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Lincoln Electric POWER WAVE SVM173-A manual

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Table of contents for the manual

  • Page 1

    SVM173-A April, 2007 Safety Depends on Y ou Lincoln arc welding and cutting equipment is designed and built with saf ety in mind. How ev er , your o v erall saf ety can be in- creased by proper installation . . . and thoughtful operation on your part. DO NOT INST ALL, OPERA TE OR REP AIR THIS EQUIPMENT WITHOUT READING THIS MANUAL AND THE SAFETY PRE[...]

  • Page 2

    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[...]

  • Page 3

    Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC 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. Use suitable c[...]

  • Page 4

    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[...]

  • Page 5

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

  • Page 6

    v v - MASTER T ABLE OF CONTENTS FOR ALL SECTIONS - POWER W A VE 455M/MSTT Page Safety .................................................................................................................................................i-iv Installation .....................................................................................................[...]

  • Page 7

    Installation ................................................................................................................... ..........Section A T echnical Specifications....................................................................................................... A-2, A-3 Safety Precautions ............................................[...]

  • Page 8

    A-2 INST ALLA TION POWER W A VE 455M/MSTT A-2 TECHNICAL SPECIFICA TIONS - POWER W A VE 455M (K2202-1, K2202-3) OUTPUT RECOMMENDED INPUT WIRE AND FUSE SIZES FOR MAXIMUM RA TED OUTPUT PHYSICAL DIMENSIONS TEMPERA TURE RANGES INPUT A T RA TED OUTPUT - THREE PHASE ONL Y INPUT VOL TS- FREQUENCY 208/230/460/575V - 60HZ. 200/220/440/575V - 50HZ. OPEN CIRCU[...]

  • Page 9

    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-3 INST ALLA TION POWER W A VE 455M/MSTT A-3 TECHNICAL SPECIFICA TIONS - POWER W A VE 455M/STT (K2203-1) OUTPUT RECOMMENDED INPUT WIRE AND FUSE SIZES FOR MAXIMUM RA TED OUTPUT P[...]

  • Page 10

    SAFETY PRECAUTIONS Read this entire installation section before you 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 w[...]

  • 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 POWER W A VE 455M/MSTT 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 VOL T AGE CHANGE OVER (FOR MUL TIPLE INPUT VOL T AGE MACHINES ONL Y) W elders are shipped connected for the highest input volt[...]

  • 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

    VOL T AGE 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 drama[...]

  • Page 15

    WORK VOL T AGE 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, ref[...]

  • 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 BOARD DIP SWITCH, BANK (S2): switch 1,2 = configure the baud rate for DeviceNET Prior to S24958-6 software switch 1 switch 2 baud rate off of f ------- on off 125K off on 250K on on 500 S24958-6 and later software switch 1 switch 2 baud rate off of f 125K off on 250K on off 500K on on 500K Programmable value. Consult local Linc[...]

  • Page 18

    A-12 A-12 NOTES POWER W A VE 455M/MSTT 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 PRECAUTIONS Read this entire section of operating instructions before operating the machine. 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 ele[...]

  • Page 21

    B-3 B-3 OPERA TION POWER W A VE 455M/MSTT 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 POWER ON OFF HIGH TEMPERA TURE MACHINE ST A TUS CIRCUIT BREAKER WIRE FEEDER POSITIVE OUTPUT NEGA TIVE OUTPUT 3 PHASE INVERTER INPU[...]

  • 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 T ransfer and pulse welding modes. The Power W ave power source is designed to be used with the family of Power Feed wire feeders, oper[...]

  • Page 23

    RECOMMENDED PROCESSES 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 , GMA W-P , FCA W , GT A W and STT for a variety of materials, includi[...]

  • Page 24

    CASE FRONT 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. NOTE: T[...]

  • Page 25

    WELDING MODE DESCRIPTIONS CONST ANT VOL T AGE 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 automa[...]

  • 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 when[...]

  • Page 27

    STT WELDING The pictures illustrate the wave shape 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 t[...]

  • Page 28

    B-10 B-10 NOTES POWER W A VE 455M/MSTT 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 ACTOR 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 g[...]

