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Lincoln Electric Power Wave 455M/STT Robotic, Service Manual

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Lincoln Electric Power Wave 455M/STT Robotic Service Manual Download Page 116

TROUBLESHOOTING & REPAIR

F-70

F-70

POWER WAVE 455M/MSTT

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3.  Secure the rear of the control box in place

using two screws and the 3/8” nut driver.

4.  Press the Voltage Sense Board onto its

standoffs.  Make sure the board snaps into
place on all three standoffs.  

5.  Connect the two molex plugs to the Voltage

Sense Board.  

6.  Install the PC board compartment cover

using the 3/8” nut driver.

7.  Install the case top and sides using the 3/8”

nut driver.

CONTROL, FEED HEAD, OR VOLTAGE SENSE PC BOARD 

REMOVAL AND REPLACEMENT 

(CONTINUED)

Summary of Contents for Power Wave 455M/STT Robotic

Page 1: ...y think before you act and be careful SERVICE MANUAL For use with machines having Code Numbers 10942 10957 11007 11008 11057 11153 11152 POWER WAVE 455M STT TM Return to Master TOC Return to Master TO...

Page 2: ...NJURY OR DEATH KEEP CHILDREN AWAY PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING Read and understand the following safety highlights For additional safety information it is strong...

Page 3: ...ver dip the electrode in water for cooling 3 h Never simultaneously touch electrically hot parts of electrode holders connected to two welders because voltage between the two can be the total of the o...

Page 4: ...possible cover them to prevent the welding sparks from starting a fire Remember that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas Av...

Page 5: ...soudage l aide d crans appropri s et non inflammables 4 Des gouttes de 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 gant...

Page 6: ...AVE 455M MSTT Page Safety i iv Installation Section A Operation Section B Accessories Section C Maintenance Section D Theory of Operation Section E Troubleshooting and Repair Section F Electrical Diag...

Page 7: ...de and Work Cable Connections A 7 Negative Electrode Polarity A 7 Voltage Sensing A 8 Work Voltage Sensing A 9 Electrode Voltage Sensing A 9 Power Wave Power Feed Wire Feeder Interconnections A 9 Cont...

Page 8: ...4 25 8 10 10 6 MIG MAG FCAW SMAW GTAW Pulse 50 570 Average Amps 40 570 Average Amps 30 570 Average Amps 15 500 Average Amps 5 750 Peak Amps PULSE VOLTAGE RANGE 5 55 VDC AUXILIARY POWER CIRCUIT BREAKE...

Page 9: ...E 75 C SUPER LAG OR BREAKER SIZE AMPS 110 100 50 40 TYPE 75 C GROUND WIRE IN CONDUIT AWG SIZES mm2 6 16 6 16 10 6 10 6 TYPE 75 C COPPER WIRE IN CONDUIT AWG SIZES mm2 4 25 4 25 8 10 10 6 PROCESS CURREN...

Page 10: ...the output is disabled to ensure all components are properly cooled If desired the F A N feature can be disabled causing the fan to run whenever the power source is on To disable F A N connect leads 4...

Page 11: ...n to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC WARNING NOTE Turn main input power to the machine OFF before performing connection procedure Failur...

Page 12: ...nd the two circuit breakers in the reconnect area will open If this occurs turn off the input voltage properly connect the A lead reset the breakers and try again WELDING WITH MULTIPLE POWER WAVES Spe...

Page 13: ...ttom of the case front Connect the other end of the electrode cable to the wire drive feed plate using the stud lockwasher and nut provided on the wire drive feed plate The electrode cable lug must be...

Page 14: ...ses electrode voltage Lead 21 senses work voltage Enable the voltage sense leads as follows TABLE A 2 Process Electrode Voltage Work Voltage Sensing 67 lead Sensing 21 lead GMAW 67 lead required 21 le...

Page 15: ...piece connection must be firm and secure especially if pulse welding is planned Excessive voltage drops at the work piece connection often result in unsatisfactory pulse welding perfor mance CONTROL...

Page 16: ...ved for future use switch 3 reserved for future use switch 4 reserved for future use switch 5 reserved for future use switch 6 reserved for future use switch 7 reserved for future use switch 8 work se...

