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Lincoln Electric SVM156-A User's Manual

1. R227 R266 L 1L ree R263 R262 CAL ress O 51 625001 33216 7 4 SRES 3 32K 1206 1 1 8W NP AM2 R123 R128 R129 R179 52 625001 22125 7 6 SRES 22 1K 1206 1 1 8W TRNP R37 R38 R35 R203 RB R39 53 525001 47856 2 SRES 47 5 1206 1 1 8W TRNP R3 R2 rM S2500147539MT 1 SRES 475K 1206 1 1 8W TRNP R100 55 525001 10035 10 SRES 100K 1206 1 1 ew 200PPm 95 111 R49 odd pee 2 t 56 525001 12136 1 5 5 121 1206 1 1 4 R70 57 525001 33225 3 SRES 33 2K 1206 1 1 8W TR NP R63 R65 R233 58 __ __525001 10005 4 SRES 100 1206 1 8W TRNP R62 R4
2. 40 524020 6 6 L1 L2 L3 L4 L5 L6 L7 L8 L9 110 12218 15 CHOKE RF FERRITE 180 OHM 515000 22 OPTOCOUPLER PHOTO Q 70V CNY17 3 VDE R1 516296 5 TRIMMER MT 1 2W 10K 10 LINEAR R2 19400 6811 RESISTOR MF 1 4W 6 81K 1 R3 R8 19400 1002 IRESISTOR MF 1 4W 10 0K 1 IRA R13 R14 R17 R18 R19 R21 R21 R23 R24 R25 R26 R27 19400 10RO RESISTOR MF 1 4W 10 0 1 R5 R9 19400 2001 IRESISTOR MF 1 4W 2 00K 196 519400 2213 IRESISTOR MF 1 4W 221K 196 R7 519400 1000 RESISTOR MF 1 4W 100 1 R10 R12 R15 519400 1003 IRESISTOR MF 1 4W 100K 196 R11 519400 6191 IRESISTOR MF 1 4W 6 19K 1 R16 R22 519400 1001 IRESISTOR MF 1 4W 1 00K 1 R28 R29 R30 R31 R32 14648 9 RESISTOR WW 5W 2 5K 5 SQ T1 112737 7 TRANSFORMER PULSE 3 WINDING 2 19612 ICURRENT TRANSDUCER 125 TURN x1 M13552 3 IC CONVERTER V F 654 x2 515128 10 VOLTAGE REF ADJ 5 0 4311 N T N U N V 11 15 04 MATION 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 CL
3. asz gldoo2oosov mm LEON 1 tt li 5 ovOH RON SIZSOOVOTARON 5 3 AAAA SSR J10 CHOPPER BD e IS oos TO P90 P91 TO J1 VOLTAGE SENSE WORK ELECTRODE 82 TO J40 J50 DIGITAL POWER SUPPLY BOARD 2400uF 100V POWER BD RECT STT CURRENT TRANSDUCER TO AUX 1 MAIN CHOKE Cm TO RECT THERM 224A CHOKE THERM 291 TO CR1 J60 _ CURRENT TRANSDUCER 27 10W SEC 196 IGHT 022 7 RIGHT SIDE STT SNUBBER 288B DIODE D5 288A TO NOTES LEFT SIDE OF MACHINE AUXILIARY TRANSFORMER 1 xt H6 POWER BD RECTIFIER w 24V N X3 X4 115V X5 SOLID STATE RELAY TO 6 108 000000000000000000000000000 13 141 J40 SWITCH BOARD 3500uF 500V 20C 19C TO MAIN TRANSFORMER TO RECONNECT SWITCH 6 3500uF 20D 19D RECONNECT MAIN TRANSFORMER SWITCH TO AUX 2 CB4 RECONNE
4. 200 208V 200 208V 5 200 208V 220 230V 220 230 e 220 230V Tu 1 A gave Ill A 380 415V 380 415V enw 380 415V 440 460V 440 460V 440 460V of TH 200 208V 220 230V o gt IN 380 415V 22 440 460V THE LINCOLN ELECTRIC CO CLEVELAND OHIO U S A VOLTAGE 200 208V 200 208V 220 230V O N N 440 460V 550 575 VOLTAGE 440 460V 200 208V 220 230V 220 230 gt 440 460 550 575 200 208V 440 460V 7 4 550 575V THE LINCOLN ELECTRIC CO CLEVELAND OHIO U S A NOTE Turn main input power to the machine OFF before performing connection procedure Failure to do so will result in damage to the machine INPUT CONNECTION A WARNING Only a qualified electrician should connect the input leads to the Power Wave Connections should be made in accordance with all local and national electrical codes and the connection diagram located on the inside of the reconnect input access door of the machine Failure to do so may result in bodily injury or death Use a three phase supply line A 1 75 inch 45 mm
5. 5 Turn on the Power Wave 455 R Check for the correct DC supply voltage to the current transducer at plug J8 A Pin 8 lead 812 to 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 both of the supply voltages are low or missing check the associated leads between plug J8 and current transducer plug P90 and the Control Board POWER WAVE 455 R LINCOLN NOTE The machine can be triggered by jumpering pin 1 to pin 2 at receptacle S7 See Figure F 14 With the Power Wave 455 R triggered check the feedback voltage from the current transducer The current feedback voltage can be read at plug J8 on the Control Board A Pin 5 lead 811 to pin 7 lead 816 should read 2 0 VDC machine loaded to 50 amps Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o 5 B Return to Section Return to Master TOC o 2 D 2 5 F 40 8 F 40 TROUBLESHOOTING amp REPAIR STT CURRENT TRANSDUCER TEST CONTINUED If for any reason the machine cannot be loaded to 50 amps Table F 6 shows what feedback voltage is produced at various cur rent loads faul
6. POWER WAVE 455 R LINCOLN 5 Return to Section Return to Master TOC Return to Section TOC Return to Master TOC 515 gt 218 5 2 Return to Section Return to Master TOC OPERATION WELDING MODE DESCRIPTIONS CONSTANT VOLTAGE WELDING For each wire feed speed a corresponding voltage is preprogrammed into the machine through special soft ware at the factory The preprogrammed voltage is the best average voltage for a given wire feed speed With synergic programs when the wire feed speed changes the Power Wave will automatically adjust the corre sponding voltage Wave control adjusts the 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 decreasing the wave control to less than 0 provides a softer hotter arc See Figure B 2 FIGURE 2 CV WAVE CONTROL CHARACTERISTICS 2 22 _ Current Time 2 2 2 p 2 I POWER WAVE 455 R LINCOLN 5 Return to Section Return to Master TOC Return to Section TOC 515 gt 218 5 2 Return to Section
7. 5 80746 2 0 GCK3 0 ADDRILI ADDROI 9 DATAUOI ADDRGI 3 xs BL_DATALL ADDRUI DATAUI E m ADDRISI i BS iW ADDRI6I DATAI4I ADDRITI DATAISI ADDREBI DATALGI CSB ADORISI DATAUTI tsp AL 4050 ADDRILO 1830 DATAIBI BERR T ADORE 48 us csz i 7552 ADDRILZ E 13 12 TE28F800 DATAIL os 8 FETH 3l 19 ADDRILS A ADORILS ALB ADR ne azk m XADDRILBI gt 4 D FETCH ADDRIL9 mU 5 5 43 ADDAIS R W ADDRIG RWIN ADORLT ADDRIB SYS RESET 101 ADDRIS PWRON INT 100 pez ADDRILO pr 38 ADDRILZ ice ADORUS 96 org ADORI amp 99 ADURILSI 0016 34 TPUCHO ALT ADURIT 23 T 32 916 ADDRITS INT CANZ TPUCHZ liis 128K X 16 SRAM TPUCH ADDROT 2 29 ADORI 28 2 CS ADDRILS 21 puch 25 ADUR 23 RESET RESET BMISO FREEZE Return
8. TEST PROCEDURE 1 Remove input power to the machine 2 Using the 3 8 nut driver remove the case top 3 Locate the DC Bus Power Supply PC Board and plugs P46 and P47 See Figure F 7 4 Carefully apply input power to the Power Wave 455 R WARNING ELECTRIC SHOCK can kill High voltage is present when input power is applied to the machine E 5 Turn on the Power Wave 455 R The LED on the DC Bus Power Supply PC Board should light POWER WAVE 455 R LINCOLN Return to Section Return to Master TOC Return to Section TOC Return to Master TOC Q BS 5 2 Return to Section Return to Master TOC 2 2 5 22 22 TROUBLESHOOTING amp REPAIR DC BUS POWER SUPPLY PC BOARD TEST CONTINUED 6 Check the DC Bus Power Supply PC Board input and output voltages according to Table See Figure F 7 and the Wiring Diagram WARNING ELECTRIC SHOCK can kill High voltage is present at the terminals of Capacitor C3 near where testing is to be done 7 If all the voltages are correct the DC Bus Power Supply PC Board is operating prop erly 8 If any of the output voltages are not 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 cor
9. E 5 Control Board E 7 Output Rectifier Output Choke STT Chopper Board E 8 Thermal Protection Protective Circuits Over Current Protection and Under Over Voltage Protection enter nennen nennt E 9 T General Description of Surface Tension Transfer E 10 e Insulated Gate Bipolar Transistor IGBT Operation sse E 11 5 Pulse Width Modulation 12 FIGURE E 1 BLOCK LOGIC DIAGRAM 2 IGBT DRIVE n TRANS POWER WAVE 455 R udis de OUTPUT DIODES ELECTRODE D1 D4 TERMINAL E pb 1 INPUT RECTIFIER 20 VDC FROM POWER BOARD CURRENT Eu IGBT DRIVE ELECTRODE RECONNECT cue STT a TRANSDUCER TERMINAL SWITCH ONTROL To CONTROL BOARD Van B I A gt 2 to RIGHT E 5 CAP VIF SWITCH DRIVE CURRENT WORK gt FEEDBACK TRANSDUCER OUTPUT TERMINAL p OK AO E O 5 SENSE R AND PRECHARGE VOU yas 3 a CONTROL SIGNALS FROM BOARD DEVICE TO E CONTROL BOARD VOLTAG
10. F 33 Current Transducer Test nde erre eei rie ndo F 37 c Output Rectifier Test creer t np F 41 Auxiliary Transformer No 1 Test F 43 Auxiliary Transformer No 2 Test F 46 Component Removal and Replacement F 48 Input Rectifier Removal and Replacement eene F 48 Input Contactor Removal and F 50 e Auxiliary Transformer No 1 Removal and Replacement F 52 5 Auxiliary Transformer No 2 Removal and Replacement F 55 8 Control Feed Head or Voltage Sense PC Board Removal and Replacement F 58 9 Gateway PC Board Removal and Replacement 2 F 62 Current Transducer Removal and Replacement F 64 c Power Wave Current Transducer Removal and F 67 Output Rectifier STT Chopper Board and Rectifier Module Removal ANG Et F 70 Switch Board and Filter Capacitor Removal and F 74 Retest after Repair F 77 o g E POWER WAVE 455 8 LINCOLN 5 Return to Section Return to Master TOC Return to Section
11. cenl T7 R229 R264 c92 5145 R252 Co cn RISS 7432 R148 RISE RIS7 R160 RER Cro CAPACITORS MFDVOLTS INDUCTANCE HENRIES RESISTANCE OHMS Eois oes E gn i C pis Cy R149 R152 R155 Rise R161 5 R249 101 R243 UBJECT DRAWINGNo 11088 102 OTHER COMPONENT SIDE BACKSIDE MATERIAL TOLERANCE 14 AGREE WITH PUBLISHED STANDARDS ENGINEER T ODONNEL SUPERSEDING APPROVED SCALE NONE DATE 4 85 o 2 5 2 2 2 g 2 n I 2 i i o g THIS SHEET CONTAINS PROPRIETARY INFORMATION OWNED BY THE LINCOLN ELECTRIC COMPANY AND IS NOT BE REPRODUCED DISCLOSED OR USED WITHOUT THE EXPRESS WRITTEN PERMISSION OF THE LINCOLN ELECTRIC COMPANY CLEVELAND U S A gt MANUFACTURING TOLERANCE PER E2056 tg Sheet No X INFO DESIGN INFORMATION REFERENCE EQUIPMENT TYPE INVERTER WELDERS ON 2 PLACE DECIMALS IS 02 5 25 2001 ON 3 PLACE DECIMALS IS 002 DRAWN BY p 2 Lincoln Electric assumes responsibility for liabliliti
12. RS232 COMMON 2311 lt ARC LINKL 216 6J8 lt CONTROL BOARD COMMON 211 34 150v Sy 213 277 212 28 lt 15 18 lt CURRENT FEEDBACK lt 15V 52 VOLTAGE SENSE RECEPTACLE gt 5 tour _216 gt 4191 5 T l l L fC 0219 om 219 2 gt 211 816 lt 738 CONTROL BOARD COMMON L1 lt 2188 MOTOR SWITCH BOARD 2 RIGHT TRANSDUCER 11 _ lt se lt STT FEEDBACK lt 2 WORK VOLTAGE SENSE 3 jp 2e QH so gt lt 1484 15VDC TACH o 813 15V lt 812 lt lt 18V 1 4 MAIN CONTACTOR CONTROL lt 2384 TACH 1A DIFF INPUT 290 5 ttv I 3190 gt tour E CHOPPER BOARD lt 1 4 STT CHOPPER DRIVE THERMAL LED lt 3484 TACH 1B DIFF INPUT 4R lt 1417 lt STT CHOPPER DRIVE V yi THERMAL 5490 X lt 484 TACH COMMON LED 612 X 911 gt gt T1 13v AUX RECONNECT s se on 200 208V PRECHARGE RELAY lt TACH 2B DIFF INPUT 220 230V 440 460V 550 575 504
13. Operation Undervoltage 30 55 VDC Detect T D23 lt 30VDC n 1A hy 6 lt lt 307 Return to Section Return to Master TOC 15Volts 250Amps SPI Overvoltage Shutdown gt 55 VDC n 5Volts 3 Amps SPI i gt i 5Volts 100 Amp 20Volts gt gt 200 Amps Gate Drive 1 2700p sw i O o 5 5 PEN 9 gt 212 5 2 o 20Volts 200 Amps Gate Drive 5Volts 100 Amp RS232 FILENAME G3631 2D2 GENERAL INFORMATION LAST NO USED ELECTRICAL SYMBOLS PER E1537 CAPACITORS 02250 UNLESS OTHERWISE SPECIFIED 4 NOTES H RESISTORS Ohms 1 4W UNLESS OTHERWISE SPECIFIED LABELS WITHOUT AFFECTING THE INTERCHANGE ABILITY OF A COMPLETE BOARD THIS DIA
14. TO J1 VOLTAGE SENSE WORK ELECTRODE 52 LEFT SIDE OF MACHINE DIGITAL POWER SUPPLY BOARD AUXILIARY TRANSFORMER 1 xt H6 2 444 TOAUX 1 224A EHE CD ge TO RECT THERM AIN CH TERM 160 gt TO SOLID STATE RELAY _ CURRENT TRANSDUCER Sao TO 6 108 MAIN TRANSFORMER 007000010717 LEFT SIDE oe ed 000000000000000000000000000 000000000000 13 141 x Ei SEC TOP EFT Y J40 SWITCH BOARD 3500uF 500V TO 20C 19C MAIN TRANSFORMER TO RECONNECT SWITCH 6 J10B COCOOO COO COO DOC OON eid 450 E POWER BD RECT SWITCH BOARD SRANSDUGI 2888 05 3500uF 1516 C10 200 190 TO Ig RECONNECT Mil srormer SWITCH N A PIN NEAREST THE FLAT EDGE OF LED LENS CATHODE ALIGNS WITH BLACK LEAD OF LED SOCKET N B PLACE SWITCH IN APPROPRIATE POSITION FOR INPUT VOLTAGE CONNECTION SHOWN IS FOR 380 460 OPERATION N C PLACE A LEAD ON APPROPRIATE CONNECTION FOR INPUT VOLTAGE CONNECTION SHOWN IS FOR 440 460V OPERATION STT SNUBBER CAPACITOR BANK CB2 ELECTRICAL SYMBOLS PER E1537 J10 J2VS LEAD COLOR CODING J74 P COMPONENT VALUES RIGHT SIDE OF MACHINE amp AUXILIARY TRANSFORMER 2 TO
15. DSO 1 NOISE_GND BERR D4 D3 asa es FREEZE IFETCH DSI R11 R41 V BL BL y BKPTDSCLK RW 4 05 15 NOISE_GND DSACKIPEO AAA VVV 510 510 DSACK PE1 PLOV 475 5V J n AVEGPE AS RMGPE3 seq R187 IRLR120 ASIPES 26 7 Q9 9 SOFTS 5120 PE6 LEZSZSINIW on 121 PE7 10A 100V 06658151 PFO MODCLK PFI IRQT OV NORMA 5V FAULT NOISE_GND V ULT NT 88 IRQS gigive FPGA INT PFA IRQ4 _ 3 2 INT CAN PF5 IRQ5 FPGA BAD FPGA BAD 96 pr IRQe QNT 100 _ 95 PF7 IRQ7 x FAULT T2CLK CAPAUV R135 a IRLR120N 4 E TPUCHO M8 r6 YOON 2 010 80 SIGNAL BUCH 3058 19 CS7 20 8 CTRL gt X27 R85 9 RED IPUCH2 8 21 ADDRi v3 70 1 LED7 6089 22 ADDR 0 21 10 100 Touche CS10 A23 ADDR3 1 3 _ 27 TPUCH6 PCOCS3 FCO ADDR 775 ADDR6 25 MICRO_CONTROLLER CAPAOV 1 00k R136 CAPA_OV Za sa AUS ALS LEZSZSININ LEcSZSININ anyo BO R183 EE WNoISE GND OV 5V FAULT 7 i 22 1K TPU
16. Return Section Return to Master 2 2 5 F 62 TROUBLESHOOTING amp REPAIR GATEWAY PC BOARD REMOVAL AND REPLACEMENT WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty For your safety and to avoid electrical shock please observe all safety 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 Service Department for electrical trou bleshooting assistance before you proceed Call 1 800 833 9353 WELD DESCRIPTION This procedure will aid the technician in the removal and replacement of the Gateway PC Board MATERIALS NEEDED Phillips head screw driver 3 8 Nut driver Anti static wrist strap This procedure should take approximately 15 minutes to perform POWER WAVE 455 R LINCOLN F 62 Return to Section Return to Master TOC Return to Section TOC Return to Master TOC o 5 B Return to Section Return to Master TOC o 2 2 5 F 63 F 63 TROUBLES