  • 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 POWER W A VE 455M/MSTT 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[...]

  • Page 34

    D-4 D-4 NOTES POWER W A VE 455M/MSTT 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 Block Logic Diagram ...................................................................................................................E-1 General Description ...................................................[...]

  • Page 36

    GENERAL DESCRIPTION The Power W ave 455M/MSTT power source is designed to be a part of a modular , multi-process weld- ing system. It is a high performance, digitally con- trolled inverter welding power source capable of com- plex, high-speed waveform control. Depending upon configuration, it can support constant current, constant voltage, surface [...]

  • Page 37

    INPUT VOL T AGE AND PRECHARGE The Power W ave 455M 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 455M 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 trans[...]

  • Page 38

    SWITCH BOARDS AND MAIN TRANSFORMER There are two switch boards in the Power W ave 455M 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 in[...]

  • Page 39

    DC BUS BOARD, POWER BOARD, AND GA TEW A Y BOARD 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 switching power supplies on the Power Board sup- ply a [...]

  • Page 40

    E-6 E-6 THEOR Y OF OPERA TION POWER W A VE 455M/MSTT 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 – POWER 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[...]

  • Page 41

    CONTROL BOARD 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 wit[...]

  • Page 42

    OUTPUT RECTIFIER AND CHOKE The output rectifier receives the AC output from the main transformer secondary and rectifies it to a DC voltage level. Since the outuput choke is in series with the negative leg of hte output rectifier and also in series with the welding load, a filtered DC output is applied to the machine output terminals. Refer to Figu[...]

  • Page 43

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

  • Page 44

    GENERAL DESCRIPTION OF THE STT (SURF ACE TENSION TRANSFER) PROCESS 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 THEOR[...]

  • 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

    Tr oubleshooting & 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 (SYMPTOM). Look under the column labeled “PROBLEM” (SYMP- T OMS). This column describes possible symp- toms that the machine may exhibit. Find the list- ing that bes[...]

  • 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 TROUBLESHOOTING GUIDE 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 assistance befor e you proceed. Call 1-888-935-3877. PROB[...]

  • Page 51

    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 assistance befor e you proceed. Call 1-888-935-3877. PROB[...]

  • Page 52

    Observe Safety Guidelines TROUBLESHOOTING GUIDE 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 assistance befor e you proceed. Call 1-888-935-3877. PROB[...]

  • Page 53

    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 assistance befor e you proceed. Call 1-888-935-3877. PROB[...]

  • Page 54

    Observe Safety Guidelines TROUBLESHOOTING GUIDE 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 assistance befor e you proceed. Call 1-888-935-3877. PROB[...]

  • Page 55

    TROUBLESHOOTING & REP AIR F-9 F-9 POWER W A VE 455M/MSTT INPUT FIL TER CAP ACITOR 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 war[...]

  • Page 56

    TROUBLESHOOTING & REP AIR F-10 F-10 POWER W A VE 455M/MSTT 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 A CITOR TERMINALS FIGURE F .1 – CAP ACITOR DISCHARGE PROCEDURE INPUT FIL TER CAP ACITOR DISCHAR[...]

  • Page 57

    TROUBLESHOOTING & REP AIR F-11 F-11 POWER W A VE 455M/MSTT SWITCH 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 a[...]

  • Page 58

    TR OUBLESHOO TING & REP AIR F-12 F-12 POWER W A VE 455M/MSTT 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 BOARD TEST (CONTINUED) TEST PROCEDURE 1. Rem[...]

  • Page 59

    TR OUBLESHOO TING & REP AIR F-13 F-13 POWER W A VE 455M/MSTT 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 BOARD TEST POINTS SWITCH BOARD TEST ([...]

  • Page 60

    F-14 F-14 NOTES POWER W A VE 455M/MSTT 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 61

    TROUBLESHOOTING & REP AIR F-15 F-15 POWER W A VE 455M/MSTT 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 safet[...]

  • Page 62

    TR OUBLESHOO TING & REP AIR F-16 F-16 POWER W A VE 455M/MSTT 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 [...]

