Lincoln Electric POWER WAVE 455 Service Manual Download Page 65

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TROUBLESHOOTING AND REPAIR

POWER WAVE 455/POWER FEED 10

SECTION F-1

TABLE OF CONTENTS

-TROUBLESHOOTING AND REPAIR SECTION-

Troubleshooting and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Section F

How to Use Troubleshooting Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

F-2

PC Board Troubleshooting Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

F-3

Troubleshooting Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

F-5

Power Wave . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

F-5

Power Feed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

F-13

Power Wave 455 Control Board LED Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

F-22

Test Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

F-23

Input Filter Capacitor Discharge Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

F-23

Switch Board Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

F-25

Output Rectifier Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

F-29

Input Rectifier Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

F-31

Input Contactor Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

F-35

Auxiliary Transformer No. 2 Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

F-37

Auxiliary Transformer No. 1 Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

F-39

Power Board Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

F-43

Current Transducer Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

F-47

Drive Motor Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

F-51

Tach Feedback Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

F-53

Voltage Sense PC Board Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

F-55

Dual Encoder PC Board Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

F-57

Control Cable Continuity Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

F-59

Component Replacement Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

F-61

Gas Solenoid Removal and Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

F-61

Wire Feeder Control Board Removal And Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

F-63

Tach (Hall Effect) Assembly Removal and Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

F-65

Gear Box and Drive Motor Removal and Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

F-67

Switch Board and Filter Capacitor Removal and Replacement . . . . . . . . . . . . . . . . . . . . . . . . .

F-71

Meter Accuracy Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

F-74

Control or Power Board Removal and Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

F-75

Auxiliary Transformer No. 1 Removal and Replacement Procedure . . . . . . . . . . . . . . . . . . . . .

F-79

Main Input Contactor Removal and Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

F-83

Input Rectifier Removal and Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

F-87

Output Rectifier and Module Removal and Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

F-89

Troubleshooting Flowcharts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

F-93

Power Source Error Interpretation Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

F-93

Performance Troubleshooting Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

F-94

Functional Troubleshooting Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

F-95

Return to Master TOC

Summary of Contents for POWER WAVE 455

Page 1: ...MENT WITHOUT READING THIS MANUAL AND THE SAFETY PRECAUTIONS CONTAINED THROUGHOUT And most importantly think before you act and be careful Return to Master TOC Return to Master TOC Return to Master TOC...

Page 2: ...BEFORE OPERATING Read and understand the following safety highlights For additional safety information it is strongly recommended that you purchase a copy of Safety in Welding Cutting ANSI Standard Z4...

Page 3: ...de holder work clamp welding cable and welding machine in good safe operating condition Replace damaged insulation 3 g Never dip the electrode in water for cooling 3 h Never simultaneously touch elect...

Page 4: ...re Remember that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas Avoid welding near hydraulic lines Have a fire extinguisher readily ava...

Page 5: ...laitier en fusion sont mises de l arc de soudage Se prot ger avec des v tements de protection libres de l huile tels que les gants en cuir chemise paisse pantalons sans revers et chaussures montantes...

Page 6: ...s Spools or Coils B 7 Feeding Electrode and Brake Adjustment B 9 Drive Roll Kit Installation KP1505 B 9 Drive Roll Pressure Setting B 9 Procedure For Setting Angle of Feedplate B 9 Wire Feed Overload...

Page 7: ...nce Protection A 6 Input Fuse and Supply Wire Considerations A 6 Input Voltage Reconnect Procedure A 6 Cable Connections A 7 Control Cable Connections A 7 Flexible Connection Possibilities A 7 Cable C...

Page 8: ...2 03 30 5 m m 0 6 1 6 mm 0 9 2 0 mm K1541 1 Power Feed 10 50 800 IPM 025 3 32 in 035 125 in 75 1200 IPM 025 1 16 in 035 5 64 in Bench Model 1 27 20 3 m m 0 6 2 4 mm 0 9 3 2 mm 2 03 30 5 m m 0 6 1 6 mm...

Page 9: ...100 100 100 60 60 60 60 Process Current Ranges DC MIG MAG FCAW SMAW Pulse Current 50 570 Amps 40 570 Amps 30 570 Amps 5 750 Amps Pulse Voltage Range 5 55 VDC Auxiliary Power 40 VDC AT 10 AMPS 115 VAC...

Page 10: ...e stacked to a maxi mum of three high The bottom machine must always be placed on a firm secure level surface There is a danger of machines toppling over if this precaution is not taken ENVIRONMENT Th...

Page 11: ...nels removed from front of Control Box 7 Place plug button saved in step 2 into hole in back panel of Control Box CONTROL BOX POWER SOURCE MOUNTING The Power Feed Control Box can be directly mount ed...

Page 12: ...and wire sizes Fuse the input circuit with the recom mended super lag fuse or delay type breakers also called inverse time or thermal magnetic circuit breakers Choose an input and grounding wire size...

Page 13: ...s This could be the control box or the FH control box depending on how the units were sepa rated A second control cable would be connected from the second connector on the control box to the other FH...

Page 14: ...he connection to the work makes tight metal to metal electrical contact Minimum work and electrode cables sizes are as fol lows When using an inverter type power source use the largest welding electro...