17. FROM CONTROL BOARD AUX RECONNECT TO FAN RELAY DRIVES CONTACTOR AND PRECHARGE CONTROL SIGNALS LINK Return to Section TOC Return to Master TOC 5V RS232 THERMOSTATS CONTROL eal POWER BOARD 40 VDC 20 VDC CONNECTION TO WIRE BUS BOARD RECTIFIER 53 5232 LEFT SB CAP V F RIGHT S B CAP V F TO ARC LINK CHOPPER WIRE BOARD LEFTCT RIGHT CT Q EE CURRENT CURRENT RECP FB STATUS THERMAL LIGHT LIGHT GENERAL DESCRIPTION The Power Wave 455 R power source is designed to Tension Transfer for a variety of materials such as be a part of a modular multi process welding system mild steel stainless steel cored wires and aluminum It is a high performance digitally controlled inverter STT process supports mild steel and stainless welding power source capable of complex high speed steel welding Depending Power Wave 455 R has an output rating of either can support constant current constant voltage surface 450 amps at 38 volts or 400 amps at 36 volts The two tension transfer and pulse welding modes Each output ratings are dependent upon input voltage and machine is factory preprogrammed with multiple weld frequency Both have a duty cycle of 100 The STT ing procedures Typically these procedures include process is rated at currents
18. 022 50V GENERAL INFORMATION ELECTRICAL SYMBOLS PER E1537 R 25 00 1 5 MFD 022 50V UNLESS OTHERWISE SPECIFIED 5 1 CR 2 6 lt 6 RESISTORS Ohms 1 4W UNLESS OTHERWISE SPECIFIED LABELS Dose Jed 6 NOTES DIODES 1 4000 UNLESS OTHERWISE SPECIFIED SUPPLY VOLTAGE NET SINCE COMPONENTS OR CIRCUITRY ON A PRINTED CIRCUIT BOARD MAY CHANGE 3 7 lt WS WITHOUT AFFECTING THE INTERCHANGEABILITY OF A COMPLETE BOARD THIS DIAGRAM MAY SUPPLY SOURCE POINT 6 NOT SHOW THE EXACT COMPONENTS OR CIRCUITRY OF CONTROLS HAVING A COMMON CODE 7 COMMON CONNECTION lt 5 lt 2 1 E e FILENAME M19528 1AA EARTH GROUND CONNECTION lt LAST NO USED UNUSED PINS THIS SHEET CONTAINS PROPRIETARY INFORMATION OWNED BY THE LINCOLN ELECTRIC CO AND IS NOT TO BE REPRODUCED DISCLOSED OR USED WITHOUT THE EXPRESS PERMISSION OF THE LINCOLN ELECTRIC CO eS ONHOLES SIZES PER E2086 sam THE LINCOLN ELECTRIC CO INVERTEC 450 650 ON 2 PLACE DECIMALS IS 02 _ CLEVELAND OHIO U S A INPUT P C BOARD SCHEMATIC ON 3 PLACE DECIMALS IS 002_ SCALE NONE ON ALL ANGLES IS 5 OF A DEGREE WITH PUBLISHED STANDARDS MAB DATE 5 25 99 CHK MATERIAL TOLERANCE t TO AGREE rm SHT SUP S D G NO M 19528 Return to Section TOC Return to Master TOC NOTE
19. Return to Section Return to Master TOC Return to Master TOC C 2 2 ACCESSORIES OPTIONAL EQUIPMENT FACTORY INSTALLED There are no factory installed options available for the Power Wave 455R FIELD INSTALLED Gas Guard Regulator K659 1 The Gas Guard regulator is available as an option al accessory for the Power Feed Robotic wire drive unit Install the 5 8 18 male outlet on the regulator to the proper 5 8 18 female gas inlet on the back panel of the wire drive Secure the fitting with the flow adjuster key at the top Voltage Sense Leads K940 10 25 or 50 The voltage sense leads connect at the front of the machine See Figure A 2 Power Wave Water Cooler K1767 1 The K1767 1 is the recommended water cooler for the Power Wave Incorporated into the cooler is an automatic flow sensor to detect low coolant flow In the event of a low flow condition a fault signal is sent to the Power Wave and welding output auto matically stops to protect 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 such as fungicides or alkalies Follow the manufacturers recommendations to achieve proper operation and long lifetime without clogging Water Flow Sensor K1536 1 Water cooled guns can be damaged very quickly if they are used even momentar
20. T CDLD INCH TANVT 243 AD7BG2ARS 2 ABS VALUE R146 20K 1 V TD gt IMDTDRAO 170 eN7OD2LTI R149 Te mwan ZS 1 1 515 BNTOALTI Y NOTES SINCE COMPONENTS OR CIRCUITRY ON PRINTED CIRCUIT BOARD MAY CHANGE CH 2 Doe 11 3 2000 WITHOUT AFFECTING THE INTERCHANGEABILITY NOT SHOW THE EXACT COMPONENTS OR CIRCUITRY OF CONTROLS HAVING A COMMON CODE NUMBER 9 16 GENERAL INFORMATION ELECTRICAL SYMBOLS PER E1537 RESISTORS Ohms FILENAME AND IS NOT BE REPRODUCED DISCLOSED OR USED WITHOUT THE EXPRESS PERMISSION OF THIS SHEET CONTAINS PROPRIETARY INFORMATION OWNED BY LINCOLN ELECTRIC CO THE LINCOLN ELECTRIC CO DIODES 1AA400V UNLESS OTHERWISE SPECIFIED CAPACITORS MFD 022 50 UNLESS OTHERWISE SPECIFIED LAST No USED R LABELS 0 SUPPLY VOLTAGE NET POWER SUPPLY SOURCE POINT 57 COMMON CONNECTION 777 FRAME CONNECTION 17 EARTH GROUND CONNECTION CH ge Shi No Y INFO OF COMPLETE BOARD THIS DIAGRAM MAY THE LINCOLN ELECTRIC CO CLEVELAN
21. 406 lt 76 4 IGBT DRIVE 1976 TACH 1B DIFF SIGNAL D gt 843 54 lt 213 lt ITACH 2 DIFF SIGNAL 2 22 857 lt COLD IN REVERSE ARCLINK L gt 182 153 414 lt 1s10a CT CURRENT TACH 2B DIFF SIGNAL orc i T SINGLE TACH INPUT G 2 847 4 ARCLINK gt 2381 741 272 lt ARCLINKH F 418 CURRENT VOLTAGE SENSE 678 858 lt 885 GAS PURGE INPUT CHOR lt 2 0 MOTOR J gt 539 ARCLINK L 1381 743 1372 ARCLINK L THERMOSTAT MOTOR K gt 541 859 lt 985 SHUTDOWN 15VDC 224 lt 205 THERMOSTAT SOLENOID 40VDC N gt 521 COMMON 3381 800 3372 COMMON NORMALLY CLOSED 522 SOLENOID INPUT gt SA 860 10085 SHUTDOWN 1 INPUT TO 292 OT 220A 220 305 THERMOSTAT 40VDC 840 40VDC 5 OUTPUT RECTIFIER i DCBUS 185 SHUTDOWN 2 INPUT S7 I O xi um COMMON gt s4825 500 3 575 lt 24VDC THERMOSTAT THERMOSTAT RECEPTACLE 0 lt 167 lt FAN CONTROL 157 lt FAN CONTROL az 40VDC gt 4182 540 23754 24V GND 10 5 SPI TRIGGER 15 0 1 gt 851 TRIGGER INPUT 2 gt 852 DUAL PROC INPUT 3 gt 853 4 STEP INPUT 4 gt 854 COLD INCH 15 0 5 gt 8
22. hii 2 qu Hs Wa 20 Mu nec m Lu 027 022 026 525024 85 C3 C4 C5 C6 C8 CAPACITOR SMD TANTALUM 10 16 10 5 513490 179 9 CAPACITOR ALEL 1000 35V 20 525024 55 10 13 27 30 CAPACITOR SMD TANTALUM 4 7MF 35V 10 525024 65 11 12 43 60 CAPACITOR SMD TANTALUM 22MF 16V 10 S 525024 25 5 1 4 4 4 14 16 20 25 CAPACITOR SMD TANTALUM 1 0MF 35V 10 525020 35 3 15 17 18 19 21 22 23 24 26 28 31 32 C33 C35 C36 C37 C38 C41 C42 C44 C45 C46 C47 C48 C49 C50 C51 C53 C54 C58 CAPACITOR SMD CERAMIC 0 1MF 50V 10 X 525020 155 29 39 40 CAPACITOR SMD CERAMIC 22PF 50V 5 COG 513490 182 56 1 3300 63 20 513490 181 59 CAP ALEL 22 63V 20 525040 105 01 05 DIODE SMD 3A 400V D0 214AB 525040 95 D2 DIODE SMD 3A 200V D0 214AB ULTRA FAST 525040 25 D3 D6 D21 DIODE SMD 1A 400V DO 214BA AC 525040 115 D4 D16 D20 DIODE SMD 1A 600V S403A ULTRA FAST RE 525040 45 w D7 D8 D9 D10 D12 D13 D14 D15 DIODE SMD DUAL 0 200A 70V UFR 525049 35 017 DIODE SMD 3A 40V SCHOTTKY CASE 403 3 525049 45 019 DIODE SMD DUAL 200MA 30V SCHOTTKY SOT 525040 55 022 023 024 025 026 027 DIODE SMD DUAL 0 2
23. From Bridge To STT Output From Bridge To STT Output C2 C3 04 C5 C6 C7 C2 C3 C4 C5 C6 07 19 Jai 05 G6 19 g MICA4518N 14538 ELECTRICAL DIAGRAMS This diagram is for reference only It may not be accurate for all machines covered by this manual NOTE 14 to 22 Vac L 11340 SCHEMATIC CHOPPER PC BOARD G 6 DOL 49159 0 SOL 5 0 DOL 49159 0 NOL uonoes DOL J91Se A DOL 01 901 J91Se N 01 uunjeH 904 uonoeg oj at ELECTRICAL DIAGRAMS enr PC BOARD ASSEMBLY CHOPPER PARTNO IDENTIFICATION 7115779 50050 513490 8 50 25 3 07 09 10 21 516668 11 1 50 C6 C8 C20 513490 173 11 14 516688 10 12 17 516668 7 820 50 18 19 520500 2 47 630 pepe 2052427 05 06 2 12705 23 1N5818 071 1 112702 29 1N4744A 1 J10 820351 6 HEADER Return to Section TOC Return to Master TOC 1 815000 10 ISOLATOR R2 RSRIRIT R5 1 19400 4752 47 5 1 4W IR8 R23 519400 4751 4 75 1 4W R9 R10 R11 R12 R13 R14 R15 R16 R17 R18 R19 R20 14 51
24. from circuit breaker CB4 Label and remove primary leads 2 2 H4 and 5 from the reconnect terminals 9 the reconnect panel Note lead place ment for reassembly Cut any necessary cable ties and clear the leads Using the 3 8 nut driver remove the two mounting screws that hold the transformer to the fan baffle and the machine base Carefully remove the transformer from the Power Wave 455 R REPLACEMENT PROCEDURE 1 Carefully place the transformer into the Power Wave 455 R Install the two mounting screws that hold the transformer to the fan baffle and the machine base using the 3 8 nut driver Install the primary leads H2 H3 H4 and H5 to the reconnect terminals on the reconnect panel Connect primary lead H1 to circuit breaker CB4 Splice the new transformer lead with the lead connected to the input board POWER WAVE 455 R LINCOLN 55 55 TROUBLESHOOTING amp REPAIR AUXILIARY TRANSFORMER NO 2 REMOVAL AND REPLACEMENT PROCEDURE WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty For your safety and to avoid electrical shock please observe all safety notes and precautions detailed throughout this manual Return to Section TOC Return to Master TOC
25. gt lt lt 5 gt tc 2 o 2 2 gt 2 LL amp 72 gt gt o gt 9 lt 25 S2 2 0 2 gt 2m lt I lt 2 6 ow lt gt gt lt mo lt ep o cn ig EA d t X o La lt lt gs ok Cu gt gt 2 5 Fo 2 gt 29 38 2 Z m amp lt 901 Je1Se A 0 901 Je1Se A 0 uunjeu 901 J91Se N 01 uunjeH 901 J91Se N 01 uunjeH DOL uonoes uumeg DOL uonoes uumeg DOL uonoes uumeg DOL uonoes uumeg D 4 NOTES POWER WAVE 455 R LINCOLN E D 4 901 Je1Se A 0 901 Je1Se A 0 uunjeH 901 J91Se N 01 uunjeH 901 J91Se N 01 uunjeH DOL uonoes DOL uonoes uumeg DOL uonoes DOL uonoes Section 1 Section E 1 TABLE OF CONTENTS THEORY OF OPERATION SECTION 5 Theory of Operation Section 8 General 2 9 Input Voltage and Precharge E 3 Switch Boards and Main E 4 c DC Bus Board Power Board Feed Head Board Gateway Board and Voltage Sense 4
26. 5 5 gt 218 5 2 Return to Section Return to Master TOC F 51 F 51 TROUBLESHOOTING amp REPAIR INPUT CONTACTOR REMOVAL AND REPLACEMENT CONTINUED FIGURE F 19 INPUT CONTACTOR REMOVAL AND REPLACEMENT INPUT CONTACTOR REMOVAL PROCEDURE REPLACEMENT PROCEDURE 1 Remove input power to the Power Wave 1 Mount the contactor and tighten the mount 455 R ing screws 2 Using the 3 8 nut driver remove the case 2 Assemble the leads to the correct terminals top sides and input access panel See Figure 18 3 Perform the Capacitor Discharge proce 3 Install the case top sides and input access dure panel using the 3 8 nut driver 4 Locate the input contactor Label and using the phillips head screwdriver careful ly remove the leads from the input contac tor terminals Note placement for reassem bly See Figure F 19 5 With the 5 16 nut driver remove the three mounting screws See Figure F 19 6 Carefully remove the input contactor POWER WAVE 455 R LINCOLN 52 52 TROUBLESHOOTING REPAIR AUXILIARY TRANSFORMER NO 1 REMOVAL AND REPLACEMENT PROCEDURE WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty For your safety and to avo
27. Return to Master TOC Return to Section TOC ro 3 ro o ro gt 5 200 145 5 200 183 5 200 188 5 200 192 5 200 193 ry ry a ROA SM200 194 SM200 200 M200 201 M200 202 SM550 079 5 550 109 SM550 122 5 550 123 SM550 148 SM550 149 5 550 125 5 550 126 51 550 128 703W31526 A262567400 51 550 104 4287245100 5 800 299 5 800 297 707 03410 HW900 379 100 160 TH100 161 TH200 132 TH300 023 A TH300 024 A TH400 053 TH600 263 TH600 264 TH600 266 PPW 11110 1 PPW 11160 1 707 04224 TH200 219 SM200 220 5 200 221 5 5 200 522 016 703 01044 5 100 523 ml m eel POWER SUPPLY SM400 059 5 100 524 5 100 525 51 100 526 51 100 409 SM900 001 9P7951 51 200 194 A262577600 5 100526 9 n4 Return to Section Return to Master TOC gt fn o 5 D E o
28. 2 2 2 tc in 2 5 CAPACITORS MFD VOLTS INDUCTANCE HENRIES RESISTANCE OHMS INVERTER WELDERS DIGITAL POWER P C BOARD AS BLY 6 2 2000A G3632 1 Return to Section TOC Return to Master TOC NOTE Lincoln Electric assumes 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 Lincoln Electric This information is pro vided for reference only Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician Improper PC board repairs could result in damage to the LINCOLN amp machine ELECTRIC POWER WAVE 455 R Sm ELECTRICAL DIAGRAMS G 14 SCHEMATIC FEEDHEAD PC BOARD 1 5 Return to Section Return to Master TOC o7 MMBTA4OSLTI 5 135 14 15 4 CONTROL 1165 12 ADIRI E ADDRB 24 eN7002LT1 mE ADDR4 ADDRS m fe wpa
29. ARC LINKH 20D SS tc RS232 COMMON 403 IGBT DRIVE gi lt 2311 lt ARCLINKL CAP A 3500uF tour lt CONTROL BOARD COMMON A 404 VIF FEED HD BD 405 gt eno I 18 lt CURRENT FEEDBACK 521 3383 SOLENOID 40 0 lt 15V 52 VOLTAGE SENSE RECEPTACLE 406 IGBT DRIVE 522 lt 483 SOLENOID INPUT INPUT BOARD lt ws MOTOR 539 NA 72131 2391 gt 4 28 15 N lt CONTROL BOARD COMMON lt 1960 2460 gt 5 CN m snam MOTOR WITCH BOARD 2 RIGHT ET Ere 4 i s 841 14 15VDC TACH 12 C lt lt asv WORK VOLTAGE SENSE gt 6 9 gt MAIN CONTACTOR CONTROL 842 lt 204 TACH DIFF INPUT lt 15V CHOPPER BOARD 17 STT CHOPPER DRIVE THERMAL LED gt 843 3 4 TACH 1B DIFF INPUT _ lt 1437 lt STT CHOPPER DRIVE fe ing YELLOW 844 494 TACH COMMON Vf 4 ZN THERMAL 612 4 9 2061 gt LQ LED 503 4 lt 6 6 lt IGBT DRIVE THERMAL LED 27 gt AUX RECONNECT 1 lt 5484 TACH
30. H2 7 000200 15V H 1144 lt 15V TRANSFORMER T2 N 500 lt aur on S8 WATER COOLER ML commi NS perc cc S5 DEVICENET 653 RECEPTACLE ARCLINK COMMON E lt 3111 4 ARCLINK COMMON CONNECTOR 40VDC POWER 40V 5 6 840 460 2 RS232 45V 5232 5V 42 24VDC 10A COMMON 40V COMMON gt 33 4 gt 33 5 95232 COMMON 5 RS232 COMMON ote 350 40VDC POWER 40V Q8 000 32 l gt 1 gt 892 lt 4 CAN H 2 COMMON 51 32 NOTES 891 lt 5 CAN_L 45 J 3 wo 200 208 i N A PC BOARD COMPONENTS SHOWN FOR 50 52 CR S4 REFERENCE ONLY ALL COMPONENTS CB1 110V ARE NOT SHOWN 10A RECEPTACLE R2 RSANDRAARE2 300 C8 AND C10 ARE 20 mfd 400V ELECTRICAL SYMBOLS PER E1537 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 U S A CO DESIGN INFORMATION REFERENCE z F EL E EQUIPMENT TYPE INVERTER WELDERS SUBJECT PW455 R MACHINE SCHEMATIC emos __ SCALE NONE _DATE 9 II 00__DRAWINGNo 4009 Return to Section
31. Return to Master TOC o 5 D G 9 PC BOARD ASSEMBLY DEVICENET GATEWAY NOTE Lincoln Electric assumes 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 Lincoln Electric This information is pro vided for reference only Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician Improper PC board repairs could result in damage to the machine ELECTRICAL DIAGRAMS PC BOARD REFERENCE DESIGNATORS DESCRIPTION GATEWAY PC BOARD BLANK PLUG KEYING PLUG POTTING TRAY SELF TAPPING SCREW 6 8702 EPOXY ENCAPSULATING RESIN X11 ELECTRICAL INSULATING COMPOUND SOFTWARE CPLD X13 SOFTWARE FLASH ITEMS LISTED BELO W REFER TO ELECTRONIC COMPONENT DATABASE FOR COMPONENT SPECIFICATIONS 525020 135 2 2 7 CAPACITOR SMD CERAMIC 150pF 100V 5 C jr 6031 NPON 1 2 Hm 5 x yur 121 m zn 92 189 goo Y 431 263 8031 1031 amp
