Lincoln Electric SVM135-B manual

P P o o w w e e r r W W a a v v e e 4 4 5 5 5 5 / / P P o o w w e e r r F F e e e e d d 1 1 0 0 SER VICE MANUAL SVM135-B July,2001 Safety Depends on You Lincoln arc welding and cutting equipment is designed and built with safety in mind. However, your overall safety can be increased by proper installation ... and thought- ful operation on your part[...]

FOR ENGINE po wered equipment. 1.a. Turn 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. _______________________________________________[...]

ii SAFETY ii 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. Use suitable clothing made from durable flame-resistant material to protect your ski[...]

FOR ELECTRICALL Y po wered equipment. 8.a. Turn 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 manufacturer’s recommendations. 8.c. Ground the equipment in accordance with the U.S. National Electrical [...]

iv SAFETY iv PRÉCA UTIONS DE SÛRETÉ Pour votre propre protection lire et observer toutes les instruc- tions et les précautions de sûreté specifiques qui parraissent dans ce manuel aussi bien que les précautions de sûreté générales suivantes: Sûreté Pour Soudage A L’Arc 1. Protegez-vous contre la secousse électrique: a. Les circuits [...]

POWER WAVE 455/POWER FEED 10 v MASTER T ABLE OF CONTENTS FOR ALL SECTIONS Page Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i-iv Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [...]

SECTION A-1 INST ALLA TION POWER WAVE 455/POWER FEED 10 SECTION A-1 T ABLE OF CONTENTS -INST ALLA TION SECTION- Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section A Technical Specifications - Power Feed 10 Wire Drive and Control Box . .[...]

A-2 POWER WAVE 455/POWER FEED 10 A-2 INST ALLA TION TECHNICAL SPECIFICA TIONS – PO WER FEED 10 WIRE DRIVE AND CONTR OL BO X WIRE DRIVE OR WIRE DRIVE SECTION OF FEEDER SPEC # TYPE LOW SPEED RATIO HIGH SPEED RATIO * Included with K1538-1 Boom package and K1541-1 Bench Feeder. ∆ Dimensions do not include wire reel. # For Control Box and Wire Drive[...]

A-3 INST ALLA TION POWER WAVE 455/POWER FEED 10 A-3 RECOMMENDED INPUT WIRE AND FUSE SIZES PHYSICAL DIMENSIONS TEMPERATURE RANGES INPUT AT RATED OUTPUT - THREE PHASE ONLY Input Volts 208V - 60Hz 230V - 60Hz 400V - 60Hz 460V - 60Hz 200V - 50Hz 220V - 50Hz 400V - 50Hz 440V - 50Hz Open Circuit Voltage 75 VDC Input Voltage / Frequency 208/60/50 230/60/5[...]

A-4 INST ALLA TION POWER WAVE 455/POWER FEED 10 A-4 SAFETY PRECA UTIONS ELECTRIC SHOCK can kill. • Only qualified personnel should per- form this installation. • Turn off the input power to the power source at the disconnect switch or fuse box before working on this equip- ment. Turn off the input power to any other equipment connected to the w[...]

A-5 INST ALLA TION POWER WAVE 455/POWER FEED 10 A-5 3. Loosen the four screws inside the Control Box located along the sides of the back of the Control Box, two near the bottom and two near the mid- dle. 4. Push the Control Box upwards and then pull the Control Box away from the wire drive. 5. Remove plug button taped to inside of Control Box and i[...]

A-6 INST ALLA TION POWER WAVE 455/POWER FEED 10 A-6 ELECTRICAL CONNECTIONS Only a qualified electrician should connect the input leads to the Power Wave. Connections should be made in accordance with all local and national electrical codes and the connection dia- gram located on the inside of the reconnect/input access door of the machine. Failure [...]

A-7 INST ALLA TION POWER WAVE 455/POWER FEED 10 A-7 CABLE CONNECTIONS CONTROL CABLE CONNECTIONS • All system control cables are the same but can vary in length. • All control cables can be connected end to end to extend their length. • All system equipment must be connected to a control cable. Welding systems using the Power Feed 10 offer pre[...]

A-8 INST ALLA TION POWER WAVE 455/POWER FEED 10 A-8 CONTROL CABLE SPECIFICATIONS The cable is a five copper conductor cable in a SO- type rubber jacket. There is one 20 gauge twisted pair for network communications. This pair has an impedance of approximately 120 ohms and a propa- gation delay per foot of < 2.1 ns. There are two 12 gauge conduct[...]

A-9 INST ALLA TION POWER WAVE 455/POWER FEED 10 A-9 ELECTRODE AND W ORK LEADS — ELECTRODE NEGA TIVE APPLICA TIONS When negative electrode polarity is required, such as in some Innershield™ applications, install as above, except reverse the output connections at the power source (electrode cable to the negative (-) stud, and work cable to the po[...]

A-10 INST ALLA TION POWER WAVE 455/POWER FEED 10 A-10 RATIO CHANGE PROCEDURE 1. Pull open the pressure door. 2. Remove the Phillips head screw retaining the pinion gear to be changed and remove the gear. If the gear is not easily accessible or difficult to remove, remove the feed plate from the gearbox. To remove feed plate: a. Loosen the clamping [...]

A-11 INST ALLA TION POWER WAVE 455/POWER FEED 10 A-11 DIP SWITCH SETUP SETTING DIP SWITCHES IN THE CONTROL BOX There are two DIP switch banks on the mother board of the Control Box. They are labeled S1 and S2 and are located and oriented as shown in Figure A.3. Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC [...]

A-12 INST ALLA TION A-12 POWER WAVE 455/POWER FEED 10 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 S1 DIP Switch Bank on Contr ol Bo x Motherboard (For software version S24004-3 & up) Switch Off On 1 Standard speed gear[...]

A-13 INST ALLA TION POWER WAVE 455/POWER FEED 10 A-13 S1 DIP Switch Bank on Contr ol Bo x Motherboard (For software version S24456) Switch Off On 1 Standard speed gearbox limits adjustable High speed gearbox limits adjustable 2 WFS Display = inches/minute WFS Display = meters/minute 3 Left Display is always preset WFS Left Display is preset WFS whe[...]

A-14 INST ALLA TION POWER WAVE 455/POWER FEED 10 A-14 SETTING DIP SWITCHES IN THE WIRE DRIVE There is one DIP switch bank on the control board of the wire drive. It’s labeled S1 and is located and ori- ented as shown in Figure A.4. FIGURE A.4 S1 DIP Switch on Wire Drive Contr ol Board (For software ver sion S24029-All & S24467) Switch Off On [...]

A-15 INST ALLA TION POWER WAVE 455/POWER FEED 10 A-15 GUN AND CABLE ASSEMBLIES GUN AND CABLE ASSEMBLIES WITH STANDARD CONNECTION The Power Feed 10 wire feeder is equipped with a factory installed K1500-2 gun connection kit. This kit is for guns having a Tweco™ #2-#4 connector. The Power Feed 10 has been designed to make connect- ing a variety of [...]

A-16 INST ALLA TION POWER WAVE 455/POWER FEED 10 A-16 CV/GOUGE PANEL NOTE : Installation Instructions for the standard equipment panels will be required only if you have removed a standard panel and wish to reinstall it. The CV/Gouge Panel fits into the lower position of the Control Box. Installation is as follows: 1. Turn off power. 2. Remove the [...]