Page 15: ...t of this section for feed speed and wire size capabilities with high and low speed gear ratios To determine whether you should be using the high or low speed ratio use the following guidelines If you...

Page 16: ...m the output shaft Lightly cover the output shaft with engine oil or equivalent Install gear onto output shaft and secure with flat washer lock washer and Phillips head screw which were previously rem...

Page 17: ...eld current when weld current is flowing CC modes override this switch regardless of position Left Display is always preset weld cur rent when weld current is not flowing and actual weld current when...

Page 18: ...d to the motherboard it automatically overrides this switch regardless of position 5 Memory change with trigger disabled Memory change with trigger enabled 6 Acceleration MSB Sets acceleration rate fo...

Page 19: ...switch bank that is furthest to the left LSB Least Significant Bit or Byte This is the bit in a binary number or DIP switch bank that is furthest to the right S2 DIP Switch Bank on Control Box Mother...

Page 20: ...to wire drive 6 Spare 7 Electrode Sense Polarity Positive Electrode Sense Polarity Negative Switch position must match polarity of weld cable attached to feed plate 8 Gear Box Ratio Low Gear Box Rati...

Page 21: ...le on the front of the wire drive unit NOTE For Fast Mate and European connector style guns connect gun to gun connector making sure all pins and gas tube line up with appropriate holes in connector T...

Page 22: ...Y 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 Control Display Panel fits into the upp...

Page 23: ...B 6 Wire Spindle Replacement B 7 Wire Reel Loading Readi Reels Spools or Coils B 7 To Mount a 30 lb 14 kg Readi Reel Package Using the Molded Plastic K363 P Readi Reel Adapter Figure B 4 B 7 To Mount...

Page 24: ...rm control The Power Feed 10 is a high performance digitally controlled modular wire feeder Properly equipped they can support the GMAW GMAW P and FCAW processes Operating as a system each component i...

Page 25: ...of non Lincoln wire feeders cannot be used CONTROLS AND SETTINGS POWER WAVE CONTROLS AND STATUS LIGHTS All operator controls and adjustments are located on the case front of the Power Wave See Figure...

Page 26: ...ust turn power source off find source of error and turn power back on to reset See Troubleshooting Section See Troubleshooting Section B 4 OPERATION B 4 FIGURE B 2 WIRE FEEDER CONTROLS When the switch...

Page 27: ...ed to adjust the parameters for either wire feed speed or output amps dependent upon the process and weld mode being used Rotating the encoder knob CCW decreases the num ber value while rotating the k...

Page 28: ...one wire feed speed this change is applied to all other wire feed speed settings For example if the operator turns up the voltage by 10 percent the machine automatically increases the preset voltages...

Page 29: ...and remove it from the spindle 2 Place the adapter on the spindle 3 Re install the retaining collar Make sure that the release bar pops up and that the collar retainers fully engage the retaining groo...

Page 30: ...Before cutting the tie wires place the coil of elec trode on the reel so it unwinds from the bottom as the reel rotates The slots in the cardboard liner should align over the spring loaded arms 3 Tigh...

Page 31: ...on and close pressure door To set drive roll pressure see Drive Roll Pressure Setting DRIVE ROLL PRESSURE SETTING The Power Feed 10 pressure is factory pre set to about position 2 as shown on the pres...

Page 32: ...seconds before the wire drive will automatically reset At that time the wire drive will issue a shutdown over command to the Control Box that will return the system to normal operation The wire drive...

Page 33: ...3 Wire Feeder Options and Accessories C 3 Drive Roll and Guide Tube Kits C 3 Input Cable Assemblies C 4 Cable Receptacles C 4 Reel Adapters C 6 Guns and Gun Adapters C 6 Conduit Adapters C 7 Dual Proc...

Page 34: ...FUME EXTRACTION GUNS K556 400XA K206 K289 K309 K489 2 FAST MATE ADAPTER KIT K1500 1 LINCOLN INNERSHEILD GUN STANDARD CONNECTION K1500 2 TWECO 2 4 CONNECTION K1500 3 TWECO 5 CONNECTION K1500 4 MILLER...

Page 35: ...id Steel Electrode in mm 0 023 0 025 0 6 KP1505 030S 0 030 0 8 KP1505 030S 0 035 0 9 KP1505 035S 0 040 1 0 KP1505 045S 0 045 1 2 KP1505 045S 0 052 1 4 KP1505 052S 1 16 1 6 KP1505 1 16S 5 64 2 0 KP1505...

Page 36: ...left hole in the bottom of the Control Box cabinet and store it in the bottom of the Control Box cabinet for future use should the Optional Output Connector be removed 5 Place the Optional Output Con...

Page 37: ...ed earlier 9 Replace the rear access door and Feed Head cover if removed RECEPTACLE INPUT Power Feed Wire Feeder Optional Input Connector Installation into the Control Box Cabinet and Conversion to Fi...

Page 38: ...ts Lincoln Readi Reel coils of electrode 30 lb 14 kg and 22 lb 10 kg to a 2 in 51 mm spindle Durable molded plastic one piece construction Designed for easy loading adapter remains on spin dle for qui...