32. XIS 8 Lo 95 1 057 055 38 52508215 1 SIND FERRITEBEAD 105 520620 1003 4 RES 100K AX 596 1 2W HI VOLT TR R73 R79 R75 RIT 1 111088 1 xo 39 525001 47525 8 5 5 47 5 1206 1 1 8 R230 R27 R28 R26 R53 R29 R110 R57 106 525040 25 8 SDIO MURS32073 3A 200V ULTRAFA 51 055 056 057 098 099 0100 0101 gt O R204 R172 D61 40 525001 22115 8 SRES 2 21K 1206 195 1 BW NP R25 R13 Riz R32 R1 R31 R134 R66 107 525020 5 5 SCAP 100 0805 100 5 C15 C18 C22 C25 27 o Oo oH gt R178 R93 R231 RIG R61 108 52500010005 6 SRES 100 0805 1 6 110W R223 R224 R240 R226 R227 R228 L8 x25 Ries Deej 5 R89 R82 R163 R135 R136 R169 R131 R112 109 T12702 60 2 DIO 1N5358B DZ DZA o icis ocs 41 525001 10015 33 SRES 1K 1206 1 1 8W TROX0056 Lco R56 R126 R71 R54 R69 ROB R143 R144 110 11270259 2 DIO IN53338 DZ 072 eus 111 525049 25 4 __ SDIO MBRATSOLTS 1A 30V SCHOTKY 076 077 0114 0115 cies R58 R206 R213 R214 R90 R168 R255 R256 c cuz at MARR MN RHBARITURATZ 9188 112 525001 33205 5 SRES 332 1206 1 1247 R262 R263 R264 R265 R266 R267 arl h R180 R91 R92 R93 R94 R95 R96 R97 R98 R22 113 S25040 6SMT 6 SDIO BAV7O 084 D85 086 089 D90 091 R174 R201 R185 R104 R87 R33 R99 R260 u TE cus R196 5
33. 334 TL7Ze6ID TL772610 R139 475 m A ii ma 475 BUSS LOW T 5CAN re 4 7 24 7 Jer 475 2144 475 1 0 3727122 w 17726 o 2 D E 09 o E 2 2 2 tc ISOLATION BARRRIER CAN COMMUNICATION CIRCUITRY DATALO 152 CAN COMMUNICATION CIRCUITRY GENERAL INFORMATION ELECTRICAL SYMBOLS PER E1537 CAPACITORS MFD 022 50V UNLESS OTHERWISE SPECIFIED RESISTORS Ohms LABELS 0 DIODES 1A400V UNLESS OTHERWISE SPECIFIED SUPPLY VOLTAGE NET POWER SUPPLY SOURCE POINT 57 COMMON CONNECTION FILENAME 717 FRAME CONNECTION THIS SHEET CONTAINS PROPRIETARY INFORMATION OWNED BY THE LINCOLN ELECTRIC CO Ei D IS NOT TO BE REPRODUCED DISCLOSED OR USED WITHOUT THE EXPRESS PERMISSION OF
34. 8 Recheck the voltage across the capacitor terminals The voltage should be zero any voltage remains repeat the discharge procedure NOTE If the capacitor voltage is present after the discharge has been performed this may indicate a faulty switch board POWER WAVE 455 R LINCOLN Return to Section Return to Master TOC Return to Section TOC 515 gt 218 5 2 Return to Section Return to Master TOC Return to Master TOC F 11 TROUBLESHOOTING amp REPAIR SWITCH BOARD TEST WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty For your safety and to avoid electrical shock please observe all safety 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 Service Department 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 rectly This test will NOT indicate if the entire PC board is functional This resistance test is preferable to a voltage test wit
35. O o Fle 99 m 218 2 1 Return to Section Return to Master TOC me ELECTRICAL DIAGRAMS G 24 SCHEMATIC 40 VDC BUS PC BOARD OEE6TW 40 VDC TN 8 gt 45 120 125 WY e y Hs J47 1000V I 53 214 Work Lead Disconnect Protection Circuitry 14 03 27 35V 600V N 71 C14 04 100pF d 30v e GENERAL INFORMATION ELECTRICAL SYMBOLS PER E1537 CAPACITORS MFD UNLESS OTHERWISE SPECIFIED RESISTORS Ohms UNLESS OTHERWISE SPECIFIED ES UNLESS OTHERWISE SPECIFIED ES SUPPLY VOLTAGE N A SINCE COMPONENTS OR CIRCUITRY ON PRINTED CIRCUIT BOARD CHANGE POWER SUPPLY SOURCE WITHOUT AFFECTING THE INTERCHANGEABILITY OF A COMPLETE BOARD THIS DIAGRAM
36. Return to Master TOC Return to Section TOC Return to Master TOC o 5 B Return to Section Return to Master TOC o 2 2 5 10 10 TROUBLESHOOTING amp REPAIR INPUT FILTER CAPACITOR DISCHARGE PROCEDURE CONTINUED FIGURE F 1 CAPACITOR DISCHARGE PROCEDURE TEST PROCEDURE 1 Remove input power to the Power Wave 455 R Using the 3 8 nut driver remove the left and right case sides Be careful not to make contact with the capacitor terminals that are located in the bottom center of the left and right side switch boards See Figure F 1 Carefully 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 If any voltage is present proceed to Step 6 If no voltage is present the capacitors are discharged NOTE Normally the capacitors discharge in about two minutes after input power is removed CAPACITOR TERMINALS Using the high wattage resistor 25 1000 ohms 25 watts minimum electrically insulated gloves and pliers connect the resistor across the two capacitor terminals Hold the resistor in place for 10 seconds DO NOT TOUCH THE CAPACITOR TERMI NALS WITH YOUR BARE HANDS NEVER USE A SHORTING STRAP FOR THIS PROCEDURE 7 Repeat procedure for the other capacitor
37. BOARD ASSEMBLY MATERIAL TOLERANCE d ENGINEER KJ SUPERSEDING WITH PUBLISHED ST 5 __ 9 22 2000A SCALE DATE2 23 98 _DRAWINGNo C 3339 1 Return to Section TOC Return to Master TOC NOTE Lincoln Electric assumes 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 Lincoln Electric This information is pro vided for reference only Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician Improper PC board repairs could result in damage to the LINCOLN amp hine LINCOLN machine POWER WAVE 455 R ELECTRICAL DIAGRAMS G 8 SCHEMATIC DEVICENET GATEWAY PC BOARD 15 1 ERVOLTAGE 018 3 voii e 4 m 1 1150 7 n ont gt 1 0481 1 2321 58 1 0681 3 SPICSI 0882 1 0881 1 0981 2 6 PWRDNINT BLOCK 2 BLOCK SW5 V OLLBL 10012818 SPLCSO 01382 1701381 12 482 701481 13 SPLCS3 01582 1 01581 1 01682 1 0168 782 1001781 42 SPI 2 R W INV 3 MOSI Return to Master TOC Return to Section TOC
38. F 45 F 45 TROUBLESHOOTING amp REPAIR AUXILIARY TRANSFORMER NO 1 TEST CONTINUED TABLE F 7 SECONDARY VOLTAGES LEAD IDENTIFICATION NORMAL EXPECTED VOLTAGE X1 to X2 X3 to X5 X3 to X4 7 Carefully apply the correct input voltage to the Power Wave 455 R WARNING ELECTRIC SHOCK can kill High voltage is present at prima ry of the Auxiliary Transformer 8 Check for the correct secondary voltages according to Table 7 NOTE The secondary voltages will vary if the input line voltage varies 10 11 12 POWER WAVE 455 R LINCOLN If the correct secondary voltages are pre sent the T1 auxiliary transformer is func tioning properly If any of the secondary voltages are missing or low check to make certain the primary is configured correctly for the input voltage applied See the Wiring Diagram If the correct input voltage is applied to the primary and the secondary voltage s are not correct the T1 transformer may be faulty Replace any cables ties and insulation removed earlier Install the case sides and top using the 3 8 nut driver Return to Section Return to Master TOC Return to Section TOC Return to Master TOC Q BS 5 2 Return to Section Return to Master TOC 2 2 5 F 46 TROUBLESHOOTING amp REPAIR AUXILIARY TRANSFORM
39. Remove input power to the Power Wave 455 R Using the 3 8 nut driver remove the case top and sides Perform the Capacitor Discharge dure Observe all static electricity precautions 5 Using the 3 8 nut driver remove the PC board compartment cover Refer to Figure F 22 POWER WAVE 455 R LINCOLN COMPARTMENT Using the 3 8 nut driver remove the two screws holding the rear of the Control Box in place Clear the leads in the sleeving and the grom mets on the sides of the control box Label and remove the molex plugs from the Control Board and the Feed Head Board Return to Section Return to Master TOC Return to Section TOC Return to Master TOC E 5 5 gt 2 2 5 2 Return to Section Return to Master TOC F 60 F 60 TROUBLESHOOTING amp REPAIR CONTROL FEED HEAD OR VOLTAGE SENSE PC BOARD REMOVAL AND REPLACEMENT CONTINUED FIGURE F 23 VOLTAGE SENSE BOARD REMOVAL AND REPLACEMENT 9 10 11 CONTROL BOARD pS VOLTAGE SENSE BOARD Tilt back the rear of the control box to access the PC board mounting nuts Using the 3 8 nut driver remove the self locking mounting nuts from the Control and Feed Head Boards Carefully remove the boards Remove plugs J1 and J2 from the Voltage Sense Board See Figure F 23 Using the needle nose pliers ca
40. Return to Master TOC NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual LINCOLN amp POWER WAVE 455 G 6 POWER WAVE 455 R 0a 905405 Ty HO 66 6 6 id SQUVONVS NON OIOV D 8 STOW TY NO oe f 30v 30 9 Tarang Y S N ONY1IAJI9 2100 9 STWNO30 30 146 NO 20 SIS WNIO30 30 42 NO 9502 3 H3d 5328 NO JONYYJTOL 09140395 3SIMHSHLO 555180 804 H3ddOHO OLLVIN3HOS SUIC TIM B3LEANI add 00 210318 NTOONM JHL VOL OvE NOLLO3NNOO 4 NOLLO3NNOO ANIod O Adans 081410399 SSIMUBHLOSSTINN 53000 SN Sav 03 0348 3SIMEBHIO SSIINN SUYO 8015530 09110348 361 10 SSTINN 05 0 1 QAN SHOLIOWdYO 18513 SIOSWAS 1VOIH10313 0851 ON 18 1 NOLLVINHONI IVH3N39 30 NOISSIWH3d SS3udX3 3HL LNOHLIM 035 035019810 38 OL LON SI ONY 00 5119313 100 1 SHL A8 NOILVWHOJNI AHvL3HdOHd SNIVINOO 1 3HS SIHL 700 91819313 SHL 3009 NOWWO9 V 9NIAVH S1081NOO 40 HO SLNINOdWO9 LOVX3 3HL MOHS LON AYN WWHOVIC SIHL 3137409 30 JHL 9NILO333V LNOHLIM SONVHO AVW 31 Y AHLINOHIO HO SIN3NOdWOO 39
41. Return to Master TOC Return to Master TOC B 8 B 8 OPERATION PULSE WELDING Pulse welding procedures are set by controlling an overall arc length variable When pulse welding the arc voltage is highly dependent upon the waveform The peak current background current rise time fall time and pulse frequency all affect the voltage The exact voltage for a given wire feed speed can only be predicted when all the pulsing waveform parameters are known Using a preset voltage becomes impracti cal and instead the arc length is set by adjusting trim Trim adjusts the arc length and ranges from 0 50 to 1 50 with a nominal value of 1 00 Trim values greater than 1 00 increase the arc length while values less than 1 00 decrease the arc length Most pulse welding programs are synergic As the wire feed speed is adjusted the Power Wave will automati cally recalculate the waveform parameters to maintain similar arc properties The Power Wave utilizes adaptive control to compen sate for changes in 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 supports a range of stickouts from 0 50 13mm to 1 25 32mm At very low or high wire feed speeds the adaptive range may be less due to reach ing the physical limitations of the welding process Wave control
42. gt m co co Return to Master TOC Return to Section TOC m ojojo alas a CAPACITORS MFD VOLTS RESISTORS OHMS 1 4 WATT UNLESS OTHERWISE SPECIFIED olo O o e 515 gt 2 o MULTI WELD 350 40V DC BUS BOARD ASSEMBLY 9 22 2000 L11078 1 Return to Section TOC Return to Master TOC NOTE Lincoln Electric assumes 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 Lincoln Electric This information is pro vided for reference only Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician Improper PC board repairs could result in damage to the LINCOLN amp i machine POWER WAVE 455 R Return to Sectio
43. 2199 o 42 525001 10025 57 SRES 10K MF 1206 196 1 8W R261 R139 R140 R121 R200 R107 R199 R103 d j 9 mes LJ R221 R229 R204 R242 R241 R216 R217 R218 ue xn 1 R243 R246 R244 R245 R247 R248 R249 R250 RES Cios 0115 199 97 mios R251 R252 R253 R254 R257 R258 R259 R195 R194 R41 R11 RB3 R86 R166 R165 RZ1 43 825001 47508 28 SRES 475 1206 1 1 8W TRNP R15 R20 R88 R81 R14 R9 R17 R19 R10 R18 R16 R141 R138 R119 R116 R85 R84 R40 R36 R190 R192 R182 R184 R137 R146 R209 R210 44 825001 47518 15 SRES 4 75K 1206 1 1 8W SM100 TOUS GAS Rue FAT RSURET COMPONENT SIDE 45 525003 20005 _ _2 SRES 200 2512 1 1W TR NP RIZ R133 46 525001 15015 7 7 SRES 1 5K 1206 1 1 8W RTS 118 R122 R74 76 R78 47 525001 75005 7 1 SRES 750 1206 1 1 8W NP R183 48 S25001 5110SMT_ 2 _SRES 511 MF 1206 1 1 8W TR R24 R23 49 525001 10045 2 SRES 1M 1206 1 5 1 8W TR 930098 R212 R211 50 525001 26725 4 SRES 26 7K THK 1206 1 1 8W 10 R187 R114 R120 672 2 TEn Eu b mio Eg Bm o a ES 5 00 o 3 E 4 le E 5 B olg 41 z g a 8 5 5 5 85 ERE 8 5 5 THERE 5 22 es 22 2 A TET z g 156 2c E Fo 0000 5 8 R240
44. 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 before you proceed Call 1 800 833 9353 WELD TEST DESCRIPTION This procedure will aid the technician in the removal and replacement of auxiliary trans former No 2 Return to Section TOC Return to Master TOC MATERIALS NEEDED 3 8 Nut driver Wire cutters This procedure should take approximately 25 minutes to perform 515 gt 218 5 2 Return to Section Return to Master TOC POWER WAVE 455 R LINCOLN F 56 F 56 TROUBLESHOOTING amp REPAIR 918 AUXILIARY TRANSFORMER 2 REMOVAL AND 8 2 REPLACEMENT PROCEDURE CONTINUED FIGURE 21 AUXILIARY TRANSFORMER 2 REMOVAL AND REPLACEMENT E S INPUT CONTACTOR 42 5 8 gle CB4 CIRCUIT BREAKER amp 115V RECEPTACLE LEADS 33 32 D 5 5 gt 218 5 2 REMOVAL PROCEDURE Return to Section TOC Return to Master TOC 1 Remove input power to the Power Wave 455 R Using the 3 8 nut driver remove the case top sides and input access panel Perform the Capacitor Discharge proce dure Using the 3 8 nut driver remove the case back POWER WAVE 455 R LINCOLN Discon
45. Q BS 5 2 Return to Section Return to Master TOC 2 2 5 TROUBLESHOOTING amp REPAIR INPUT FILTER CAPACITOR DISCHARGE PROCEDURE WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty For your safety and to avoid electrical shock please observe all safety 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 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 maintenance or repair procedures are attempted on the Power Wave 455 R Capacitance normally discharges within 2 minutes of removing input power This procedure is used to check that the capac itors have properly discharged MATERIALS NEEDED 3 8 Nut driver Volt ohmmeter 25 1000 ohms 25 watts minimum resistor Electrically insulated gloves and pliers This procedure should take approximately 15 minutes to perform POWER WAVE 455 R LINCOLN Return to Section
