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ELECTRICAL DIAGRAMS

G-4

POWER WAVE 455/R

SCHEMATIC - COMPLETE MACHINE 10675

MANUFACTURING TOLERANCE PER E2056

UNLESS OTHERWISE SPECIFIED TOLERANCE

SCALE:

DO NOT SCALE THIS DRAWING

ON 3 PLACE DECIMALS IS

±

 .002

THIS SHEET CONTAINS PROPRIETARY INFORMATION OWNED BY THE LINCOLN ELECTRIC COMPANY AND IS NOT TO BE REPRODUCED,  DISCLOSED OR USED WITHOUT THE EXPRESS WRITTEN PERMISSION OF THE LINCOLN ELECTRIC COMPANY,  CLEVELAND,  OHIO U.S.A.

DESIGN INFORMATION

t

DRAWN BY:

WITH PUBLISHED STANDARDS.

DATE:

ON 2 PLACE DECIMALS  IS

±

.02

MATERIAL TOLERANCE ("  ") TO AGREE

ON ALL ANGLES IS

±

 .5 OF A DEGREE

SUBJECT:

ENGINEER:

EQUIPMENT TYPE:

DRAWING No.:

KJ

KJ

INVERTER WELDERS

PW455/R MACHINE SCHEMATIC

G

NONE

7/11/00

REFERENCE:

SUPERSEDING:

G3450

APPROVED:

3791

Chg. Sheet No.

"X" INFO.

XB

11-3-2000A

A

B

FAN CONTROL (-)

IGBT DRIVE (-)

-15V

RS232 +5V

TP4

RS232 COMMON

3J40

403

MAIN TRANSFORMER T1

+

404

4J40

405

5J40

6J40

406

+

418

H3

H4

H3A

H2

H5

H2A

H6

NEG

C3

TRANSFORMER T2

X2

POS

X5

H2A

H3A

H4A

H5A

24000uF/100V

213

212

812

4R

813

ARCLINK -

811

A

A

1W

1B

RED/GREEN

STATUS

LED

53

54

67A

B

+13V

WORK VOLTAGE SENSE

THERMAL LED

S2 VOLTAGE SENSE

RECEPTACLE

THERMAL LED

2B

2W

A

216

292

816

4W

1

J

9

0

2

J

9

0

3

J

9

0

4

J

9

0

+

1

5

V

-1

5

V

I 

O

U

T

202

506

G

N

D

CURRENT FEEDBACK

IGBT DRIVE (+)

-

TRANSDUCER

816

811

813

812

CURRENT

C5

(CAP "B")

3500uF

500V

H3

(550-575)

H1

5

H2

612A

H4

(200-208)

H1

232

CR1

X4

612

L1

U

L

3

A

OFF

H1D

A

SW1

612B

L

1

A

ON

V

POWER

G

(220-230)

612

4

1

F

S

F

14

15

16

13

CB4

6A

7J7

3J7

4J7

DCBUS

THERMOSTAT

CHOKE

THERMOSTAT

2J60

D5

5J60

10J61

8J61

2J61

4J60

3J60

8J60

1J46

2J46

3J46

4J46

FAN

10J6

1J9

3J9

6J8

1J8

3J8

2J8

1J10B

13J7

5J6

14J6

14J7

P90

8J8

7J8

5J8

4J8

R1

CONTROL BOARD

0V

24V

H5

(440-460)

(380-415)

POS

ELECTRICAL SYMBOLS PER E1537

15J6

2J5

3J5

15J7

16J7

9J6

12J6

1J6

2J6

12J4

8J4

10J4

11J4

4J11

5J4

10J43

5J47

7J47

6J47

8J47

5J43

9J43

6J4

4J43

1J47

3J11

3J47

65VDC

X4

}

 10A

CONTROL BOARD COMMON

+5V A5V

ARCLINK COMMON

6J10

ELECTRODE

SWITCH BOARD #1 (LEFT)

INPUT

RECTIFIER

RECONNECT

SWITCH

3R

475

+

477

3W

476

478

274

273

DC BUS BD

NEG

NEG

226

POS

POS

SOLID STATE RELAY

3J10

+

STT

PRECHARGE RELAY

T2

+13V

T1

T3

+13V

SINGLE PHASE DETECT

 (LOW=1 PHASE)