Page 39: ...N The K1500 2 gun adapter comes factory installed on the Power Feed 10 wire feeder Use this adapter for guns that have a Tweco 2 4 connector Such guns include Magnum 200 300 400 guns with K466 10 conn...

Page 40: ...IT Install per the instructions shipped with the kit K659 1 GAS GUARD REGULATOR Adjustable flow regulator with removable adjuster key for CO2 and Argon blend gases Mounts onto feeder inlet and reduces...

Page 41: ...board 10 pin Make sure the connector latches in place 4 Position the new panel taking care not to dam age the switch connections on the back 5 Align the screw holes replace the two screws and tighten...

Page 42: ...he active parameter Available Modes CV MIG CV FLUX CORED CC STICK CRISP CC STICK SOFT Due to the nature of the system the following feature is required for safety reasons Upon entering any constant cu...

Page 43: ...s upper or lower limit advancing ceases until the direction of the switch is changed Installation is as follows 1 Turn off power 2 Remove the two screws from the front of the blank option panel at the...

Page 44: ...til the switch is released When the indicator reaches its upper or lower limit advancing ceases until the direction of the switch is changed GMAW Pulse Procedures In these procedures the actual voltag...

Page 45: ...ed by the position of the switch located at the gun Under this condition indicators will show that the gun switch has been selected and also which procedure the gun switch is requesting Memory Selecti...

Page 46: ...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 The value of the active Set Up paramet...

Page 47: ...ce strange display values used for troubleshooting and service If encountered reset Run In to 150 IPM or less Arc Control Unitless characteristic also known as Inductance or Wave Control Allows operat...

Page 48: ...Turn the system power off Return S2 7 to off If a Dual Procedure panel is installed repeat the above procedure with the Procedure B selected When done attach the Control Display panel to the Control B...

Page 49: ...TENANCE SECTION Maintenance Section D Safety Precautions D 2 Routine Maintenance D 2 Power Wave D 2 Wire Feeder D 2 Periodic Maintenance D 2 Wire Drive Motor and Gearbox D 2 Gun and Cable Maintenance...

Page 50: ...EL MOUNTING READI REELS AND 10 THROUGH 30 LB 4 5 14 KG SPOOLS No routine maintenance required Do not lubricate 2 in 51 mm spindle AVOIDING WIRE FEEDING PROBLEMS Wire feeding problems can be avoided by...

Page 51: ...put Voltage and Precharge E 5 Switch Boards and Main Transformer E 6 Control Board E 7 Output Rectifier and Choke E 8 Thermal Protection E 9 Protective Circuits E 9 Over Current Protection E 9 Under O...

Page 52: ...he Welding Network is an assembly of welding equipment joined together by a common network communication cable These individual welding components con sist of a power source Power Wave 455 a user inte...

Page 53: ...to Figure E 2 The combi nation Control Box user interface and power source Power Wave 455 make up one of the circuit elements This combina tion unit is coupled to the wire drive module Power Feed 10...

Page 54: ...source Power Wave 455 the Control Box user interface and the wire drive Power Feed 10 are the three dis crete and physically separate circuit compo nents employed in this configuration Refer to Figur...

Page 55: ...igh performance digitally controlled inverter capable of complex high speed waveform control With the appropriate modular components it can sup port constant current constant voltage and pulse welding...

Page 56: ...ured for a lower input voltage below 300 VAC the input capacitors are connected in parallel When the machine is configured for higher input voltages 300 VAC and above the input capacitors are connecte...

Page 57: ...d or the RS232 connector The software that is contained within the control board processes and compares these commands with the voltage and current feedback infor mation it receives from the current s...

Page 58: ...T CONTROL BOARD RIGHT SWITCH BOARD LEFT SWITCH BOARD MAIN TRANSFORMER CURRENT SENSOR CHOKE OUTPUT TERMINAL OUTPUT TERMINAL POWER BOARD 115VAC RECEPTACLE P O W E R S W I T C H I N P U T B O A R D FAN...

Page 59: ...located on the heat sink of the output rectifier and the other is located near the fan On later pro duction machines this thermostat is located on the output choke Excessive tempera tures may be cause...

Page 60: ...R IGBT OPERATION An IGBT is a type of transistor IGBT are semiconductors well suited for high frequen cy switching and high current applications Example A in Figure E 8 shows an IGBT in passive mode T...

Page 61: ...TH MODULATION The term Pulse Width Modulation is used to describe how much time is devoted to con duction in the positive and negative portions of the cycle Changing the pulse width is known as modula...

Page 62: ...s the main entry point for all system parameters and from it the user can control both power source and wire feeder functions Refer to Figure E 10 The user interface motherboard is the heart of the Co...

Page 63: ...is designed to be part of a modu lar multi process welding system Refer to Figure E 11 Network communications intelligence PC board input power and arc voltage feed back is received and transmitted t...

Page 64: ...ES 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 Ma...

Page 65: ...Test F 55 Dual Encoder PC Board Test F 57 Control Cable Continuity Test F 59 Component Replacement Procedures F 61 Gas Solenoid Removal and Replacement F 61 Wire Feeder Control Board Removal And Repl...