OPERA TION POWER WAVE 455/POWER FEED 10 T ABLE OF CONTENTS -OPERA TION SECTION- Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section B Operating Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .[...]

B-2 OPERA TION B-2 OPERA TING INSTR UCTIONS Read and understand this entire section of operating instructions before operating the machine. SAFETY INSTR UCTIONS 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 insulat[...]

B-3 OPERA TION B-3 DUTY CYCLE AND WELDING CAP ABILITIES The Power Feed 10 wire feeder is capable of welding at a 100% duty cycle (continuous welding). The power source will be the limiting factor in determining system duty cycle capability. The Power Wave 455 is rated 450 amps at 38 volts, 100% duty cycle, and 570 amps at 43 volts, 60% duty cycle. [...]

3. HIGH TEMPERATURE LIGHT (thermal overload): A yellow light that comes on when an over tem- perature situation occurs. Output is disabled until the machine cools down. When cool, the light goes out and output is enabled. 4. 10 AMP WIRE FEEDER CIRCUIT BREAKER: Protects 40 volt DC wire feeder power supply. 5. 10 AMP AUXILIARY POWER CIRCUIT BREAK- ER[...]

B-5 OPERA TION B-5 Cold feed function: When this switch is held in the up position, the unit automatically feeds wire, but does not activate output to the power source or gas solenoid. The speed of this cold feed is factory preset to 200 IPM. It can be adjusted while the switch is held up, by rotating the WFS encoder knob on the Control Box. Note t[...]

B-6 OPERA TION B-6 6. CV/GOUGE PANEL The CV/Gouge Panel provides a fixed toggle switch selection of two power source modes. The upper position selects the generic CV/MIG mode from the power source while the lower position selects the GOUGE mode. OPTIONAL PANELS A number of Optional Features are available for use with the Power Feed 10. Some Install[...]

B-7 OPERA TION B-7 WIRE SPINDLE PLA CEMENT The reel stand provides two mounting locations for the 2 inch diameter wire reel spindle to accommo- date various reel sizes. Each mounting location con- sists of a tube in the center of the reel stand, and a locating pin on the right side (viewed from the front) of the reel stand. The bolt, used with a pl[...]

B-8 OPERA TION B-8 T O MOUNT 10 T O 44 LB (4.5 T O 20 KG) SPOOLS [12 IN. (300 MM) DIAMETER] OR 14 LB (6 KG) INNERSHIELD COILS (FIGURE B.4): The spindle should be located in the LOWER mounting hole. (For 8 in. (200 mm) spools, a K468 spindle adapter must first be slipped onto spindle.) (For 13 to 14 lb (6 kg) Innershield coils, a K435 coil adapter m[...]

B-9 OPERA TION B-9 FEEDING ELECTR ODE AND BRAKE ADJUSTMENT 1. Turn the reel or spool until the free end of the electrode is accessible. 2. While tightly holding the electrode, cut off the bent end and straighten the first 6 in. (150 mm). Cut off the first 1 in. (25 mm). (If the electrode is not properly straightened, it may not feed or may jam caus[...]

B-10 OPERA TION B-10 WIRE FEED O VERLO AD PR O TECTION The wire drive has solid-state overload protection of the wire drive motor. If the wire drive motor becomes overloaded for an extended period of time the wire drive will issue a shutdown command to the Control Box and force its STATUS light to blink between green and red. The Control Box turns [...]

A CCESSORIES POWER WAVE 455/POWER FEED 10 SECTION C-1 SECTION C-1 T ABLE OF CONTENTS -A CCESSORIES SECTION- Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section C General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [...]

C-2 A CCESSORIES C-2 GENERAL The following is a list of the accessories that can be used with the Power Feed 10 wire feeder and the Power Wave 455. A description of each item is given later in the section. POWER WAVE 455/POWER FEED 10 K1570-1 DUAL CYLINDER UNDERCARRIAGE KP1505 Series DRIVE ROLL AND GUIDE TUBE KITS K1543 INPUT CABLE ASSEMBLY (CONTRO[...]

C-3 A CCESSORIES C-3 PO WER W A VE OPTIONS AND A CCESSORIES The following is a list of available Power Wave options. F A CT OR Y INST ALLED There are no factory installed options available for the Power Wave machines. FIELD INST ALLED The following options/accessories are available for your Power Wave from your local Lincoln Distributor. K1570-1 DU[...]

C-4 A CCESSORIES C-4 POWER WAVE 455/POWER FEED 10 INPUT CABLE ASSEMBLIES K1543 (Control Cable Only) - Consists of a 5-con- ductor control cable with a 5-pin control cable plug, without electrode cable, and is available in lengths of 10 ft, 15 ft, 20 ft, 50 ft, and 100 ft. K1544 - Consists of a 5-conductor control cable with a 5-pin control cable pl[...]

C-5 A CCESSORIES C-5 POWER WAVE 455/POWER FEED 10 Feed Head Enclosure Procedure 1. Turn power off. 2. Remove the Feed Head rear access door. The Feed Head cover can be removed to aid installa- tion, but is not required. 3. Remove the plastic plug (black) from the hole at the right rear of the Feed Head and store it in the left side of the Feed Head[...]

C-6 A CCESSORIES C-6 POWER WAVE 455/POWER FEED 10 10. Install an Optional Output Connector into the Control Box cabinet, if not already present. 11. Mount the Control Box cabinet to the work sta- tion fixture at this time, if desired. The four holes in the back wall of the Control Box cabinet can be used for this purpose. 12. Re-install the lower a[...]

C-7 A CCESSORIES C-7 POWER WAVE 455/POWER FEED 10 MAGNUM 200/300/400 GUNS The easiest and least expensive way to use Magnum 200/300/400 guns with the Power Feed 10 wire feed- er is to order them with the K466-10 connector kit, or to buy a completely assembled Magnum gun having the K466-10 connector (such as the K471-21, -22, and -23 dedicated Magnu[...]

C-8 A CCESSORIES C-8 POWER WAVE 455/POWER FEED 10 DU AL PROCEDURE SWITCH OPTIONS K683-3 DUAL PROCEDURE SWITCH Kit includes gun switch and mountings for Lincoln Innershield and Magnum guns, with 15 ft (4.5 m) control cable and 5-pin plug with two leads to con- nect to gun trigger. Connect the 5-pin plug of the K683-3 Dual Procedure Switch to the Pow[...]

C-9 A CCESSORIES C-9 POWER WAVE 455/POWER FEED 10 4. Position the new door between the panel holes and re-install the rod so the screw holes can be accessed. 5. Replace the two screws and tighten. 6. Swing the door into the up position. A lock may be installed through the side holes for security purposes. K1555-1 INSULATED LIFT BAIL For application[...]

C-10 A CCESSORIES C-10 Constant Voltage (CV/MIG and CV/Flux Cored) Procedures When in this mode, the ARC CONTROL adjusts the inductance. (This adjustment is often referred to as “pinch”. Inductance is inversely proportional to pinch.) Increasing the ARC CONTROL setting decreases the inductance, which results in the arc getting colder and pinche[...]

C-11 A CCESSORIES C-11 Mode Selection The MODE SELECT switch is a momentary large three position toggle switch that defaults to the center (off) position. Moving the switch up advances the mode indicator in the upward direction, down advances it in the downward direction. Holding the switch in either direction will result in the indicator advancing[...]