MAIN CONTACTOR CONTROL

+13V

INPUT BOARD

6J61

X3

612B

4

4J61

1J60

33

S4

110V

RECEPTACLE

32

.05uF

-

320V

80J

TRANSDUCER

CURRENT

202A

TP3

206A

+

1

5

V

I 

O

U

T

MAIN

CHOKE

L1

+

ELECTRODE

-1

5

V

G

N

D

150V

P91

OUTPUT DIODES

D1-D4

212

601

CR1

T3

T2

T1

L3

POS

L2

W

AC1

NEG

AC2

NEG

AC3

604

238

231

STT CHOPPER DRIVE (-)

STT CHOPPER DRIVE (+)

-15V

+

10W

+

150V

R3

R2

C8

4

J

9

1

213

216

3

J

9

1

211

2

J

9

1

1

J

9

1

80J

YELLOW

THERMAL

LED

253

254

S3 RS232

CONNECTOR

251

RS232 TRANSMIT

E

D

RS232 COMMON

0VDC

21A

+40VDC

THERMOSTAT

H4A

H5A

H6A

P80

X1

50

10A

+40VDC POWER

444

X3A

NEG

SWITCH BOARD #2 (RIGHT)

NOTES :

  N.A.  PC BOARD COMPONENTS SHOWN FOR
          REFERENCE ONLY.  ALL COMPONENTS
          ARE NOT SHOWN.

  N.C.  R2, R3 AND R4 ARE 2

 /300.

           C8 AND C10 ARE 20 mfd/400V.

51

228

31

+15

50

CONTROL BOARD COMMON

- ELECTRODE VOLTAGE SENSE

+ELECTRODE VOLTAGE SENSE

2J40

C4

(CAP "A")
3500uF

500V

2

3

4

5

6

7

1

4

2

3

20

3J2

4J2

1J2

6J9

8J7

L5

ELECTRODE SENSE

S1 WIRE FEEDER

RECEPTACLE

ARCLINK -

STATUS LED (HI FOR RED)

52

C

51

L2

L4

+5V

+15V

232

STATUS LED (HI FOR GREEN)

231

604

238

3W

3R

MAIN CONTACTOR CONTROL

220

224

PRECHARGE CONTROL

403

505

514

504

RS232 RECEIVE

FAN CONTROL (+)

(NORMALLY CLOSED)

THERMOSTAT

211

4R

206

COMMON

4W

17

12

F

F

S

CHOPPER BOARD

11

D

S

15

16

S

18

C

(380-415)

3

(440-460)

2

(220-230)

52V

6

115V

X3

H2

H4

H3

H5

A

200-208V

220-230V

380-415V

440-460V

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

AUXILIARY

TRANSFORMER T1

H6A

(550-575)

H6

H1

H1A

1

10A

CB3

(200-208)

2

X3

1J42

3J42

5J42

2J42

225

221

222

223

1J41

2J41

3J41

4J41

POWER BOARD

52

352A

32

33A

352

350

2

3

4

1

S8 WATER COOLER

RECEPTACLE

TP6

R4

C10

TP2

C2

600V

160J

320V

TP1

160J

.05uF

C1

600V

320V

TP5

160J

.05uF

C6

600V

2J10B

518

220A

OUTPUT RECTIFIER

THERMOSTAT

291

224A

FEED HD BD

GATEWAY  BD

4J81

3J81

4J82

3J82

2J81

1J81

1J85

851

2J85

852

3J85

853

4J85

854

5J85

855

6J85

856

7J85

857

8J85

858

9J85

859

10J85

860

11J85

861

12J85

862

7J4

4J42

227

1J84

841

2J84

842

3J84

843

4J84

844

5J84

845

6J84

846

7J84

847

RECEPTACLE

841

A

B

C

D

E

F

G

I

J

K

N

P

T

S7 I/O

RECEPTACLE

851

1

2

3

4

5

6

7

8

9

10

11

12

INTERFACE

S6  ROBOTIC

844

842

843

845

846

847

67B
539

541

521

522

GND-A

852

853

854

855

856

857

858

859

860

861

862

TACH 1A DIFF SIGNAL

TACH 1B DIFF SIGNAL

TACH 2A DIFF SIGNAL

TACH 2B DIFF SIGNAL

SINGLE  TACH INPUT

VOLTAGE SENSE

MOTOR "+"