46. Return to Section TOC Return to Master TOC 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 before you proceed Call 1 800 833 9353 WELD TEST DESCRIPTION This procedure will aid the technician in the removal and replacement of the Power Wave Current Transducer Return to Section TOC Return to Master TOC MATERIALS NEEDED 3 8 Nut driver 5 16 Open end wrench 9 16 Wrench 3 4 Wrench Phillips head screw driver Wire cutters Wiring Diagram This procedure should take approximately 25 minutes to perform 515 gt 218 5 2 Return to Section Return to Master TOC POWER WAVE 455 R LINCOLN Return to Section Return to Master TOC Return to Section TOC Return to Master TOC Q BS 5 2 Return to Section Return to Master TOC o 2 2 5 68 68 TROUBLESHOOTING amp REPAIR POWER WAVE CURRENT TRANSDUCER REMOVAL AND REPLACEMENT CONTINUED FIGURE F 26 POWER WAVE CURRENT TRANSDUCER REMOVAL AND REPLACEMENT PROCEDURE CURRENT TRANSDUCER HEAVY LEAD BOLTED CONNECTION BEHIND CASE FRONT REMOVAL PROCEDURE 1 Remove input power to the Power Wave
47. THE LINCOLN ELECTRIC CO ETH GROUND COMECTION Chige Sht No X INFO THE LINCOLN ELECTRIC Fou COMMON DIGITAL CONTROLS NOTES Us EC ON S PRINTED CCU Bo PLACE DECIMALS 154 02 Eum LEYELAND OHIO U S A _FEEDHEAD PC BOARD SCHEMATIC WITHOUT AFFECTING THE INTERCHANGEABILITY OF A COMPLETE BOARD THIS DIAGRAM MAY SCALE NONE um NOT SHOW THE EXACT COMPONENTS OR CIRCUITRY OF CONTROLS HAVING A COMMON CODE DR pate 07 17 2000 SUP S D G no 63822 1 1 4 NUMBER WITH PUBLISHED STANDARDS Return to Section TOC Return to Master TOC NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual LINCOL POWER WAVE 455 R Return to Section Return to Master TOC Return to Section TOC Return to Master TOC O o 5 5 o PEN 9 gt 212 5 2 o Return to Section Return to Master TOC G 16 ELECTRICAL DIAGRAMS SCHEMATIC FEEDHEAD PC BOARD 3 V MDNITUR J85 8 N DUAL PROCEDURE TANVT POWER MONITOR 13 06 NMBTA4O1LTI TANVT 00 p 85 5 Al GAS PURGE J85 8 MG J85 6
48. diameter access hole for the input supply is located on the upper left case back next to the input access door Connect L1 L2 L3 and ground according to the Input Supply Connection Diagram decal located on the inside of the input access door or refer to Figure A 1 INPUT FUSE AND SUPPLY WIRE CONSIDERATIONS Refer to the Technical Specifications at the beginning of this Installation section for recommended fuse and wire sizes Fuse the input circuit with the recommend ed super lag fuse or delay type breakers also called inverse time or thermal magnetic circuit breakers Choose an input and grounding wire size according to local or national electrical codes Using fuses or circuit breakers smaller than recommended may result in nuisance shut offs from welder inrush currents even if the machine is not being used at high currents POWER WAVE 455 R LINCOLN 8 Return to Section Return to Master TOC o Q o 2 5 Return to Master INSTALLATION INPUT VOLTAGE CHANGE OVER FOR MULTIPLE INPUT VOLTAGE MACHINES ONLY Welders are shipped connected for the highest input voltage listed on the rating plate To move this con nection to a different input voltage see the diagram located on the inside of the input access door Figure If the main reconnect switch or link position is placed in the wrong position the welder will not pro duce output power If the Aux
49. peak current is adjusted by wave control values A value of 10 0 maximizes the peak current while a wave control of 10 0 minimizes peak current In general the peak current is proportional to torch arc length See Figure B 5 Trim 1 50 Trim 1 00 Trim 0 50 NOTE The ranges on Wave Control and Trim are dependent on the weld programs The values shown are typical ranges FIGURE B 5 STT WAVE CONTROL CHARACTERISTICS Current Wave Control 10 0 Wave Control 0 00 Wave Control 10 0 POWER WAVE 455 R LINCOLN 5 10 5 POWER WAVE 455 R LINCOLN E B 10 901 Je1Se A 0 901 Je1Se A 0 uunjeH 901 J91Se N 01 uunjeH 901 J91Se N 01 uunjeH DOL uonoes DOL uonoes uumeg DOL uonoes DOL uonoes Section C 1 Section C 1 TABLE OF CONTENTS ACCESSORIES SECTION Noo eL oT AN E A oe E a a ee Section C 322 vn terret rre a 2 Factory Installed 2 Field Instale HH 2 Return to Master Return to Master TOC o o gt 0 iv z o 4 c tc Return to Master TOC POWER WAVE 455 R LINCOLN 5 Return to Section Return to Master TOC Return to Section TOC E 5 5 gt 2 2 5 2
50. would be due to improper input voltage connec tions 4 Internal component damage POWER WAVE 455 R LINCOLN 5 Return to Section Return to Master TOC Return to Section TOC Return to Master TOC Q BS 5 2 Return to Section 2 2 5 Return to Master E 10 E 10 THEORY OF OPERATION FIGURE E 8 STT WAVEFORMS Wave Control 10 0 Wave Control 0 00 Wave Control 10 0 Current STT Wave control characteristics Trim 1 50 Current Trim 1 00 Time Trim 0 50 STT Trim control characteristics GENERAL DESCRIPTION OF THE STT SURFACE TENSION TRANSFER PROCESS The STT process cannot be classified as either a con stant current CC or a constant voltage CV applica tion The STT function produces current of a desired waveform to reduce spatter and fumes The STT process is optimized for short circuit GMAW welding only POWER WAVE 455 R LINCOLN 5 Return to Section Return to Master TOC Return to Section TOC Ojo 515 gt 218 5 2 Return to Section Return to Master TOC Return to Master TOC THEORY OF OPERATION FIGURE E 9 IGBT OPERATION GATE SOURCE O BODY REGION lt BUFFER LAYER lt INJECTING LAYER DRAIN A PASSIVE INSULATED GATE BIPOLAR TRANSI
51. 074 072 j LI 27 C 18 C42 C137 141 C142 71 524020 6 1 CON 6P TIN MINI NP J9 m 1 5 val LU LU L cm T 12 514390 173 2 637 10 136 C135 72 524020 2 2 CON2P TIN MINI NP JIOA J108 136 16 oat wl 13 525020 25 2 SCAP 0 022uF 0805 OV XIR 10 C86 CT 73 518248 10 1 03 pie 5 JO ra 5 S2502008MT 2 SCAP 4700pF 0805 50V XTR 10 CEJ 74 51824816 1 CCON 16P MN NP 3 LES Ue Rao ps5 042 15 525020 55 4 SCAP 22pF 0805 50V COG 5 IR N C118 116 C128 C130 75 524020 16 2 26 7 po X xs D28 m Pe L 16 525020 185 1 SCAP 10pF CER 0805 100V 5 C32 76 524020 12 1 4 sells X5 cn 17 525020 135 7 SCAP 150pF 0805 100V COG 5 o TR C64 C89 C26 C35 C36 C38 C37 77 524020 8 1 CON 8P TIN MINI NP or TH600 265 J8 LEDs 107 2d R76 RTE Co jt L 11079 ciz Les Coe 18 525020 45 11 SCAP 820pF 0805 50V COG 5 1R C43 C74 C3 C71 C19 C70 C5 C72 C6 C17 78 520353 45 1 SICS MAX485ESA NP_ 09 eS the XE xm 55 co csi 19 524833 1 2 CAP 0 27uF MF 50V 5mm 5 TR NP 56 C34 79 525065 25 1 SICS 74ACT573 OCTAL TRANS LAT xn ot 137 Core 20 525020 145 2 SCAP 330pF 100V 6126 6148 80 52507075 1 SICS TMS320F240PQA NP 2 gt d 21 525025 55 8 SCAP
52. 1 4W 47 5 1 9400 1000 RESISTOR MF 1 4W 100 1 9400 1002 RESISTOR MF 1 4W 10 0K 1 9400 1821 RESISTOR MF 1 4W 1 82K 1 9400 2213 RESISTOR MF 1 4W 221K 1 9400 2672 RESISTOR MF 1 4W 26 7K 1 5 5 5 e gt 1 017 7 C8 C9 C10 5 R16 2 R18 Return to Section TOC Return to Master TOC D 20 gt co oo i 4 822 R20 R21 9400 3323 RES R MF 1 4W 332K 1 9400 4752 RES R ME 1 4W 47 5K 196 9400 5622 RES 1 4W 56 2K 196 9400 8251 RESISTOR MF 1 4W 8 25K 196 20500 2 0 47 630 10 0 24020 4 CONNECTOR MOLEX MINI PCB 4 PIN TIN 24020 8 CONNECTOR MOLEX MINI PCB 8 PIN TIN 2199 1 DIODE AXLDS 1A 400V 2199 2 DIODE AXLDS 1A 1000V 2218 16 CHOKE HIGH CURRENT 100UH 10A 1096 LOW 2300 86 RESISTOR WW 3W 0 05 196 2702 25 ZENER DIODE 5W 20V 5 1 5357 2702 45 ZENER DIODE 1W 18V 5 1N4746A 2705 23 DIODE AXLDS 1A 30V SCHOTTKY 1N5818 2705 34 DIODE AXLDS 1A 400V FR 1N4936 2705 59 DIODE AXLDS 3A 600V UFR 3640 15 MOV 50VRMS 15J 14MM 3640 24 MOV 175VRMS 120J 20MM 3657 2 LED T 1 3 4 RED HLMP 3003 4648 17 RESISTOR WW 5W 270 5 SQ R9 R10 R11 i BUSS 111078 1 2 R26 R27 x DZ4 DZ5 DZ6 r oeigiieloljsiimsm d 155 5 5 5 o gt gt m a m
53. 19 TROUBLESHOOTING amp REPAIR INPUT CONTACTOR TEST CONTINUED FIGURE F 6 INPUT CONTACTOR TEST POINTS 13 _ L2 Li T2 5 With the 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 faulty Replace the input contactor When the contactor is NOT activated the resistance should be infinite or very high across the contacts If the resistance is low the input contactor is faulty 7 8 POWER WAVE 455 R LINCOLN Reconnect the two leads 601 X4 to the input contactor coil Install the input access door and case top using the 3 8 nut driver Return to Section Return to Master TOC Return to Section TOC Return to Master TOC Q BS 5 2 Return to Section Return to Master TOC 2 2 5 F 20 TROUBLESHOOTING amp REPAIR DC BUS POWER SUPPLY PC BOARD TEST WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will inval
54. 3 G 16 PC Board Assembly FeedHead PC G 17 Schematic Input PC 1 nennen nensis nnne nnn nennen ns G 18 PC Board Assembly Input PC 2 G 19 Schematic Switch PC Board eene entente nnne nnns G 20 PC Board Assembly Switch PC 2 22224 1 0 0000 G 21 Schematic Voltage Sense canine tete G 22 PC Board Assembly Voltage Sense PC Board G 23 8 Schematic 40 VDC Bus PC Board tnnt G 24 9 Board Assembly 40 VDC Bus 25 5 o g E 2 o POWER WAVE 455 8 LINCOLN 5 Return to Section Return to Section TOC Return to Master TOC O10 E E 5 gt 91 8 tlt 5 5 o 1 Return to Section Return to Master TOC Return to Master TOC G 2 WIRING DIAGRAM POWER WAVE 455 R CODE 10675 WORK H 1 S5 DEVICENET CONNECTOR 894 893 56 WIREDRIVE INTERFACE RECEPTACLE 841 844 842 843 845 846 847 67B 539 lt z rx ro0mmooo 1777111 57 12 PIN CONNECTOR 851 852 853 85
55. 348 SIVDG REEDER 509 ps R2 RgBANDRAARE2 300 rs purum EQUIPMENT TYPE INVERTER WELDERS t XB 3 PLACE DECIMALS IS 000 wee BY KJ s ON ALL ANGLES 15 5 OF ADEGREE 11 3 2000A i SUBJECT PW455 R MACHINE SCHEMATIC DONOSA DATE 7 11 00 DRAWNGNo G 3791 Return to Section TOC Return to Master TOC NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual LINCOLN amp POWER WAVE 455 0 5 ELECTRICAL DIAGRAMS lid SCHEMATIC COMPLETE MACHINE CODE 10676 CONTROL BOARD RECONNECT ELECTRODE S3 RS232 INPUT SWITCH CONNECTOR OUTPUT DIODES RS232 RECEIVE 2 196 D1 D4 HARMONIC RS232 TRANSMIT gt 42 gt lt 3 ELECTRODE VOLTAGE SENSE 19D 19 CURRENT 20 CTCURRENT 1 TRANSDUCER CT CURRENT AA 20 aL IGBT DRIVE c4 20D 4 CAP MA VIF FEED HD BD 2275 VIF x 521 lt 383 SOLENOID 40VDC IGBT DRIVE N A 522 lt 4483 SOLENOID INPUT INPUT BOARD i lt 1483 MOTOR NA x a ELECTRODE VOLTAGE SENSE SSS ARC LINK H ELECTRODE Return to Section TOC Return to Master TOC
56. 455 R Using the 3 8 nut driver remove the case top and sides and the control box cover Perform the Capacitor Discharge proce dure Using the 3 8 socket wrench or nut driver remove the three screws along the bottom case front See Figure F 26 Using the 3 8 socket wrench remove the four screws that hold the case front to the machine Label all leads to all output terminals Using the 5 16 wrench and the 3 4 wrench remove all leads from the three output termi nals See the Wiring Diagram Cut any necessary cable ties Then careful ly swing the front panel aside Remove the insulating tape from the heavy lead bolted connection See Figure F 26 Using the 9 16 wrenches remove the bolt lock washer and nut POWER WAVE 455 R LINCOLN Return to Section Return to Master TOC Return to Section TOC Return to Master TOC o 5 B Return to Section Return to Master TOC o 2 2 5 69 69 TROUBLESHOOTING amp REPAIR POWER WAVE CURRENT TRANSDUCER REMOVAL AND REPLACEMENT CONTINUED 9 Using the phillips head screw driver 10 11 remove the screws and lock washers that hold the transducer to the front panel Remove the Power Wave current trans ducer Remove the standoffs from the transducer and save them for reassembly with the new
57. 525001 47515 4 99 8114 8132 8127 5 5 4 75 1206 1 1 8W NP SM 1 638220 1 FEED HEAD PC BOARD BLANK R101 R104 R125 R126 R127 2 19436 5 1 POTTING TRAY s25000 4751SMT 14 R128 R129 R130 R131 R133 SRES 4 75K 0805 1 RNP 3 58025 80 2 SELF TAPPING SCREW R134 R145 R90 R109 195 78 525001 15088MT 1 R15 RES 150K 1206 1 5 1 BW NP amp per 688 5 EPOXY ENCAPSULATING RESIN 79 525000 12115 1 8135 SRES 1 21K 0805 1 1 10W TR NP 5 E3539 AS REO ELECTRICAL INSULATING COMPOUND 80 525000 20025 3__ R146 R147 R76 SRES 20K TKF 0805 1 01 10W TR ND 16622 SOFTWARE NE 7 9248232 1 pe ISOFTWARE FLASH B1 MT 24 RS4R77R80R106 R116 R138 RESISTOR SMD METAL FILM 1 10W 10 0K 1 FOR ITEMS LISTED BELOW REFER TO ELECTRONIC COMPONENT DATABASE FOR COMPONENT SPECIFICATIONS E ESSE 1 Eu 8 52502425 3 21 22 07 050 5 1 3528 35 83 5203758 1 5936 Noreast Switching Pwr 3 C4 C5 C6 C8 C9 C12 C14 84 525068 75 SICS 4 6V 2 VOLT DETECTOR 15 19 20 22 25 85 15101 145 1 X2 SICS MC68332 MICRCONTROLLER TQ 26 27 28 29 30 31 86 1 X3 SICS 25128 SERIAL EEPR NP_ i C32 C34 C35 C38 C39 C41 87 1 SICS MC145407 RECEIVERIDRVR RS 47 c43 045 C46 C47 C48 C49 SCAR OUR 0805 SOV ATR TI TR 88 S25070 6SMT 1 16 SICS XC9572 15 CPLD TQ100 NP 51 054 C56 C57 C59 C60 89 517900 245 1 SICS 74
58. BOARD RECTIFIER BRIDGE REMOVAL PROCEDURE 1 Remove input power to the Power Wave 4 455 R 2 Using the 3 8 nut driver remove the case 5 top sides and input access panel 3 Perform the Capacitor Discharge dure POWER WAVE 455 R LINCOLN INPUT CONTACTOR Using the 3 8 nut driver remove the case back Remove lead X4 from the input contactor coil terminal Return to Section Return to Master TOC Return to Section TOC Return to Master TOC o 5 B Return to Section Return to Master TOC o 2 D 2 5 F 54 10 11 12 13 F 54 TROUBLESHOOTING amp REPAIR AUXILIARY TRANSFORMER NO 1 REMOVAL AND REPLACEMENT PROCEDURE CONTINUED Remove leads X1 and X2 from the power 6 Splice the new transformer fan leads to board rectifier bridge Refer to the fan motor leads X3 and X5 7 Connect lead X4 to the main contactor Cut X3 and X5 from the fan motor leads coil terminal Leave enough lead length to splice in the 8 Connect leads X1 and X2 to the power new transformer leads board rectifier bridge Cut the X3 lead that is connected to the m 9 Reposition any wire leads and install input board Leave enough lead length to E cable ties as necessary splice in the new transformer lead Locate label and remove primary lead H1 19 22