C-12 A CCESSORIES C-12 Mode Schedule - Table on the front of the option used by the operator to correlate the displayed mode number to an actual power source mode. Due to the nature of the system, the following feature is required for safety reasons. Upon entering any constant current (CC) mode, the right encoder, labeled VOLTS, TRIM, on the Displa[...]

C-13 A CCESSORIES C-13 Installation is as follows: 1. Turn off power. 2. Remove the two screws from the front of the blank option panel at the location you choose to install your new option (bottom) of the Control Box cabinet. Save the screws, discard the old panel or save for future use. 3. Tilt the new option panel away from the front opening of [...]

C-14 A CCESSORIES C-14 Installation is as follows: 1. Turn off power. 2. Remove the two screws from the front of the blank option panel at the location you choose to install your new option (bottom) of the Control Box cabinet. Save the screws, discard the old panel or save for future use. 3. Tilt the new option panel away from the front opening of [...]

C-15 A CCESSORIES C-15 The value of the active set up parameter is shown on the MSP2 panel digital display. The value can be modi- fied with the Set switch. The Set switch is an up/down center-off momentary toggle switch. Moving the switch bat up or down adjusts the displayed value in the cor- responding direction. Holding the switch in either dire[...]

C-16 A CCESSORIES C-16 CONTR OL BO X -- SETTING OPERA TING LIMITS Upper and lower operating limits can be set for the WFS/Amps setting and the Volts/Trim setting. Doing so requires knowledge of how to set the limits, and access to the PC board in the Control Box. There are two independent sets of limits, Procedure A limits and Procedure B limits. I[...]

SECTION D-1 MAINTENANCE SECTION D-1 POWER WAVE 455/POWER FEED 10 T ABLE OF CONTENTS -MAINTENANCE SECTION- Maintenance ............................................................................................................................... .............. Section D Safety Precautions ............................................................[...]

D-2 MAINTENANCE D-2 SAFETY PRECA UTIONS ELECTRIC SHOCK can kill. • Do not touch electrically live parts such as output terminals or internal wiring. • Only qualified personnel should perform maintenance work. Observe all additional Safety Guidelines detailed throughout this manual. ----------------------------------------------------------- R O[...]

SECTION E-1 THEOR Y OF OPERA TION SECTION E-1 POWER WAVE 455/POWER FEED 10 T ABLE OF CONTENTS -THEOR Y OF OPERA TION SECTION- Theory of Operation ................................................................................................................................. Section E Modular Inverter Based Welding System...........................[...]

E-2 THEOR Y OF OPERA TION E-2 POWER WAVE 455/POWER FEED 10 specific requirements and also locate and identify each piece of equipment for maxi- mum efficiency and ease of operation. SYSTEM DIA GRAM A This basic system utilizes two physical pieces of equipment. Refer to Figure E.1. The power source (Power Wave 455) and the combination Control Box an[...]

E-3 THEOR Y OF OPERA TION E-3 POWER WAVE 455/POWER FEED 10 The communication cable is depicted by the heavy black connector line. PC board power, communications and intelligence between the wire drive and combination power source/Control Box unit are con- veyed through this cable. SYSTEM DIA GRAM B This system utilizes two physical pieces of equipm[...]

E-4 THEOR Y OF OPERA TION E-4 POWER WAVE 455/POWER FEED 10 cables. All PC board power, communica- tions and intelligence are transmitted via the two cables. This component configuration might be used if the wire drive unit was mounted on a boom and the Control Box located remotely from the power source. SYSTEM DIA GRAM C The power source (Power Wav[...]

E-5 THEOR Y OF OPERA TION E-5 POWER WAVE 455/POWER FEED 10 voltage developed by the No. 2 auxiliary transformer is applied to the 115 VAC receptacle. The 65 VDC produced from the power board rectifier is utilized by the power board to provide various DC voltages for the con- trol board and wire feeder. The two phases which are connected to the inpu[...]

E-6 THEOR Y OF OPERA TION E-6 POWER WAVE 455/POWER FEED 10 Each switch board feeds current to a sepa- rate, oppositely wound primary winding of the main transformer. The reverse direc- tions of current flow through the main trans- former primaries and the offset timing of the IGBT switch boards induce an AC square wave output signal at the secondar[...]

E-7 THEOR Y OF OPERA TION E-7 POWER WAVE 455/POWER FEED 10 pulse width modulation (PWM) signal (See Pulse Width Modulation in this section) is sent to the switch board IGBTs. In this manner, the digitally controlled high-speed welding waveform is created. The control board also monitors the ther- mostats, main transformer primary current, and capac[...]

E-8 THEOR Y OF OPERA TION E-8 POWER WAVE 455/POWER FEED 10 rectifies it to a DC voltage level. Since the output choke is in series with the negative leg of the output rectifier and also in series with the welding load, a filtered DC output is applied to the machine output terminals. Refer to Figure E.7. OUTPUT RECTIFIER AND CHOKE The output rectifi[...]

E-9 THEOR Y OF OPERA TION E-9 POWER WAVE 455/POWER FEED 10 O VER CURRENT PR O TECTION If the average current exceeds 590 amps, then the peak current will be limited to 100 amps until the average current decreases to under 50 amps. UNDER/O VER V OL T A GE PR O TECTION A protective circuit is included on the control board to monitor the voltage acros[...]

E-10 THEOR Y OF OPERA TION E-10 POWER WAVE 455/POWER FEED 10 connected to the source. The circuit is turned OFF like a light switch. Example B shows the IGBT in an active mode. When the gate signal , a positive DC voltage relative to the source, is applied to the gate terminal of the IGBT, it is capable of conducting current. A voltage supply con- [...]

E-11 THEOR Y OF OPERA TION E-11 POWER WAVE 455/POWER FEED 10 microsecond. The negative portion is the other IGBT group 1 . The dwell time (off time) is 48 microseconds (both IGBT groups off). Since only two microseconds of the 50- microsecond time period is devoted to con- ducting, the output power is minimized. MAXIMUM OUTPUT By holding the gate s[...]

E-12 THEOR Y OF OPERA TION E-12 POWER WAVE 455/POWER FEED 10 In addition to the large and smaller size options, there is a Display Panel which is standard on the Control Box unit. The Display Panel, typically installed in the upper position of the Control Box assembly, houses the encoder controls and the STA- TUS LED. The controls are used to adjus[...]

E-13 THEOR Y OF OPERA TION E-13 POWER WAVE 455/POWER FEED 10 the correct commands are transmitted to the feed drive. The feed drive control board then sends the signals to energize the active components such as the solenoid and wire drive motor. The tach feedback signal is processed on the control board which regulates the motor armature voltage so[...]

E-14 NO TES POWER WAVE 455/POWER FEED 10 E-14 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC[...]

TROUBLESHOOTING AND REP AIR POWER WAVE 455/POWER FEED 10 SECTION F-1 SECTION F-1 T ABLE OF CONTENTS -TROUBLESHOOTING AND REP AIR SECTION- Troubleshooting and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section F How to Use Troubleshooting Guide . . . . . . . . . . . . . [...]

