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Lincoln Electric POWER WAVE SVM156-A manual

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Table of contents for the manual

  • Page 1

    SVM156-A October , 2001 Safety Depends on Y ou Lincoln arc welding and cutting equipment is designed and built with safety in mind. However , your overall safety can be in- creased by proper installation . . . and thoughtful operation on your part. DO NO T INST ALL, OPERA TE OR REP AIR THIS EQUIPMENT WITHOUT READING THIS MANU AL AND THE SAFETY PREC[...]

  • Page 2

    CALIFORNIA PROPOSITION 65 W ARNINGS i i SAFETY 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 vent the engine exhaust fumes outdoors. [...]

  • Page 3

    ii ii SAFETY Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ARC RA YS can b urn. 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. [...]

  • Page 4

    iii iii SAFETY 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 off 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 manufactu[...]

  • Page 5

    iv iv SAFETY Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC PRÉCA UTIONS 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 P ou[...]

  • Page 6

    v v - MASTER T ABLE OF CONTENTS FOR ALL SECTIONS - PO WER W A VE 455/R Page Safety .................................................................................................................................................i-iv Installation ........................................................................................................[...]

  • Page 7

    Installation ................................................................................................................... ..........Section A T echnical Specifications ..............................................................................................................A-2 Safety Precautions ..........................................[...]

  • Page 8

    A-2 A-2 INST ALLA TION 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 TECHNICAL SPECIFICA TIONS - PO WER W A VE 455/R (K1761-1), (K1761-2) OUTPUT RECOMMENDED INPUT WIRE AND FUSE SIZES INPUT A T RA TED OUTPUT - THREE PHASE ONL[...]

  • Page 9

    A-3 A-3 INST ALLA TION PO WER W A VE 455/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 TECHNICAL SPECIFICA TIONS - PO WER W A VE 455/R (K1761-1), (K1761-2) (continued) PHYSICAL DIMENSIONS TEMPERA TURE RANGES HEIGHT 26.10 i[...]

  • Page 10

    SAFETY PRECA UTIONS Read this entire installation section before y ou start installation. ELECTRIC SHOCK can kill. • Only qualified personnel should per- form this installation. • T urn the input power OFF at the dis- connect switch or fuse box before working on this equipment. T urn off the input power to any other equip- ment connected to the[...]

  • Page 11

    INPUT CONNECTION Only a qualified electrician should connect the input leads to the Power W ave. Connections should be made in accordance with all local and national electrical codes and the connection diagram located on the inside of the reconnect/input access door of the machine. Failure to do so may result in bodily injury or death. Use a three-[...]

  • Page 12

    A-6 A-6 INST ALLA TION PO WER W A VE 455/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 INPUT V OL T A GE CHANGE O VER (FOR MUL TIPLE INPUT V OL T A GE MA CHINES ONL Y) Welders are shipped connected for the highest input vo[...]

  • Page 13

    When these parameters are identical, the pulsing fre- quency will be the same, helping to stabilize the arcs. Every welding gun requires a separate shielding gas regulator for proper flow rate and shielding gas cover- age. Do not attempt to supply shielding gas for two or more guns from only one regulator . If an anti-spatter system is in use, each[...]

  • Page 14

    V OL T A GE SENSING The best arc performance occurs when the Power W ave has accurate data about the arc conditions. Depending upon the process, inductance within the electrode and work lead cables can influence the volt- age apparent at the terminals of the welder . V oltage sense leads improve the accuracy of the arc conditions and can have a dra[...]

  • Page 15

    WORK V OL T A GE SENSING The Power W ave is shipped from the factory with the work sense lead enabled. For processes requiring work voltage sensing, connect the (21) work voltage sense lead from the Power W ave to the work. Attach the sense lead to the work as close to the weld as practical. T o enable the work voltage sensing in the Power W ave, r[...]

  • Page 16

    DIP SWITCH SETTINGS AND LOCA TIONS DIP switches on the PC boards allow for custom con- figuration of the Power W ave. Access the DIP switch- es as follows: ELECTRIC SHOCK CAN KILL. • Do not touch electrically live parts or electrodes with your skin or wet cloth- ing. • Insulate yourself from the work and ground. • Always wear dry insulating g[...]

  • Page 17

    DEVICENET/GA TEW A Y BO ARD DIP SWITCH, B ANK (S2): switch 1,2 = configure the baud rate for DeviceNET Prior to S24958-6 software switch 1 s witch 2 baud rate off of f ------- on off 125K off on 250K on on 500 S24958-6 and later software switch 1 s witch 2 baud rate off of f 125K off on 250K on off 500K on on 500K Programmable value. Consult local [...]

  • Page 18

    A-12 A-12 NO TES PO WER W A VE 455/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[...]

  • Page 19

    Operation ............................................................................................................................... Section B Safety Precautions ............................................................................................................. .........B-2 Graphic Symbols ............................................[...]

  • Page 20

    SAFETY PRECA UTIONS Read this entire section of operating instructions before operating the mac hine . ELECTRIC SHOCK can kill. • Unless using cold feed feature, when feeding with gun trigger , the electrode and drive mechanism are always electrically energized and could remain energized several seconds after the welding ceases. • Do not touch [...]