59. CONNECTOR PLUG J43 POWER BOARD CONNECTOR PLUG J41 POWER BOARD CONNECTOR PLUG J43 POWER BOARD CONNECTOR PLUG J43 F 25 TROUBLESHOOTING amp REPAIR POWER BOARD TEST CONTINUED TABLE F 4 POWER BOARD VOLTAGE CHECKS TEST CONNECTOR LEAD NO OR NORMAL DESCRIPTION PLUG PIN NO IDENTITY ACCEPTABLE VOLTAGE READING CHECK 40 VDC 477 38 42 VDC INPUT FROM 475 DC BUS BOARD aa 15 15 VDC SUPPLY FROM POWER BOARD CHECK 5 VDC 5 VDC SUPPLY FROM POWER BOARD CHECK 15 VDC 15 VDC SUPPLY FROM POWER BOARD CHECK 5 VDC 5 VDC ARCLINK SUPPLY FROM POWER BOARD CHECK 5 VDC 5 VDC RS 232 SUPPLY FROM POWER BOARD CHECK 15 VDC 15 VDC SPI SUPPLY FROM POWER BOARD CHECK 40 VDC 38 42 VDC INPUT FROM DC BUS BOARD CHECK 45 VDC 45 VDC SPI SUPPLY FROM MB POWER BOARD CHECK 20 VDC STT 20 VDC SUPPLY FROM 6 POWER BOARD POWER WAVE 455 R LINCOLN Return to Section Return to Master TOC Return to Section TOC Return to Master TOC Q BS 5 2 Return to Section Return to Master TOC 2 2 5 F 26 TROUBLESHOOTING amp REPAIR INPUT BOARD TEST WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel Unauthorized repairs performed on this equipmen
60. D61 060 D13 012 D1 D46 82 S25068 85M 1 SICS MCTSLOSABD X R218 Co 4 L__ 30 525046 35 4 500 5252488 18 2 053 052 058 059 93 525065 35 2 SICS 74VHC14 NP 340 x30 S R146 021 31 S25044 10SMT 3 SDIO B5930 16V 1 5W ZENER TR N D18 D15 D43 RIT D54 94 525057 35 2 SICS ADB403ARUT0 X632 s Lu 1 F 32 325044 55 a 500 15 5931 3 3 18 5 127 0321028 D30 031 0291024 014 DIS 95 15105 95 1 SICS 7045 12 eo 7 H 8 oan 099 33 52504445 2 SDIO B5829 16V 1 5W ZENER TRIN 010011 56 515018215 2 1 5 4457 EE O Oo gt 97 525067 25 1 SICS ADG409BR Xi5 D66 050 033 D49 019 078 079 0102 0103 oon x22 525040 55 13 SDIO BAV99LT1 SOT23 DUAL SWITC 0105 010010107 98 52507035 1 TCS XC9536 15 044 XT He a X6 Co 99 25069 28MT 1 SICS 25128 SERIAL EEPR NP mes 35 52504945 8 SDIO BATS4S DUAL 30V 200mA 034 054 028 D47 D80 D81 082 083 100 815128215 2 SICS LTI016 COMPARATOR XX R169 mm 51 101 519869 8 1 SWT 78B08S DIP SPST 8P NP_ 1 4 36 525080 25 8 SLED GRN 1206 TRNP pue 102 525066 25 1 SICS AD7862 DUAL 12B1T 250kSPS Xi9 le go oy 103 52506875 1 51 5 4 6 2 DETECTOR SO EZ o RI66 me pee 37 525080 15 2 1206 TED LEDIO 104 52507045 1 51 5 520
61. DIFF SIGNAL D gt 843 TACH ee DEF SIONAL am re Es EOLDINIREVERSE ARCU 414 lt 1310a CT CURRENT SINGLE TACH INPUT G gt 847 VOLTAGE SENSE gt 678 ARCLINK ARCLINK T CHOKE MOTOR J gt 539 ARCLINK L ARCLINK L THERMOSTAT MOTOR 541 lt s385 SHUTDOWN 15VDC 224 lt 245 lt THERMOSTAT SOLENOID 40VDC gt 521 COMMON COMMON NORMALLY CLOSED lt 885 GAS PURGE INPUT 418 lt 2s10A CURRENT SOLENOID INPUT gt 522 4005 SHUTDOWN 1 INPUT OTO 292 220A O 220 lt 315 THERMOSTAT T gt GND A lt 40VDC 4381 40VDC OUTPUT RECTIFIER 1 lt 167 4 FAN CONTROL SHUTDOWN 2 INPUT THERMOSTAT DCBUS lt nues 7 VO s COMMON avez Se Be THERMOSTAT RECEPTACLE crimes INPUTB D 40VDC 4482 2375 24V GND 262 268 5V SPI TRIGGER 15VDC 1 gt Rd VOLTAGE SENSE SELECT 44485 175 CAN TRIGGER INPUT 2 gt DUAL PROC INPUT 3 gt 853 4 STEP INPUT 4 gt 854 gt gt 3R 157 4 FAN CONTROL VOLTAGE SENSE SELECT 513185 lt ANSC 238 4 936 lt 13V COLD INCH 15VDC 5 gt 855 M PEN COLD IN
62. FORWARD 6 gt 856 COLD IN REVERSE 7 gt 857 GAS PURGE INPUT 8 gt 858 SHUTDOWN 15 0 9 gt 859 SHUTDOWN 1 INPUT 10 gt 860 SOLID STATE RELAY VOLT SENSE BD 282 lt 26 4 MAIN CONTACTOR CONTROL SHUTDOWN 2 INPUT 11 gt 861 R T POWER BOARD s man Su I INPUT B 12 862 p AUXILIARY lt 22 ROBOTIC VOLTAGE SENSE 15 SPI 643 45V SPI Me VOLTAGE SENSE SELECT gt 4n gt 511 E 550575 604 lt 126 lt PRECHARGE CONTROL SINGLE PHASE DETECT 231 lt 16 lt LOW 1 PHASE ojo o E E 29 a gt 23 cic 5 5 o 53 lt ARCLINK 444 VOLTAGE SENSE SELECT 141 gt 512 SPI COMMON gt 11J43 gt SPI COMMON POWER BD RECT MS WOESTE SN 54 lt ARCLINK VOLTAGE SENSE OUTPUT gt 3 1 67 POWER DOWN INTERUPT gt 4142 gt i POWER DOWN INTERUPT PERTTI rd 346 1443 4 STT COMMON C ELECTRODE SENSE POS WIRE FEEDER VOLTAGE SENSE 15V 15V 220 230 65VDC N 262 lt 12J43 SPI COMMON lt D 40VDC T 24000uF 100V asd NEG 0VDC 268 lt 3443 4 SPI 45V N A DC BUS BD CONTROL BOARD COMMON 10J4 lt CONTROL BOARD COMMON
63. GMAW O OFF FCAW 5 E HIGH TEMPERATURE GTAW 9 2 15 OPEN CIRCUIT VOLT MACHINE STAT ac C STATUS Ug AGE 82 2775 CIRCUIT BREAKER 04 INPUT VOLTAGE olo WIRE FEEDER Us OUTPUT VOLTAGE S POSITIVE OUTPUT ly INPUT CURRENT 515 o o NEGATIVE OUTPUT Ip OUTPUT CURRENT ili PROTECTIVE 3 ec 3 PHASE INVERTER QD GROUND do INPUT POWER THREE PHASE CAUTION DIRECT CURRENT Return to Section TOC Return to Master TOC POWER WAVE 455 R LINCOLN 5 Return to Section Return to Master TOC Return to Section TOC 5 5 gt 218 5 2 Return to Section Return to Master TOC Return to Master TOC B 4 B 4 OPERATION GENERAL DESCRIPTION The Power Wave power source is designed to be a part of a modular multi process welding system Depending on configuration it can support constant current constant voltage Surface Tension Transfer and pulse welding modes The Power Wave power source is designed to be used with the family of Power Feed wire feeders operating as a system Each component in the system has spe cial circuitry to talk with the other system compo nents so each component power source wire feeder electrical accessories knows what the other is doing at all times The components communicate using ArcLink protocol Robotic systems can comm
64. INTERCHANGEABILITY OF COMPLETE BOARD THIS DIAGRAM MAY PG SCALE sm NOT SHOW THE EXACT COMPONENTS OR CIRCUITRY OF CONTROLS HAVING COMMON CODE TERIAL pr LRW pate 07 17 2000 SUP S D G No 3823 1 1 NUMBER PUBLISHED STANDARDS Return to Section TOC Return to Master TOC NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual LINCOLN E POWER WAVE 455 R 0 15 ELECTRICAL DIAGRAMS G 15 SCHEMATIC FEEDHEAD PC BOARD 2 Return to Section TOC Return to Master TOC RECEIVER DRIVER y SOLENOID FULL DUPLEX RS232 COMMUNICATION LINK IRSF3OL1L GAS SOLENOID CIRCUITRY TPD j j Return to Section TOC Return to Master TOC jo S 8 GREEN LED RED LED K mean tm 1 J85 J85 18 286 10 v ae mes Ped PEN 86 1 Y 86 2 ARCLINK STATUS LED Lo H e 386 7 miso T a
65. MAY URER SUPPLY SUURLE PU NOT SHOW THE EXACT COMPONENTS OR CIRCUITRY OF CONTROLS HAVING A COMMON CODE 57 COMMON CONNECTION NUMBER E M19330 1BA 7 1 FRAME CONNECTIO THIS SHEET CONTAINS PROPRIETARY INFORMATION OWNED BY THE LINCOLN ELECTRIC CO EARTH GROUND CONNECTIO IS TO BE REPRODUCED DISCLOSED OR USED WITHOUT THE EXPRESS PERMISSION THE LINCOLN ELECTRIC CO UNLESS OTHERWISE SPECIFIED TOLE esht No gt 2 COLN ELECTRIC CO 2 MULTI SYSTEMS 40 VDC BUSS ON 3 PLACE DECIMALS 15 002 ELAND OHIO U S A SUBJECT POWER SUPPLY PCB SCHEMATIC ON ALL ANGLES 15 5 OF DEGREE OO MATERIAL TOLERANCE t TO AGREE a SEALE NNE _ SHT WITH PUBLISHED STANDARDS pate 09 01 99 Bk NO 19330 NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual LINCOLN je POWER WAVE 455 R 6 25 ELECTRICAL DIAGRAMS PC BOARD ASSEMBLY 40 VDC BUS IDENTIFICATION Px 1 15458 4 IC PWM CONTROLLER IMODE 2842A 3490 25 CAPACITOR TAEL 4 7 35V 10 3490 42 CAPACITOR TAEL 1 0 35V 10 3490 66 CAPACITOR TAEL 47 35V 10 3490 93 CAPACITOR TAEL 27 35V 10 3490 174 CAPACITOR ALEL 470 100V 50 10 5018 16 CMOS DRIVER MOSFET 2110 SS 6668 3 CAPACITOR CEMO 100P 100V 5 6668 10 CAPACITOR CEMO 4700P 50V 2 6668 11 CAPACITOR CEMO 0 1 50V 1096 9400 47R5 RESISTOR MF
66. N 01 uunjeH 901 J91Se N 01 uunjeH DOL uonoes DOL uonoes uumeg DOL uonoes DOL uonoes Section B 1 Section B 1 TABLE OF CONTENTS OPERATION SECTION 5 jer mme O Section B 8 Safety xi tero oit EC E B 2 9 Graphic cts Haan EUR ae ali NAE Ege uS ERR ERR Ra B 3 E General M 4 c Design Features and Advantages B 4 Recommended Processes and B 5 Recommended B 5 Recommended tcrtia B 5 Required tre tacit iet ttr es tr dg B 5 sc RI E iE E B 5 Duty Cycle and Time Period B 5 5 Front MIL ns ea eat i dau tun dust eile 6 8 Welding Mode Descriptions 22 B 7 9 Constant Voltage Welding essent nennen enn B 7 E B 8 c B 9 o o g E o d z g E 2 o POWER WAVE 455 8 LINCOLN 5 Return to Section Return to M
67. POWER WAVE 455 R LINCOLN 5 Return to Section Return to Master TOC Return to Section TOC Return to Master TOC o 5 B Return to Section Return to Master TOC o 2 2 5 RECOMMENDED PROCESSES AND EQUIPMENT RECOMMENDED PROCESSES The Power Wave 455 R can be set up in a number of configurations some requiring optional equipment or welding programs Each machine is factory prepro grammed with multiple welding procedures typically including GMAW GMAW P FCAW GTAW and STT for a variety of materials including mild steel stainless steel cored wires and aluminum The STT process supports mild steel and stainless steel welding The Power Wave 455 R is recommended only for automatic or mechanized applications such as robotic welding RECOMMENDED EQUIPMENT Automatic Operation All welding programs and procedures are set through software for the robotic Power Wave FANUC robots equipped with RJ 3 controllers may communicate directly with the Power Wave Other pieces of equip ment such as PLCs or computers can communicate with the Power Wave using DeviceNET All wire weld ing processes require a robotic Power Feed wire feeder REQUIRED EQUIPMENT 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 a
68. SO8 21 513490 184 1 C84 330 100 104 5 SICS LM2576HVS 5 0 VREG 60V SWI 22 525020 45 2 85086 CAPACITOR SMD 820 50 5 06 30805 105 4 X28 51 5 74 245 501 20 5 23 525040 125 2 01 012 SDIO MURS320T3 3A 200V ULTRAFA 106 524841 1 ICS DC DC 5V OUT 36 75V IN 24 525040 25 4 02017020027 5210 400 0 8 107 525082 15 1 M SXTL 16MHz HC40 20pF NP 28 s 3 sno siut 26 525049 45 4 0708010019 SDIO BAT54S DUAL SERIES 30V 20 27 525040 45 5 011013014015 016 SDIO BAW56LT1 50T23 DUAL SWT T 28 525040 115 4 022 23 24 025 SDIO MURS160 1A 600V FAST RECO 29 525040 05 1 026 SDIO 3A 200V D0 214AB UFR 30 525040 105 1 090 DIODE SMD 3A 400V 6 34 21 525046 35 4 071 072 073 074 SDIO MMSZ5248B 18V ZENER TR NP 32 525046 15 3 075 02280729 SDIO MMSZ5231BT1 5 1V NP 33 525044 95 6 076 077 078 079 07250227 5010 15 85920873 6 2 DZ10 DZ11 DZ12 DZ13 DZ14 4 34 525044 15 8 0248 SDIO 1SMB5918BT3 3W 5 1V 5 TR NP 35 525046 25 4 0220 0221 0722 0723 SDIO MMSZ5240BT1 10V S00mW ZEN 36 518380 5 2 RES 50 VAR PTC NP F3 F4 F5 F6 F7 F8 FO F10 E 37 518380 4 2 RES 500 PTC 265V 38 524020 4 2181 82 CON MOLEX 15 97 7042 MINI PCB 4 PIN TIN 39 524020 6 1 CON MOLEX 15 97 7062 MINI PCB 6 PIN TIN 40 5240208 1 e CON MOLEX 15 97 7082 MINI PCB 8 PIN TIN 41 5
69. SW1 6121 10 CIRCUIT i BREAKER TO AUX 2 TO J61 CB4 CB3 6A 612 CIRCUIT BREAKER TO AUX 1 TO SOLID STATE RELAY x5 TO AUX 1 THIS AREA VIEWED FROM REAR OF MACHINE N B RECONNECT SWITCH TO SWITCH BD 2 49D SWITCH 1 19 Toswi POS NC TO AUX 1 200 208V H2 220 230V 380 415V SWITCH BD 1 440 460V T 20 H5 To SWITCH BD 2 NEG TO INPUT RECT TO INPUT RECT 58 WATER COOLER RECEPTACLE TO RECONNECT SWITCH LA NEG NPUT POS RECTIFIER ANIHOVW 30 TO AUX 1 L3 12 L1 TO SW1 TO SW1 L3A L1A Ww V U TO SUPPLY LINES A SYSTEM GROUND PER NATIONAL ELECTRICAL CODE J2 J5 J11 J1VS J9 J10CH J8 41 46 72 J73 J76 J81 J82 J14 40J42 47 160 4 413 J1 46 J7 450 J75 J83 J84 J43 371 J10 70 J85 J87 13 1 4 4 CAPACITORS MFD VOLTS o RESISTORS OHMS WATTS o 2 ooo o ooo oooo 6 4 8 B8 16 11 3 2000 CONNECTOR CAVITY NUMBERING SEQUENCE VIEWED FROM COMPONENT SIDE OF BOARD G3792 NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual The wiring diagram specific to your code is pasted inside one of the enclosure panels of your machine POWER WA
70. This diagram is for reference only It may not be accurate for all machines covered by this manual LINCOLN B POWER WAVE 455 R Return to Section Return to Master TOC Return to Section TOC Return to Master TOC O o e 515 Bjo gt 2 o Return to Section Return to Master TOC G 19 ELECTRICAL DIAGRAMS PC BOARD ASSEMBLY INPUT LINCOLN B NOTE HEADER 524020 10 HEADER CI I 1 515000 22 ISOLATOR _ R 1 R2 83 87 88 9 810 8 524376 3 000 Ra 1007 10w S19400 2673 26 1 4 S19400 4750 475 vaw RTI RI2 813 814 815 RIG 19400 3011 3 01 1743 HO IAM R23 R24 R25 4 TP TP2 T13640 23 250 660v RESISTORS OHMS WATTS CAPACITORS MFD VOLTS INVERTEC 455 6558 460 _ L11396 1 INVERTER WELDERS INPUT BOARD ASSEMBLY 11 89 2000 L11396 1 G 19 Lincoln Electric assumes no responsibility for l
71. and test the machine 6 Always indicate that this procedure was followed when warranty reports are to be submitted NOTE Following this procedure and writing on the warranty report INSTALLED SWITCHED PC BOARDS TO VERIFY PROB LEM will help avoid denial of legitimate PC board warranty claims POWER WAVE 455 R LINCOLN 5 Return to Section Return to Master TOC Return to Section TOC Return to Master TOC Q BS 5 2 Return to Section Return to Master TOC 2 2 5 4 TROUBLESHOOTING amp REPAIR Observe Safety Guidelines detailed in the beginning of this manual PROBLEMS SYMPTOMS Major physical or electrical damage is evident when the sheet metal covers are removed POSSIBLE AREAS OF MISADJUSTMENT S OUTPUT PROBLEMS Contact your local authorized Lincoln Electric Field Service Facility for technical assistance TROUBLESHOOTING GUIDE RECOMMENDED COURSE OF ACTION Contact the Lincoln Electric Service Department at 1 800 833 9353 WELD The input fuses repeatedly fail or the input circuit breakers keep trip ping Make certain the fuses or break ers are properly sized Make certain the reconnect panel is configured properly for the applied voltage The welding procedure may be drawing too much input current or the duty cycle may be too