  • Page 63

    TROUBLESHOOTING & REP AIR F-17 F-17 POWER W A VE 455M/MSTT 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 .1. 7. If the[...]

  • Page 64

    F-18 F-18 NOTES POWER W A VE 455M/MSTT 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 65

    TROUBLESHOOTING & REP AIR F-19 F-19 POWER W A VE 455M/MSTT INPUT CONT ACTOR 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 safe[...]

  • Page 66

    TROUBLESHOOTING & REP AIR F-20 F-20 POWER W A VE 455M/MSTT 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 CT OR 601 X4 FIGURE F .5 – INPUT CONT ACTOR COIL INPUT CONT ACTOR TEST (CONTINUED) TEST PROCEDURE 1.[...]

  • Page 67

    TROUBLESHOOTING & REP AIR F-21 F-21 POWER W A VE 455M/MSTT 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 ACTOR TEST POINTS INPUT CONT ACTOR TEST (CONTINUED) 5. With the input [...]

  • Page 68

    F-22 F-22 NOTES POWER W A VE 455M/MSTT 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 69

    TROUBLESHOOTING & REP AIR F-23 F-23 POWER W A VE 455M/MSTT DC BUS POWER SUPPL Y PC 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 . [...]

  • Page 70

    TROUBLESHOOTING & REP AIR F-24 F-24 POWER W A VE 455M/MSTT 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 POWER SUPPL Y PC BOARD CAP ACITOR C3 CAUTION! J47 J46 J46 J47 3 4 5 6 7 8 LED 1 2 3 4 1 2 POWER BOARD FAN RE[...]

  • Page 71

    TROUBLESHOOTING & REP AIR F-25 F-25 POWER W A VE 455M/MSTT 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 POWER SUPPL Y PC BOARD TEST (CONTINUED) 6. Check the DC Bus Power Supply PC Board input and output voltages [...]

  • Page 72

    F-26 F-26 NOTES POWER W A VE 455M/MSTT 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 73

    TROUBLESHOOTING & REP AIR F-27 F-27 POWER W A VE 455M/MSTT POWER 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 an[...]

  • Page 74

    TROUBLESHOOTING & REP AIR F-28 F-28 POWER W A VE 455M/MSTT 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 – POWER BOARD TEST POWER BOAR[...]

  • Page 75

    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 76

    F-30 F-30 NOTES POWER W A VE 455M/MSTT 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 77

    TROUBLESHOOTING & REP AIR F-31 F-31 POWER W A VE 455M/MSTT 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 an[...]

  • Page 78

    TROUBLESHOOTING & REP AIR F-32 F-32 POWER W A VE 455M/MSTT 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 ACTOR CR1 [...]

  • Page 79

    TROUBLESHOOTING & REP AIR F-33 F-33 POWER W A VE 455M/MSTT 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 .4 – INPUT BOARD VOL T AGE CHECKS INPUT BOARD FUNCTION TEST (CONTINUED) TEST POINTS PLUG J61 PIN 8 (H1D)[...]

  • Page 80

    TROUBLESHOOTING & REP AIR F-34 F-34 POWER W A VE 455M/MSTT 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 455M. If any of the voltages are low or not p[...]

  • Page 81

    TROUBLESHOOTING & REP AIR F-35 F-35 POWER W A VE 455M/MSTT STT CHOPPER 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 saf[...]

  • Page 82

    TROUBLESHOOTING & REP AIR F-36 F-36 POWER W A VE 455M/MSTT 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[...]

  • Page 83

    TROUBLESHOOTING & REP AIR F-37 F-37 POWER W A VE 455M/MSTT 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 BOARD TEST (CONTINUED) 4. Carefully apply input power to the Power W ave 455M. ELECTRIC SHOCK can kill.[...]

  • Page 84

    F-38 F-38 NOTES POWER W A VE 455M/MSTT 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 85

    TROUBLESHOOTING & REP AIR F-39 F-39 POWER W A VE 455M/MSTT POWER 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 86

    TROUBLESHOOTING & REP AIR F-40 F-40 POWER W A VE 455M/MSTT 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 .1 1 – POWER W A VE CU[...]

