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F-41

TROUBLESHOOTING AND REPAIR

F-41

POWER WAVE 455/POWER FEED 10

High voltage is present at primary of
Auxiliary Transformer.

9. If the correct input voltage is applied to

the primary, and the secondary volt-
age(s) are not correct, the T1 trans-
former may be faulty.

10. Install the case sides and top using the

3/8 in. nutdriver.

7. Carefully apply the correct input voltage

to the Power Wave 455 and check for
the correct secondary voltages per
Table F.3.

NOTE: The secondary 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 missing or low,
check to make certain the primary is
configured correctly for the input volt-
age applied. See wiring diagram.

TABLE F.3 — SECONDARY VOLTAGES.

AUXILIARY TRANSFORMER NO. 1 TEST

(continued)

NORMAL EXPECTED

LEAD IDENTIFICATION

VOLTAGE

X1 to X2

52 VAC

X3 to X5

115 VAC

X3 to X4

24 VAC

WARNING

Return to Section TOC

Return to Master TOC

Содержание POWER WAVE 455

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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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