 R34 475 R29 10.0 R27 10.0 R25 10.0 R19 475 R37 10.0 R26 IRFD110 IRFD110 2N4403 2N4403 A A1[...]

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 troub[...]

ELECTRICAL DIAGRAMS G-24 G-24 POWER W A VE 450 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC 1 2 3 4 5 6 7 8 9 DCD RD TD DTR GND DSR RTS CTS RI 2 3 4 5 6 7 8 20 22RI TD RD RTS CTS DSR GND DCD DTR 1 1 2 3 4 5 6 7 8 9 #302 #30[...]

SVM ERROR REPORTING FORM We need to know if there are errors in our manuals. W e also value any suggestions as to additional tests or procedures that would make this SVM a better tool for you. If you discover new or different “ Problems or Symptoms ” that are not covered in the three col- umn troubleshooting chart, please share this information[...]