  • Page 21

    B-3 B-3 OPERA TION PO WER W A VE 455/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 INPUT PO WER ON OFF HIGH TEMPERA TURE MA CHINE ST A TUS CIRCUIT BREAKER WIRE FEEDER POSITIVE OUTPUT NEGA TIVE OUTPUT 3 PHASE INVERTER INPUT[...]

  • Page 22

    GENERAL DESCRIPTION The Power W ave power source is designed to be a part of a modular , multi-process welding system. Depending on configuration, it can support constant current, constant voltage, Surface T ension Transfer and pulse welding modes. The Power W ave power source is designed to be used with the family of Power Feed wire feeders, opera[...]

  • Page 23

    RECOMMENDED PR OCESSES AND EQUIPMENT RECOMMENDED PROCESSES The Power W ave 455/R can be set up in a number of configurations, some requiring optional equipment or welding programs. Each machine is factory prepro- grammed with multiple welding procedures, typically including GMA W , GMAW -P , FCAW , GT A W and STT for a variety of materials, includi[...]

  • Page 24

    CASE FR ONT CONTROLS All operator controls and adjustments are located on the case front of the Power W ave. (See Figure B.1) 1. POWER SWITCH: Controls input power to the Power W ave. 2. ST A TUS LIGHT : A two color light that indicates sys- tem errors. Normal operation is a steady green light. Error conditions are indicated, per T able B.1. NO TE:[...]

  • Page 25

    WELDING MODE DESCRIPTIONS CONST ANT V OL T A GE WELDING For each wire feed speed, a corresponding voltage is preprogrammed into the machine through special soft- ware at the factory . The preprogrammed voltage is the best average voltage for a given wire feed speed. With synergic programs, when the wire feed speed changes, the Power W ave will auto[...]

  • Page 26

    PULSE WELDING Pulse welding procedures are set by controlling an overall “ arc length ” variable. When pulse welding, the arc voltage is highly dependent upon the waveform. The peak current, background current, rise time, fall time and pulse frequency all affect the voltage. The exact voltage for a given wire feed speed can only be predicted wh[...]

  • Page 27

    STT WELDING The pictures illustrate the waveshape of current for the process. They are not drawn to scale, and are intend- ed only for the purpose of showing how the variables affect the waveform. T rim in the STT mode adjusts the tailout and back- ground portion of the waveform. T rim values greater than 1.0 add more energy to the weld and make th[...]

  • Page 28

    B-10 B-10 NO TES PO WER W A VE 455/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[...]

  • Page 29

    Accessories .................................................................................................................... ......Section C Optional Equipment ....................................................................................................................C-2 Factory Installed ................................................[...]

  • Page 30

    OPTIONAL EQUIPMENT F ACT OR Y INST ALLED There are no factory installed options available for the Power W ave 455R. FIELD INST ALLED • Gas Guard Regulator (K659-1) The Gas Guard regulator is available as an option- al accessory for the Power Feed Robotic wire drive unit. Install the 5/8-18 male outlet on the regulator to the proper 5/8-18 female [...]

  • Page 31

    Maintenance .................................................................................................................... ......Section D Safety Precautions ......................................................................................................................D-2 Routine and Periodic Maintenance ...............................[...]

  • Page 32

    SAFETY PRECAUTIONS ELECTRIC SHOCK can kill. • Only Qualified personnel should perform this maintenance. • T urn the input power OFF at the disconnect switch or fuse box before working on this equipment. • Do not touch electrically hot parts. ROUTINE AND PERIODIC MAINTENANCE 1. Disconnect input AC power supply lines to the machine before perfo[...]

  • Page 33

    D-3 D-3 MAINTENANCE PO WER W A VE 455/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 1 7 7 7 3 4 6 5 2 2 2 FIGURE D .1 – MAIN ASSEMBL Y (EXPLODED VIEW) 1. CASE FRONT ASSEMBL Y 2. TRANSFORMER AND OUTPUT RECTIFIER ASSEMBL Y[...]

  • Page 34

    D-4 D-4 NO TES PO WER W A VE 455/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[...]

  • Page 35

    Theory of Operation ............................................................................................................ .Section E General Description ....................................................................................................................E-2 Input V oltage and Precharge .........................................[...]

  • Page 36

    GENERAL DESCRIPTION The Power W ave 455/R power source is designed to be a part of a modular , multi-process welding system. It is a high performance, digitally controlled inverter welding power source capable of complex, high-speed waveform control. Depending upon configuration, it can support constant current, constant voltage, surface tension tr[...]

  • Page 37

    INPUT V OL T A GE AND PRECHARGE The Power W ave 455/R can be connected for a variety of three-phase input voltages. Refer to Figure E.2. The initial input power is applied to the Power W ave 455/R through a line switch located on the front of the machine. T wo phases of the three-phase input power are applied to the Input Board and both auxiliary t[...]

  • Page 38

    SWITCH BO ARDS AND MAIN TRANSFORMER There are two switch boards in the Power W ave 455/R machine. Each contains an input capacitor and insu- lated gate bipolar transistor (IGBT) switching circuitry . Refer to Figure E.3. When the machine reconnect switches are configured for a lower input voltage (below 300V AC), the input capacitors are connected [...]

  • Page 39

    DC BUS BO ARD , PO WER BO ARD , FEED HEAD BO ARD, GA TEW A Y BO ARD AND V OL T A GE SENSE BO ARD The DC Bus Board receives approximately 65VDC from the Bus Board rectifier . The DC Bus Board regu- lates that 65VDC to a +40VDC supply . This regulated 40VDC is applied to the Feed Head Board, the Power Board, and the wire feeder receptacle. The switch[...]