POWER WAVE 455/POWER FEED 10 F-2 TR OUBLESHOO TING AND REP AIR F-2 This Troubleshooting Guide is provided to help you locate and repair possible machine malfunctions. Simply follow the three-step procedure listed below. Step 1. LOCATE PROBLEM (SYMPTOM). Look under the column labeled “PROBLEM (SYMPTOMS)”. This column describes possible symptoms [...]

F-3 TR OUBLESHOO TING AND REP AIR F-3 ELECTRIC SHOCK can kill. Have an electrician install and service this equipment. Turn the input power OFF at the fuse box before working on equipment. Do not touch electrically hot parts. ------------------------------------------------- Sometimes machine failures appear to be due to PC board failures. These pr[...]

F-4 TR OUBLESHOO TING AND REP AIR F-4 4. Test the machine to determine if the failure symptom has been corrected by the replacement PC board. NOTE : It is desirable to have a spare (known good) PC board available for PC board troubleshooting. NOTE : Allow the machine to heat up so that all electrical components can reach their operating temperature[...]

F-5 TR OUBLESHOO TING AND REP AIR F-5 POWER WAVE 455/POWER FEED 10 TR OUBLESHOO TING GUIDE PO WER W A VE Observe all Safety Guidelines detailed throughout this manual. CA UTION PROBLEMS (SYMPT OMS) POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF A CTION Major physical or electrical dam- age is evident when the sheet metal cover(s) are remo[...]

F-6 TR OUBLESHOO TING AND REP AIR F-6 POWER WAVE 455/POWER FEED 10 PO WER W A VE Observe all Safety Guidelines detailed throughout this manual. If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric Service Department for technical troubleshooting assistance before[...]

F-7 TR OUBLESHOO TING AND REP AIR F-7 POWER WAVE 455/POWER FEED 10 PO WER W A VE Observe all Safety Guidelines detailed throughout this manual. If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric Service Department for technical troubleshooting assistance before[...]

F-8 TR OUBLESHOO TING AND REP AIR F-8 POWER WAVE 455/POWER FEED 10 PO WER W A VE Observe all Safety Guidelines detailed throughout this manual. If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric Service Department for technical troubleshooting assistance before[...]

F-9 TR OUBLESHOO TING AND REP AIR F-9 POWER WAVE 455/POWER FEED 10 PO WER W A VE Observe all Safety Guidelines detailed throughout this manual. If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric Service Department for technical troubleshooting assistance before[...]

F-10 TR OUBLESHOO TING AND REP AIR F-10 POWER WAVE 455/POWER FEED 10 PO WER W A VE 455 ST A TUS LED CHAR T If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed. Call 216-383-2531 or 1-[...]

F-11 TR OUBLESHOO TING AND REP AIR F-11 POWER WAVE 455/POWER FEED 10 ST A TUS LED ERR OR CODE T ABLE If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed. Call 216-383-2531 or 1-800-83[...]

F-12 TR OUBLESHOO TING AND REP AIR F-12 POWER WAVE 455/POWER FEED 10 ST A TUS LED ERROR CODE T ABLE (Continued) If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed. Call 216-383-2531 [...]

F-13 TR OUBLESHOO TING AND REP AIR F-13 POWER WAVE 455/POWER FEED 10 PO WER FEED Observe all Safety Guidelines detailed throughout this manual. If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric Service Department for technical troubleshooting assistance before[...]

F-14 TR OUBLESHOO TING AND REP AIR F-14 POWER WAVE 455/POWER FEED 10 PO WER FEED Observe all Safety Guidelines detailed throughout this manual. If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric Service Department for technical troubleshooting assistance before[...]

F-15 TR OUBLESHOO TING AND REP AIR F-15 POWER WAVE 455/POWER FEED 10 PO WER FEED Observe all Safety Guidelines detailed throughout this manual. If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric Service Department for technical troubleshooting assistance before[...]

F-16 TR OUBLESHOO TING AND REP AIR F-16 POWER WAVE 455/POWER FEED 10 PO WER FEED Observe all Safety Guidelines detailed throughout this manual. If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric Service Department for technical troubleshooting assistance before[...]

F-17 TR OUBLESHOO TING AND REP AIR F-17 POWER WAVE 455/POWER FEED 10 PO WER FEED Observe all Safety Guidelines detailed throughout this manual. If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric Service Department for technical troubleshooting assistance before[...]

F-18 TR OUBLESHOO TING AND REP AIR F-18 POWER WAVE 455/POWER FEED 10 PO WER FEED Observe all Safety Guidelines detailed throughout this manual. If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric Service Department for technical troubleshooting assistance before[...]

F-19 TR OUBLESHOO TING AND REP AIR F-19 POWER WAVE 455/POWER FEED 10 PO WER FEED Observe all Safety Guidelines detailed throughout this manual. If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric Service Department for technical troubleshooting assistance before[...]

F-20 TR OUBLESHOO TING AND REP AIR F-20 POWER WAVE 455/POWER FEED 10 PO WER FEED ERROR CODE CHART If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed. Call 216-383-2531 or 1-800-833-9[...]

F-21 TR OUBLESHOO TING AND REP AIR F-21 POWER WAVE 455/POWER FEED 10 PO WER FEED ERROR CODE CHART Observe all Safety Guidelines detailed throughout this manual. If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric Service Department for technical troubleshooting [...]

F-22 NO TES POWER WAVE 455/POWER FEED 10 F-22 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 PW 455 CONTROL BOARD LED DEFINITIONS LED COLOR AND NUMBER CIRCUIT INDICATORS Green LED 1 -15 VDC Supply Green LED 3 +15 VDC Supply G[...]

F-23 TR OUBLESHOO TING AND REP AIR F-23 INPUT FIL TER CAP A CIT OR DISCHARGE PR OCEDURE Service and repair should only be performed by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in dan- ger to the technician or machine operator and will invalidate your factory warran- ty. For your safety [...]

F-24 TR OUBLESHOO TING AND REP AIR F-24 POWER WAVE 455/POWER FEED 10 6. Using the high wattage resistor (25- 1000 ohms @ 25 watts (minimum), electrically insulated gloves and pliers, connect the resistor across the two capacitor terminals. Hold the resistor in place for 10 seconds. DO NOT TOUCH THE CAPACITOR TERMI- NALS WITH YOUR BARE HANDS. NEVER [...]

F-25 TR OUBLESHOO TING AND REP AIR F-25 SWITCH BO ARD TEST Service and repair should only be performed by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in dan- ger to the technician or machine operator and will invalidate your factory warran- ty. For your safety and to avoid electrical shock[...]

F-26 TR OUBLESHOO TING AND REP AIR F-26 POWER WAVE 455/POWER FEED 10 4. Locate label and remove leads 19C and 19D from the reconnect switches with the 3/8 in. wrench. Note lead placement for reassembly. Clear leads. Refer to Figure F.2. 5. Using the Analog ohmmeter, perform the resistance tests detailed in Table F.1. Refer to Figure F.3 for the tes[...]

F-27 TR OUBLESHOO TING AND REP AIR F-27 POWER WAVE 455/POWER FEED 10 8. Reconnect leads 19C and 19D to the reconnect switches. Ensure that the leads are installed in the same location they were removed from. 9. Install the right and left case sides using the 3/8 in. nutdriver. 6. If any test fails replace both switch boards. See Switch Board Remova[...]

F-28 NO TES POWER WAVE 455/POWER FEED 10 F-28 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC[...]