72. applied to the machine TROUBLESHOOTING GUIDE RECOMMENDED COURSE OF ACTION 1 Check the receptacle and asso ciated wiring for loose or faulty connections Diagram 2 Perform the 72 Auxiliary Transformer Test See the Wiring The Power Wave 455R is trig gered for output but there is welding output Make sure that the triggering method and device is correct and operating properly Check circuit breaker 4 Reset if tripped Use troubleshooting software to find the problem Contact Lincoln Electric Service Department to obtain software When the STT mode the spatter is higher than normal and the arc is inconsistent Make certain the work sense lead 21 is connected properly Make certain the electrode cable is connected only to the STT output terminal and NOT the Power Wave positive output terminal Make sure the welding parame ters are correct for the process 1 Perform the STT Chopper Board Test 2 Perform the Transducer STT Test 3 The Control Board may be faulty CAUTION 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 troubleshooting assistance before you proceed Call 1 800 833 9353 POWER WAVE 455 R LINCOLN 5 Return to Section Return to Master TOC Return to Section TOC Return to Master TOC
73. case top using the 3 8 nut dri F 48 F 48 TROUBLESHOOTING amp REPAIR INPUT RECTIFIER REMOVAL AND REPLACEMENT WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty For your safety and to avoid electrical shock please observe all safety notes and precautions detailed throughout this manual Return to Section TOC Return to Master TOC 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 before you proceed Call 1 800 833 9353 WELD olo Ee AE DESCRIPTION 8 This procedure will aid the technician in the removal and replacement of the input er module ala MATERIALS NEEDED 3 8 nut driver 3 16 Allen wrench Phillips head screwdriver This procedure should take approximately 15 minutes to perform 515 gt 218 5 2 Return to Section Return to Master TOC POWER WAVE 455 R LINCOLN Return to Section Return to Master TOC Return to Section TOC Return to Master TOC o 5 B Retur
74. correct terminal Install the mylar insulating shield covering leads 11 12 or 15 16 Replace the cable tie Connect molex plug J40 J50 to the top of the switch board Using the 5 16 nut driver install the glastic high voltage protective shield Install the case top and sides using the 3 8 nut driver 77 77 TROUBLESHOOTING amp REPAIR RETEST AFTER REPAIR Retest a machine If it is rejected under test for any reason that requires you to remove any part which could affect the machine s electrical characteristics Return to Section TOC Return to Master TOC OR If you repair or replace any electrical components INPUT IDLE AMPS AND WATTS Input Volts Hertz Maximum Idle Amps Maximum Idle KW 208 60 230 60 400 60 460 60 575 60 Return to Section TOC Return to Master TOC MAXIMUM OUTPUT VOLTAGES Input Volts Hertz Output Terminals X1 X2 115 Volt Receptacles No load 208 60 230 60 OCV 10 Amp Load 400 60 50 70 VDC 48 5 55 VDC 460 60 115 123 VAC 111 119 VAC 575 60 Ojo 515 gt 218 5 2 Return to Section Return to Master TOC POWER WAVE 455 R LINCOLN 78 5 POWER WAVE 455 R LINCOLN E F 78 901 Je1Se A 0 901 Je1Se A 0 uunjeH 901 J91Se N 01 uunjeH 901 J91Se N 01 uunjeH DOL uonoes DOL uonoes uumeg DOL uonoes DOL uonoes
75. cse dA qi E ADDR ap DATA 4 VOLTAGE SENSE CIRCUITRY an DATAS 4o DATA PEE CR an DATAR me 0 0 0 0 a man as mran aa a DATAIS UD 4 62 28 80085 890 CDM Return to Master TOC ARCLINK CONFIGURATION CRYSTALS Return to Section TOC 8 S se 5 7 MURS16073 516 35 TACH A 5 EE zi 5 TACH ces E Dres sov J MAXABSCSA ADSEL 194 DUTPUT DUTPUT 102 TDSACKD SYS RESET OL SYS RESET PVRIN NT 100 FAULT FAULT 99 58 INT CAN INT CAN 97 DT 96 MMBTA403LTI MICRO CONTROLLER vece jaa MAXABSCSA 128 16 8 MMBTA403LTI no L2 DATAD 284 6 o erat 20 DATA 55 1 19 529 ac se converteR AN I 1 4 Es TARCTS73MTC C84 Hcso sa
76. high Reduce the welding cur rent and or reduce the duty cycle 1 Check the reconnect switches and associated wiring See the Wiring Diagram 2 Perform the Input Rectifier 3 Perform the Switch Board Test 4 Perform the nput Contactor CAUTION 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 troubleshooting assistance before you proceed Call 1 800 833 9353 POWER WAVE 455 R LINCOLN 5 Return to Section Return to Master TOC Return to Section TOC Return to Master TOC Q BS 5 2 Return to Section Return to Master TOC 2 2 5 F 5 F 5 TROUBLESHOOTING amp REPAIR TROUBLESHOOTING GUIDE PROBLEMS SYMPTOMS The machine is dead no lights no output the machine appears to be off Observe Safety Guidelines detailed in the beginning of this manual POSSIBLE AREAS OF MISADJUSTMENT S OUTPUT PROBLEMS Make certain the input power switch SW1 is in the ON posi tion Check the main input fuses or breakers If open replace or reset Check the 6 amp 4 breaker located in the reconnect area Reset if tripped Make certain the reconnect panel is configured correctly for the applied input voltage RECOMMENDED
77. in pulse programs usually adjusts the focus or shape of the arc Wave control values greater than 0 increase the pulse frequency while decreasing the background current resulting in a tight stiff arc best for high speed sheet metal welding Wave control values less than 0 decrease the pulse frequency while increasing the background current for a soft arc good for out of position welding See Figure B 3 FIGURE B 3 PULSE WAVE CONTROL CHARACTERISTICS Wave Control 10 0 Wave Control 0 00 Current Wave Control 10 0 Time POWER WAVE 455 R LINCOLN 5 Return to Section Return to Master TOC Return to Section TOC Return to Master TOC Q BS 5 2 Return to Section Return to Master TOC 2 2 5 STT WELDING The pictures illustrate the waveshape of current for the process They are not drawn to scale and are intend ed only for the purpose of showing how the variables affect the waveform Trim in the STT mode adjusts the tailout and back ground portion of the waveform Trim values greater than 1 0 add more energy to the weld and make the weld puddle hotter trim values less than 1 0 reduce energy to weld A nominal value of 1 0 will work for most applications See Figure B 4 FIGURE B 4 STT TRIM CONTROL CHARACTERISTICS Current Time For most programs
78. lt vie na gt 8160 gt y 514 lt 11108 CT CURRENT x 505 550 vir STATUS LED HI FOR GREEN 518 2 lt CT CURRENT 506 lt IGBT DRIVE 403 156 IGBT DRIVE 503 66 IGBT DRIVE THERMAL LED TACH 2A DIFF INPUT 514 1450 CT CURRENT 812 813 504 lt 56 lt VIF 811 816 518 lt 2150 CT CURRENT 1 STATUS LED HI FOR RED 0 20 STT _ 345 110 lt 505 106 amp VIF 503 lt 3150 IGBT DRIVE gt 4361 gt lt 7384 SINGLE TACH INPUT Hq COMMON RED GREEN 346 lt 506 1446 4 IGBT DRIVE 4 7 STATUS S LED SINGLE PHASE DETECT 285 TRIGGER INPUT Low 1 PHASE 7 98 gt S6 ROBOTIC lt 385 DUAL PROC INPUT INTERFACE PE M RECEPTACLE lt 45 4 STEP INPUT 40VDC gt 6ue3 gt NA Return to Master TOC Return to Section TOC VIF x TACH 15VDC 841 5485 COLD INCH 15VDC 40VDC gt 583 BD lt 86 lt VIF TACH COMMON 2 844 53 lt 173 lt ARCLINK TACH DIFF SIGNAL C 5 842 _ 6 85 COLD IN FORWARD IRCLINK 2 2 406 lt 746 4 IGBT DRIVE 1B
79. nut driver ELECTRIC SHOCK can kill High voltage is present when input power is applied to the machine Return to Section TOC Return to Master TOC 515 gt 218 5 2 Return to Section Return to Master TOC POWER WAVE 455 R LINCOLN 29 F 29 TROUBLESHOOTING amp REPAIR INPUT BOARD TEST CONTINUED TABLE F 5 INPUT BOARD VOLTAGE CHECKS Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC 515 gt 218 5 2 Return to Section Return to Master TOC LEAD NUMBERS EXPECTED VOLTAGE READINGS TEST POINTS COMMENTS PLUG J61 PIN 8 H1D SAME AS TO INPUT PLUG J61 PIN 2 612 VOLTAGE PLUG J61 PIN 10 T3 A LITTLE LESS TO THAN INPUT PLUG J61 PIN 2 T1 VOLTAGE PLUG J60 PIN 3 238 TO PLUG J60 PIN 4 604 13 15 VDC 238 604 GOGG PLUG J60 PIN 3 238 TO PLUG J60 PIN 5 232 13 15 VDC POWER WAVE 455 R LINCOLN 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 approximately 6 seconds and then be removed This is the Coil Voltage for the Pre Charge Relay Normally this DC Voltage will be present 6 sec onds after Input Switch SW1 is activated
80. output terminal The reading should be less than 500 ohms If both the polarity resistance tests are low either the STT Chopper Module is faulty or diode D6 is shorted See the Wiring Diagram Return to Section Return to Master TOC Return to Section TOC Return to Master TOC o 2 Return Section Return to Master TOC 2 2 5 32 32 TROUBLESHOOTING amp REPAIR STT CHOPPER BOARD TEST CONTINUED 4 Carefully apply input power to the Power 6 Wave 455 R WARNING ELECTRIC SHOCK can kill High voltage is present when input power is applied to the 7 machine For steps 5 and 6 see Figure F 10 8 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 correct the Power Board may be faulty POWER WAVE 455 R LINCOLN Measure the voltage from Control Board plug J7 lead 4W pin 13 to lead 4R pin 14 4 The voltage should be 4 5 VDC This is the pulse width modulation signal to the STT Chopper Board f not correct the Control Board may be faulty When the test is completed remove input power from the Power Wave 455 R Install the case top using the 3 8 nut driver F 33 F 33 TROUBLESHOOTING amp REPAIR POWER WAVE CURR
81. procedure nected to the Power Wave 455 7 Reconnect lead 202A to the negative output 5 With the analog ohmmeter measure the terminal resistance between the positive and nega Replace the case top and sides tive output terminals NOT the STT termi nal Refer to Figure F 15 Return to Section TOC Return to Master TOC POWER WAVE 455 R LINCOLN 43 43 TROUBLESHOOTING amp REPAIR AUXILIARY TRANSFORMER NO 1 TEST WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty For your safety and to avoid electrical shock please observe all safety notes and precautions detailed throughout this manual Return to Section TOC Return to Master TOC 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 before you proceed Call 1 800 833 9353 WELD TEST DESCRIPTION This test will determine if the correct voltage is being applied to the primary of Auxiliary Transformer No 1 and also if the correct voltages are being induced on the secondary windings of the transformer Return to Section TOC Return to Master TOC MATERIALS NEEDED Volt ohmmeter Multimeter 3 8 Nut dr
82. sure not to touch any electrically live parts at the same time Tools which come in contact with the PC Board must be either conductive anti static or static dissipative Remove the PC Board from the static shielding bag and place it directly into the equipment Don t set the PC Board on or near paper plastic 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 e the PC Board uses protective shorting jumpers don t remove them until installation is complete e If you return a PC Board to The Lincoln Electric Company for credit it must be in the static shielding bag This will prevent further damage and allow prop er failure analysis 4 Test the machine to determine if the failure symp tom has been corrected by the replacement PC board NOTE Allow the machine to heat up so that all electri cal components can reach their operating tem perature 5 Remove the replacement PC board and substitute it with the original PC board to recreate the original problem a f the original problem does not reappear by substituting the original board 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 substitution of the original board then the PC board was the problem Reinstall the replacement PC board
83. to Section TOC Return to Master TOC 5 DSACKO SYS_RESET INT_CAN Ale A15 Alk A13 0158 12 1 014 3 TPUCHS ADORI12 5 att yon 22 ADORI 23 DATAIL 10 1 012 ADORI10 A9 011 DATAIZ ADDR m DATA AB 1 010 18 TPUCHI3 ADDRIBI AT 1 09 15 PATAN ADDRITI Uu DATAIS 6 1 08 18 15 SIS ADDRIGI AS vort 65 2050 ADURLSI vost 68 051 ADDRIAT vast 612052 DATAS ADORI A 1 68 pasa DATAUS ADDRIZI 1012816 1 03 DATALZ ADORI DATAUZI 7 pass DATAE DATAGI Tl pose DATAILZ DATAIOI 05 13 DATAIS 52 74 1 26 RS232 TXD lt DATAN JATAILS DATAI14 3 DATAL2 DATAISI DATAIE DATAITI 19 18 217 16 DATAIBI 5 DATAIZI O o 5 5 o PEN 9 gt 212 5 2 o RS232 RX0 VSTDBY MC68332GCPV25 DATAIO15 lt 15 GENERAL INFORMATION LAST NO USE
84. transducer REPLACEMENT PROCEDURE 1 Attach the standoffs to the transducer 2 Position the transducer on the back of the front panel and attach it with the two phillips screws and lock washers Feed the output leads through the transducer Run the heavy lead through transducer and secure the bolted connection with the 9 16 bolt lock washer and nut Replace the insulating tape around the connection POWER WAVE 455 R LINCOLN 6 Install the case top and sides using the 3 Using the 5 16 wrench and the 3 4 wrench attach all leads to the three output terminals See the Wiring Diagram Replace all cable ties cut during removal nut driver Return to Section Return to Master TOC Return to Section TOC Return to Master TOC Q BS 5 2 Return to Section Return to Master TOC 2 2 5 70 TROUBLESHOOTING amp REPAIR F 70 OUTPUT RECTIFIER STT CHOPPER BOARD AND RECTIFIER MODULE REMOVAL AND REPLACEMENT WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty For your safety and to avoid electrical shock please observe all safety notes and precautions detailed throughout t
85. transducer and the control board See the Wiring Diagram Install the right side case cover using the 3 8 nut driver TABLE F 6 CURRENT FEEDBACK AT VARIOUS OUTPUT LOADS OUTPUT LOAD CURRENT POWER WAVE 455 R LINCOLN EXPECTED TRANSDUCER FEEDBACK VOLTAGE Return to Section Return to Master TOC Return to Section TOC Return to Master TOC Q BS 5 2 Return to Section Return to Master TOC 2 2 5 37 TROUBLESHOOTING amp REPAIR STT CURRENT TRANSDUCER TEST WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty For your safety and to avoid electrical shock please observe all safety 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 Service Department for electrical trou bleshooting assistance before you proceed Call 1 800 833 9353 WELD TEST DESCRIPTION This test will help determine if the STT current transducer and associated wiring is func tioning correctly MATERIALS NEEDED 3 8 nut driver Volt Ohmmeter This procedure should ta