Page 17: ...125K off on 250K on off 500K on on 500K Programmable value Consult local Lincoln Technical representative switch 5 reserved for future use switch 6 reserved for future use switch 7 reserved for future...

Page 18: ...A 12 NOTES POWER WAVE 455M MSTT Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master...

Page 19: ...B 5 Recommended Equipment B 5 Required Equipment B 5 Limitations B 5 Duty Cycle and Time Period B 5 Case Front Controls B 6 Welding Mode Descriptions B 7 Constant Voltage Welding B 7 Pulse Welding B...

Page 20: ...nd ground Always wear dry insulating gloves FUMES AND GASES can be dangerous Keep your head out of fumes Use ventilation or exhaust to remove fumes from breathing zone WELDING SPARKS can cause fire or...

Page 21: ...n to Master TOC INPUT POWER ON OFF HIGH TEMPERATURE MACHINE STATUS CIRCUIT BREAKER WIRE FEEDER POSITIVE OUTPUT NEGATIVE OUTPUT 3 PHASE INVERTER INPUT POWER THREE PHASE DIRECT CURRENT GMAW FCAW GTAW OP...

Page 22: ...450 amps 38 volts or 400 amps 36 volts both at 100 duty cycle depending on input voltage and frequency The Surface Tension transfer process STT is supported at currents up to 325 amps at 100 duty cycl...

Page 23: ...PMENT PF 10 R Wire Feeder K1780 1 Control Cables 22 pin to 22 pin K1795 10 25 50 100 Control Cables for use on FANUC robot arm 22 pin to 14 pin 10 ft K1804 1 Control Cables for use on FANUC robot arm...

Page 24: ...urce of error and turn power back on to reset See Troubleshooting Guide Steady See Troubleshooting Guide Red 3 HIGH TEMPERATURE LIGHT thermal overload A yellow light that comes on when an over tem per...

Page 25: ...nductance of the wave shape This adjustment is often referred to as pinch Inductance is inversely proportional to pinch In creasing wave control greater than 0 results in a harsh er colder arc while d...

Page 26: ...ectrical stick out while welding Electrical stick out is the distance from the contact tip to the work piece The Power Wave waveforms are optimized for a 0 75 19mm stick out The adaptive behavior supp...

Page 27: ...Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Current Time Trim 1 50 Trim...

Page 28: ...B 10 NOTES POWER WAVE 455M MSTT Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master...

Page 29: ...nal Equipment C 2 Factory Installed C 2 Field Installed C 2 Section C 1 Section C 1 TABLE OF CONTENTS ACCESSORIES SECTION POWER WAVE 455M MSTT Return to Master TOC Return to Master TOC Return to Maste...

Page 30: ...the torch The water cooler is designed to cool only one welding gun and should be not used to cool multiple guns or other devices Water cooler manufacturers often specify additives to the coolant suc...

Page 31: ...D 2 Routine and Periodic Maintenance D 2 Main Assembly Exploded View D 3 Section D 1 Section D 1 TABLE OF CONTENTS MAINTENANCE SECTION POWER WAVE 455M MSTT Return to Master TOC Return to Master TOC R...

Page 32: ...to the machine for cooling 3 Inspect the electrode cables for any slits or punc tures in the cable jacket or any condition that would affect the proper operation of the machine PERFORM PERIODICALLY C...

Page 33: ...aster TOC Return to Master TOC Return to Master TOC Return to Master TOC 1 7 7 7 3 4 6 5 2 2 2 FIGURE D 1 MAIN ASSEMBLY EXPLODED VIEW 1 CASE FRONT ASSEMBLY 2 TRANSFORMER AND OUTPUT RECTIFIER ASSEMBLY...

Page 34: ...D 4 NOTES POWER WAVE 455M MSTT Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master...

Page 35: ...D OUTPUT CHOKE STT ELECTRODE TERMINAL ELECTRODE TERMINAL THERMOSTATS T1 T2 AUX RECONNECT RELAY WATER COOLER 115 VAC RECP 115 VAC FAN ARC LINK WIRE FEEDER RECP S1 S6 CONNECTION TO WIRE DRIVE S1 S6 VOLT...