F-29 TR OUBLESHOO TING AND REP AIR F-29 OUTPUT RECTIFIER TEST Service and repair should only be performed by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in dan- ger to the technician or machine operator and will invalidate your factory warran- ty. For your safety and to avoid electrical sh[...]

F-30 TR OUBLESHOO TING AND REP AIR F-30 POWER WAVE 455/POWER FEED 10 3. With the analog ohmmeter, measure the resistance between the positive and negative output terminals. Refer to Figure F.4. IMPORTANT: The positive (+) meter probe must be attached to the positive (+) output terminal and the negative (-) meter probe must be attached to the negati[...]

F-31 TR OUBLESHOO TING AND REP AIR F-31 INPUT RECTIFIER TEST Service and repair should only be performed by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in dan- ger to the technician or machine operator and will invalidate your factory warran- ty. For your safety and to avoid electrical sho[...]

F-32 TR OUBLESHOO TING AND REP AIR F-32 POWER WAVE 455/POWER FEED 10 NOTE : Some RTV sealant may have to be removed from the input rectifier terminals. The RTV should be replaced when test is complete. 5 . With the Phillips head screwdriver remove the positive and negative leads from the rectifier. 6. Us e t he a na l og o hm m et er t o p er fo r [...]

F-33 TR OUBLESHOO TING AND REP AIR F-33 POWER WAVE 455/POWER FEED 10 9. If the input rectifier is good, be sure to reconnect the positive and negative leads to the correct terminals and torque to 31 in/lbs. See wiring diagram. 10. Replace any RTV sealant previously removed. 11. Install the case top. 7. If the input rectifier does not meet the accep[...]

F-34 NO TES POWER WAVE 455/POWER FEED 10 F-34 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC[...]

F-35 TR OUBLESHOO TING AND REP AIR F-35 INPUT CONT A CT OR TEST Service and repair should only be performed by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in dan- ger to the technician or machine operator and will invalidate your factory warran- ty. For your safety and to avoid electrical [...]

F-36 TR OUBLESHOO TING AND REP AIR F-36 POWER WAVE 455/POWER FEED 10 FIGURE F.7 — INPUT CONTACTOR TEST POINTS. 6. When the contactor is NOT activated, the resistance should be infinite or very high across the contacts. If the resis- tance is low, the input contactor is faulty. 7. Reconnect the four leads (601, 601A, X4, and X4A) to the input cont[...]

F-37 TR OUBLESHOO TING AND REP AIR F-37 A UXILIAR Y TRANSFORMER NO . 2 TEST Service and repair should only be performed by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in dan- ger to the technician or machine operator and will invalidate your factory warran- ty. For your safety and to avoid[...]

F-38 TR OUBLESHOO TING AND REP AIR F-38 POWER WAVE 455/POWER FEED 10 8. If 115 VAC is not present between pins #1 and #4, check the associated leads and plugs for loose or faulty connec- tions. High voltage is present at plug P80. 9. Carefully test for the correct AC input voltage applied to the primary windings at plug P80. See wiring diagram. 10.[...]

F-39 TR OUBLESHOO TING AND REP AIR F-39 A UXILIAR Y TRANSFORMER NO . 1 TEST Service and repair should only be performed by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in dan- ger to the technician or machine operator and will invalidate your factory warran- ty. For your safety and to avoid[...]

F-40 TR OUBLESHOO TING AND REP AIR F-40 POWER WAVE 455/POWER FEED 10 4. Locate secondary leads X1 and X2 (at power board rectifier bridge). Refer to Figure F.9. 5. Locate secondary leads X3 and X5 (fan motor leads). 6. Locate secondary lead X4 (at main contactor). TEST PROCEDURE 1. Remove the main input supply power to the Power Wave 455 machine. 2[...]

F-41 TR OUBLESHOO TING AND REP AIR F-41 POWER WAVE 455/POWER FEED 10 High voltage is present at primary of Auxiliary Transformer. 9. If the correct input voltage is applied to the primary, and the secondary volt- age(s) are not correct, the T1 trans - former may be faulty. 10. Install the case sides and top using the 3/8 in. nutdriver. 7. Carefully[...]

F-42 NO TES POWER WAVE 455/POWER FEED 10 F-42 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC[...]

F-43 TR OUBLESHOO TING AND REP AIR F-43 PO WER BO ARD TEST Service and repair should only be performed by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in dan- ger to the technician or machine operator and will invalidate your factory warran- ty. For your safety and to avoid electrical shock[...]

F-44 TR OUBLESHOO TING AND REP AIR F-44 POWER WAVE 455/POWER FEED 10 6. Carefully test for the correct voltages at the power board as per Table F.4. NOTE : Capacitor C3 (25000 mfd/100 V) may hold a charge. Do not come in con- tact with the capacitor terminals . 7. If the 65 VDC is low or not present at plug J32, check the rectifier bridge and C3 fi[...]

F-45 TR OUBLESHOO TING AND REP AIR F-45 POWER WAVE 455/POWER FEED 10 TABLE F.4 — POWER BOARD VOLTAGE CHECKS. PO WER BO ARD TEST (continued) NORMAL LEAD NO. ACCEPTABLE CHECK POINT TEST CONNECTOR OR VOLTAGE LOCATION DESCRIPTION PLUG PIN NO. IDENTITY READING POWER PC CHECK 65 VDC 1 & 2(+) POS(+) 73 VDC BOARD SUPPLY FROM 4 & 5(-) NEG(-) CONNE[...]

F-46 NO TES POWER WAVE 455/POWER FEED 10 F-46 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC[...]

F-47 TR OUBLESHOO TING AND REP AIR F-47 CURRENT TRANSDUCER TEST Service and repair should only be performed by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in dan- ger to the technician or machine operator and will invalidate your factory warran- ty. For your safety and to avoid electrical [...]

F-48 TR OUBLESHOO TING AND REP AIR F-48 POWER WAVE 455/POWER FEED 10 7. Check for the correct DC supply volt- ages to the current transducer at plug P90. A. Pin 1 (lead 212+) to pin 4 (lead 216-) should read +15 VDC. B. Pin 2 (lead 213-) to pin 4 (lead 216+) should read -15 VDC. 8. If either of the supply voltages are low or missing, check the asso[...]

F-49 TR OUBLESHOO TING AND REP AIR F-49 POWER WAVE 455/POWER FEED 10 11. If the correct supply voltages are applied to the current transducer, and with the machine loaded, the feedback voltage is missing or not correct, the current transducer may be faulty. Also make certain that lead #211 has conti- nuity (zero ohms) between the current transducer[...]

F-50 NO TES POWER WAVE 455/POWER FEED 10 F-50 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC[...]

F-51 TR OUBLESHOO TING AND REP AIR F-51 DRIVE MO T OR TEST Service and repair should only be performed by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in dan- ger to the technician or machine operator and will invalidate your factory warran- ty. For your safety and to avoid electrical shock[...]

F-52 TR OUBLESHOO TING AND REP AIR F-52 POWER WAVE 455/POWER FEED 10 5. If the correct voltages are NOT present at the motor leads, check the associat- ed leads between the motor and plug J3 on the control board. If the leads are OK, the control board may be faulty. 6. If the correct voltages are present at the motor armature leads and the motor do[...]