  • Page 40

    E-6 E-6 THEOR Y OF OPERA TION PO WER W A VE 455/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 FIGURE E.5 – PO WER W A VE 455/R COMMUNICA TIONS Arc Link A A r r c c L L i i n n k k Device Net D D e e v v i i c c e e N N e[...]

  • Page 41

    CONTR OL BO ARD The Control Board performs the primary interfacing functions to establish and maintain output control of the Power W ave 455R machine. The function generator and weld files exist within the Control Board hardware and software. Digital command signals and feedback information is received and processed at the Control Board. Software w[...]

  • Page 42

    OUTPUT RECTIFIER, OUTPUT CHOKE AND STT CHOPPER BO ARD The output rectifier receives the AC output from the main transformer secondary and rectifies it to a DC voltage level. The output choke is in series with the negative leg of the output rectifier and also in series with the welding load. Due to the current "smoothing" capability of the[...]

  • Page 43

    THERMAL PR O TECTION Three normally closed (NC) thermostats protect the machine from excessive operating temperatures. These thermostats are wired in series and are con- nected to the control board. One of the thermostats is located on the heat sink of the output rectifier , one on the DC bus, and one on the output choke. Excessive temperatures may[...]

  • Page 44

    GENERAL DESCRIPTION OF THE STT (SURF A CE TENSION TRANSFER) PR OCESS The STT process cannot be classified as either a con- stant current (CC) or a constant voltage (CV) applica- tion. The STT function produces current of a desired waveform to reduce spatter and fumes. The STT process is optimized for short-circuit GMA W welding only . E-10 E-10 THE[...]

  • Page 45

    INSULA TED GA TE BIPOLAR TRANSIST OR (IGBT) OPERA TION An IGBT is a type of transistor . IGBT s are semicon- ductors well suited for high frequency switching and high current applications. Drawing A shows an IGBT in a passive mode. There is no gate signal, zero volts relative to the source, and therefore, no current flow . The drain terminal of the[...]

  • Page 46

    PULSE WIDTH MODULA TION The term PULSE WIDTH MODULA TION (PWM) is used to describe how much time is devoted to conduc- tion in the positive and negative portions of the cycle. Changing the pulse width is known as MODULA TION. Pulse Width Modulation is the varying of the pulse width over the allowed range of a cycle to affect the output of the machi[...]

  • Page 47

    T roubleshooting & Repair ...................................................................................................Section F How to Use T roubleshooting Guide ...........................................................................................F-2 PC Board T roubleshooting Procedures .............................................[...]

  • Page 48

    This T roubleshooting Guide is provided to help you locate and repair possible machine malfunc- tions. Simply follow the three-step procedure listed below . Step 1. LOCA TE PROBLEM (SYMPT OM). Look under the column labeled “ PROBLEM ” (SYMP- TOMS). This column describes possible symp- toms that the machine may exhibit. Find the list- ing that b[...]

  • Page 49

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

  • Page 50

    Observe Safety Guidelines TROUBLESHOO TING GUIDE detailed in the beginning of this manual. CA UTION If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely , contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-800-833-9353. PROBLEMS[...]

  • Page 51

    TROUBLESHOO TING GUIDE Obser ve Safety Guidelines detailed in the beginning of this manual. CA UTION If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely , contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-800-833-9353. PROBLEM[...]

  • Page 52

    Observe Safety Guidelines TROUBLESHOO TING GUIDE detailed in the beginning of this manual. CA UTION If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely , contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-800-833-9353. PROBLEMS[...]

  • Page 53

    TROUBLESHOO TING GUIDE Obser ve Safety Guidelines detailed in the beginning of this manual. CA UTION If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely , contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-800-833-9353. PROBLEM[...]

  • Page 54

    Observe Safety Guidelines TROUBLESHOO TING GUIDE detailed in the beginning of this manual. CA UTION If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely , contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-800-833-9353. PROBLEMS[...]

  • Page 55

    TROUBLESHOOTING & REP AIR F-9 F-9 PO WER W A VE 455/R INPUT FIL TER CAP A CIT OR DISCHARGE PROCEDURE W ARNING Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warr[...]

  • Page 56

    TROUBLESHOOTING & REP AIR F-10 F-10 PO WER W A VE 455/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 SWITCH BO ARD CAP ACITOR TERMINALS FIGURE F .1 – CAP A CIT OR DISCHARGE PROCEDURE INPUT FIL TER CAP A CIT OR DISCHAR[...]

  • Page 57

    TROUBLESHOOTING & REP AIR F-11 F-11 PO WER W A VE 455/R SWITCH BO ARD TEST W ARNING Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty . For your safety and[...]

  • Page 58

    TROUBLESHOOTING & REP AIR F-12 F-12 PO WER W A VE 455/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 19C 19D RECONNECT SWITCHES FIGURE F .2 – RECONNECT SWITCHES SWITCH BO ARD TEST (CONTINUED) TEST PROCEDURE 1. Remove [...]

  • Page 59

    TROUBLESHOOTING & REP AIR F-13 F-13 PO WER W A VE 455/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 SWITCH BO ARD 1 1/12 OR 15/16 13/14 OR 17/18 -20 +19 FIGURE F .3 – SWITCH BO ARD TEST POINTS SWITCH BO ARD TEST (CON[...]