86. your safety and to avoid electrical shock please observe all safety 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 Service Department for electrical trou bleshooting assistance before you proceed Call 1 800 833 9353 WELD TEST DESCRIPTION This test will help determine if the Power Board is receiving the correct voltages and also if the Power Board is regulating and producing the correct DC voltages MATERIALS NEEDED 3 8 Nut driver Volt ohmmeter Wiring Diagram This procedure should take approximately 30 minutes to perform POWER WAVE 455 R LINCOLN F 23 Return to Section Return to Master TOC Return to Section TOC Return to Master TOC Q BS 5 2 Return to Section Return to Master TOC 2 2 5 24 TROUBLESHOOTING amp REPAIR POWER BOARD TEST CONTINUED FIGURE F 8 POWER BOARD TEST J42 J41 J43 1 2 3 1 2 123456 4 5 6 3 4 7 8 910 11 12 J42 J41 J43 TEST PROCEDURE 1 Remove inp
87. 0 208 230V 60HZ 570 6096 460V 60HZ 570 6096 575V 60HZ 570 6096 200 220V 50HZ 500 6096 440V 50HZ 500 6096 Ojo 515 gt 218 5 2 m gt gt tl Sa Sa Return to Section TOC Return to Master LINCOLN 5 3 3 INSTALLATION TECHNICAL SPECIFICATIONS POWER WAVE 455 K1761 1 1761 2 continued PHYSICAL DIMENSIONS HEIGHT WEIGHT 1761 1 247 Ibs 26 10 in 112 kg 663 mm K1761 2 254 165 Return to Section TOC Return to Master TOC 115 kg TEMPERATURE RANGES OPERATING TEMPERATURE RANGE STORAGE TEMPERATURE RANGE 20 C to 40 40 C to 40 C Return to Section TOC Return to Master TOC 5 5 5 218 5 2 Return to Section Return to Master TOC POWER WAVE 455 R LINCOLN 5 Return to Section Return to Master TOC Return to Section TOC O10 515 gt 8 2 EIS 2 Return to Section Return to Master TOC Return to Master TOC A 4 A 4 INSTALLATION SAFETY PRECAUTIONS Read this entire installation section before you start installation WARNING ELECTRIC SHOCK can kill Only qualified personnel should per form this installation Turn th
88. 00A 70V UFR 525046 15 021 ZENER DIODE SMD 0 5W 5 1V 5 SOD123 525046 35 DZ2 DZ3 DZ4 DZ5 ZENER DIODE SMD 0 5W 18V 5 SOD123 525044 95 2 DZ6 DZ7 DZ8 DZ10 DZ11 DZ12 DZ13 ZENER DIODE SMD 3W 6 2V 5 SMB 518248 16 J70 CONNECTOR MOLEX 16 518248 10 471 CONNECTOR MOLEX MINI PCB 10 PIN 524020 4 J72 J73 J76 CONNECTOR MOLEX MINI PCB 4 PIN TIN 524020 2 074 CONNECTOR MOLEX MINI PCB 2 PIN TIN 524020 6 475 CONNECTOR MOLEX MINI PCB 6 PIN TIN 525080 25 LED1 LED2 LED3 LED5 LED7 LED9 LED SMD GREEN CLEAR S1206 525080 15 LED4 LED6 LED8 LED SMD RED CLEAR S1206 515000 285 1 2 4 OPTOCOUPLER SMD TTL OUT HI SPD HI CMR 515000 325 5 6 OPTOCOUPLER SMD CMOS HIGH SPEED HIGH 525050 25 02 04 05 012 013 TRANSISTOR SMS PNP SOT23 0 5A 40 525051 45 06 07 08 09 010 011 TRANSISTOR SMD NMF SOT 23 0 115A 60V 525000 47505 R1 R2 R39 R40 R66 R67 RESISTOR SMD METAL FILM 1 10W 4750HMS 525003 20005 alo R3 R4 RESISTOR SMD 1W 2000HMS 1 525000 10025 a R5 R8 R9 R10 R11 R12 R13 R14 R15 R16 R17 R19 R20 R21 R22 R23 R24 R25 R29 R34 R35 R42 R60 R61 R69 RESISTOR SMD METAL FILM 1 10W 10 0K 1 525000 47515 R6 R38 R43 R45 R101 RE
89. 240206 1 45 ICON MOLEX 15 97 7162 MINI PCB 16 PIN TIN 42 51824810 1 CON 10P MINLNP ee 43 518248 6 1 17 39 28 1163 16 PIN TIN ee 44 515000 255 4 0 1 0612 0613 04 SICS Optocoupler HCPL 0601 50 8 45 515000 265 1 005 SICS HCPL 0201 OPTOCOUPLE e 46 525051 45 5 01 012013 015 016 STRA 2N7002 TR NP 5 400 020 eo 47 525050 25 5 02 03 07 014 017 STRA 2N4403 8023 TR 500475 lin 04 05 06 019 020 021 022 023 02 48 525050415 STRA 2N4401 SOT 23 NPN TR g 49 525051 55 4 08 09 0100 STRA 75A 55V 0 007 OHM FET N CHAN m 50 523060 15 1 IC SMD SWITCH LO SIDE 2 2A60V a E RORIS Hl 51 525000 10025 24 SRES 10K 0805 1 1 10W TR NP D e 116 138 148 8149 52 525001 10025 6 810 813 883 8100 8118 10K MF 1206 1 5 1 8W TR ar e 53 _ 525001 4752 4 R84 R85 R86 R152 RESISTOR SMD 47 5K 1 4W 1206 19 zm m i6 BE e 54 525003 20005 2 SRES 200 2512 5 1W TR NP t a RT4 RI5 R62 107 _ 1111 mim 2 55 525001 47505 9 SRES 475 1206 1 1 8W TR NP 9 56 525000 10015 8 SRES 1K 0805 1 1 10W TR NP e e 5 84 57 525000 47505 2 826827 SRES 475 0805 1 TR NP 58 525004 24305 12 SR
90. 2A DIFF INPUT CT CURRENT gt 46 604 CURRENT 504 lt 58 lt VIF STATUS LED HI FOR RED 2 200 208V PRECHARGE RELAY lt 6 84 TACH 2B DIFF INPUT H3 220 230V IGBT DRIVE H4 380 415V I TUM SINGLE TACH INPUT ap gang 506 4 146 lt IGBT DRIVE RED OREEN sd 851 1485 TRIGGER 15 0 2056 29 NES 130 gt 3160 gt 500V 514 lt 1 08 lt CT CURRENT 50 VIF STATUS LED HI FOR GREEN SINGLE PHASE DETECT 852 x 246 TRIGGER INPUT 518 CURRENT 40VDC gt 683 gt 880 20 STT 345 lt 505 10J6 lt VIF 2108 gt 860 LOW 1 PHASE lt 6450 IGBT DRIVE S6 ROBOTIC 853 lt 365 DUAL PROC INPUT t INTERFACE ue i RECEPTACLE 854 lt 485 4STEP INPUT Return to Section TOC Return to Master TOC 403 156 IGBT DRIVE 404 1636 VIF Q TACH 15 841 855 lt 585 COLD INCH 15VDC 40VDC gt 5183 5 886 1 GATEWAY BD 2 ee EO TACH COMMON B gt 844 53 lt 1073 ARCLINK DIFF SIGNAL C gt 842 856 lt 685 COLD IN FORWARD RCLINK H gt 2J82 5 154
91. 4 855 856 74 857 84 858 941 859 104 860 11 861 124 862 lt gt LL 2 na GND B 17 Smo gt TTTTTTTTTTTTTIS c1 05 600 Tm 51 7 WIRE FEEDER RECEPTACLE A 111111117 52 VOLTAGE SENSE RECEPTACLE 3 CONDUCTOR 1WISTED SHELDED SHIELD GROUND TO esl 4411444114 RON 5 N TO 483 184 J2VS 1 0 52 TO 1 10 12 50 TO TP3 WORK ELECTRODE 54 115 RECEPTACLE To 502 1 ELECTRODE CB2 lo 31 To 10A CIRCUIT S4 BREAKER 0 33 AUX 2 STATUS LED R G TO J7 Tow NA oN THERMAL LED Y TO J7 C6 05 600V TO BECO ene PANEL TOP STT TO J61 LOAD LINE CONTACTOR HID O ELECTRICAL DIAGRAMS POWER WAVE 455 R WIRING DIAGRAM CONTROL BOARD 1 B2gooxoorom TM JJ UJ J J m 11 m RON OY 20 os 20 STT SNUBBER RESISTOR BANK FEED HEAD BOARD
92. 4 R52 R30 wo 59 525001 22105 5 SRES 221 1206 196 1 8W NP REO R48 R102 R197 RAS o gt 9 S0 52601 26745 1 SRES 2 67 1206 1 BW TRNP R109 61 25001 15025MT_ 2 SRES 150K 1206 1 1 8W NP R117 R125 oe OOOOOOOO FOR ITEMS LISTED BELOW REFER ELECTRICAL DATABASE FOR COMPONENT Se r 133 SPECEICATIONS RAST RIGA 157 RIGO R148 R161 R158 R155 v Coe C138 C134 C133 C125 655 696 C98 C100 C28 64 25006 10R0 10 SRES 10 R152 R149 E n 875 R79 C82 C14 C11 C83 C103 C121 C101 C117 C115 65 525050 25 5 STRA 2N4403 5023 TR 500475 N 1017 016 015 013 014 M MN m C111 C113 C85 C90 C48 C93 C109 C120 C127 66 525051 65 2 STRA IRLRI20N 10 100V MOSFET Q9 Q1 2 OO ez ms 87 CR nm og 1 525020 35 68 SCAP 0 1uF 0805 50V x7R 10 TR 106 C95 C105 C73 C68 C8 C114 C108 C99 67 525050 15 9 STRA MMBT4401LT NPN SOT 23 012 04 Q7 Q5 06 Q1 018 019 020 E Nes roe 04 cipa 03 C77 C76 C75 C84 C79 C67 C88 C80 C50 C78 68 525051 45 2 STRA 2N7002 TRNP 03 02 OO pia mes 1 1227 C23 C21 C91 C51 C92 C58 C57 C52 C60 C59 69 525051 75 1 SICS IRF7103 NP 11 T7 Dus CO C131 C123 C122 C124 C30 C129 C139 C140 70 524020 4 3 CONAP TIN MINI NP J5 311 J2 am 7
93. 55 Eos IN 604 1218 PRECHARGE CONTROL COLD IN REVERSE 7 gt as SINGLE PHASE DETECT E 24 GAS PURGE INPUT 8 gt 858 LOW 1 PHASE SHUTDOWN 15VDC 9 gt 859 SHUTDOWN 1 INPUT 10 gt 860 SOLID STATE RELAY VOLT SENSE BD an 1 POWER BOARD 67 4 9 lt VOLTAGE SENSE VOLTAGE SENSE SELECT gt 14s85 gt 511 15 CAN H VOLTAGE SENSE SELECT 13485 512 4 5 CANL 238 _ lt 9 lt 216 lt CONTACTOR CONTROL AUXILIARY 67B lt 212 ROBOTIC VOLTAGE SENSE 15V SPI gt 6m3 gt 15V SPI TRANSFORMERTI VOLTAGE SENSE SELECT gt 4t 5 511 650 575 2 ojo o E E 29 a gt 23 cic 5 5 o ARCLINK n VOLTAGE SENSE SELECT 141 5 512 1 SPI COMMON lt SPI COMMON E POWER BD RECT T38 ST 20v TON M VOLTAGE SENSE OUTPUT gt j 67 POWER DOWN INTERUPT POWER DOWN INTERUPT in E 545 lt lt C ELECTRODE SENSE t Pos WIRE FEEDER VOLTAGE SENSE gt 12 gt _ 67A 45V 15V 220 230 65VDC 262 12 3 lt S
94. 9400 3010 301 14W IR21 R22 R25 1 _ 519400 2213 221 1 4 R26 1 519400 3323 332 1 4 x1 515018 9 CMOS MC14538B x2 515018 21 IC DRIVER 12A MOSFET SS x3 515018 15 14 PIN IC 4 515128 6 VOLTAGE REGULATOR XXXXXX CAPACITORS MFD VOLTS RESISTORS OHMS STT CHOPPER G3339 1 Return to Master TOC Return to Section TOC gt lt gt lt XXXXXX O o 5 5 PEN 9 gt 212 5 5 o 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 ALEACTURNG PER Ens INFO 2 DESIGN INFORMATION REFERENCE EQUIPMENT TYPE INVERTER WELDERS n zu JON 3 PLACE DECIMALS IS 002 DRAWNBY 631354 ONALANGLES IS SOF ADEGREE 8 42000 CHOPPER
95. ACEMENT WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty For your safety and to avoid electrical shock please observe all safety 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 Service Department for electrical trou bleshooting assistance before you proceed Call 1 800 833 9353 WELD DESCRIPTION This procedure will aid the technician in the removal and replacement of either the Control Board the Feed Head Board or the Voltage Sense Board MATERIALS NEEDED 3 8 Nut driver Anti static wrist strap This procedure should take approximately 15 minutes to perform POWER WAVE 455 R LINCOLN F 58 Return to Section Return to Master TOC Return to Section TOC Return to Master TOC 5 5 gt 2 2 EIS 2 1 Return to Section Return to Master TOC F 59 F 59 TROUBLESHOOTING amp REPAIR CONTROL FEED HEAD OR VOLTAGE SENSE PC BOARD REMOVAL AND REPLACEMENT CONTINUED FIGURE F 22 CONTROL OR FEED HEAD BOARD REMOVAL AND REPLACEMENT COVER CONTROL REMOVAL PROCEDURE 1
96. ATuF 7343 35V 1096 TR NP C12 C102 C3 C40 C16 C61 51 EISE aen ESSE oca O OF B co x15 22 525024 25 8 SCAP 1uF TAN 3528 35V TR NP C94 C97 C104 C107 C47 C2 46 52 i 23 S25024 85MT a SCAP 10uF TAN 6032 TR NP C66 C62 C65 C63 gt x33 Lees 2 84 52035315 1 SICS MC145407 RECEIVERIDRVR RS Xi6 c 24 525024105MT_ 4 SCAP 22uF TAN 7343 25V 10 C118 C110 C49 C54 rara st 12 an R2t6 25 S13490 179 1 CAP 20x NE va 85 825067 38MT 2 SICS ADG417 SPST CMOS SWT SOB MIS XBT p ALU SSV 2096 426 86 51790015 1 74HC245 NEW PACKAGE X3 H Co E pi STSBCTES T SGAP T20ME SV 20S RADIALAE i 87 Si5128 33SMT 1 SICS OP 27G OPAMP SO8 1R NP xi Co x o5 xn 7047 L Nee 6 34 27 525040 25 13 214 068 067 04 03 075 063 064 065 070 072 071 88 815128186 3 SICS MC33074 QUAD OPAMP SO14 T EELE e Lt 4 gt m m NIE 89 S25069 38MT 1 SICS 28F800B5 80 FLASH RO 90n 05 CI me Ie L 28 525046 15 19 SDIO MMSZ5231BT1 5 1V NP 90 S25069 18MT 1 SICS 128Kx16 20nS TSOP 07 8 cse 881057 042 0411540139 068 91 15101 145 1 SICS MC68332 EZI 5 L 17 9137 026 29 525044 95 7 8000 1SMB5920BT3 6 2V NP 162
97. C 2 2 5 SAFETY PRECAUTIONS WARNING ELECTRIC SHOCK can kill Only Qualified personnel should perform this maintenance Turn the input power OFF at the disconnect switch or fuse box before working on this equipment Do not touch electrically hot parts ROUTINE AND PERIODIC MAINTENANCE 1 Disconnect input AC power supply lines to the machine before performing periodic maintenance PERFORM THE FOLLOWING DAILY Check that no combustible materials are in the welding or cutting area or around the machine 2 Remove any debris dust dirt or materials that could block the air flow 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 Clean the inside of the machine with a low pressure air stream Clean the following parts Refer to Figure Transformer and output rectifier assembly Electrode and work cable connections PC board connections Intake and outlet louvers on the machine case Figure D 1 machine Fan Assembly NOTE The fan motor has sealed bearings which require no maintenance POWER WAVE 455 R LINCOLN 5 D 3 gt a Lu 9 gt lt lt Z lt gt 2
98. C is applied to the Feed Head Board the Power Board and the wire feeder receptacle The switching power supplies on the Power Board sup ply a variety of regulated DC voltages to the Control Board and a 20VDC to the STT Chopper Board The Control Board uses these regulated voltages to power the many circuits and communication functions incor porated within the Control Board CONNECTION 5 WIRE TO WIRI DRIVE POWER EE SPI BOARD SPI 40 VDC PRECHARGE CONTROL SIGNALS THERMOSTATS S2 WORK O SENSE 53 RS232 LEFT S B CAP V F RIGHT S B CAP ARC LINK 45V RS232 CONTROL BOARD 420 VDC TO CHOPPER BOARD STATUS THERMAL LIGHT LIGHT LEFTCT RIGHT CT CURRENT CURRENT FB FB When the Feed Head Board activates the Voltage Sense Board the actual arc voltage is sensed lead 67 and this information is delivered through the volt age sense board to the Control Board The Power Wave 455R uses two digital communication platforms Internally the PC boards communicate via ArcLink Externally the Power Wave 455R communi cates using the industry standard Device Net protocol The Gateway Board makes the translation between the two platforms possible The Power Wave 455R does not have a dedicated interface device or board The robot or other input device PLC etc acts as the user interface issuing commands through the Device Net protocol that are tra
99. CER TEST CONTINUED FIGURE F 11 POWER WAVE CURRENT TRANSDUCER TEST CONTROL BOARD 2 211 212 213 14243 4 lt gt WTR 5 6 7 8 216 4 CURRENT TRANSDUCER TEST PROCEDURE A WARNING 1 Remove input power to the Power Wave 455 R ELECTRIC SHOCK can kill 2 Using the 3 8 nut driver remove the case High voltage is present when top and the control box cover input power is applied to the 3 Locate the Power Wave current transducer machine leads at Control Board plug J8 See Figure 11 4 Carefully apply input power to the Power Wave 455 R POWER WAVE 455 R LINCOLN 35 35 TROUBLESHOOTING amp REPAIR POWER WAVE CURRENT TRANSDUCER TEST CONTINUED FIGURE F 12 RECEPTACLE 57 TRIGGERED Return to Section TOC Return to Master TOC RECEPTACLE S7 Return to Section Return to Master TOC 5 Turn on the Power Wave 455 R Check for NOTE The machine can be triggered by the correct DC supply voltage to the current jumpering pin 1 to pin 2 at receptacle transducer at plug J8 Figure 11 S7 See Figure F 12 A Pin 2 lead 212 to pin 6 lead 216 7 With the Power Wave 455 R triggered should read 15 VDC check the feedback voltage fr