  • Page 87

    TROUBLESHOOTING & REP AIR F-41 F-41 POWER W A VE 455M/MSTT 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 POWER W A VE CURRENT TRANSDUCER TEST (CONTINUED) RECEPT A CLE S7 STT POWE[...]

  • Page 88

    TROUBLESHOOTING & REP AIR F-42 F-42 POWER W A VE 455M/MSTT 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 - CURRENT FEEDBACK A T V ARIOUS OUTPUT LOADS POWER W A VE CURRENT TRANSDUCER TEST (CONTINUED) 8. If for[...]

  • Page 89

    TROUBLESHOOTING & REP AIR F-43 F-43 POWER W A VE 455M/MSTT 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 you[...]

  • Page 90

    TROUBLESHOOTING & REP AIR F-44 F-44 POWER W A VE 455M/MSTT 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 TRAN[...]

  • Page 91

    TROUBLESHOOTING & REP AIR F-45 F-45 POWER W A VE 455M/MSTT 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 WAVE FIGURE F .14 – RECEPT ACLE S7 TRIGGERED STT CURRENT TRANSDUCER TEST (CONTINUED) 5.[...]

  • Page 92

    TROUBLESHOOTING & REP AIR F-46 F-46 POWER W A VE 455M/MSTT 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 s[...]

  • Page 93

    TROUBLESHOOTING & REP AIR F-47 F-47 POWER W A VE 455M/MSTT 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 safe[...]

  • Page 94

    TROUBLESHOOTING & REP AIR F-48 F-48 POWER W A VE 455M/MSTT 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 A VE 455/R I ON O OFF FIGURE [...]

  • Page 95

    TROUBLESHOOTING & REP AIR F-49 F-49 POWER W A VE 455M/MSTT AUXILIAR 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 . F[...]

  • Page 96

    TROUBLESHOOTING & REP AIR F-50 F-50 POWER W A VE 455M/MSTT 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 F AN MOTOR LEADS X3 X5 PO WER BO ARD RECTIFIER BRIDGE X1 X2 + - FIGURE F .16 – AUXILIAR [...]

  • Page 97

    TROUBLESHOOTING & REP AIR F-51 F-51 POWER W A VE 455M/MSTT 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 – SECONDAR Y VOL T AGES AUXILIAR Y TRANSFORMER NO. 1 TEST (CONTINUED) 7. Carefully apply the correct [...]

  • Page 98

    F-52 F-52 NOTES POWER W A VE 455M/MSTT 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 99

    TROUBLESHOOTING & REP AIR F-53 F-53 POWER W A VE 455M/MSTT AUXILIAR 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 . F[...]

  • Page 100

    TROUBLESHOOTING & REP AIR F-54 F-54 POWER W A VE 455M/MSTT 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 5 3 4 3 1 2 H1 H6 33A 350 352 VIEWED FROM TRANSFORMER LEAD END VIEWED FROM TRANSFORMER LEAD SIDE FIGURE F .[...]

  • Page 101

    TROUBLESHOOTING & REP AIR F-55 F-55 POWER W A VE 455M/MSTT INPUT RECTIFIER REMOV AL AND REPLACEMENT 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 warra[...]

  • Page 102

    TR OUBLESHOO TING & REP AIR F-56 F-56 POWER W A VE 455M/MSTT 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 REMOV AL AND REPLACEMENT INPUT RECTIFIER R[...]

  • Page 103

    TROUBLESHOOTING & REP AIR F-57 F-57 POWER W A VE 455M/MSTT INPUT CONT ACTOR REMOV AL AND REPLACEMENT 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 104

    TROUBLESHOOTING & REP AIR F-58 F-58 POWER W A VE 455M/MSTT 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 FIGURE F .19 – INPUT CONT ACTOR REMOV AL AND REPLACEMENT INPUT CONT ACTOR REMOV AL AND R[...]

  • Page 105

    TROUBLESHOOTING & REP AIR F-59 F-59 POWER W A VE 455M/MSTT AUXILIAR Y TRANSFORMER NO. 1 REMOV AL AND REPLACEMENT 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 invali[...]