  • Page 60

    TROUBLESHOOTING & REP AIR F-14 F-14 PO WER W A VE 455/R INPUT RECTIFIER TEST W ARNING Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty . For your safety a[...]

  • Page 61

    TROUBLESHOOTING & REP AIR F-15 F-15 PO WER W A VE 455/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 NEG (-) POS (+) A B C INPUT RECTIFIER FIGURE F .4 – INPUT RECTIFIER TEST INPUT RECTIFIER TEST (CONTINUED) TEST PROCE[...]

  • Page 62

    TROUBLESHOOTING & REP AIR F-16 F-16 PO WER W A VE 455/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 INPUT RECTIFIER TEST (CONTINUED) 6. Use the analog ohmmeter to perform the tests detailed in T able F .2. 7. If the in[...]

  • Page 63

    TROUBLESHOOTING & REP AIR F-17 F-17 PO WER W A VE 455/R INPUT CONT A CT OR TEST W ARNING Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty . For your safet[...]

  • Page 64

    TROUBLESHOOTING & REP AIR F-18 F-18 PO WER W A VE 455/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 INPUT CONT ACTOR 601 X4 FIGURE F .5 – INPUT CONT ACT OR COIL INPUT CONT A CT OR TEST (CONTINUED) TEST PROCEDURE 1. R[...]

  • Page 65

    TROUBLESHOOTING & REP AIR F-19 F-19 PO WER W A VE 455/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 L3 L2 L1 T3 T2 T1 FIGURE F .6 – INPUT CONT ACT OR TEST POINTS INPUT CONT A CT OR TEST (CONTINUED) 5. With the input [...]

  • Page 66

    TROUBLESHOOTING & REP AIR F-20 F-20 PO WER W A VE 455/R DC BUS PO WER SUPPL Y PC BO ARD TEST W ARNING Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty . F[...]

  • Page 67

    TROUBLESHOOTING & REP AIR F-21 F-21 PO WER W A VE 455/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 DC BUS PO WER SUPPL Y PC BO ARD CAP ACITOR C3 CA UTION! J47 J46 J46 J47 3 4 5 6 7 8 LED 1 2 3 4 1 2 FIGURE F .7 – DC[...]

  • Page 68

    TROUBLESHOOTING & REP AIR F-22 F-22 PO WER W A VE 455/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 DC BUS PO WER SUPPL Y PC BO ARD TEST (CONTINUED) 6. Check the DC Bus Power Supply PC Board input and output voltages a[...]

  • Page 69

    TROUBLESHOOTING & REP AIR F-23 F-23 PO WER W A VE 455/R PO WER BO ARD TEST W ARNING Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty . For your safety and[...]

  • Page 70

    TROUBLESHOOTING & REP AIR F-24 F-24 PO WER W A VE 455/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 J42 J41 J43 4 5 6 3 4 7 8 9 10 1 1 12 J42 J41 J43 1 2 3 1 2 1 2 3 4 5 6 FIGURE F .8 – PO WER BO ARD TEST PO WER BO A[...]

  • Page 71

    POWER BOARD CONNECTOR PLUG J41 POWER BOARD CONNECTOR PLUG J42 POWER BOARD CONNECTOR PLUG J42 POWER BOARD CONNECTOR PLUG J42 POWER BOARD CONNECTOR PLUG J43 POWER BOARD CONNECTOR PLUG J43 POWER BOARD CONNECTOR PLUG J43 POWER BOARD CONNECTOR PLUG J41 POWER BOARD CONNECTOR PLUG J43 POWER BOARD CONNECTOR PLUG J43 CHECK 40 VDC INPUT FROM DC BUS BOARD CHE[...]

  • Page 72

    TROUBLESHOOTING & REP AIR F-26 F-26 PO WER W A VE 455/R INPUT BOARD TEST W ARNING Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty . For your safety and t[...]

  • Page 73

    TROUBLESHOOTING & REP AIR F-27 F-27 PO WER W A VE 455/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 INPUT CONT A CTOR 601 X4 J60 J61 6 7 8 9 10 J61 1 2 3 4 5 6 7 8 1 2 3 4 5 J60 FIGURE F .9 – INPUT CONT ACT OR CR1 IN[...]

  • Page 74

    TROUBLESHOOTING & REP AIR F-28 F-28 PO WER W A VE 455/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 INPUT BOARD TEST (CONTINUED) 6. Remove input power to the Power W ave 455/R. If any of the voltages are low or not pre[...]

  • Page 75

    TROUBLESHOOTING & REP AIR F-29 F-29 PO WER W A VE 455/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 T ABLE F .5 – INPUT BO ARD V OL T A GE CHECKS INPUT BOARD TEST (CONTINUED) TEST POINTS PLUG J61 PIN 8 (H1D) TO PLUG [...]

  • Page 76

    TROUBLESHOOTING & REP AIR F-30 F-30 PO WER W A VE 455/R STT CHOPPER BO ARD TEST W ARNING Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty . For your safet[...]

  • Page 77

    TROUBLESHOOTING & REP AIR F-31 F-31 PO WER W A VE 455/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 J7 9 10 1 1 12 13 14 15 16 1 2 3 4 5 6 7 8 J7 4W 4R J43 7 8 9 10 1 1 12 J43 1 2 3 4 5 6 346 345 STT OUTPUT TERMINAL PO[...]