Page 66: ...order listed to eliminate one possibility at a time until you locate the cause of your problem All of the referenced test procedures referred to in the Troubleshooting Guide are described in detail a...

Page 67: ...istive cord con nected to a grounded part of the equipment frame If you don t have a wrist strap touch an unpainted grounded part of the equipment frame Keep touching the frame to prevent static build...

Page 68: ...then the PC board was not the problem Continue to look for bad connections in the control wiring harness junction blocks and termi nal strips b If the original problem is recreated by the substitutio...

Page 69: ...for the applied input voltage 3 The welding procedure may be drawing too much input current or the duty cycle may be too high Reduce the welding cur rent and or reduce the duty cycle If for any reason...

Page 70: ...the reconnect panel is configured correctly for the applied input voltage 3 If the machine is connected for 380 VAC or higher and has not been used for a long period of time the capacitors may requir...

Page 71: ...ctly 1 Check the 10 amp circuit break er CB2 located on the case front Reset if necessary 2 Check the 10 amp circuit break er CB3 located in the recon nect area Reset if necessary 1 The input voltage...

Page 72: ...current exceeds a maximum limit the machine will phase back to protect itself Adjust the proce dure or reduce the load to lower the current draw from the Power Wave 455 machine Power Wave 455 When th...

Page 73: ...he 6 amp circuit breaker CB4 located on the reconnect panel Reset if necessary 4 Check the control cable between the power source and the wire feeder Check for loose or broken con nections Check conti...

Page 74: ...Instruction Manual If the wire drive unit and Control Box are properly configured consult the Status LED Error Code Table The Power Wave 455 cannot communicate with the wire drive unit and or the Cont...

Page 75: ...f 1 2 sec red 1 6 sec off 0 4 sec red 2 sec green 1 2 sec red 0 4 sec off 1 2 sec red 1 6 sec off 0 4 sec red 0 4 sec off 0 4 sec red 2 sec green 1 2 sec red 0 4 sec off 1 2 sec red 1 6 sec off 0 4 se...

Page 76: ...1 2 sec red 1 6 sec off 0 4 sec red 0 4 sec off 0 4 sec red 0 4 sec off 0 4 sec red 2 sec green 1 2 sec red 0 4 sec off 1 2 sec red 0 4 sec off 1 2 sec red 1 6 sec off 0 4 sec red 0 4 sec off 0 4 sec...

Page 77: ...ce 2 Make certain the Control Box is configured for a wire feeding mode 3 Check option panel connec tions and switch s for proper operation 1 Check for a mechanical restric tion in the wire feed path...

Page 78: ...perating properly 2 Check for loose or faulty leads between the COLD INCH GAS PURGE switch and the wire drive control board See wiring diagram 1 Make sure the DIP switches are configured correctly for...

Page 79: ...2 Check the following connections on the Power Wave 455 machine Check for loose or faulty connections between plug J90 at the current transducer and plug J21 on the Power Wave 455 control board 1 Chec...

Page 80: ...emote dual procedure switch 1 Check for 12 VDC at plug J1 pin 7 lead 512 to plug J1 pin 8 lead 500 on the display board If the 12 VDC is present then the display board may be faulty 2 If the 12 VDC is...

Page 81: ...hut down circuit in the wire drive unit may be electrical ly open Make sure leads 570 and 571 are connected together 2 The drive motor may be over loaded due to a mechanial restriction in the wire fee...

Page 82: ...ck plug J3 on the wire drive control board and leads 550 and 551 for loose or faulty con nections See wiring diagram 1 The drive roll pressure may be incorrect Set drive roll pres sure See Operation s...

Page 83: ...ricant such as Graphite Grease may be applied to tip threads 1 Make sure the weld procedures are correct for the process being used Check gas wire feed speed and arc voltage 2 Remove the gun liner and...

Page 84: ...s Remove any objects over seven either by changing the group DIP switch set tings or physically disconnecting the extra objects See Instal lation section of this manual Adjust the DIP switch setting t...

Page 85: ...e flash ing red on the problem unit Otherwise check for any units that are flashing green This indicates that the particular unit has not been recognized and there is a power source problem See Power...

Page 86: ...DEFINITIONS LED COLOR AND NUMBER CIRCUIT INDICATORS Green LED 1 15 VDC Supply Green LED 3 15 VDC Supply Green LED 4 5 VDC Supply Red LED 5 On when jumper removed from J26 Green 6 LED 5 VDC Communicati...

Page 87: ...or technical troubleshooting assistance before you proceed Call 216 383 2531 or 1 800 833 9353 WELD TEST DESCRIPTION This safety procedure should be performed before any internal maintenance or repair...

Page 88: ...a switch board problem TEST PROCEDURE 1 Remove input power to the Power Wave 455 2 Using the 3 8 in nutdriver remove the left and right case sides 3 Be careful not to make contact with the capacitor...

Page 89: ...leshooting assistance before you proceed Call 216 383 2531 or 1 800 833 9353 WELD TEST DESCRIPTION This test will help determine if the power section of the switch boards are functioning correctly Thi...