  • Page 106

    TROUBLESHOOTING & REP AIR F-60 F-60 POWER W A VE 455M/MSTT 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 F AN MOTOR LEADS X3 X5 PO WER BO ARD RECTIFIER BRIDGE X1 X2 + - RECONNECT TERMINALS CB4 H1[...]

  • Page 107

    TROUBLESHOOTING & REP AIR F-61 F-61 POWER W A VE 455M/MSTT 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 AUXILIAR Y TRANSFORMER NO. 1 REMOV AL AND REPLACEMENT PROCEDURE (CONTINUED) 6. Remove leads X1 and X2 from the powe[...]

  • Page 108

    F-62 F-62 NOTES POWER W A VE 455M/MSTT 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 109

    TROUBLESHOOTING & REP AIR F-63 F-63 POWER W A VE 455M/MSTT AUXILIAR Y TRANSFORMER NO. 2 REMOV AL AND REPLACEMENT 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 invali[...]

  • Page 110

    TROUBLESHOOTING & REP AIR F-64 F-64 POWER W A VE 455M/MSTT 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 CT OR 601 X4 CB4 CIRCUIT BREAKER & 1 15V RECEPT A CLE LEADS 33/32 P50 P52 FIGURE F .21 – AUXILIA[...]

  • Page 111

    TROUBLESHOOTING & REP AIR F-65 F-65 POWER W A VE 455M/MSTT 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 AUXILIAR Y TRANSFORMER NO. 2 REMOV AL AND REPLACEMENT PROCEDURE (CONTINUED) REPLACEMENT PROCEDURE 1. Carefully plac[...]

  • Page 112

    F-66 F-66 NOTES POWER W A VE 455M/MSTT 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 113

    TROUBLESHOOTING & REP AIR F-67 F-67 POWER W A VE 455M/MSTT CONTROL, FEED HEAD, OR VOL T AGE SENSE PC BOARD REMOV AL AND REPLACEMENT 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 wi[...]

  • Page 114

    TROUBLESHOOTING & REP AIR F-68 F-68 POWER W A VE 455M/MSTT 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 COVER CONTROL BOARD POWER BOARD DC BUS POWER BOARD FIGURE F .22 – CONTROL OR FEED HEAD BOARD REMOV A[...]

  • Page 115

    TROUBLESHOOTING & REP AIR F-69 F-69 POWER W A VE 455M/MSTT 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 CONTROL, FEED HEAD, OR VOL T AGE SENSE PC BOARD REMOV AL AND REPLACEMENT (CONTINUED) 9. T ilt back the rear of the [...]

  • Page 116

    TROUBLESHOOTING & REP AIR F-70 F-70 POWER W A VE 455M/MSTT 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 S[...]

  • Page 117

    TROUBLESHOOTING & REP AIR F-71 F-71 POWER W A VE 455M/MSTT GA TEW A Y PC BOARD REMOV AL AND REPLACEMENT 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 118

    TROUBLESHOOTING & REP AIR F-72 F-72 POWER W A VE 455M/MSTT 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 BOARD REMOV [...]

  • Page 119

    TROUBLESHOOTING & REP AIR F-73 F-73 POWER W A VE 455M/MSTT STT CURRENT TRANSDUCER REMOV AL AND REPLACEMENT 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 factor[...]

  • Page 120

    TROUBLESHOOTING & REP AIR F-74 F-74 POWER W A VE 455M/MSTT 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 TRANSDU[...]

  • Page 121

    TROUBLESHOOTING & REP AIR F-75 F-75 POWER W A VE 455M/MSTT 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 REMOV AL AND REPLACEMENT (CONTINUED) 6. With the 5/16” open end wrench, remove the small s[...]

  • Page 122

    F-76 F-76 NOTES POWER W A VE 455M/MSTT 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 123

    TROUBLESHOOTING & REP AIR F-77 F-77 POWER W A VE 455M/MSTT POWER W A VE CURRENT TRANSDUCER REMOV AL AND REPLACEMENT 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 124

    TROUBLESHOOTING & REP AIR F-78 F-78 POWER W A VE 455M/MSTT 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 – POWER W A VE CURRENT TRANSDU[...]