MOTOR "-"

SO40VDC

SOLENOID INPUT

TACH  COMMON

TACH +15VDC

T15VDC

TRIGGER  INPUT

DUAL PROC. INPUT

4 STEP INPUT

COLD INCH +15VDC

COLD IN. FORWARD

COLD IN. REVERSE

GAS PURGE INPUT

SH15VDC

SHUTDOWN 1 INPUT

SHUTDOWN 2 INPUT

INPUT B

T15VDC

TRIGGER  INPUT

DUAL PROC. INPUT

4 STEP INPUT

COLD INCH +15VDC

COLD IN. FORWARD

COLD IN. REVERSE

GAS PURGE INPUT

SH15VDC

SHUTDOWN 1 INPUT

SHUTDOWN 2 INPUT

INPUT B

POWER BD. RECT.

COMMON

+40VDC FEEDER

COMMON

+40VDC POWER

COMMON

COMMON

+15VDC TACH

TACH 1A DIFF. INPUT

TACH 1B DIFF. INPUT

TACH COMMON

TACH 2A DIFF. INPUT

TACH 2B DIFF. INPUT

SINGLE TACH  INPUT

CB2

33

2J83

1J83

4J83

3J83

541

539

522

521

SO40VDC

SOLENOID INPUT

MOTOR "+"

MOTOR "-"

POWER DOWN INTERUPT

+15V

+5V

CONTROL BOARD COMMON

-15V

 A5V

ARCLINK COMMON

RS232 +5V

RS232 COMMON

1J43

STT COMMON

346

7J43

345

STT +20V

POWER DOWN INTERUPT

+24VDC

2

+24V GND

894

3

5 CAN_L

CAN_H

S5 DEVICENET

CONNECTOR

4

893

892

891

3J50

503

504

4J50

505

5J50

6J50

506

518

2J50

514

1J50

511

512

741

743

800

840

500

540

ARCLINK H

ARCLINK L

COMMON

+40VDC

2J72

1J72

3J72

4J72

ARCLINK H

ARCLINK L

5J75

2J75

1J75

4J75

IGBT DRIVE (+)

503

6J6

16J6

404

8J6

405

7J6

406

1J10A

414

418

IGBT DRIVE (-)

2J10A

N.A.

N.A.

N.A.

CB1

1J73

2J73

53

894

893

892

891

+24VDC

+24V GND

CAN_L

CAN_H

N.A.

N.A.

N.A.

N.C.

115V

230V

0V

1J76

3J76

830

54

346

345

1J10

4J10

D6

880

886

6J83

5J83

+40VDC

880

886

+40VDC

VOLT SENSE BD

N.A.

14J85

13J85

1J1

3J1

1J2

4J1

511

N.A.

2J47

4J47

500

540

+40VDC  POWER

512

67

67A

4J9

67

2J2

67B

R5

10

3J4

268

12J43

262

3J43

268A

268A

262

N.C.

ROBOTIC VOLTAGE SENSE

VOLTAGE SENSE SELECT (-)

VOLTAGE SENSE  OUTPUT

WIRE FEEDER VOLTAGE SENSE

VOLTAGE SENSE SELECT (+)

COMMON

+40VDC

VOLTAGE SENSE SELECT (-)

VOLTAGE SENSE SELECT (+)

CT CURRENT (-)

CT CURRENT (+)

IGBT DRIVE (+)

V/F (+)

V/F (-)

IGBT DRIVE (-)

CT CURRENT (-)

CT CURRENT (+)

IGBT DRIVE (+)

V/F (+)

V/F (-)

IGBT DRIVE (-)

+20V STT

COMMON

+40VDC

CT CURRENT (-)

CT CURRENT (+)

V/F (+)

V/F (-)

V/F (+)

V/F (-)

CT CURRENT (-)

CT CURRENT (+)

SPI COMMON

SPI +5V

+40V

+40V

+40V COMMON

+40V COMMON

SINGLE PHASE DETECT

 (LOW=1 PHASE)

+5V SPI

VOLTAGE SENSE

1J4

11J43

267

SPI COMMON

2J4

6J43

266

+15V SPI

+15V SPI

SPI COMMON

N.A.