Page 90: ...ts detailed in Table F 1 Refer to Figure F 3 for the test points TEST PROCEDURE 1 Remove input power to the Power Wave 455 2 Using the 3 8 in nutdriver remove the case top and sides 3 Perform the Capa...

Page 91: ...3 SWITCH BOARD TEST POINTS SWITCH BOARD 20 19 11 12 OR 15 16 13 14 OR 17 18 SWITCH BOARD TEST continued APPLY POSITIVE TEST APPLY NEGATIVE TEST NORMAL PROBE TO TERMINAL PROBE TO TERMINAL RESISTANCE RE...

Page 92: ...ES 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 Ma...

Page 93: ...ason you do not understand the test procedures or are unable to per form the test repairs safely contact the Lincoln Electric service department for technical troubleshooting assistance before you pro...

Page 94: ...acement Procedure TEST PROCEDURE 1 Remove main input supply power to the Power Wave 455 NOTE Later code machines have a 50 ohm resistor across the welding output ter minals It will be necessary to rem...

Page 95: ...st procedures or are unable to per form the test repairs safely contact the Lincoln Electric service department for technical troubleshooting assistance before you proceed Call 216 383 2531 or 1 800 8...

Page 96: ...rform the tests detailed in Table F 2 TEST PROCEDURE 1 Remove input power to the Power Wave 455 2 Using the 3 8 in nutdriver remove the case top 3 Perform the Capacitor Discharge Procedure 4 Locate th...

Page 97: ...put rectifier see Input Rectifier Removal and Replacement procedure TABLE F 2 INPUT RECTIFIER TEST POINTS AND ACCEPTABLE READINGS INPUT RECTIFIER TEST continued TEST POINT TERMINALS ANALOG METER X10 R...

Page 98: ...ES 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 Ma...

Page 99: ...rocedures or are unable to per form the test repairs safely contact the Lincoln Electric service department for technical troubleshooting assistance before you proceed Call 216 383 2531 or 1 800 833 9...

Page 100: ...ds 601 601A X4 and X4A that are connected to the input contactor coil Refer to Figure F 6 4 Using the external 24 VAC supply apply 24 VAC to the terminals of the input contactor coil If the contactor...

Page 101: ...est repairs safely contact the Lincoln Electric service department for technical troubleshooting assistance before you proceed Call 216 383 2531 or 1 800 833 9353 WELD TEST DESCRIPTION This test will...

Page 102: ...EST PROCEDURE 1 Remove the main input supply power to the Power Wave 455 machine 2 Remove any load that may be connect ed to the 115 VAC receptacle 3 Using the 3 8 in nutdriver remove the left and rig...

Page 103: ...est repairs safely contact the Lincoln Electric service department for technical troubleshooting assistance before you proceed Call 216 383 2531 or 1 800 833 9353 WELD TEST DESCRIPTION This test will...

Page 104: ...nput supply power to the Power Wave 455 machine 2 Using the 3 8 in nutdriver remove the case sides and top 3 Perform the Capacitor Discharge Procedure FIGURE F 9 AUXILIARY TRANSFORMER NO 1 TEST FAN MO...

Page 105: ...dary voltages will vary if the input line voltage varies 8 If the correct secondary voltages are present the T1 auxiliary transformer is functioning properly If any of the sec ondary voltages are miss...

Page 106: ...ES 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 Ma...

Page 107: ...to per form the test repairs safely contact the Lincoln Electric service department for technical troubleshooting assistance before you proceed Call 216 383 2531 or 1 800 833 9353 WELD TEST DESCRIPTI...

Page 108: ...case sides and top using the 3 8 in nutdriver TEST PROCEDURE 1 Remove input power to the Power Wave 455 2 Using the 3 8 in nutdriver remove the case sides and top 3 Perform the Capacitor Discharge Pr...

Page 109: ...SUPPLY FROM 4 222 CONNECTOR POWER PC PLUG J31 BOARD POWER PC CHECK 15 VDC 4 222 15 VDC BOARD SUPPLY FROM 3 223 CONNECTOR POWER PC PLUG J31 BOARD POWER PC CHECK 5 VDC 11 274 5 VDC BOARD CAN SUPPLY 12 2...

Page 110: ...ES 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 Ma...

Page 111: ...erstand the test procedures or are unable to per form the test repairs safely contact the Lincoln Electric service department for technical troubleshooting assistance before you proceed Call 216 383 2...

Page 112: ...ower to the Power Wave 455 2 Using the 3 8 in nutdriver remove the right side case cover 3 Perform the Capacitor Discharge Procedure 4 Locate the current transducer at the lower right front of the mac...

Page 113: ...tem in a constant current mode and the machine loaded to 250 amps the current feedback voltage can be read at plug P90 A Pin 3 lead 211 to pin 4 lead 216 should read 2 0 VDC machine loaded to 250 amps...

Page 114: ...ES 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 Ma...

Page 115: ...procedures or are unable to per form the test repairs safely contact the Lincoln Electric service department for technical troubleshooting assistance before you proceed Call 216 383 2531 or 1 800 833...

Page 116: ...re feed unit 2 Using the 3 8 in nutdriver remove the cover from the wire feeder 3 Locate the two quick connectors in the two motor armature leads Refer to Figure F 12 Do NOT disconnect the leads 4 App...