  • Page 78

    TROUBLESHOOTING & REP AIR F-32 F-32 PO WER W A VE 455/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 STT CHOPPER BO ARD TEST (CONTINUED) 4. Carefully apply input power to the Power W ave 455/R. ELECTRIC SHOCK can kill. [...]

  • Page 79

    TROUBLESHOOTING & REP AIR F-33 F-33 PO WER W A VE 455/R PO WER W A VE CURRENT TRANSDUCER TEST W ARNING Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty . [...]

  • Page 80

    TROUBLESHOOTING & REP AIR F-34 F-34 PO WER W A VE 455/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 J8 216 21 1 212 213 P91 CURRENT TRANSDUCER 1234 CONTROL BO ARD J8 5 6 7 8 1 2 3 4 FIGURE F .11 – PO WER W A VE CURRE[...]

  • Page 81

    TROUBLESHOOTING & REP AIR F-35 F-35 PO WER W A VE 455/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 FIGURE F .12 – RECEPT ACLE S7 TRIGGERED PO WER W A VE CURRENT TRANSDUCER TEST (CONTINUED) RECEPT A CLE S7 STT POWER [...]

  • Page 82

    TROUBLESHOOTING & REP AIR F-36 F-36 PO WER W A VE 455/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 T ABLE F .6 - CURRENT FEEDBA CK A T V ARIOUS OUTPUT LO ADS PO WER W A VE CURRENT TRANSDUCER TEST (CONTINUED) 8. If for[...]

  • Page 83

    TROUBLESHOOTING & REP AIR F-37 F-37 PO WER W A VE 455/R STT CURRENT TRANSDUCER TEST W ARNING Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty . For your s[...]

  • Page 84

    TROUBLESHOOTING & REP AIR F-38 F-38 PO WER W A VE 455/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 J8 81 1 813 CURRENT TRANSDUCER CONTROL BO ARD 816 812 P90 1234 J8 5 6 7 8 1 2 3 4 FIGURE F .13 – STT CURRENT TRANSDU[...]

  • Page 85

    TROUBLESHOOTING & REP AIR F-39 F-39 PO WER W A VE 455/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 RECEPT A CLE S7 STT POWER WAV E FIGURE F .14 – RECEPT ACLE S7 TRIGGERED STT CURRENT TRANSDUCER TEST (CONTINUED) 5. T[...]

  • Page 86

    TROUBLESHOOTING & REP AIR F-40 F-40 PO WER W A VE 455/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 STT CURRENT TRANSDUCER TEST (CONTINUED) 8. If for any reason the machine cannot be loaded to 50 amps, T able F .6 show[...]

  • Page 87

    TROUBLESHOOTING & REP AIR F-41 F-41 PO WER W A VE 455/R OUTPUT RECTIFIER TEST W ARNING Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty . For your safety [...]

  • Page 88

    TROUBLESHOOTING & REP AIR F-42 F-42 PO WER W A VE 455/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 STT OUTPUT TERMINAL POSITIVE (+) OUTPUT TERMINAL NEGA TIVE (-) OUTPUT TERMINAL POWERW AVE 455/R I ON O OFF FIGURE F .1[...]

  • Page 89

    TROUBLESHOOTING & REP AIR F-43 F-43 PO WER W A VE 455/R A UXILIAR Y TRANSFORMER NO . 1 TEST W ARNING Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty . Fo[...]

  • Page 90

    TROUBLESHOOTING & REP AIR F-44 F-44 PO WER W A VE 455/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 INPUT CONT ACTOR 601 X4 F AN MOTOR LEADS X3 X5 PO WER BO ARD RECTIFIER BRIDGE X1 X2 + - FIGURE F .16 – A UXILIAR Y T[...]

  • Page 91

    TROUBLESHOOTING & REP AIR F-45 F-45 PO WER W A VE 455/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 T ABLE F .7 – SECONDAR Y V OL T A GES A UXILIAR Y TRANSFORMER NO . 1 TEST (CONTINUED) 7. Carefully apply the correct[...]

  • Page 92

    TROUBLESHOOTING & REP AIR F-46 F-46 PO WER W A VE 455/R A UXILIAR Y TRANSFORMER NO . 2 TEST W ARNING Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty . Fo[...]

  • Page 93

    TROUBLESHOOTING & REP AIR F-47 F-47 PO WER W A VE 455/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 P50 P52 4 5 6 3 4 1 2 3 1 2 H4 H3 H1 H5 H6 H2 33A 350 352 VIEWED FROM TRANSFORMER LEAD END VIEWED FROM TRANSFORMER LEA[...]

  • Page 94

    TROUBLESHOOTING & REP AIR F-48 F-48 PO WER W A VE 455/R INPUT RECTIFIER REMO V AL AND REPLA CEMENT W ARNING Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warran[...]

  • Page 95

    TROUBLESHOOTING & REP AIR F-49 F-49 PO WER W A VE 455/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 NEG (-) POS (+) A B C INPUT RECTIFIER FIGURE F .18 – INPUT RECTIFIER REMO V AL AND REPLACEMENT INPUT RECTIFIER REMO [...]