  • Page 125

    TROUBLESHOOTING & REP AIR F-79 F-79 POWER W A VE 455M/MSTT 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 CURRENT TRANSDUCER REMOV AL AND REPLACEMENT (CONTINUED) 9. Using the phillips head screw driver , remo[...]

  • Page 126

    F-80 F-80 NOTES POWER W A VE 455M/MSTT 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 127

    TROUBLESHOOTING & REP AIR F-81 F-81 POWER W A VE 455M/MSTT OUTPUT RECTIFIER, STT CHOPPER BOARD AND RECTIFIER MODULE REMOV AL AND REPLACEMENT 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 128

    TROUBLESHOOTING & REP AIR F-82 F-82 POWER W A VE 455M/MSTT 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 2[...]

  • Page 129

    TROUBLESHOOTING & REP AIR F-83 F-83 POWER W A VE 455M/MSTT 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 BOARD AND RECTIFIER MODULE REMOV AL AND REPLACEMENT (CONTINUED) 7. Using the needle-n[...]

  • Page 130

    TROUBLESHOOTING & REP AIR F-84 F-84 POWER W A VE 455M/MSTT 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 BOARD AND RECTIFIER MODULE REMOV AL AND REPLACEMENT (CONTINUED) RECTIFIER MODULE REMO[...]

  • Page 131

    TROUBLESHOOTING & REP AIR F-85 F-85 POWER W A VE 455M/MSTT SWITCH BOARD AND FIL TER CAP ACIT OR REMOV AL AND REPLACEMENT 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 invalida[...]

  • Page 132

    TROUBLESHOOTING & REP AIR F-86 F-86 POWER W A VE 455M/MSTT 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 133

    TROUBLESHOOTING & REP AIR F-87 F-87 POWER W A VE 455M/MSTT 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 BOARD AND FIL TER CAP ACIT OR REMOV AL AND REPLACEMENT (CONTINUED) 7. Using the 7/16” wrench, remove leads[...]

  • Page 134

    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 VOL T AGES TROUBLESHOOTING & REP AIR F-88 F-88 POWER W A VE 455M/MSTT Return to Secti[...]

  • Page 135

    Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Section G-1 Section G-1 T ABLE OF CONTENTS - ELECTRICAL DIAGRAMS SECTION - POWER W A VE 455M/MSTT Electrical Diagrams .............................................................................................................. Section G Wiring Diagram (Code 10942)[...]

  • Page 136

    ELECTRICAL DIAGRAMS G-2 G-2 WIRING DIAGRAM - ENTIRE MACHINE - CODE 10942 (G4212) NOTE: This diagram is for reference only . It may not be accurate for all machines covered by this manual. The wiring diagram specific to your code is pasted inside one of the enclosure panels of your machine. POWER W A VE 455M/MSTT Return to Section TOC Return to Sect[...]

  • Page 137

    ELECTRICAL DIAGRAMS G-3 G-3 WIRING DIAGRAM - ENTIRE MACHINE - CODES 10957 - 1 131 1 (G4420) NOTE: This diagram is for reference only . It may not be accurate for all machines covered by this manual. The wiring diagram specific to your code is pasted inside one of the enclosure panels of your machine. POWER W A VE 455M/MSTT Return to Section TOC Ret[...]

  • Page 138

    ELECTRICAL DIAGRAMS G-4 G-4 SCHEMA TIC - ENTIRE MACHINE - CODE 10942 (G421 1) NOTE: This diagram is for reference only . It may not be accurate for all machines covered by this manual. POWER W A VE 455M/MSTT 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 Ma[...]

  • Page 139

    ELECTRICAL DIAGRAMS G-5 G-5 SCHEMA TIC - ENTIRE MACHINE - CODES 10957 - 1 1311 PG 1 OF 3 (G4421) NOTE: This diagram is for reference only . It may not be accurate for all machines covered by this manual. POWER W A VE 455M/MSTT Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Mast[...]

  • Page 140

    ELECTRICAL DIAGRAMS G-6 G-6 SCHEMA TIC - ENTIRE MACHINE - CODES 10957 - 1 1311 PG 2 OF 3 (G4421) NOTE: This diagram is for reference only . It may not be accurate for all machines covered by this manual. POWER W A VE 455M/MSTT Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Mast[...]