Page 117: ...to per form the test repairs safely contact the Lincoln Electric service department for technical troubleshooting assistance before you proceed Call 216 383 2531 or 1 800 833 9353 WELD TEST DESCRIPTIO...

Page 118: ...Using the 3 8 in nutdriver remove the cover from the wire feeder 3 Locate plug J4 on the control board Refer to Figure F 13 Do NOT remove the plug from the control board 4 Apply the correct input powe...

Page 119: ...rm the test repairs safely contact the Lincoln Electric service department for technical troubleshooting assistance before you proceed Call 216 383 2531 or 1 800 833 9353 WELD TEST DESCRIPTION This te...

Page 120: ...ve input power from the wire feed unit 2 Using the 3 8 in nutdriver remove the cover from the wire feeder 3 Locate the voltage sense PC board and plugs J1 and J2 Do not remove the plugs from the volta...

Page 121: ...erstand the test procedures or are unable to per form the test repairs safely contact the Lincoln Electric service department for technical troubleshooting assistance before you proceed Call 216 383 2...

Page 122: ...rol box assembly 2 Using the Phillips head screwdriver remove the display encoder assembly panel from the Control Box Refer to Figure F 15 NOTE The panel assembly cannot be removed completely without...

Page 123: ...f for any reason you do not understand the test procedures or are unable to per form the test repairs safely contact the Lincoln Electric service department for technical troubleshooting assistance be...

Page 124: ...ave 455 machine 2 Disconnect the control cable amphe nols from the power source and the wire feeder 3 Using the ohmmeter measure the resis tance of the individual control cable leads from the amphenol...

Page 125: ...st procedures or are unable to per form the test repairs safely contact the Lincoln Electric service department for technical troubleshooting assistance before you proceed Call 216 383 2531 or 1 800 8...

Page 126: ...ve input power to the wire feeder 2 Using the 3 8 in nutdriver remove the cover from the wire feeder 3 Locate the gas solenoid on the rear panel of the wire feeder Refer to Figure F 17 4 Using the 3 4...

Page 127: ...son you do not understand the test procedures or are unable to per form the test repairs safely contact the Lincoln Electric service department for technical troubleshooting assistance before you proc...

Page 128: ...over from the wire feeder 3 Observe static precautions detailed in PC Board Troubleshooting Procedures at the beginning of this section 4 Disconnect the molex type plugs from the control board Refer t...

Page 129: ...ou do not understand the test procedures or are unable to per form the test repairs safely contact the Lincoln Electric service department for technical troubleshooting assistance before you proceed C...

Page 130: ...he wire feeder 2 Using the 3 8 in nutdriver remove the case cover 3 Locate the tach assembly on the top of the gear box Refer to Figure F 19 4 Locate and remove plug J4 from the control board 5 Thread...

Page 131: ...eshooting assistance before you proceed Call 216 383 2531 or 1 800 833 9353 WELD DESCRIPTION This test will aid the technican in the removal and replacement of the wire feed drive motor Removal and in...

Page 132: ...input power to the wire drive unit 2 Using the 3 8 in nutdriver remove the case cover 3 Locate and remove plug J4 from the control board Refer to Figure F 20 FIGURE F 20 GEAR BOX AND DRIVE MOTOR REMO...

Page 133: ...feeder cover using the 3 8 in nutdriver 7 Using the needlenose pliers discon nect the gas hose from the brass gun connector block 8 Using the 7 16 in socket wrench remove the four mounting bolts lock...

Page 134: ...ES 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 Ma...

Page 135: ...e test procedures or are unable to per form the test repairs safely contact the Lincoln Electric service department for technical troubleshooting assistance before you proceed Call 216 383 2531 or 1 8...

Page 136: ...ROCEDURE NOTE Observe all static electricity precau tions 1 Remove input power to the Power Wave 455 2 Using the 3 8 in nutdriver remove the case top and sides 3 Perform the Capacitor Discharge Proced...

Page 137: ...the 3 16 in Allen wrench care fully remove the four cap screws that mount the switch board to the heatsink 10 Carefully remove the switch board from the heatsink 11 If the filter capacitor is to be re...

Page 138: ...cated on the upper left corner of the Control PC board If the display is still in error either the Control PC board or LEM Current Transducer may be faulty Perform the Current Transducer Test POWER WA...

Page 139: ...e test procedures or are unable to per form the test repairs safely contact the Lincoln Electric service department for technical troubleshooting assistance before you proceed Call 216 383 2531 or 1 8...

Page 140: ...he power or the control board from the PC board assembly REMOVAL PROCEDURE 1 Remove input power to the Power Wave 455 2 Using the 3 8 in nutdriver remove the case top and sides 3 Perform the Capacitor...

Page 141: ...ower or control board to the PC board assembly and secure it in place using the Phillips head mount ing screws 2 Carefully slide the power and control PC board assembly into place making sure to clear...

Page 142: ...ES 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 Ma...

Page 143: ...t understand the test procedures or are unable to per form the test repairs safely contact the Lincoln Electric service department for technical troubleshooting assistance before you proceed Call 216...