Page 36: ...r TOC INPUT BOARD RECONNECT SWITCH LEFT SWITCH BOARD RIGHT SWITCH BOARD INPUT RECTIFIER CR1 GATEWAY BOARD DC BUS BOARD FEED HEAD BOARD POWER BOARD CONTROL BOARD STT CHOPPER BOARD OUTPUT CHOKE STT ELEC...

Page 37: ...ed to the input rectifier through the CR1 precharge relay During the precharge or soft start sequence these two phas es are current limited by the Input Board The AC input voltage is rectified and the...

Page 38: ...out put E 4 E 4 THEORY OF OPERATION POWER WAVE 455M MSTT Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Ma...

Page 39: ...55M MSTT Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC NOTE Unshaded areas...

Page 40: ...urn to Master TOC Return to Master TOC Return to Master TOC FIGURE E 5 POWER WAVE 455 R COMMUNICATIONS Arc Link A Ar rc c L Li in nk k Device Net D De ev vi ic ce e N Ne et t PW 455R C Co on nt tr ro...

Page 41: ...tac tor will be de energized E 7 E 7 THEORY OF OPERATION POWER WAVE 455M MSTT Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Mas...

Page 42: ...ER CR1 GATEWAY BOARD DC BUS BOARD FEED HEAD BOARD POWER BOARD CONTROL BOARD STT CHOPPER BOARD OUTPUT CHOKE STT ELECTRODE TERMINAL ELECTRODE TERMINAL THERMOSTATS T1 T2 AUX RECONNECT RELAY WATER COOLER...

Page 43: ...S Protective circuits are designed into the Power Wave 455 R to sense trouble and shut down the machine before damage occurs to the machine s internal com ponents OVER CURRENT PROTECTION If the averag...

Page 44: ...is optimized for short circuit GMAW welding only E 10 E 10 THEORY OF OPERATION POWER WAVE 455M MSTT Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Ma...

Page 45: ...s applied to the gate terminal of the IGBT it is capable of conducting current A voltage supply connected to the drain terminal will allow the IGBT to conduct and supply current to circuit components...

Page 46: ...nds both IGBT groups off Since only 2 microseconds of the 50 microsecond time period are devoted to conducting the output power is minimized MAXIMUM OUTPUT By holding the gate signals on for 24 micros...

Page 47: ...F 55 Input Rectifier Removal and Replacement F 55 Input Contactor Removal and Replacement F 57 Auxiliary Transformer No 1 Removal and Replacement Procedure F 59 Auxiliary Transformer No 2 Removal and...

Page 48: ...of the referred to test points components terminal strips etc can be found on the referenced elec trical wiring diagrams and schematics Refer to the Electrical Diagrams Section Table of Contents to l...

Page 49: ...ic or cloth which could have a static charge If the PC Board can t be installed immediately put it back in the static shielding bag If the PC Board uses protective shorting jumpers don t remove them u...

Page 50: ...ip ping 1 Make certain the fuses or break ers are properly sized 2 Make certain the reconnect panel is configured properly for the applied voltage 3 The welding procedure may be drawing too much input...

Page 51: ...set 3 Check the 6 amp CB4 breaker located in the reconnect area Reset if tripped 4 Make certain the reconnect panel is configured correctly for the applied input voltage 1 Check the input power switch...

Page 52: ...tch Board Test 7 Perform the Power Board Test 8 The Control Board may be faulty F 6 F 6 TROUBLESHOOTING REPAIR POWER WAVE 455M MSTT Return to Section TOC Return to Section TOC Return to Section TOC Re...

Page 53: ...rd may be faulty The machine often noodle welds when running an STT process STT work Electrode sense lead routing 1 Refer to sense lead route rec ommendations section 2 Perform the Current Transducer...

Page 54: ...but there is no welding output 1 Make sure that the triggering method and device is correct and operating properly Use troubleshooting software to find the problem Refer to L E setup utility user man...

Page 55: ...orm the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 1 888 935 3877 DESCRIPTION This safety procedure should b...

Page 56: ...check for a DC voltage at the capacitor terminals on both boards Note the polarity is marked on the PC board and also lead 19 is positive 5 If any voltage is present proceed to Step 6 If no voltage is...

Page 57: ...t the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 1 888 935 3877 DESCRIPTION This test will help determine if the power section of the switch...