F-53 TR OUBLESHOO TING AND REP AIR F-53 T A CH FEEDBA CK TEST Service and repair should only be performed by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in dan- ger to the technician or machine operator and will invalidate your factory warran- ty. For your safety and to avoid electrical sh[...]

F-54 TR OUBLESHOO TING AND REP AIR F-54 POWER WAVE 455/POWER FEED 10 5. With the gun trigger activated and the motor running, check the feedback volt- age at plug J4 pin #2 (blue wire) posi- tive to pin #3 (black wire) negative. Normal feedback voltage is approxi- mately 5 VDC. If the correct supply volt- age is present and the feedback volt- age i[...]

F-55 TR OUBLESHOO TING AND REP AIR F-55 V OL T A GE SENSE PC BO ARD TEST Service and repair should only be performed by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in dan- ger to the technician or machine operator and will invalidate your factory warran- ty. For your safety and to avoid el[...]

F-56 TR OUBLESHOO TING AND REP AIR F-56 POWER WAVE 455/POWER FEED 10 5. With the gun trigger activated and arc voltage present at the conductor block, check for arc voltage from plug J1 pin 3 (lead 67) to the workpiece. If actual arc voltage is NOT present, check the continuity of lead 67 from the conductor block to plug J1 pin 3 on the voltage sen[...]

F-57 TR OUBLESHOO TING AND REP AIR F-57 DU AL ENCODER PC BO ARD TEST Service and repair should only be performed by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in dan- ger to the technician or machine operator and will invalidate your factory warran- ty. For your safety and to avoid electr[...]

F-58 TR OUBLESHOO TING AND REP AIR F-58 POWER WAVE 455/POWER FEED 10 6. While rotating the wire feed speed (WFS) control check for a “pulsing” 0 to 5 VDC signal at plug J1 pin 5 + (lead 553) to J1 pin 1 - (lead 500C). Also check for a “pulsing” 0 to 5 VDC signal from plug J1 pin 6 + (lead 554) to J1 pin 1 - (lead 500C). 7. While rotating th[...]

F-59 TR OUBLESHOO TING AND REP AIR F-59 CONTROL CABLE CONTINUITY TEST Service and repair should only be performed by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in dan- ger to the technician or machine operator and will invalidate your factory warran- ty. For your safety and to avoid elect[...]

F-60 TR OUBLESHOO TING AND REP AIR F-60 POWER WAVE 455/POWER FEED 10 feeder/Control Box end. Refer to Figure F.16 and Table F-6. 4. If any conductor resistance measures greater than 1.0 ohm, the cable is faulty and should be replaced. If the resistance between any two conductors or any conductor and the amphenol body is less than 0.5M ohms, the cab[...]

F-61 TR OUBLESHOO TING AND REP AIR F-61 GAS SOLENOID REMO V AL AND REPLA CEMENT Service and repair should only be performed by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in dan- ger to the technician or machine operator and will invalidate your factory warran- ty. For your safety and to a[...]

F-62 TR OUBLESHOO TING AND REP AIR F-62 POWER WAVE 455/POWER FEED 10 INST ALLA TION 1. If a new solenoid is to be installed, it may be necessary to remove the hose fitting from the “old” solenoid and install it into the new solenoid using the 1/2 in. wrench. 2. Place the gas solenoid into the wire feeder and secure it to the rear case panel usi[...]

F-63 TR OUBLESHOO TING AND REP AIR F-63 WIRE FEEDER CONTR OL BO ARD REMO V AL AND REPLA CEMENT Service and repair should only be performed by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in dan- ger to the technician or machine operator and will invalidate your factory warran- ty. For your [...]

F-64 TR OUBLESHOO TING AND REP AIR F-64 POWER WAVE 455/POWER FEED 10 INST ALLA TION NOTE : Press the PC board onto the support by pressing near the mounting hole you are securing. Pressing near the center of the PC board could damage the circuitry within the board. 1. Align the holes on the PC board with the supports attached to the wire feeder and[...]

F-65 TR OUBLESHOO TING AND REP AIR F-65 T A CH (HALL EFFECT) ASSEMBL Y REMO V AL AND REPLA CEMENT Service and repair should only be performed by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in dan- ger to the technician or machine operator and will invalidate your factory warran- ty. For yo[...]

F-66 TR OUBLESHOO TING AND REP AIR F-66 POWER WAVE 455/POWER FEED 10 REPLA CEMENT PROCEDURE 1. Carefully screw the Hall Effect device into the gear box assembly until it gen- tly “bottoms out” on the rotary magnet inside. 2. Unscrew the Hall Effect device 1/2 turn from the rotary magnet. Tighten the locking nut to 8 in/lbs. 3. Thread the J4 lea[...]

F-67 TR OUBLESHOO TING AND REP AIR F-67 GEAR BO X AND DRIVE MO TOR REMO V AL AND REPLA CEMENT Service and repair should only be performed by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in dan- ger to the technician or machine operator and will invalidate your factory warran- ty. For your s[...]

F-68 TR OUBLESHOO TING AND REP AIR F-68 POWER WAVE 455/POWER FEED 10 4. Thread plug J4 and associated leads through the vertical baffle. Cut any necessary cable ties. 5. Locate and disconnect the motor leads (#551 and #550) at the quick connects. Cut any necessary cable ties. 6. Using the Phillips head screwdriver, remove the #67 lead from the cond[...]

F-69 TR OUBLESHOO TING AND REP AIR F-69 POWER WAVE 455/POWER FEED 10 2. Tighten the two Allen type screws at the bottom of the wire drive unit using the 3/16 in. Allen wrench. 3. Attach lead #67 to the conductor block. 4. Carefully slide the drive motor into the gear box assembly. Be sure to position the motor leads so that they can be properly con[...]

F-70 NO TES POWER WAVE 455/POWER FEED 10 F-70 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC[...]

F-71 TR OUBLESHOO TING AND REP AIR F-71 SWITCH BO ARD AND FIL TER CAP A CIT OR REMO V AL AND REPLA CEMENT Service and repair should only be performed by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in dan- ger to the technician or machine operator and will invalidate your factory warran- ty[...]

F-72 TR OUBLESHOO TING AND REP AIR F-72 POWER WAVE 455/POWER FEED 10 4. Remove the molex plug from the top of the switch board. Refer to Figure F.21. 5. Using the 7/16 in. wrench, remove leads 11/12 or 15/16 from the switch board. 6. Using the 7/16 in. wrench, remove leads 13/14 or 17/18 from the switch board. 7. Using the 7/16 in. wrench, remove l[...]

F-73 TR OUBLESHOO TING AND REP AIR F-73 POWER WAVE 455/POWER FEED 10 5. Mount the new switch board and tight- en the four cap head screws in the fol- lowing manner. • Tighten all until snug. • Tighten all from 24 to 28 in/lbs. • Tighten all from 40 to 48 in/lbs. 6. Make sure the capacitor is positioned correctly. Connect leads 19+ and 20- to [...]

F-74 TR OUBLESHOO TING AND REP AIR F-74 METER A CCURA CY CHECK 1. With power off, locate DIP switch bank S2 on the PF-10 Control PC board. (There are 8 switches, number 1 on the left, through number 8). 2. Set switch 8 to the up position. 3. Connect a resistive load between the out- put block of the PF-10 and the work ter- minal of the PW-455 machi[...]