  • Page 96

    TROUBLESHOOTING & REP AIR F-50 F-50 PO WER W A VE 455/R INPUT CONT A CT OR REMO V AL AND REPLA CEMENT W ARNING Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory war[...]

  • Page 97

    TROUBLESHOOTING & REP AIR F-51 F-51 PO WER W A VE 455/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 INPUT CONT ACTOR 601 X4 FIGURE F .19 – INPUT CONT ACT OR REMO V AL AND REPLA CEMENT INPUT CONT A CT OR REMO V AL AND[...]

  • Page 98

    TROUBLESHOOTING & REP AIR F-52 F-52 PO WER W A VE 455/R A UXILIAR Y TRANSFORMER NO . 1 REMO V AL AND REPLA CEMENT PROCEDURE W ARNING Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will inval[...]

  • Page 99

    TROUBLESHOOTING & REP AIR F-53 F-53 PO WER W A VE 455/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 INPUT CONT ACTOR 601 X4 F AN MOTOR LEADS X3 X5 PO WER BO ARD RECTIFIER BRIDGE X1 X2 + - RECONNECT TERMINALS CB4 H1 H2 [...]

  • Page 100

    TROUBLESHOOTING & REP AIR F-54 F-54 PO WER W A VE 455/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 A UXILIAR Y TRANSFORMER NO . 1 REMO V AL AND REPLA CEMENT PROCEDURE (CONTINUED) 6. Remove leads X1 and X2 from the pow[...]

  • Page 101

    TROUBLESHOOTING & REP AIR F-55 F-55 PO WER W A VE 455/R A UXILIAR Y TRANSFORMER NO . 2 REMO V AL AND REPLA CEMENT PROCEDURE W ARNING Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will inval[...]

  • Page 102

    TROUBLESHOOTING & REP AIR F-56 F-56 PO WER W A VE 455/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 INPUT CONT ACTOR 601 X4 CB4 CIRCUIT BREAKER & 1 15V RECEPT A CLE LEADS 33/32 P50 P52 FIGURE F .21 – A UXILIAR Y [...]

  • Page 103

    TROUBLESHOOTING & REP AIR F-57 F-57 PO WER W A VE 455/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 A UXILIAR Y TRANSFORMER NO . 2 REMO V AL AND REPLA CEMENT PROCEDURE (CONTINUED) REPLA CEMENT PROCEDURE 1. Carefully pl[...]

  • Page 104

    TROUBLESHOOTING & REP AIR F-58 F-58 PO WER W A VE 455/R CONTR OL, FEED HEAD, OR V OL T A GE SENSE PC BO ARD REMO V AL AND REPLA CEMENT W ARNING Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and[...]

  • Page 105

    TROUBLESHOOTING & REP AIR F-59 F-59 PO WER W A VE 455/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 COMP ARTMENT CO VER CONTROL BO ARD PO WER BO ARD FIGURE F .22 – CONTROL OR FEED HEAD BO ARD REMO V AL AND REPLACEMEN[...]

  • Page 106

    TROUBLESHOOTING & REP AIR F-60 F-60 PO WER W A VE 455/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 CONTR OL, FEED HEAD, OR V OL T A GE SENSE PC BO ARD REMO V AL AND REPLA CEMENT (CONTINUED) 9. T ilt back the rear of t[...]

  • Page 107

    TROUBLESHOOTING & REP AIR F-61 F-61 PO WER W A VE 455/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 3. Secure the rear of the control box in place using two screws and the 3/8 ” nut driver . 4. Press the V oltage Sen[...]

  • Page 108

    TROUBLESHOOTING & REP AIR F-62 F-62 PO WER W A VE 455/R GA TEW A Y PC BO ARD REMO V AL AND REPLA CEMENT W ARNING Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory w[...]

  • Page 109

    TROUBLESHOOTING & REP AIR F-63 F-63 PO WER W A VE 455/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 PHILLIPS SCREW DEVICENET/ GA TEW A Y BO ARD (LOCA TED BEHIND FRONT CO VER) FIGURE F .24 – GA TEW A Y BO ARD REMO V A[...]

  • Page 110

    TROUBLESHOOTING & REP AIR F-64 F-64 PO WER W A VE 455/R STT CURRENT TRANSDUCER REMO V AL AND REPLA CEMENT W ARNING Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory[...]

  • Page 111

    TROUBLESHOOTING & REP AIR F-65 F-65 PO WER W A VE 455/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 CURRENT TRANSDUCER P90 1234 RESISTOR ASSEMBL Y STT OUTPUT TERMINAL (TOP RIGHT) FIGURE F .25 – STT CURRENT TRANSDUCER[...]

  • Page 112

    TROUBLESHOOTING & REP AIR F-66 F-66 PO WER W A VE 455/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 STT CURRENT TRANSDUCER REMO V AL AND REPLA CEMENT (CONTINUED) 6. With the 5/16 ” open end wrench, remove the small s[...]

  • Page 113

    TROUBLESHOOTING & REP AIR F-67 F-67 PO WER W A VE 455/R PO WER W A VE CURRENT TRANSDUCER REMO V AL AND REPLA CEMENT W ARNING Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate yo[...]

  • Page 114

    TROUBLESHOOTING & REP AIR F-68 F-68 PO WER W A VE 455/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 CURRENT TRANSDUCER HEA VY LEAD BOL TED CONNECTION (BEHIND CASE FRONT) FIGURE F .26 – PO WER W A VE CURRENT TRANSDUCE[...]