Page 58: ...ect switches with the 3 8 wrench Note lead placement for reassem bly Clear leads Refer to Figure F 2 4 Using the Analog ohmmeter perform the following resistance tests Refer to Figure F 3 for the test...

Page 59: ...aster TOC Return to Master TOC Return to Master TOC SWITCH BOARD 11 12 OR 15 16 13 14 OR 17 18 20 19 FIGURE F 3 SWITCH BOARD TEST POINTS SWITCH BOARD TEST CONTINUED 8 Reconnect leads 19C and 19D to th...

Page 60: ...F 14 NOTES POWER WAVE 455M MSTT Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master...

Page 61: ...throughout this manual If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou...

Page 62: ...CTIFIER TEST CONTINUED TEST PROCEDURE 1 Remove input power to the Power Wave 455M 2 Using the 3 8 nut driver remove the case top 3 Perform the Capacitor Discharge Procedure 4 Locate the Input Rectifie...

Page 63: ...ve leads to the correct terminals and torque to 31 in lbs See the Wiring Diagram 10 Replace any silicone sealant previously removed 11 Reassemble and test TEST POINT TERMINALS A B C A B C NEG NEG NEG...

Page 64: ...F 18 NOTES POWER WAVE 455M MSTT Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master...

Page 65: ...oughout this manual If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou ble...

Page 66: ...INPUT CONTACTOR COIL INPUT CONTACTOR TEST CONTINUED TEST PROCEDURE 1 Remove input power to the Power Wave 455 2 Using the 3 8 nut driver remove the input access panel and case top 3 Locate mark and r...

Page 67: ...nput contactor activated check the continuity across the three sets of contacts Zero ohms or very low resistance is nor mal Refer to Figure F 6 If the resistance is high the input contactor is faulty...

Page 68: ...F 22 NOTES POWER WAVE 455M MSTT Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master...

Page 69: ...detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electri...

Page 70: ...OARD FAN RELAY FIGURE F 7 DC BUS POWER SUPPLY POWER SUPPLY PC BOARD DC BUS POWER SUPPLY PC BOARD TEST CONTINUED TEST PROCEDURE 1 Remove input power to the machine 2 Using the 3 8 nut driver remove the...

Page 71: ...output voltages are not correct and the input voltage is correct the DC Bus Power Supply PC Board may be faulty or the supplied board may be bad 9 If the input voltage is not correct check the leads...

Page 72: ...F 26 NOTES POWER WAVE 455M MSTT Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master...

Page 73: ...for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance bef...

Page 74: ...he Power Board and plugs J42 and J43 Do not remove plugs or leads from the Power Board Refer to Figure F 8 5 Carefully apply input power to the Power Wave 455M ELECTRIC SHOCK can kill High voltage is...

Page 75: ...VDC INPUT FROM DC BUS BOARD CHECK 5 VDC SPI SUPPLY FROM POWER BOARD CHECK 20 VDC STT SUPPLY FROM POWER BOARD 2 1 1 5 3 5 2 5 5 10 4 9 6 11 4 3 3 12 7 1 477 475 225 222 221 222 222 223 274 273 226 228...

Page 76: ...F 30 NOTES POWER WAVE 455M MSTT Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master...

Page 77: ...f for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electric trou bleshooting assistance bef...

Page 78: ...CONTACTOR CR1 INPUT BOARD TEST CONTINUED TEST PROCEDURE 1 Remove input power to the Power Wave 455M 2 Using the 3 8 nut driver remove the case top and input access cover 3 Remove lead X4 from the coil...

Page 79: ...e Coil Voltage for the Pre Charge Relay Normally this DC Voltage will be present 6 sec onds after Input Switch SW1 is activated This 13 15 VDC will remain for approximately 6 sec onds and then be remo...

Page 80: ...tac tor CR1 coil terminal 8 Carefully apply the correct input voltage to the Power Wave 455M ELECTRIC SHOCK can kill High voltage is present when input power is applied to the machine 9 Turn on the Po...

Page 81: ...his manual If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electric trou bleshooting as...

Page 82: ...OPPER BOARD TEST DETAILS STT CHOPPER BOARD TEST CONTINUED TEST PROCEDURE 1 Remove input power to the Power Wave 455M 2 Using the 3 8 nut driver remove the case top and the control box cover See Figure...