154

ARC LINK L

1J11

2J11

ARC LINK H

153

2J82

1J82

ARCLINK  H

154

153

ARCLINK L

G-4

NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.

Содержание POWER WAVE 455/R

Страница 1: ...ore you act and be careful SERVICE MANUAL For use with machines having Code Numbers 10675 10676 POWER WAVE 455 R TM Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC...

Страница 2: ...RS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING Read and understand the following safety highlights For additional safety information it is strongly recommended that you purchase a copy of Safety...

Страница 3: ...ork or metal to be welded to a good electrical earth ground 3 f Maintain the electrode holder work clamp welding cable and welding machine in good safe operating condition Replace damaged insulation 3...

Страница 4: ...If this is not 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 ad...

Страница 5: ...proximit au soudage l aide d crans appropri s et non inflamma bles 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...

Страница 6: ...WAVE 455 R 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 Diagra...

Страница 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...

Страница 8: ...6 10 6 8 10 10 6 6 10 10 6 10 6 8 10 10 6 TYPE 75 C COPPER WIRE IN CONDUIT AWG IEC SIZES mm2 4 25 8 10 4 25 8 10 4 25 8 10 4 25 8 10 4 25 10 6 10 6 6 10 10 6 4 25 8 10 10 6 8 10 10 6 INPUT AMPERE RAT...

Страница 9: ...aster TOC Return to Master TOC Return to Master TOC TECHNICAL SPECIFICATIONS POWER WAVE 455 R K1761 1 K1761 2 continued PHYSICAL DIMENSIONS TEMPERATURE RANGES HEIGHT 26 10 in 663 mm WIDTH 19 86 in 505...

Страница 10: ...r 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 dis able F A N connect lead...

Страница 11: ...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 Failure...

Страница 12: ...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 Speci...

Страница 13: ...bottom 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...

Страница 14: ...enses 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...

Страница 15: ...rk 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 CONTRO...

Страница 16: ...erved 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...

Страница 17: ...f 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 futu...

Страница 18: ...12 A 12 NOTES POWER WAVE 455 R Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master T...

Страница 19: ...es 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...

Страница 20: ...and 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...

Страница 21: ...o 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 OPEN...

Страница 22: ...r 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 cy...

Страница 23: ...UIPMENT 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 ar...

Страница 24: ...source 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 p...

Страница 25: ...e inductance of the waveshape This adjustment is often referred to as pinch In ductance is inversely proportional to pinch Increasing wave control greater than 0 results in a harsher colder arc while...

Страница 26: ...electrical 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 su...

Страница 27: ...urn 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 1 0...

Страница 28: ...10 B 10 NOTES POWER WAVE 455 R Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master T...

Страница 29: ...ional Equipment C 2 Factory Installed C 2 Field Installed C 2 Section C 1 Section C 1 TABLE OF CONTENTS ACCESSORIES SECTION POWER WAVE 455 R Return to Master TOC Return to Master TOC Return to Master...

Страница 30: ...ct 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 s...

Страница 31: ...ns 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 455 R Return to Master TOC Return to Master TOC Ret...

Страница 32: ...ow 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...

Страница 33: ...ter 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 3...

Страница 34: ...4 D 4 NOTES POWER WAVE 455 R Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TO...

Страница 35: ...INAL 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 SENSE BOARD MAIN TRANSFORMER S5...

Страница 36: ...D 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 ELECTRODE TERMINAL E...

Страница 37: ...cted 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 t...

Страница 38: ...ng of the two switch boards occurs during halves of a 50 microsecond interval creating a constant 20 KHZ out put E 4 E 4 THEORY OF OPERATION POWER WAVE 455 R Return to Section TOC Return to Section TO...

Страница 39: ...RATION POWER WAVE 455 R Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC NOTE...

Страница 40: ...n 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 ol...

Страница 41: ...ontac tor will be de energized E 7 E 7 THEORY OF OPERATION POWER WAVE 455 R Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Maste...