F-75 TR OUBLESHOO TING AND REP AIR F-75 CONTROL OR PO WER BO ARD REMO V AL AND REPLA CEMENT Service and repair should only be performed by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in dan- ger to the technician or machine operator and will invalidate your factory warran- ty. For your saf[...]

F-76 TR OUBLESHOO TING AND REP AIR F-76 POWER WAVE 455/POWER FEED 10 6. Remove the eight molex plugs from the control board. 7. Remove the two molex plugs and white and black wires with quick connects from the power PC board. 8. Using the 3/8 in. nutdriver, remove the two screws holding the rear of the Control Box in place. 9. Clear the lead harnes[...]

F-77 TR OUBLESHOO TING AND REP AIR F-77 POWER WAVE 455/POWER FEED 10 4. Connect two molex plugs and black and white wires with quick disconnects to the power PC board. 5. Connect the eight molex plugs to the control PC board. 6. Install the PC board compartment cover using the 3/8 in. nutdriver. 7. Install the case top and sides using the 3/8 in. n[...]

F-78 NO TES POWER WAVE 455/POWER FEED 10 F-78 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC[...]

F-79 TR OUBLESHOO TING AND REP AIR F-79 A UXILIAR Y TRANSFORMER NO . 1 REMO V AL AND REPLA CEMENT PROCEDURE Service and repair should only be performed by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in dan- ger to the technician or machine operator and will invalidate your factory warran- [...]

F-80 TR OUBLESHOO TING AND REP AIR F-80 POWER WAVE 455/POWER FEED 10 5. Remove leads X1 and X2 from the power board rectifier bridge. Refer to Figure F.23. 6. Cut X3 and X5 from the fan motor leads. Leave enough lead length to splice in the new transformer leads. 7. Remove lead X4 from the main contac- tor coil terminal. REMO V AL PROCEDURE 1. Remo[...]

F-81 TR OUBLESHOO TING AND REP AIR F-81 POWER WAVE 455/POWER FEED 10 and the machine base using the 3/8 in. nutdriver. 3. Install the primary leads H2, H3, H4, and H5 to the reconnect terminals on the reconnect panel. 4. Connect primary lead H1 to circuit breaker CB4. 5. Splice the new transformer lead with the X3 lead connected to the input board.[...]

F-82 NO TES POWER WAVE 455/POWER FEED 10 F-82 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC[...]

F-83 TR OUBLESHOO TING AND REP AIR F-83 MAIN INPUT CONT A CT OR REMO V AL AND REPLA CEMENT Service and repair should only be performed by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in dan- ger to the technician or machine operator and will invalidate your factory warran- ty. For your safe[...]

F-84 TR OUBLESHOO TING AND REP AIR F-84 POWER WAVE 455/POWER FEED 10 remove the small T2 lead. Label leads for reassembly. 6. Remove the two small leads T1 and T3 from the quick disconnect terminals. 7. Remove leads 601, 601A, and X4, X4A from the contactor coil terminals. 8. Remove leads L1A and L3A from the contactor line side quick-disconnect te[...]

F-85 TR OUBLESHOO TING AND REP AIR F-85 POWER WAVE 455/POWER FEED 10 5. Install the two small leads T1 and T3 to the quick-disconnect terminals. 6. Install the three input lines (L1, L2 and L3) to the main contactor using the slot head screwdriver. 7. Install the three heavy leads (T1, T2 and T3) from the input contactor using the slot head screwdr[...]

F-86 NO TES POWER WAVE 455/POWER FEED 10 F-86 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC[...]

F-87 TR OUBLESHOO TING AND REP AIR F-87 INPUT RECTIFIER REMO V AL AND REPLA CEMENT Service and repair should only be performed by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in dan- ger to the technician or machine operator and will invalidate your factory warran- ty. For your safety and t[...]

F-88 TR OUBLESHOO TING AND REP AIR F-88 POWER WAVE 455/POWER FEED 10 7. Carefully remove the module. REPLA CEMENT PROCEDURE 1. Clean heatsink surfaces. 2. Apply an even coating of joint com- pound (Penetrox A-13) to both the heatsink and module mounting sur- faces. The joint compound should be 0.002 in/0.005 in. thick per surface. 3. Mount the modu[...]

F-89 TR OUBLESHOO TING AND REP AIR F-89 OUTPUT RECTIFIER AND MODULE REMO V AL AND REPLA CEMENT Service and repair should only be performed by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in dan- ger to the technician or machine operator and will invalidate your factory warran- ty. For your [...]

F-90 TR OUBLESHOO TING AND REP AIR F-90 POWER WAVE 455/POWER FEED 10 5. Using the 7/16 in. wrench, remove the eight transformer leads from the rectifi- er modules. Label the leads and take note of lead placement for reassembly. Note that each screw has two flat washers and one lock washer. 6. Remove leads #220 and #290 from the rectifier thermostat[...]

F-91 TR OUBLESHOO TING AND REP AIR F-91 POWER WAVE 455/POWER FEED 10 RECTIFIER ASSEMBL Y REPLA CEMENT PROCEDURE 1. Position the assembly in place with the mounting bolts. 2. Assemble the nuts and associated washers to the mounting bolts. 3. Using the 7/16 in. wrench, tighten the four nuts on the mounting bolts. 4. Replace leads #220 and #290 to the[...]

F-92 NO TES POWER WAVE 455/POWER FEED 10 F-92 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC[...]

TROUBLESHOOTING AND REP AIR F-93 POWER W A VE 455/POWER FEED 10 FLOWCHART - POWER SOURCE ERROR INTERPRET A TION GUIDE Code 12? Start Codes 21, 22, or 23? Code 36? Code 31? Codes 32, 33, 34, and 35? UI previously recognized by the system is no longer communicating, but power appears to be present at the UI. Check for intermittent connections in the [...]

TROUBLESHOOTING AND REP AIR F-94 POWER W A VE 455/POWER FEED 10 FLOWCHART - PERFORMANCE TROUBLESHOOTING GUIDE Turn On Performance T est Configuration (USE STD STUD)** GMAW (.045 Steel - 3/8" Plate) Mode = 5 WFS =400 ipm V oltage = 28V Gas =90/10 ArCO2 Arc Control= 0 ** Configuration may be altered based on available materials. A spray procedur[...]

TROUBLESHOOTING AND REP AIR F-95 POWER W A VE 455/POWER FEED 10 FLOWCHART - FUNCTIONAL TROUBLESHOOTING GUIDE N UI Status on? PS Status on? Check For 40VDC at UI Control Board V erify 12 VDC is being supplied to UI Display PCBD (J1 pin 7 to 8) Y OK At this point, voltage is being supplied to the UI Control Board, and the on board supply is properly [...]

G-1 ELECTRICAL DIA GRAMS G-1 T ABLE OF CONTENTS -ELECTRICAL DIA GRAMS SECTION- ELECTRICAL DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION G POWER WAVE 455 WIRING DIAGRAM - CODE 10372 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-2 POWER WAVE 455 W[...]

NO TES POWER WAVE 455/POWER FEED 10 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[...]

G-2 ELECTRICAL DIA GRAMS PO WER W A VE 455/PO WER FEED 10 P ower W ave 455 Wiring Diagram - Code 10372 1 3 TO CONTACTOR L3A 53 TO CT P90 10 3 4 6 406 239 G3051 19C 220 NEG NEG NEG RIGHT) RIGHT) RIGHT SIDE INPUT BOARD 1 601 TO CURRENT TRANSFORMER + C5 17 H5 CB3 2 1 405 604 274 6 1 2 3 4 5 6 J31 52 50 TP3 TO J81 CB2 33 32 3 4 3 4 5 7 15 J25 TP2 .05/6[...]