Page 83: ...steps 5 and 6 see Figure F 10 5 Turn on the Power Wave 455M Measure the voltage from Power Board plug J43 lead 345 pin 7 to lead 346 pin 1 The volt age should be approximately 20 VDC If not correct t...

Page 84: ...F 38 NOTES POWER WAVE 455M MSTT Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master...

Page 85: ...utions detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for...

Page 86: ...D J8 5 6 7 8 1 2 3 4 FIGURE F 11 POWER WAVE CURRENT TRANSDUCER TEST POWER WAVE CURRENT TRANSDUCER TEST CONTINUED TEST PROCEDURE 1 Remove input power to the Power Wave 455 2 Using the 3 8 nut driver re...

Page 87: ...lead 212 to pin 6 lead 216 should read 15 VDC B Pin 3 lead 213 to pin 6 lead 216 should read 15 VDC If the DC supply voltages are not present the control board may be faulty 6 If both of the supply v...

Page 88: ...shows what feedback voltage is produced at various cur rent loads 9 If the correct supply voltages are applied to the current transducer and with the machine loaded the feedback voltage is missing or...

Page 89: ...tions detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for e...

Page 90: ...12 P90 1234 J8 5 6 7 8 1 2 3 4 FIGURE F 13 STT CURRENT TRANSDUCER TEST STT CURRENT TRANSDUCER TEST CONTINUED TEST PROCEDURE 1 Remove input power to the Power Wave 455 2 Using the 3 8 nut driver remove...

Page 91: ...o pin 7 lead 816 should read 15 VDC B Pin 4 lead 813 to pin 7 lead 816 should read 15 VDC If the DC supply voltages are not present the control board may be faulty 6 If both of the supply voltages are...

Page 92: ...to 50 amps Table F 6 shows what feedback voltage is produced at various cur rent loads S T T stud is limited to 325 amps 9 If the correct supply voltages are applied to the current transducer and with...

Page 93: ...ecautions detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department f...

Page 94: ...positive and nega tive output terminals NOT the STT termi nal Refer to Figure F 15 4 If the reading is approx 50 ohms the output rectifier modules are not shorted If the reading is less than 10 ohms...

Page 95: ...do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electric trou bleshooting assistance before you proceed Call...

Page 96: ...OWER BOARD RECTIFIER BRIDGE X1 X2 FIGURE F 16 AUXILIARY TRANSFORMER NO 1 TEST AUXILIARY TRANSFORMER NO 1 TEST CONTINUED TEST PROCEDURE 1 Remove the main input power to the Power Wave 455 machine 2 Usi...

Page 97: ...according to Table F 6 NOTE The secondary voltages will vary if the input line voltage varies 10 If the correct secondary voltages are pre sent the T1 auxiliary transformer is func tioning properly If...

Page 98: ...F 52 NOTES POWER WAVE 455M MSTT Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master...

Page 99: ...do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electric trou bleshooting assistance before you proceed Call...

Page 100: ...gure F 17 5 Carefully apply the correct input power ELECTRIC SHOCK can kill High voltage is present at both plugs 6 Check for 115 VAC at plug P52 pins 1 and 4 leads 350 to 33A Check for 230 VAC at plu...

Page 101: ...ns detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for elec...

Page 102: ...using the phillips head screwdriv er carefully remove the five leads from the input rectifier terminals Note placement for reassembly See Figure F 18 6 Using the 3 16 allen wrench remove the two moun...

Page 103: ...ions detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for el...

Page 104: ...he 3 8 nut driver remove the case top and input access panel 3 Perform the Capacitor Discharge proce dure 4 Locate the input contactor Label and using the phillips head screwdriver careful ly remove t...

Page 105: ...recautions detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department...

Page 106: ...ARD RECTIFIER BRIDGE X1 X2 RECONNECT TERMINALS CB4 H1 H2 H3 H4 H5 FIGURE F 20 AUXILIARY TRANSFORMER NO 1 REMOVAL AND REPLACEMENT AUXILIARY TRANSFORMER NO 1 REMOVAL AND REPLACEMENT PROCEDURE CONTINUED...

Page 107: ...ary cable ties and clear the leads 12 Using the 3 8 nut driver remove the two mounting screws that hold the transformer to the fan baffle and the machine base 13 Carefully remove the transformer from...