Страница 42: ...WITCH 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 ELECTRODE TERMINAL ELECTRODE TERMINAL THERMOS...

Страница 43: ...ITS 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 aver...

Страница 44: ...s is optimized for short circuit GMAW welding only E 10 E 10 THEORY OF OPERATION POWER WAVE 455 R Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Mast...

Страница 45: ...is 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 component...

Страница 46: ...conds 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 micr...

Страница 47: ...e F 48 Input Rectifier Removal and Replacement F 48 Input Contactor Removal and Replacement F 50 Auxiliary Transformer No 1 Removal and Replacement Procedure F 52 Auxiliary Transformer No 2 Removal an...

Страница 48: ...e the cause of your problem All of the referenced test procedures referred to in the Troubleshooting Guide are described in detail at the end of this section Refer to the Troubleshooting and Repair Ta...

Страница 49: ...stic 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...

Страница 50: ...Lincoln Electric Service Department at 1 800 833 9353 WELD The input fuses repeatedly fail or the input circuit breakers keep trip ping 1 Make certain the fuses or break ers are properly sized 2 Make...

Страница 51: ...reset 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 swit...

Страница 52: ...nput Rectifier Test 5 Perform the Switch BoardTest 6 Perform the Power Board Test 7 The Control Board may be faulty F 6 F 6 TROUBLESHOOTING REPAIR POWER WAVE 455 R Return to Section TOC Return to Sect...

Страница 53: ...t draw from the Power Wave 455R machine 1 Perform the Current Transducer Test 2 The Control Board may be faulty The Power Wave 455R will not pro duce full output 1 The input voltage may be too low lim...

Страница 54: ...Wiring Diagram 2 Perform the T2 Auxiliary Transformer Test The Power Wave 455R is trig gered for output but there is no welding output 1 Make sure that the triggering method and device is correct and...

Страница 55: ...he Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 1 800 833 9353 WELD DESCRIPTION This safety procedure should be performed before any internal...

Страница 56: ...als 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 present the capacitors are discharged NOTE No...

Страница 57: ...epartment for electrical trou bleshooting assistance before you proceed Call 1 800 833 9353 WELD DESCRIPTION This test will help determine if the power section of the switch boards are functioning cor...

Страница 58: ...the case top and sides 3 Perform the Capacitor Discharge Procedure 4 Locate label and remove leads 19C and 19D from the reconnect switches with the 3 8 wrench Note lead placement for reassem bly Clear...

Страница 59: ...that the leads are installed in the same location they were removed from 9 Install the right and left case sides and top using the 3 8 nut driver APPLY POSITIVE TEST PROBE TO TERMINAL APPLY NEGATIVE T...

Страница 60: ...ason 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 before you pr...

Страница 61: ...EST INPUT RECTIFIER TEST CONTINUED TEST PROCEDURE 1 Remove input power to the Power Wave 455 R 2 Using the 3 8 nut driver remove the case top 3 Perform the Capacitor Discharge Procedure 4 Locate the I...

Страница 62: ...ing a new input rectifier see Input Rectifier Removal and Replacement procedure 9 If the input rectifier is good be sure to reconnect the positive and negative leads to the correct terminals and torqu...

Страница 63: ...n 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 before you proce...

Страница 64: ...PUT CONTACTOR COIL INPUT CONTACTOR TEST CONTINUED TEST PROCEDURE 1 Remove input power to the Power Wave 455 R 2 Using the 3 8 nut driver remove the input access panel and case top 3 Locate mark and re...

Страница 65: ...input 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 fault...

Страница 66: ...or 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 befo...

Страница 67: ...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 case top 3 Lo...

Страница 68: ...cor rect and the input voltage is correct the DC Bus Power Supply PC Board may be faulty 9 If the input voltage is not correct check the leads between the DC Bus Power Supply PC Board and the Power P...

Страница 69: ...the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 1 800 833 9353...

Страница 70: ...cate the 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 455 R ELECTRIC SHOCK can kill High volt...

Страница 71: ...0 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 22...

Страница 72: ...d the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 1 800 833 9353...

Страница 73: ...9 INPUT CONTACTOR CR1 INPUT BOARD TEST CONTINUED TEST PROCEDURE 1 Remove input power to the Power Wave 455 R 2 Using the 3 8 nut driver remove the case top 3 Remove lead X4 from the coil terminal of m...