  • Page 141

    ELECTRICAL DIAGRAMS G-7 G-7 SCHEMA TIC - ENTIRE MACHINE - CODES 10957 - 1 1311 PG 3 OF 3 (G4421) NOTE: This diagram is for reference only . It may not be accurate for all machines covered by this manual. POWER W A VE 455M/MSTT Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Mast[...]

  • Page 142

    ELECTRICAL DIAGRAMS G-8 G-8 SCHEMA TIC - CHOPPER PC BD - (STT MODELS ONL Y) (L1 1340-2) NOTE: This diagram is for reference only . It may not be accurate for all machines covered by this manual. POWER W A VE 455M/MSTT Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Re[...]

  • Page 143

    ELECTRICAL DIAGRAMS G-9 G-9 PC BOARD ASSEMBL Y - CHOPPER PC BD - (STT MODELS ONL Y) - (G3339-2) NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your factory warranty. Individual Printed Circuit Board Components are not available from Lincoln Electric. Thi[...]

  • Page 144

    ELECTRICAL DIAGRAMS G-10 G-10 SCHEMA TIC - DEVICENET/GA TEWA Y PC BOARD (ROBOTIC MODEL ONL Y) PG 1 OF 2 (G3821-2) NOTE: This diagram is for reference only . It may not be accurate for all machines covered by this manual. POWER W A VE 455M/MSTT Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master T[...]

  • Page 145

    ELECTRICAL DIAGRAMS G-11 G-11 SCHEMA TIC - DEVICENET/GA TEWA Y PC BOARD (ROBOTIC MODEL ONL Y) PG 2 OF 2 (G3821-2) NOTE: This diagram is for reference only . It may not be accurate for all machines covered by this manual. POWER W A VE 455M/MSTT Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master T[...]

  • Page 146

    ELECTRICAL DIAGRAMS G-12 G-12 PC BOARD ASSEMBL Y - DEVICENET/GA TEWA Y PC BOARD (ROBOTIC MODEL ONL Y) (L1 1046-2) NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your factory warranty . Individual Printed Circuit Board Components are not available from Li[...]

  • Page 147

    ELECTRICAL DIAGRAMS G-13 G-13 SCHEMA TIC - CONTROL PC BOARD (ALL CODES) PG 1 OF 4 (G3789-2) NOTE: This diagram is for reference only . It may not be accurate for all machines covered by this manual. POWER W A VE 455M/MSTT Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TO[...]

  • Page 148

    ELECTRICAL DIAGRAMS G-14 G-14 SCHEMA TIC - CONTROL PC BOARD (ALL CODES) PG 2 OF 4 (G3789-2) NOTE: This diagram is for reference only . It may not be accurate for all machines covered by this manual. POWER W A VE 455M/MSTT Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TO[...]

  • Page 149

    ELECTRICAL DIAGRAMS G-15 G-15 SCHEMA TIC - CONTROL PC BOARD (ALL CODES) PG 3 OF 4 (G3789-2) NOTE: This diagram is for reference only . It may not be accurate for all machines covered by this manual. POWER W A VE 455M/MSTT Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TO[...]

  • Page 150

    ELECTRICAL DIAGRAMS G-16 G-16 SCHEMA TIC - CONTROL PC BOARD (ALL CODES) PG 4 OF 4 (G3789-2) NOTE: This diagram is for reference only . It may not be accurate for all machines covered by this manual. POWER W A VE 455M/MSTT Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TO[...]

  • Page 151

    ELECTRICAL DIAGRAMS G-17 G-17 PC BOARD ASSEMBL Y - CONTROL PC BOARD (ALL CODES) (L11088-2) NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your factory warranty . Individual Printed Circuit Board Components are not available from Lincoln Electric. This in[...]

  • Page 152

    ELECTRICAL DIAGRAMS G-18 G-18 SCHEMA TIC - DIGIT AL POWER SUPPL Y PC BOARD (ALL CODES) (G3631-3) NOTE: This diagram is for reference only . It may not be accurate for all machines covered by this manual. POWER W A VE 455M/MSTT Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Mast[...]