Page 108: ...F 62 NOTES POWER WAVE 455M MSTT Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master...

Page 109: ...fety notes and precautions detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Ser...

Page 110: ...ILIARY TRANSFORMER NO 2 REMOVAL AND REPLACEMENT AUXILIARY TRANSFORMER NO 2 REMOVAL AND REPLACEMENT PROCEDURE CONTINUED REMOVAL PROCEDURE 1 Remove input power to the Power Wave 455 2 Using the 3 8 nut...

Page 111: ...CONTINUED REPLACEMENT PROCEDURE 1 Carefully place the transformer into the Power Wave 455 2 Install the two mounting screws that hold the transformer to the machine base using the 3 8 nut driver 3 Con...

Page 112: ...F 66 NOTES POWER WAVE 455M MSTT Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master...

Page 113: ...ions detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for el...

Page 114: ...PC BOARD REMOVAL AND REPLACEMENT CONTINUED REMOVAL PROCEDURE 1 Remove input power to the Power Wave 455M 2 Using the 3 8 nut driver remove the case top 3 Perform the Capacitor Discharge proce dure 4 O...

Page 115: ...remove the boards 10 Remove plugs J1 and J2 from the Voltage Sense Board See Figure F 23 11 Using the needle nose pliers carefully pinch the three plastic standoffs Remove the Voltage Sense Board REPL...

Page 116: ...ar of the control box in place using two screws and the 3 8 nut driver 4 Press the Voltage Sense Board onto its standoffs Make sure the board snaps into place on all three standoffs 5 Connect the two...

Page 117: ...ons detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for ele...

Page 118: ...r Wave 455 2 Using the phillips head screw driver remove the six screws from the case front cover Tilt open the cover and support it See Figure F 24 3 Observe all static electricity precautions 4 Labe...

Page 119: ...ny reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electric trou bleshooting assistance before you...

Page 120: ...Remove input power to the Power Wave 455 2 Using the 3 8 nut driver remove the case top and right side 3 Perform the Capacitor Discharge proce dure 4 Using the wire cutters cut all cable ties to the...

Page 121: ...er to the front panel 9 Remove the STT current transducer care fully feeding the output leads through it 10 Remove the standoffs from the transducer and save them for reassembly with the new transduce...

Page 122: ...F 76 NOTES POWER WAVE 455M MSTT Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master...

Page 123: ...s manual If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electric trou bleshooting assi...

Page 124: ...the 3 8 nut driver remove the case top and sides and the control box cover 3 Perform the Capacitor Discharge proce dure 4 Using the 3 8 socket wrench or nut driver remove the three screws along the b...

Page 125: ...from the transducer and save them for reassembly with the new transducer REPLACEMENT PROCEDURE 1 Attach the standoffs to the transducer 2 Position the transducer on the back of the front panel and at...

Page 126: ...F 80 NOTES POWER WAVE 455M MSTT Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master...

Page 127: ...e Lincoln Electric Service Department for electric trou bleshooting assistance before you proceed Call 1 888 935 3877 TEST DESCRIPTION This procedure will aid the technician in the removal and replace...

Page 128: ...ARD AND RECTIFIER MODULE REMOVAL AND REPLACEMENT CONTINUED RECTIFIER ASSEMBLY REMOVAL PROCEDURE 1 Remove input power to the Power Wave 455 2 Using the 3 8 nut driver remove the case top and sides 3 Pe...

Page 129: ...t sink assem bly can be removed by carefully sliding the assembly forward and removing the mount ing bolts STT CHOPPER BOARD REMOVAL AND REPLACEMENT PROCEDURE 1 Place the output rectifier assembly on...

Page 130: ...turns by hand 6 Tighten each of the outer screws to between 5 and 10 in lbs 7 Tighten the center screw to between 12 and 18 in lbs 8 Tighten each of the outer screws again this time to between 30 and...

Page 131: ...his manual If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electric trou bleshooting as...

Page 132: ...AL AND REPLACEMENT CONTINUED REMOVAL PROCEDURE NOTE Observe all static electricity precau tions Lead and plug references below use a slash to indicate machine right side left side wire number differen...

Page 133: ...o the mount ing bracket Position the capacitor so the correct polarity terminal is lined up with the correct hole on the switch board 2 All heat sink and IGBT mounting surfaces must be clean 3 Apply a...