Page 144: ...iver remove the case top sides and input access panel 3 Perform the Capacitor Discharge Procedure 4 Using the 3 8 in nutdriver remove the case back FIGURE F 23 AUXILIARY TRANSFORMER NO 1 REMOVAL AND R...

Page 145: ...t is connected to the input board Leave enough lead length to splice in the new transformer lead 9 Locate label and remove primary lead H1 from circuit breaker CB4 10 Label and remove primary leads H2...

Page 146: ...ES 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 Ma...

Page 147: ...t understand the test procedures or are unable to per form the test repairs safely contact the Lincoln Electric service department for technical troubleshooting assistance before you proceed Call 216...

Page 148: ...Remove input power to the Power Wave 455 2 Using the 3 8 in nutdriver remove the case top sides and input access panel 3 Perform the Capacitor Discharge Procedure 4 Using the slot head screwdriver rem...

Page 149: ...nd input access panel using the 3 8 in nutdriver REPLACEMENT PROCEDURE 1 Carefully place the input contactor into position 2 Install the three mounting screws that hold the input contactor to the meta...

Page 150: ...ES 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 Ma...

Page 151: ...nd the test procedures or are unable to per form the test repairs safely contact the Lincoln Electric service department for technical troubleshooting assistance before you proceed Call 216 383 2531 o...

Page 152: ...AL PROCEDURE 1 Remove input power to the Power Wave 455 2 Using the 3 8 in nutdriver remove the case top sides and input access panel 3 Perform the Capacitor Discharge Procedure 4 Locate and remove th...

Page 153: ...s safely contact the Lincoln Electric service department for technical troubleshooting assistance before you proceed Call 216 383 2531 or 1 800 833 9353 WELD DESCRIPTION This procedure will aid the te...

Page 154: ...and removing the mounting bolts RECTIFIER ASSEMBLY REMOVAL PROCEDURE 1 Remove input power to the Power Wave 455 2 Using the 3 8 in nutdriver remove the case top and sides 3 Perform the Capacitor Disc...

Page 155: ...ove the cap screw from the center of the rectifier module that is to be replaced 2 Using the 7 16 in wrench remove the two mounting bolts and associated washers from the rectifier module to be replace...

Page 156: ...ES 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 Ma...

Page 157: ...Control board 5VDC normal 0VDC fault Code 32 and 34 Code 33 and 35 Perform the Switch Board Test on Side A left side facing the front of machine Perform the Switch Board Test on Side B right side fac...

Page 158: ...res when replacing this board OK Matches Display Value 1V Does not match Display Value 1V N N Under load as defined previously Check for actual voltage at the PS Control PC Bd from P20 6 to P20 2 The...

Page 159: ...Look for open circuit in the PS secondary N System is stuck in Remapping loop Most likely cause is the loss of the 5Vcan Supply Check J27 on PS Control Board check Power Board Etc Flashing Green Y Ve...

Page 160: ...G 10 POWER WAVE 455 CONTROL PC BOARD SCHEMATIC 1 of 3 G 11 POWER WAVE 455 CONTROL PC BOARD SCHEMATIC 2 of 3 G 12 POWER WAVE 455 CONTROL PC BOARD SCHEMATIC 3 of 3 G 13 POWER WAVE 455 POWER PC BOARD SCH...

Page 161: ...ES 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...

Page 162: ...N H3A CB4 TO 5 14 1 VIEWED FROM COMPONENT SIDE OF BOARD 4 X3 F4 800V F4 022 F3 F3 022 800V F2 022 F2 800V POS X2 MAIN CHOKE L1 S3 TO CURRENT TRANSFORMER TO INPUT RECT POS 19D 19C TO SWITCH BD 2 TO SWI...

Page 163: ...REAR OF MACHINE TO L7 206A 405 404 1 TO CURRENT X3A TO SOLID STATE RELAY TO AUX 1 P6 USER INTERFACE 220 14 15 CURRENT 800V 022 800V 022 P91 CURRENT TRANSDUCER TO J24 TO J22 50 CB1 10A CIRCUIT BREAKER...

Page 164: ...B 17B N C TO SWITCH BD 2 AUXILIARY TRANSFORMER 2 AUXILIARY TRANSFORMER 1 CONTROL BOARD CB2 10A CIRCUIT BREAKER SWITCH BOARD 2 VOLTAGE CONNECTION SHOWN IS FOR 550 575V OPERATION N D 800V 022 N D 10W 2...

Page 165: ...EDGE OF LED LENS CATHODE ALIGNS WITH BLACK LEAD OF LED SOCKET L10586 500 8 7 W B NOTES N A CAVITY NUMBERING SEQUENCE AS VIEWED FROM COMPONENT SIDE OF PC BOARD N F CAVITY NUMBERING SEQUENCE AS VIEWED...

Page 166: ...57 J4 5 6 1 2 1 N E 67 GAS SOLENOID 5 4 3 4 1 3 2 1 12 11 C A B E D 500 N A 542 540C 500D 542D 541 2 7 8 6 10 9 558 2 570 7 SELECT P C BOARD VOLTAGE SENSE RECTIFIER N A R F 6 AC 512B 5 4 3 2 1 553 552...