  • Page 115

    TROUBLESHOOTING & REP AIR F-69 F-69 PO WER W A VE 455/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 PO WER W A VE CURRENT TRANSDUCER REMO V AL AND REPLA CEMENT (CONTINUED) 9. Using the phillips head screw driver , remo[...]

  • Page 116

    TROUBLESHOOTING & REP AIR F-70 F-70 PO WER W A VE 455/R OUTPUT RECTIFIER, STT CHOPPER BO ARD AND RECTIFIER MODULE REMO V AL AND REPLA CEMENT W ARNING Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operat[...]

  • Page 117

    TROUBLESHOOTING & REP AIR F-71 F-71 PO WER W A VE 455/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 TRANSFORMER LEADS RECTIFIER MODULE POSITIVE OUTPUT LEAD HEA TSINK MOUNT BOL TS (4X) RECTIFIER THERMOST A T (LEADS 291 [...]

  • Page 118

    TROUBLESHOOTING & REP AIR F-72 F-72 PO WER W A VE 455/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 OUTPUT RECTIFIER, STT CHOPPER BO ARD AND RECTIFIER MODULE REMO V AL AND REPLA CEMENT (CONTINUED) 7. Using the needle-n[...]

  • Page 119

    TROUBLESHOOTING & REP AIR F-73 F-73 PO WER W A VE 455/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 OUTPUT RECTIFIER, STT CHOPPER BO ARD AND RECTIFIER MODULE REMO V AL AND REPLA CEMENT (CONTINUED) RECTIFIER MODULE REMO[...]

  • Page 120

    TROUBLESHOOTING & REP AIR F-74 F-74 PO WER W A VE 455/R SWITCH BO ARD AND FIL TER CAP A CIT OR REMO V AL AND REPLA CEMENT W ARNING Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalid[...]

  • Page 121

    TROUBLESHOOTING & REP AIR F-75 F-75 PO WER W A VE 455/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 13/14 OR 17/18 NYLON SCREW (2X) 19+ 20- 1 1/12 OR 15/16 SWITCH BO ARD MOLEX PLUG MOUNTING SCREW (4X) FIGURE F .28 – [...]

  • Page 122

    TROUBLESHOOTING & REP AIR F-76 F-76 PO WER W A VE 455/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 SWITCH BO ARD AND FIL TER CAP A CIT OR REMO V AL AND REPLA CEMENT (CONTINUED) 7. Using the 7/16 ” wrench, remove lea[...]

  • Page 123

    Retest a machine: If it is rejected under test for any reason that requires you to remove any part which could affect the machine ’ s electrical characteristics. OR If you repair or replace any electrical components. INPUT IDLE AMPS AND W A TTS MAXIMUM OUTPUT V OL T A GES TROUBLESHOOTING & REP AIR F-77 F-77 PO WER W A VE 455/R Return to Secti[...]

  • Page 124

    F-78 F-78 NO TES PO WER W A VE 455/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[...]

  • Page 125

    Section G-1 Section G-1 T ABLE OF CONTENTS - ELECTRICAL DIA GRAMS SECTION - PO WER W A VE 455/R Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Electrical Diagrams .............................................................................................................. Section G Wiring Diagram (Code 10675) .[...]

  • Page 126

    ELECTRICAL DIAGRAMS G-2 POWER W A VE 455/R WIRING DIAGRAM - POWER W A VE 455/R CODE 10675 - TO J9 202 WORK 202A TO R1 TO TP6 TO TP3 TO CB1 S1 WIR E FEEDER RECEPTA CLE J47 + ELECT RODE 223 221 206A R3 C8 TO D5 289D R2 2 Ω 288C 288D 289E 288E TM J1 4 5 TO 3R 3R 3W 238 15 5 J10 TO SSR RECT THERM 223 222 CHOPPER BD SEC (BOTTOM LEFT) PO WER BD RECTIFI[...]

  • Page 127

    ELECTRICAL DIAGRAMS G-3 POWER W AVE 455/R WIRING DIAGRAM- POWER W A VE 455/R CODE 10676 - TO J9 202 WORK 202A TO R1 TO TP6 TO TP3 TO CB1 S1 WIR E FEEDER RECEPTA CLE J47 + ELECT RODE 223 221 206A R3 C8 TO D5 289D R2 2 Ω 288C 288D 289E 288E TM J1 4 5 TO 3R 3R 3W 238 15 5 J10 TO SSR RECT THERM 223 222 CHOPPER BD SEC (BOTTOM LEFT) PO WER BD RECTIFIER[...]

  • Page 128

    Return to Section TOC Retur n 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 AVE 455/R SCHEMA TIC - COMPLETE MACHINE 10675 MANUFAC TURING TOLE RANCE PER E2056 UNLESS OTHERWISE S PECIFIED TOLERANCE SCALE: DO NOT SCALE THI S[...]

  • Page 129

    ELECTRICAL DIAGRAMS G-5 POWER W AVE 455/R SCHEMA TIC-COMPLETE MACHINE CODE 10676 MANUFAC TURING TOLE RANCE PER E2056 UNLESS OTHERW ISE SPECIFIED TOLERANCE SCALE: DO NOT SCALE THI S DRAWING ON 3 PLACE DECIMALS IS ± .002 THIS SH EET CONTAINS PROPRIETA RY INFORMATION OWNED BY THE LINCOLN ELECTRIC COMPANY AND IS NOT TO BE REPRODUCED, DISCLOSED OR USED[...]