Page 134: ...M MSTT Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC RETEST AFTER REPAIR I...

Page 135: ...rol PC Board All Codes Pg 3 of 4 G3789 2 G 15 Schematic Control PC Board All Codes Pg 4 of 4 G3789 2 G 16 PC Board Assembly Control PC Board All Codes L11088 2 G 17 Schematic Digital Power Supply PC B...

Page 136: ...3 816 7 8 21A 418 514 1 273 274 5 6 2 1 TO J6 J10B RIGHT SIDE 13 512 4R 4 3 4W 2 1 VOLTAGE SENSE SELECT BOARD TO SWITCH BD 1 D4 J40 F4 403 F4 THERM 9 1 2 3 4 1 2 3 4 J72 J75 FEED HEAD BOARD 11 J42 TO...

Page 137: ...42 J43 TO POWER BD RECTIFIER 51V 380 415 X3 W H3 TO X3 AUX 2 X5 RECONNECT PANEL TO MAIN TRANSFORMER TO D5 3 4 TO J4 SOLID STATE RELAY 2 1 W H5 440 460 H4 H5 2 15 14 11 12 13 16 10 11 12 10 14 15 11 12...

Page 138: ...220 230V 440 460V 550 575V AUX RECONNECT 19C 19D 20C 20D 380 460V 208 230V 022u 800V 022u 800V 022u 800V 022u 800V 2 7 2 7 2 7 2 7 10W 10W 10W CONTROL BOARD COMMON STT FEEDBACK 15V 15V 414 1J40 AUXIL...

Page 139: ...ocated on rear horizontal baffle located on case front located on reconnect panel located on reconnect panel Located on rear of control box center 8 Hertz per Volt 325 Volts 2600 Hertz 15 15 frequency...

Page 140: ...LINK L ARCLINK H ARCLINK L 40VDC VOLTAGE SENSE SELECT VOLTAGE SENSE SELECT 40VDC 40VDC 5J83 6J83 840 800 743 741 S7 I O RECEPTACLE 851 1 2 3 4 5 6 7 8 9 10 11 12 852 853 854 855 856 857 858 859 860 86...

Page 141: ...ver Polarity ON indicates proper ethernet signal polarity 12 Green Indicates I O 5V Supply is ON This is used by differential I O pair 4 circuitry J712 pins 1 and 2 Voltage Sense Board M19540 J1 99 08...

Page 142: ...diagram is for reference only It may not be accurate for all machines covered by this manual POWER WAVE 455M MSTT Return to Section TOC Return to Section TOC Return to Section TOC Return to Section T...

Page 143: ...UBJECT TO DAMAGE BY STATIC 490 005 N G ELECTRONIC MODULES TO BE ASSEMBLED AND ENCAPSULATED PER E3875 N H THIS DIMENSION APPLIES TO THESE TWO OF THE FOUR EYELETS AS SHOWN RESTRAINED CAPACITORS MFD VOLT...

Page 144: ...1 2 NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual POWER WAVE 455M MSTT Return to Section TOC Return to Section TOC Return to Section TOC Return...

Page 145: ...1 2 NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual POWER WAVE 455M MSTT Return to Section TOC Return to Section TOC Return to Section TOC Return...

Page 146: ...25040 9SMT 1 D2 DIODE SMD 3A 200V D0 214AB ULTRA FAST 21 S25040 2SMT 3 D3 D6 D21 DIODE SMD 1A 400V DO 214BA AC 22 S25040 11SMT 3 D4 D16 D20 DIODE SMD 1A 600V S403A ULTRA FAST RE 23 S25040 4SMT 8 D7 D8...

Page 147: ...This diagram is for reference only It may not be accurate for all machines covered by this manual POWER WAVE 455M MSTT Return to Section TOC Return to Section TOC Return to Section TOC Return to Secti...

Page 148: ...This diagram is for reference only It may not be accurate for all machines covered by this manual POWER WAVE 455M MSTT Return to Section TOC Return to Section TOC Return to Section TOC Return to Secti...

Page 149: ...This diagram is for reference only It may not be accurate for all machines covered by this manual POWER WAVE 455M MSTT Return to Section TOC Return to Section TOC Return to Section TOC Return to Secti...