G-3 ELECTRICAL DIA GRAMS PO WER W A VE 455/PO WER FEED 10 P ower W a ve 455 Wiring Diagram - Code 10555 G-3 Retur n 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 1 L3A 18 TO AUX #1 TO CURRENT 32 33 4 POS X2 4 POWER BD RECTIFIER J[...]

G-4 ELECTRICAL DIA GRAMS PO WER W A VE 455/PO WER FEED 10 P ower W a ve 455 Wiring Diagram - Code 10553 G-4 Retur n 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 LEFT SIDE OF MACHINE CB4 6A CIRCUIT BREAKER S1 WIRE FEEDER RECEPTACLE[...]

G-5 ELECTRICAL DIA GRAMS PO WER W A VE 455/PO WER FEED 10 P o wer Feed 10 Control Bo x Wiring Dia gram 500D LINC-NET D C 540 B A TOROID R.F. (OPTIONAL FOR E BOOM SET UP) 500 E (P7) RECEPTACLE TOROID N.B. N.D. 500 2 3 4 540 (J6) INPUT 542 541 R.F. (J8) P.C. BOARD ENCODER DUAL LOWER OPTION N.E. 1 2 1 4 3 4 3 2 4 3 3 4 2 1 540A 500A 542A 541A 12 6 500[...]

G-6 ELECTRICAL DIA GRAMS PO WER W A VE 455/PO WER FEED 10 G-6 Retur n 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 P o wer Feed 10 Wire Drive Wiring Dia gram 554 555 557 556 512 559 (J8) R B E D C A 6 TRIGGER GAS PURGE (J7) 1 3 4 [...]

G-7 ELECTRICAL DIA GRAMS PO WER W A VE 455/PO WER FEED 10 G-7 Retur n 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 FEED 10 MA CHINE SCHEMA TIC 5J1 3J1 3J1 L2 L2 L1 L1 541 542 540 500 9J1 7J1 541 542 540 500 10J1 6J1 540B 54[...]

G-8 ELECTRICAL DIA GRAMS PO WER W A VE 455/PO WER FEED 10 PO WER W A VE 455 MA CHINE SCHEMA TIC - CODE 10372 U CR1 NEG NEG POS AC2 L2 L1 W V L3 T3 T2 T1 AC1 AC3 380-460V 208-230V NONE XA 11-14-97A 3-19-99D t UNLESS OTHERWISE SPECIFIED TOLERANCE ON HOLE SIZES PER E2056 ON 2 PLACE DECIMALS IS .02 WITH PUBLISHED STANDARDS. ON 3 PLACE DECIMALS IS .002 [...]

G-9 ELECTRICAL DIA GRAMS PO WER W A VE 455/PO WER FEED 10 G-9 Retur n 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 455 MA CHINE SCHEMA TIC - CODE 10555 50 224 220 3R 3W THERMOSTAT THERMOSTAT 222 223 226 FAN CONTROL ([...]

G-10 ELECTRICAL DIA GRAMS PO WER W A VE 455/PO WER FEED 10 G-10 Retur n 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 455 MA CHINE SCHEMA TIC - CODE 10553 1 H1A H1 1 (115V) NOTES : N.A. PC BOARD COMPONENTS SHOWN FOR R[...]

G-11 ELECTRICAL DIA GRAMS PO WER W A VE 455/PO WER FEED 10 PO WER W A VE 455 CONTROL PC BO ARD SCHEMA TIC (1 of 3) G-11 Retur n 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 NO TE: Lincoln Electric assumes no responsibility for lia[...]

G-12 ELECTRICAL DIA GRAMS PO WER W A VE 455/PO WER FEED 10 G-12 Retur n 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 455 CONTR OL PC BO ARD SCHEMA TIC (2 of 3) NO TE: Lincoln Electric assumes no responsibility for li[...]

G-13 ELECTRICAL DIA GRAMS PO WER W A VE 455/PO WER FEED 10 G-13 Retur n 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 455 CONTR OL PC BO ARD SCHEMA TIC (3 of 3) NO TE: Lincoln Electric assumes no responsibility for li[...]

G-14 ELECTRICAL DIA GRAMS PO WER W A VE 455/PO WER FEED 10 G-14 Retur n 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 455 PO WER PC BO ARD SCHEMA TIC FEEDBACK PRI. CURRENT 50V 0.1 C29 G D S 250V 38A Q3 3.32K R23 4.7 3[...]

G-15 ELECTRICAL DIA GRAMS PO WER W A VE 455/PO WER FEED 10 G-15 Retur n 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 455 INPUT PC BO ARD SCHEMA TIC 5-17-96 SINGLE PHASE DETECT NOTES : CHK. 1A, 400V CAPACITORS = 1A 15[...]

G-16 ELECTRICAL DIA GRAMS PO WER W A VE 455/PO WER FEED 10 G-16 Retur n 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 455 SWITCH PC BO ARD SCHEMA TIC - CODE 10372 & 10555 TRANSFORMER PRIMARY A 10.0 R26 1W 15V DZ1 [...]

G-17 ELECTRICAL DIA GRAMS PO WER W A VE 455/PO WER FEED 10 G-17 Retur n 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 455 SWITCH PC BO ARD SCHEMA TIC - CODE 10553 +15V 50V .022 C4 1.82K R23 CNY17-3V OCI2 4 2 1 6 5 681[...]

G-18 ELECTRICAL DIA GRAMS PO WER W A VE 455/PO WER FEED 10 G-18 Retur n 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 FEED 10 MO THER CONTR OL PC BO ARD SCHEMA TIC 540 500N 500D /SS PA3 +5V /IRQ SCK A15 MISO XTAL A14 MOSI 1.[...]

G-19 ELECTRICAL DIA GRAMS PO WER W A VE 455/PO WER FEED 10 G-19 Retur n 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 FEED 10 CONTROL PC BO ARD SCHEMA TIC J5 6 DATA GND NC DS2501 X10 3.32K R14 J5 3 T1 25t 20t 6 8 7 10.0 R88 [...]

G-20 ELECTRICAL DIA GRAMS PO WER W A VE 455/PO WER FEED 10 G-20 Retur n 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 FEED 10 DISPLA Y PC BO ARD SCHEMA TIC LED- 4 FILENAME: L10276_1AB LED2 LED1 14 3 Rx Vdd d BANK1 g DATA OUT[...]

G-21 ELECTRICAL DIA GRAMS PO WER W A VE 455/PO WER FEED 10 G-21 Retur n 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 FEED 10 ENCODER PC BO ARD SCHEMA TIC +5VDC 22920 D3 D9 J1 5 10.0 R5 J1 6 J1 1 J1 8 18 15V C2 475 R2 J1 7 J[...]

G-22 ELECTRICAL DIA GRAMS PO WER W A VE 455/PO WER FEED 10 G-22 Retur n 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 FEED 10 V OL T A GE SENSE PC BO ARD SCHEMA TIC EARTH GROUND CONNECTION S OCI2 1 4 6 2 5 160J 320V TP1 475 [...]