  • Page 130

    Return to Section TOC Retur n 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 AVE 455/R SCHEMA TIC - CHOPPER PC BOARD 100V 100p C15 X3 9 8 10 100V 100p C16 475 R6 D7 50V 820p C17 301 R19 301 R17 4.7 5K R23 301 R21 301 R18 3[...]

  • Page 131

    Return to Section TOC Retur n 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-7 POWER W AVE 455/R PC BOARD ASSEMBL Y -CHOPPER S O L I D E D G E EN-170 MANUFAC TURING TOLE RANCE PER E2056 UNLESS OTHERWISE S PECIFIED TOLERANCE SCALE: D[...]

  • Page 132

    ELECTRICAL DIAGRAMS G-8 POWER W AVE 455/R SCHEMA TIC-DEVICENET/GATEW A Y PC BOARD G-8 NOTE: This diagram is for reference only . It may not be accurate for all machines covered by this manual. Return to Section TOC Retur n to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Retur[...]

  • Page 133

    Return to Section TOC Retur n 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 AVE 455/R PC BOARD ASSEMBL Y-DEVICENET/GA TEW A Y . L11046-1 11-3-2000A UN LESS OTHERWISE SPECIFIED: RESISTANCE = OHMS . (5.84) (6.34) I TEM PART[...]

  • Page 134

    ELECTRICAL DIAGRAMS G-10 POWER W AVE 455/R SCHEMA TIC - CONTROL PC BOARD SOLID EDGE MANUFACTURING TOLE RANCE PER E2056 UNLESS OTHERWIS E SPECIFIED TOL ER ANCE SC ALE: DO NOT SC ALE THI S D RAWING ON 3 PLACE DECIMALS IS ± .002 THI S SH EE T C ON TAI NS PRO PR I ETARY I NFORM AT I ON O WNE D BY T HE LINCOL N ELECTRIC COMPAN Y AND I S NOT TO BE RE PR[...]

  • Page 135

    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[...]

  • Page 136

    Return to Section TOC Retur n 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-12 POWER W AVE 455/R SCHEMA TIC - DIGITIAL POWER SUPPL Y PC BOARD .1 C53 Vfb2 Vref 1 100K R29 CNY17-3 OCI2 42 1 6 5 .5W 27V DZ2 VFB CS COMP RT/CT VCC OUT V[...]

  • Page 137

    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[...]

  • Page 138

    ELECTRICAL DIAGRAMS G-14 POWER W AVE 455/R SCHEMA TIC - FEEDHEAD PC BOARD #1 3823-1C1 /1 07/17/2000 LRW COMMON DIGI TAL CO NTROLS FEEDHEA D PC BOA RD SCHEMATI C 11 -3-2000A XA 1 OF 3 G-14 NOTE: This diagram is for reference only . It may not be accurate for all machines covered by this manual. Return to Section TOC Retur n to Section TOC Return to [...]

  • Page 139

    ELECTRICAL DIAGRAMS G-15 POWER W AVE 455/R SCHEMA TIC- FEEDHEAD PC BOARD #2 3823-1C1 /2 07/17/2000 LRW COMMON DIGITAL CONTROLS FEEDHEA D PC BOA RD SCHEMATI C 11-3-2000A XA TPD TPE 2 OF 3 G-15 NOTE: This diagram is for reference only . It may not be accurate for all machines covered by this manual. Return to Section TOC Retur n to Section TOC Return[...]

  • Page 140

    ELECTRICAL DIAGRAMS G-16 POWER W AVE 455/R SCHEMA TIC- FEEDHEAD PC BOARD #3 3823-1C1 /3 07/17/2000 LRW COMMON DIGITAL CONTROLS FEEDHEA D PC BOA RD SCHEMATI C 11-3-2000A XA 3 OF 3 G-16 NOTE: This diagram is for reference only . It may not be accurate for all machines covered by this manual. Return to Section TOC Retur n to Section TOC Return to Sect[...]

  • Page 141

    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[...]

  • Page 142

    Return to Section TOC Retur n 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 AVE 455/R SCHEMA TIC - INPUT PC BOARD FILENAME: M19528-1AA J60 2 J60 4 J61 8 10W 100 R7 10W 100 R10 10W 100 R2 J61 6 10W 100 R8 10W 100 R1 250J [...]

  • Page 143

    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[...]

  • Page 144

    Return to Section TOC Retur n 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 SCHEMA TIC -SWITCH PC BOARD G-20 NOTE: This diagram is for reference only . It may not be accurate for all machines covered by this manual.[...]

  • Page 145

    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[...]

  • Page 146

    Return to Section TOC Retur n 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-22 POWER W AVE 455/R SCHEMA TIC - VOLT AGE SENSE PC BOARD G-22 NOTE: This diagram is for reference only . It may not be accurate for all machines covered b[...]

  • Page 147

    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[...]

  • Page 148

    Return to Section TOC Retur n 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-24 POWER W AVE 455/R SCHEMA TIC - 40 VDC BUS PC BOARD G-24 NOTE: This diagram is for reference only . It may not be accurate for all machines covered by th[...]

  • Page 149

    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[...]

  • Page 150

    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[...]