Page 150: ...This diagram is for reference only It may not be accurate for all machines covered by this manual POWER WAVE 455M MSTT Return to Section TOC Return to Section TOC Return to Section TOC Return to Secti...

Page 151: ...7 SDIO 1SMB5920BT3 6 2V NP D62 D61 D60 D13 D12 D1 D46 S25040 5SMT 13 SDIO BAV99LT1 SOT23 DUAL SWITC D66 D50 D33 D49 D19 D78 D79 D102 D103 D104 D105 D106 D107 S25040 2SMT 13 SDIO 1A 400V DO 214BA GLS...

Page 152: ...This diagram is for reference only It may not be accurate for all machines covered by this manual POWER WAVE 455M MSTT Return to Section TOC Return to Section TOC Return to Section TOC Return to Sect...

Page 153: ...L 82 35V 20 LOW ESR C2 C5 C7 C9 C14 C21 C22 C25 C34 C39 C44 C53 12 S25020 3SMT CAPACITOR SMD CERAMIC 0 1MF 50V 10 X7R S0805 C4 C8 2 S25020 4SMT CAPACITOR SMD CERAMIC 820pF 50V 5 COG S0805 C11 C43 2 S1...

Page 154: ...NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual POWER WAVE 455M MSTT Return to Section TOC Return to Section TOC Return to Section TOC Return to...

Page 155: ...NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual POWER WAVE 455M MSTT Return to Section TOC Return to Section TOC Return to Section TOC Return to...

Page 156: ...NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual POWER WAVE 455M MSTT Return to Section TOC Return to Section TOC Return to Section TOC Return to...

Page 157: ...9 RESISTOR SMD 9 09K 1 10W 0805 0 1 82 S19869 8 1 S1 SWT 78B08S DIP SPST 8P NP 83 S20375 8 1 T1 TFM L5936 Noreast Switching Pwr 84 S25068 7SMT 1 X1 SICS 4 6V 2 VOLT DETECTOR 85 M15101 14SMT 1 X2 SICS...

Page 158: ...iagram is for reference only It may not be accurate for all machines covered by this manual POWER WAVE 455M MSTT Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC...

Page 159: ...ON CHANGE DETAIL SOLID EDGE STRP CAPACITORS MFD VOLTS RESISTORS OHMS WATTS N A THIS AREA TO BE COVERED ON BOTH SIDES OF BOARD WITH ITEM 2 PRIOR TO ENCAPSULATION MATERIAL MUST BE APPLIED THRU SLOTS FRO...

Page 160: ...diagram is for reference only It may not be accurate for all machines covered by this manual POWER WAVE 455M MSTT Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TO...

Page 161: ...R SOLDERING INSPECT TERMINAL CONNECTIONS PER E1880 N D COPPER SIDE 116 CRIMP HEIGHT MAX R 045 EYELET DETAIL 275 285 2 N Q N M N S N Q BUY COMPLETE AS G3734 E 4 LAYER BOARD PER E3281 P C BOARD BLANK RE...

Page 162: ...TE This diagram is for reference only It may not be accurate for all machines covered by this manual POWER WAVE 455M MSTT Return to Section TOC Return to Section TOC Return to Section TOC Return to Se...

Page 163: ...PER E2056 ON 2 PLACE DECIMALS IS 02 ON 3 PLACE DECIMALS IS 002 ON ALL ANGLES IS 5 OF A DEGREE WITH PUBLISHED STANDARDS MATERIAL TOLERANCE TO AGREE t DO NOT SCALE THIS DRAWING DRAWN BY DESIGN INFORMATI...

Page 164: ...s diagram is for reference only It may not be accurate for all machines covered by this manual POWER WAVE 455M MSTT Return to Section TOC Return to Section TOC Return to Section TOC Return to Section...

Page 165: ...2 C3 C5 3 S13490 25 CAPACITOR TAEL 4 7 35V 10 C6 1 S13490 66 CAPACITOR TAEL 47 35V 10 C7 C8 C9 C10 4 S16668 11 CAPACITOR CEMO 0 1 50V 10 C11 C17 2 S16668 10 CAPACITOR CEMO 4700P 50V 2 C13 1 S20500 2 C...

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