  • Page 153

    ELECTRICAL DIAGRAMS G-19 G-19 PC BOARD ASSEMBL Y - DIGIT AL POWER SUPPL Y PC BOARD (ALL CODES) (G3632-3) 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 Elec[...]

  • Page 154

    ELECTRICAL DIAGRAMS G-20 G-20 SCHEMA TIC - FEEDHEAD PC BOARD #1 (ROBOTIC MODEL ONL Y) PG 1 OF 3 (G3823-3) NOTE: This diagram is for reference only . It may not be accurate for all machines covered by this manual. POWER W A VE 455M/MSTT Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Retur[...]

  • Page 155

    ELECTRICAL DIAGRAMS G-21 G-21 SCHEMA TIC - FEEDHEAD PC BOARD #2 (ROBOTIC MODEL ONL Y) PG 2 OF 3 (G3823-3) NOTE: This diagram is for reference only . It may not be accurate for all machines covered by this manual. POWER W A VE 455M/MSTT Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Retur[...]

  • Page 156

    ELECTRICAL DIAGRAMS G-22 G-22 SCHEMA TIC - FEEDHEAD PC BOARD #3 (ROBOTIC MODEL ONL Y) PG 3 OF 3 (G3823-3) NOTE: This diagram is for reference only . It may not be accurate for all machines covered by this manual. POWER W A VE 455M/MSTT Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Retur[...]

  • Page 157

    ELECTRICAL DIAGRAMS G-23 G-23 PC BOARD ASSEMBL Y - FEEDHEAD PC BOARD (ROBOTIC MODEL ONL Y) (L11087-3) 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 Electr[...]

  • Page 158

    ELECTRICAL DIAGRAMS G-24 G-24 SCHEMA TIC - INPUT PC BOARD (ALL CODES) (M19528-2) NOTE: This diagram is for reference only . It may not be accurate for all machines covered by this manual. POWER W A VE 455M/MSTT 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[...]

  • Page 159

    ELECTRICAL DIAGRAMS G-25 G-25 PC BOARD ASSEMBL Y - INPUT PC BOARD (ALL CODES) (L1 1396-2) NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your factory warranty . Individual Printed Circuit Board Components are not available from Lincoln Electric. This inf[...]

  • Page 160

    ELECTRICAL DIAGRAMS G-26 G-26 SCHEMA TIC - SWITCH PC BOARD (ALL CODES) (L1 1385-3) NOTE: This diagram is for reference only . It may not be accurate for all machines covered by this manual. POWER W A VE 455M/MSTT 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 [...]

  • Page 161

    ELECTRICAL DIAGRAMS G-27 G-27 PC BOARD ASSEMBL Y - SWITCH PC BOARD (ALL CODES) (G3734-3) NOTE: This diagram is for reference only . It may not be accurate for all machines covered by this manual. POWER W A VE 455M/MSTT Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC R[...]

  • Page 162

    ELECTRICAL DIAGRAMS G-28 G-28 SCHEMA TIC - VOL T AGE SENSE PC BOARD (ROBOTIC MODEL ONL Y) (S24779-3) NOTE: This diagram is for reference only . It may not be accurate for all machines covered by this manual. POWER W A VE 455M/MSTT Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to [...]

  • Page 163

    ELECTRICAL DIAGRAMS G-29 G-29 PC BOARD ASSEMBL Y - VOL T AGE SENSE PC BOARD (ROBOTIC MODEL ONL Y) (M19540-3) 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 [...]

  • Page 164

    ELECTRICAL DIAGRAMS G-30 G-30 SCHEMA TIC - 40 VDC BUS PC BOARD (ALL CODES) (M19330-2) NOTE: This diagram is for reference only . It may not be accurate for all machines covered by this manual. POWER W A VE 455M/MSTT Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Retu[...]

  • Page 165

    ELECTRICAL DIAGRAMS G-31 G-31 PC BOARD ASSEMBL Y - 40 VDC BUS PC BOARD (ALL CODES) (L1 1078-2) NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your factory warranty. Individual Printed Circuit Board Components are not available from Lincoln Electric. This[...]