Страница 74: ...put contac tor CR1 coil terminal 8 Carefully apply the correct input voltage to the Power Wave 455 R ELECTRIC SHOCK can kill High voltage is present when input power is applied to the machine 9 Turn o...

Страница 75: ...13 15 VDC COMMENTS Present when Input Switch SW1 is closed This is Pre Charge Voltage and will normally be present 6 sec onds after activating Input Switch SW1 The Pre Charge Voltage should remain for...

Страница 76: ...ot understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 1...

Страница 77: ...PER BOARD TEST DETAILS STT CHOPPER BOARD TEST CONTINUED TEST PROCEDURE 1 Remove input power to the Power Wave 455 R 2 Using the 3 8 nut driver remove the case top and the control box cover See Figure...

Страница 78: ...chine For steps 5 and 6 see Figure F 10 5 Turn on the Power Wave 455 R 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...

Страница 79: ...l 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 bleshooting assistanc...

Страница 80: ...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 R 2 Using the 3 8 nut driver remo...

Страница 81: ...ead 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 vol...

Страница 82: ...ows 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 no...

Страница 83: ...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 bleshooting assistance...

Страница 84: ...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 R 2 Using the 3 8 nut driver remove...

Страница 85: ...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 l...

Страница 86: ...nnot be loaded to 50 amps Table F 6 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...

Страница 87: ...anual 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 bleshooting assis...

Страница 88: ...rench remove and insu late lead 202A from the negative output ter minal 4 Remove any output load that may be con nected to the Power Wave 455 R 5 With the analog ohmmeter measure the resistance betwee...

Страница 89: ...or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 1 800 833 9353 WELD TEST DESCRIPTIO...

Страница 90: ...RD 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 R machine 2 Using the...

Страница 91: ...to Table F 7 NOTE The secondary voltages will vary if the input line voltage varies 9 If the correct secondary voltages are pre sent the T1 auxiliary transformer is func tioning properly If any of the...

Страница 92: ...or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 1 800 833 9353 WELD TEST DESCRIPTIO...

Страница 93: ...Refer to Figure 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...

Страница 94: ...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 be...

Страница 95: ...d 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 mou...

Страница 96: ...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 bleshooting assistance...

Страница 97: ...8 nut driver remove the case top sides 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...

Страница 98: ...anual 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 bleshooting assis...

Страница 99: ...CTIFIER 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 REMOVA...

Страница 100: ...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 the...

Страница 101: ...hroughout 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 b...

Страница 102: ...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 R 2 Using the 3 8 nut driv...

Страница 103: ...TINUED REPLACEMENT PROCEDURE 1 Carefully place the transformer into the Power Wave 455 R 2 Install the two mounting screws that hold the transformer to the machine base using the 3 8 nut driver 3 Conn...

Страница 104: ...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 bleshooting assistance...

Страница 105: ...AND REPLACEMENT CONTINUED REMOVAL PROCEDURE 1 Remove input power to the Power Wave 455 R 2 Using the 3 8 nut driver remove the case top and sides 3 Perform the Capacitor Discharge proce dure 4 Observe...

Страница 106: ...move 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 REPLAC...

Страница 107: ...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 mo...

Страница 108: ...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 electrical trou bleshooting assistance b...

Страница 109: ...ave 455 R 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 Label...

Страница 110: ...est procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 1 800 833 9353 WELD D...

Страница 111: ...move input power to the Power Wave 455 R 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 t...

Страница 112: ...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 transducer...

Страница 113: ...understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 1 80...

Страница 114: ...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 bo...

Страница 115: ...rom 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 atta...

Страница 116: ...for electrical trou bleshooting assistance before you proceed Call 1 800 833 9353 WELD TEST DESCRIPTION This procedure will aid the technician in the removal and replacement of the output recti fier...

Страница 117: ...AND RECTIFIER MODULE REMOVAL AND REPLACEMENT CONTINUED RECTIFIER ASSEMBLY REMOVAL PROCEDURE 1 Remove input power to the Power Wave 455 R 2 Using the 3 8 nut driver remove the case top and sides 3 Per...