Page 167: ...P7 3P7 4P7 6P7 5P7 COMMUNICATION COMMUNICATION L2 L2 L1 L1 541 542 540 500 541 542 540 500 A B D E C 67 2J1 1J1 L9 L8 L7 3J1 4J1 541D 542D 540D 500D 40 VDC 0 VDC 40 VDC 0 VDC J6 OPTIONAL OUTPUT RECEPT...

Page 168: ...C2 TP2 TP3 POS NEG POS POS NEG NEG 2 3 4 5 6 7 20 MAIN TRANSFORMER T1 CR1 S5 RS232 CONNECTOR 7J22 9J22 S1 WIRE FEEDER RECEPTACLE ARCLINK CURRENT FEEDBACK 15V 15V 2J20 4J21 8J21 13J23 6J22 8J22 50WT IN...

Page 169: ...T 022u 800V C1 TP1 4J91 05uF 600V C4 CAP A 3400uF 450V 506 C5 CAP B 3400uF 450V X3 T3 T1 9J23 4J23 5J23 14J23 7J23 13J23 6J23 12J23 3J23 10J23 2J21 4J22 3J21 1J21 10J22 6J21 8J23 2J20 11J23 1J23 6J20...

Page 170: ...T DR DATE TYPE EQUIP CLEVELAND OHIO U S A CHK REF SHT SUP S D G NO EMS NOT TO BE REPRODUCED DISCLOSED OR USED WITHOUT THE EXPRESS PERMISSION OF UNLESS OTHERWISE SPECIFIED TOLERANCE ON 2 PLACE DECIMALS...

Page 171: ...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...

Page 172: ...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...

Page 173: ...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...

Page 174: ...NERAL INFORMATION 1 4W Ch ge Sht No ELECTRICAL SYMBOLS PER E1537 RESISTORS Ohms G SHT NO EARTH GROUND CONNECTION 3026 POWER SUPPLY SOURCE POINT SUPPLY COMMON CONNECTION UNLESS OTHERWISE SPECIFIED UNLE...

Page 175: ...HOUT AFFECTING THE INTERCHANGEABILITY OF A COMPLETE BOARD THIS DIAGRAM MAY ON 3 PLACE DECIMALS IS OO2 THE LINCOLN ELECTRIC CO ON 2 PLACE DECIMALS IS O2 MATERIAL TOLERANCE t TO AGREE THIS SHEET CONTAIN...

Page 176: ...GE NOT SHOW THE EXACT COMPONENTS OR CIRCUITRY OF CONTROLS HAVING A COMMON CODE WITHOUT AFFECTING THE INTERCHANGEABILITY OF A COMPLETE BOARD THIS DIAGRAM MAY DATE DR LC 2 10 97 RECONNECT RESISTORS BLEE...

Page 177: ...ERANCE WITHOUT AFFECTING THE INTERCHANGEABILITY OF A COMPLETE BOARD THIS DIAGRAM MAY MATERIAL TOLERANCE t TO AGREE ON 2 PLACE DECIMALS IS O2 WITH PUBLISHED STANDARDS NUMBER Ch ge Sht No DIODES N A SIN...

Page 178: ...X6 6 5 4 75K R9 J1AMISO 5V SCK 500D 50V 0 1 C21 50V 0 1 C9 50V 0 1 C11 50V 0 1 C50 54HC74 X11 7 14 500D MC68HC705J1 X10 10 9 50V 0 1 C12 74AC138 X26 16 8 74AC138 X12 16 8 Vdd Vss MC68HC11E1 X9 1 26 5...

Page 179: ...A0 G OFF ON 505 B 825 R79 C51 825 R81 S1 12 5 C46 4 75K R3 6 81K R5 1 30K R83 4 75K R9 S1 15 2 505 2 21K R2 DIP1 500 505 505 TR 4 75K R86 825 R90 825 R82 C47 X7 2 4 5 1 30K R91 S1 9 8 X7 13 10 11 S1 1...

Page 180: ...6 10K R7 475 R10 J1 4 X5 2 1 5VB 500 5VA 500 500 500 10276 512 L SCK 7805 7805 MOSI X5 12 13 VOLTS HEXINV X5 14 7 LED3 DISP6 2 1 4 9 5 10 7 6 8 3 DISP5 2 1 4 9 5 10 7 6 8 3 TRIM DISP7 2 1 4 9 5 10 7 6...

Page 181: ...N A PRINTED N A OR CIRCUITRY OF ON 3 PLACE DECIMALS IS OO2 CONTROLS HAVING A COMMON BOARD OF A COMPLETE 3 11 96 USER INTERFACE DUAL ENCDR PCB SCHEM NO UNLESS OTHERWISE SPECIFIED DR CLEVELAND OHIO U S...

Page 182: ...CED DISCLOSED OR USED WITHOUT THE EXPRESS PERMISSION OF UNLESS OTHERWISE SPECIFIED S WITH PUBLISHED STANDARDS TO HEAD P C B ELECTRICAL SYMBOLS PER E1537 DIODES FRAME BRASS BLOCK NOTES MFD 022 50V CAPA...

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Lincoln Electric POWER WAVE 455, Service Manual

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