Страница 118: ...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 a...

Страница 119: ...rns 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 40...

Страница 120: ...ot understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 1...

Страница 121: ...REPLACEMENT CONTINUED REMOVAL PROCEDURE NOTE Observe all static electricity precautions Lead and plug references below use a slash to indicate machine right side left side wire number differences 1 Re...

Страница 122: ...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 t...

Страница 123: ...WAVE 455 R Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC RETEST AFTER REPA...

Страница 124: ...78 F 78 NOTES POWER WAVE 455 R Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master T...

Страница 125: ...oard Assembly DeviceNet Gateway PC Board G 9 Schematic Control PC Board G 10 PC Board Assembly Control PC Board G 11 Schematic Digital Power Supply PC Board G 12 PC Board Assembly Digital Power Supply...

Страница 126: ...O J5 6 5 4 3 2 225 1 SEC TOP RIGHT 15 16 2 3 5 J50 C5 J60 10 10 9 8 7 6 5 4 273 3 228 274 226 TO J8 4 TO S3 1 2 J43 251 253 254 J1 9 13 7 DEVICE NET GATEWAY BOARD 14 8 6 5 4 1 3 2 NEG DIGITAL POWER SU...

Страница 127: ...TOP RIGHT 15 16 2 3 5 J50 C5 J60 10 10 9 8 7 6 5 4 273 3 228 274 226 TO J8 4 TO S3 1 2 J43 251 253 254 J1 9 13 7 DEVICE NET GATEWAY BOARD 14 8 6 5 4 1 3 2 NEG DIGITAL POWER SUPPLY BOARD 3R TO 3W J7 MA...

Страница 128: ...514 504 RS232 RECEIVE FAN CONTROL NORMALLY CLOSED THERMOSTAT 211 4R 206 COMMON 4W 17 12 F F S CHOPPER BOARD 11 D S 15 16 S 18 C 380 415 3 440 460 2 220 230 52V 6 115V X3 H2 H4 H3 H5 A 200 208V 220 23...

Страница 129: ...00 208V 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 1J4...

Страница 130: ...Output ON 2 PLACE DECIMALS IS O2 ON HOLES SIZES PER E 2056 NUMBER NOTES MATERIAL TOLERANCE t TO AGREE UNLESS OTHERWISE SPECIFIED TOLERANCE com 47 5K R5 com 15 15 com MC14538B X1 16 8 15 com 63V 1 0 C8...

Страница 131: ...668 11 1 50 C6 C8 C20 3 S13490 173 CAP MPF 1 0 uF 63VDC C11 C14 2 S16668 10 4700pF 50 C12 C17 2 S16668 7 820pF 50 C13 C15 C16 3 S16668 3 100pF 100 C18 C19 2 S20500 2 47 630 C22 1 S16668 9 150pF 100 C2...

Страница 132: ...G 8 NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Retur...

Страница 133: ...0 2 S M T 5 Q 2 Q 4 Q 5 Q 1 2 Q 1 3 T R A N S I S T O R S M S P N P S O T 2 3 0 5 A 4 0 V M M 40 S 2 5 0 5 1 4 S M T 6 Q 6 Q 7 Q 8 Q 9 Q 1 0 Q 1 1 T R A N S I S T O R S M D N M F S O T 2 3 0 1 1 5 A 6...

Страница 134: ...A17 A16 VCC VPP 37 13 16 17 48 47 12 14 28 11 26 27 46 45 43 41 39 36 34 32 30 44 42 40 38 35 33 31 29 1 2 3 4 5 6 7 8 18 19 20 21 22 23 24 25 X25 TE28F800B5 B90 3 2 1 D90 BAV70LT1 3 2 1 D91 BAV70LT1...

Страница 135: ...R107 R199 R103 R221 R229 R204 R242 R241 R216 R217 R218 R243 R246 R244 R245 R247 R248 R249 R250 R251 R252 R253 R254 R257 R258 R259 43 S25001 4750SMT 28 SRES 475 1206 1 1 8W TR NP R195 R194 R41 R11 R83...

Страница 136: ...8 T1 1 2 11 12 10 0 R60 t 60V 13 R50 10 0 R9 47 5 R6 47 5 R7 10 0 R61 5Volts 750 Amp 100 16V C41 332 R53 50V 0 1 C39 6A 200V D18 33 2 R16 LED2 5V Vref 1 Machine Control Power Supply 47 5 R57 T1 10 3 1...

Страница 137: ...C22 C25 C34 C39 C44 30 SM200 200 2 SCAP 10pF CER 0805 100V 5 TR C28 C32 31 SM200 201 1 SCAP 33uF TAN 7343 25V 10 TR LOW ESR C11 32 SM200 202 5 SCAP 100uF TAN 7343 10V 20 TR C35 C36 C37 C41 C43 33 SM55...

Страница 138: ...DHEAD PC BOARD SCHEMATIC 11 3 2000A XA 1 OF 3 G 14 NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual Return to Section TOC Return to Section TOC Re...

Страница 139: ...D PC BOARD SCHEMATIC 11 3 2000A XA TPD TPE 2 OF 3 G 15 NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual Return to Section TOC Return to Section TO...

Страница 140: ...DHEAD PC BOARD SCHEMATIC 11 3 2000A XA 3 OF 3 G 16 NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual Return to Section TOC Return to Section TOC Re...

Страница 141: ...1 R142 R143 R144 RESISTOR SMD 332ohms 1 4W 1206 1 75 S25005 1SMT 2 R97 R98 SRES 0 05 3W 1 TR NP 76 S25001 4751SMT 4 R99 R114 R132 R137 SRES 4 75K 1206 1 1 8W NP SM 77 S25000 4751SMT 14 R101 R104 R125...

Страница 142: ...ERWISE SPECIFIED TOLERANCE GENERAL INFORMATION THE LINCOLN ELECTRIC CO NOT SHOW THE EXACT COMPONENTS OR CIRCUITRY OF CONTROLS HAVING A COMMON CODE AND IS NOT TO BE REPRODUCED DISCLOSED OR USED WITHOUT...

Страница 143: ...in damage to the machine ELECTRICAL DIAGRAMS G 19 POWER WAVE 455 R PC BOARD ASSEMBLY INPUT 11 3 2000A INVERTER WELDERS L11396 1 CAPACITORS MFD VOLTS ITEM REQ D PART NO IDENTIFICATION 0 0 3 00 25 25 4...

Страница 144: ...Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ELECTRICAL DIAGRAMS G 20 SCHEMATIC SWITCH PC BOARD G 20 NOTE This diagram is for reference on...

Страница 145: ...Z4 DZ7 DZ3 DZ2 DZ6 DZ5 DZ1 SH1 B14 C1 R1 B11 C1 1 S2 0500 14 CAPACITOR PPMF 022 100V BOX 5 C2 1 S16668 11 CAPACITOR CEMO 0 1 50V 10 C3 1 S16668 5 CAPACITOR CEMO 022 50V 20 C4 C6 C7 3 S16668 6 CAPACITO...

Страница 146: ...ection TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ELECTRICAL DIAGRAMS G 22 POWER WAVE 455 R SCHEMATIC VOLTAGE SENSE PC BOARD G 22 NOTE This diagram is for...

Страница 147: ...TRICAL DIAGRAMS G 23 POWER WAVE 455 R PC BOARD ASSEMBLY VOLTAGE SENSE 0 1 55 1 75 0 04 2 00 20 1 00 1 80 20 04 COMMON DIGITAL CONTROLS VOLTAGE SENSE SELECT P C BD AS BLY M19540 1 1 3 2000A ITEM REQD P...

Страница 148: ...Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ELECTRICAL DIAGRAMS G 24 POWER WAVE 455 R SCHEMATIC 40 VDC BUS PC BOARD G 24 NOTE This diagram is for re...

Страница 149: ...ITOR CEMO 100P 100V 5 C11 C17 2 S16668 10 CAPACITOR CEMO 4700P 50V 2 C7 C8 C9 C10 4 S16668 11 CAPACITOR CEMO 0 1 50V 10 R15 R16 2 S19400 47R5 RESISTOR MF 1 4W 47 5 1 R12 R13 2 S19400 1000 RESISTOR MF...

Страница 150: ..._________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ______________...

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