100. CH7 PC1CS4 TPUCH8 PC2CS5 2 TPUCH9 TPUCH10 TPUCH11 TPUCH12 TPUCH13 TPUCH14 TPUCH15 R203 CAPB_OV 65 X PQSOMISO b2 1K eek 87 pasascK PQS3PCS0 SS CAPBUV UV PQS4PCS1 PQSSPCS2 PQS6PCS3 PQS7TXD RXD o 2 D E vIOVVZ rs o E 2 2 2 tc 8d gt eT Res _ 72 820pF LEZSZSWN 820pF 162525 C69 4700 LB GND1 UB GND2 9536 15 0441 FILTER CAPACITOR VOLTAGE MONITORING NOISE_GND Vb MN CNT FAULT INT PRI OC BW 1014 588 19128 DISABLE_455 222 c2 LLATCHT 34 617A 660 10178 552 lij 35V Ub vey YANUFACTURNG TOLERANCE DESIGN RFOPMATION REFERENCE SNR RT z EI rerenence EQUIPMENT TYPE INVERTER WELDERS 6 50 T ee SUBJECT DIGITAL CONTROL SCHEMATIC D4TEI2 15 99 _DRAWINGNo 3789 1D0A Retur
101. COURSE OF ACTION 1 Check the input power switch SW1 for proper operation Also check the associated leads for loose or faulty connections See the Wiring Diagram Check circuit breaker 4 for proper operation 3 Perform the 77 Auxiliary Transformer Test 4 The power board rectifier may be faulty Check rectifier and associated wiring See the Wiring Diagram 5 Perform the DC Bus Board 6 Perform the Power Board Test 7 The Control faulty Board may be CAUTION 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 troubleshooting assistance before you proceed Call 1 800 833 9353 POWER WAVE 455 R LINCOLN 5 Return to Section Return to Master TOC Return to Section TOC Return to Master TOC o 2 Return to Section Return to Master TOC 2 2 5 6 6 TROUBLESHOOTING amp REPAIR Observe Safety Guidelines detailed in the beginning of this manual PROBLEMS SYMPTOMS The Power Wave 455R does not have welding output The main input contactor CR1 is not activat ing POSSIBLE AREAS OF MISADJUSTMENT S OUTPUT PROBLEMS Turn the input power off and make certain the reconnect panel is configured correctly for the applied inp
102. CT PANEL THIS AREA VIEWED FROM REAR OF MACHINE RECONNECT SWITCH TO SWITCH BD 2 TO SWITCH BD 1 POS Pit E 19 TO HARMONIC FILTER TO SWITCH BD 1 20D NEG TO SWITCH BD 2 20 TO HARMONIC FILTER HARMONIC FILTER oo0o oosoma TO SW1 612 10 CIRCUIT 612A e BREAKER TO AUX 2 7 9 RCUIT Hi o BREAKER TO AUX 1 TO SOLID STATE RELAY 444 5 TO AUX 1 PANEL SW1 NC TO AUX 1 2 H6 200 208V 220 230V 440 460V 550 575V 350 gt 1 352 0 2 TO AUX 2 gt 3 gt 4 TO RECONNECT SWITCH INPUT RECTIFIER TO AUX 1 913 12 QL1 TO 5 1 S8 WATER COOLER RECEPTACLE ANIHOVW 30 SW1 PIN NEAREST THE FLAT EDGE OF LED LENS CATHODE L3A ALIGNS WITH BLACK LEAD OF LED SOCKET TO SUPPLY LINES N B PLACE SWITCH IN APPROPRIATE POSITION FOR INPUT VOLTAGE CONNECTION SHOWN IS FOR 440 575V OPERATION C6 05 600V 380 415 N C PLACE A LEAD ON APPROPRIATE CONNECTION FOR 220 230 INPUT VOLTAGE CONNECTION SHOWN IS FOR 550 575 OPERATION SYSTEM GROUND NATIONAL ELECTRICAL CODE STT SNUBBER CAPACITOR BANK AUXILIARY TRANSFORMER 2 20 CB2 J10J2VS J41J46 72 J14 340J42 E RIGHT SIDE OF MACHINE ELECTRICAL SYMBOLS PER E1537 ANS MAMOZ 20 LEAD COLOR CO
103. D CRT aS 0743 ELECTRICAL SYMBOLS PER E1537 VT 61 72 86 89 108 171 135 144 25 MFD 50 UNLESS OTHERWISE 22 C6 1 1 i a 1 LW UNLESS OTHERWISE SPECIFI LABELS 0 2 2501 01 4 1 x10 X13 01 X15 1 X31 1 1A40 4 SS WISE SI 7 1 0 0 400V UNLESS OTHERWISE SPECIFIED p MC 6332G6CPV25 50 50 5 3v 28 00 50 156112816 TAACTST3 SUPPLY VOLTAGE 9 1 J 2 12 20 35 4854 62 74 82 91107120128 13426 ae X POWER SUPPLY SOURCE POIN COMMON CONNECTION 1 FRAMI Vo Vo 7 EARTH GROUND CONNECTION SINCE COMPONENTS OR CIRCUITRY ON PRINTED ff UNO 5 LINCOLN ELECTRIC COMMON DIGITAL CONTROLS AGILITY OF A COMPLETE BOARD 3 CLEVELAND OHIO U S A gj SCHEMATIC GATEWAY PCB THIS DIAGRAM MAY NOT SHOW EXACT 4 12 2001 Obf 02 scare NONE COMPONENTS OR CIRCUITRY OF CONTI 5 HAVING ps 7 SHT 29 COMMON NUMBER p tk 08 09 01 SUP S D G no 3821 100 1 Return to Section TOC Return to Master TOC NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual LINCOLN amp POWER WAVE 455 Return to Section Return to Master TOC Return to Section TOC Return to Master TOC o 2 2 3 Return to Section
104. D OHIO U S A NONE pare 0717 2000 CHK EQUIP TYPE SUBJECT COMMON DIGITAL CONTROLS FEEDHEAD PC BOARD SCHEMATIC SUP S D G 07 63823 1 1 NOTE This diagram is for reference only It may be accurate for all machines covered by this manual POWER WAVE 455 R Return to Section Return to Master TOC Return to Section TOC O o Fle 8 nl 218 2 1 Return to Section Return to Master TOC Return to Master TOC G 17 ELECTRICAL DIAGRAMS PC BOARD ASSEMBLY FEEDHEAD LINCOLN amp ELECTRIC NOTE 74 525001 32205 6 139 8140 8141 8142 8143 8144 RESISTOR SMD 332ohms 1 4W 1206 1 ITEM PART NO ary DESCRIPTION 75 S25005 1SMT 2 897 898 SRES 0 05 3W 1 TR NP DESIGNATORS 76
105. DE ELECTRODE SENSE LEAD CONNECT ALL WORK SENSE LEADS AT THE END OF THE JOINT WORK LEAD WORK LEAD CONNECT ALL WELDING WORK LEADS AT THE BEGINNING OF THE JOINT Return to Section TOC Return to Master TOC POWER WAVE 455 R LINCOLN 8 Return to Section Return to Master TOC Return to Section TOC 515 gt 218 5 2 Return to Section Return to Master TOC Return to Master TOC A 7 A 7 INSTALLATION When these parameters are identical the pulsing fre quency will be the same helping to stabilize the arcs Every welding gun requires a separate shielding gas regulator for proper flow rate and shielding gas cover age Do not attempt to supply shielding gas for two or more guns from only one regulator If an anti spatter system is in use each gun must have its own anti spatter system Figure A 2 ELECTRODE AND WORK CABLE CONNECTIONS Connect a work lead of sufficient size and length per Table A 1 between the proper output terminal on the power source and the work Be sure the connection to the work makes tight metal to metal electrical contact To avoid interference problems with other equipment and to achieve the best possible operation route all cables directly to the work or wire feeder Avoid exces sive lengths and do not coil excess cable Do not tight ly bundle the electrode and work cables togethe
106. DING BD Bt STT SNUBBER B BLACK COMPONENT VALUES 12 14 301 4 gt RESISTOR BANK G GREEN CAPACITORS MFD VOLTS o oo o RESISTORS OHMS WATTS oooo 5 42 6 5 8 ELES RODE TO RECONNECT PANEL TOP SIT TO J61 LOAD LINE CONTACTOR Hib O 0 TO CONTACTOR L1A J2 J5 J11 J1VS J9 J10CH J8 J4 J13 J43 J71 J1 46 J7 J10 J70 J85 W WHITE 5 11 2001F CONNECTOR CAVITY NUMBERING SEQUENCE VIEWED FROM COMPONENT SIDE OF BOARD G4010 NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual The wiring diagram specific to your code is pasted inside one of the enclosure panels of your machine Return to Section TOC Return to Master TOC POWER WAVE 455 R ELECTRICAL DIAGRAMS GA SCHEMATIC COMPLETE MACHINE 10675 NA SWITCH BOARD 1 LEFT MAIN TRANSFORMER 1 3007 dv RECONNECT F CONTROL BOARD INPUT SWITCH 27 S3 85232 RECTIFIER 2 4 maw ZNI CONNECTOR 27 Pos 5 OUTPUT DIODES RS232 RECEIVE gt 32 gt lt 2 01 04 5232 TRANSMIT ELECTRODE VOLTAGE SENSE CURRENT 414 440 CT CURRENT ELECTRODE VOLTAGE SENSE Return to Section TOC Return to Master TOC S 20 418 CT CURRENT n lt 111
107. E SENSE SELECT sa GATEWAY connection 2 FROM CONTROL nM BOARD mE F 4 BOARD s B 40 AUX H 40 VDC RECONNECT C IGBT TO FAN RELAY DRIVES CONTACTOR AND RELAY ARC LINK 9 PRECHARGE VE CONTROL SIGNALS quem THERMOSTATS 52 VAC 65 VDC CONNECTION CONTROL TO WIRE BOARD M DC POWER gw BEER as BOARD 15V SPI BOARD 40 VDC 53 40 VDC LEFT S B lt CAP VIF 40 VDC 20 VDC HR TO o ARC LINK CHOPPER S 51 WIRE T RIGHT CT EFTCT z FEEDER CURRENT CURRENT O O o RECP FB FB STATUS THERMAL a LIGHT LIGHT E POWER WAVE 455 R LINCOLN 5 2 2 THEORY OPERATION a RU s OUTPUT DIODES ELECTRODE olo PP ac FIGURE E 2 INPUT VOLTAGE AND PRECHARGE HE o2 co MAN 2 8 POWER WAVE 455 R NES 2 d 51 54 TERMINAL CAP V F FEEDBACK SWITCH CR1 INPUT 20 VDC FROM RECTIFIER 1 POWER BOARD dr CURRENT RECONNECT SELpRVE STT CHOPPER TRANSDUCER PEOR CURRENT SWITCH kw TO CONTROL BOARD BOARD CURRENT TRANSDUCER CAP V F FEEDBACK WORK OUTPUT CHOKE TERMINAL CONTACTOR AND PRECHARGE CONTROL SIGNALS FROM CONTROL BOARD VOLTAGE SENSE BOARD OUTPUT DEVICE NET VOLTAGE SENSE SELECT GATEWAY BOARD CONNECTION TO ARC LINK ROBOT
108. ELECTRIC CO CLEVELAND OHIO U S A LABELS LAST 0 USED GENERAL INFORMATION CE COMPONENTS OR CIRCUITRY ON PRINTED natn a nie RCUIT BOARD MAY CHANGE WITHOUT AFFECTING ELECTRICAL SYMBOLS EIOS 7 TERCHANGEABILITY OF COMPLETE BOARD CAPACITORS POWER SUPPLY SOURCE POINT L EARTH GROUND CONNECTION DIAGRAM NOT SHOW THE EXACT COMPONENTS RESISTORS Ohms UNLESS OTHERWISE SPECIFIED RCUITRY OF CONTROLS HAVING A COMMON CODE NUMBER DIODES UNLESS OTHERWISE SPECIFIED COMMON CONNECTION FILENAME SUPPLY VOLTAGE NET 77 FRAME CONNECTION eee DESIGN INFORMATION HOLES SIZES PER E2056 c 5 ON 2 PLACE DECIMALS IS 02 F EQUIPMENT SW ON 3 PLACE DECIMALS IS 002 DRAWN BY FM ON ALL ANGLES IS 5 OF A DEGREE 3j MATERIAL TOL RANCE TO AGREE ee GENE ENGINEER SUBJECT VI TAGE o SEI E T TH PUBLISHED STANDARDS E THIS DRAWING EVISED BY 10 23 00 SCAL Return to Section Return to Master TOC NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual LINCOLN POWER WAVE 455 R ee ELECTRICAL DIAGRAMS G 23 PC BOARD ASSEMBLY VOLTAGE SENSE 7777 PART IDENTIFICATION D1 T12199 1 1N4004 J1 524020 6 HEADER J2 S24020 2G HEADER L1 T12218 7 330uH OCI1 OCI2 15000 20
109. EMBLY SWITCH ELECTRICAL DIAGRAMS PART G 21 IDENTIFICATION 52 0500 14 CAPACITOR PPMF 022 100V BOX 5 516668 11 516668 5 0 1 50V 10 ICAPACITOR CEMO 022 50V 20 516668 6 ICAPACITOR CEMO 4700p 50V 10 13490 93 CAPACITOR TAEL 27 35V 10 C8 C9 C10 C11 C12 C13 C14 C15 C16 C17 520500 1 CAPACITOR PPMF 0 1 1000V 10 BOX D1 D2 T12705 44 IDIODE AXLDS 1A 1000V FR 818 D3 D4 D5 D6 D7 D8 D9 D10 011 012 6 00 04 T12705 32 DIODE T220 15A 600V FR MUR1560 071 022 023 025 026 112702 4 T12702 29 ZENER DIODE 1W 20V 5 1N4747A ZENER DIODE 1 15 5 1N4744A 074 077 112702 40 ZENER DIODE 1W 6 2V 5 1 4735
110. ENT TRANSDUCER TEST WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty For your safety and to avoid electrical shock please observe all safety notes and precautions detailed throughout this manual Return to Section TOC Return to Master TOC 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 before you proceed Call 1 800 833 9353 WELD TEST DESCRIPTION This test will help determine if the Power Wave current transducer and associated wiring is functioning correctly Return to Section TOC Return to Master TOC MATERIALS NEEDED 3 8 nut driver Volt Ohmmeter This procedure should take approximately 25 minutes to perform 515 gt 218 5 2 Return to Section Return to Master TOC POWER WAVE 455 R LINCOLN Return to Section Return to Master TOC Return to Section TOC Return to Master TOC 515 gt 218 5 2 Return to Section Return to Master TOC F 34 F 34 TROUBLESHOOTING amp REPAIR POWER WAVE CURRENT TRANSDU
111. ER NO 2 TEST WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty For your safety and to avoid electrical shock please observe all safety 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 Service Department for electrical trou bleshooting assistance before you proceed Call 1 800 833 9353 WELD TEST DESCRIPTION This test will determine if the correct voltage is being applied to the primary of Auxiliary Transformer No 2 and also if the correct voltages are being induced on the secondary windings of the transformer MATERIALS NEEDED Volt ohmmeter Multimeter 3 8 Nut driver Wiring Diagram This procedure should take approximately 25 minutes to perform POWER WAVE 455 R LINCOLN F 46 Return to Section Return to Master TOC Return to Section TOC Return to Master TOC Q BS 5 2 Return to Section Return to Master TOC o 2 2 5 F 47 F 47 TROUBLESHOOTING amp REPAIR AUXILIARY TRANSFORMER NO 2 TEST CONTINUED FIGURE F 17 AUXIL
112. ES 243 WSC 1 1 1W TR NP 5 EIL 59 525000 33205 9 SRES 332 0805 1 1 10W TRNP E og R43 RA4 RAS 6 RA ROD zm B 60 525000 22105 9 ISRES 221 TKF 0805 1 1 10W TR s R56 R57 R58 R61 R64 RES ALI 61 525001 20005 SRES 200 1206 1 1 8W TR NP 62 525001 75005 RESISTOR SMD 750ohms 1 4W 1206 1 63 525000 22135 1 663 SRES 221K TKF 0805 1 01 10W 1R m ze 64 525000 47525 2 867872 SRES 47 5K TKF 0805 1 01 10W TR ay 65 S25000 1003SMT 6 69 871 873 875 882 8117 SRES 100K TKF 0805 1 01 10W TR 20 66 525001 10015 870 SRES 1K 1206 1 5 1 8W TR NP 09 67 25000 9092SMT 2 R74RBi SRES 90 9K TKF 0805 1 5 1 10W A 68 S25000 39215MT 1 R SRES 3 92K TKF 0805 1 5 1 10W TR Ej 69 525001 47535 27 8878120 ISRES A75K 1206 1 1 1 8W TR NP 70 525001 47525 2 68 8119 5 5 47 5 1206 1 1 8 u 71 525001 10005 9 R89 R93 R96 R155 R156 R157 SRES 100 1206 1 1 8W TR NP 72 S25001 15R0SMT 2 891892 SRES 15 1206 1 1 8W TRNP 73 525001 15005 4 R94ROSRIS RIST SRES 150 1206 1 1 8W TR NP UNLESS OTHERWISE SPECIFIED RESISTANCE OHMS COMMON DIGITAL CONT
113. EVELAND OHIO U S A INVERTER WELDERS SWITCH P C BOARD AS BLY INFO Chg Sheet No t XD RW 5 11 2001 1 MATERIAL TOLERANCE t TO AGREE WITH PUBLISHED STAI 5 TDONOTSCALE THIS DRAWING EQUIPMENT TYPE aa ENGINEER L C SUPERSEDING CNN NN DATE 10 3 2000 3730 NOTE Lincoln Electric assumes 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 Lincoln Electric This information is pro vided for reference only Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician Improper PC board repairs could result in damage to the LINCOLN machine POWER WAVE 455 R 3 22 ELECTRICAL DIAGRAMS G 22 SCHEMATIC VOLTAGE SENSE PC BOARD GELLIG 555 FRAME 2 gt Return to Section TOC Return to Master TOC TO HEAD P CB 1 Return to Section Return to Master TOC L gt gt 67 LEAD NETWORK olo o 0 12 2 2 5 THIS SHEET CONTAINS PROPRIETARY INFORMATION OWNED BY THE LINCOLN ELECTRIC CO AND IS NOT TO BE REPRODUCED DISCLOSED OR USED WITHOUT THE EXPRESS PERMISSION OFTHE LINCOLN
114. G BAV70LT NOISE_GND D90 Za 2 1 GND THERMAL ys 1 88 4 75 25 gp pum plow plow 100pF Return to Section TOC Return to Master TOC 13 Vb 29 __ 35 A EO DATAS 42 DATAB ADDR 1 19 1629251 NOISE GN 4401 475 C22 10 0K Ti BAV70LT1 D91 D76 PWRDN INT Q5 41 DATAI3 43 DATAi4 45 DATAS e VS1 VS2 queue UTPUT2 GND1 n GND2 R51 NC 4 gt CONTROL AAA INPUT 4 75 C27 445 LLT0 AV8 M Fr aber 1 699 151 46 27 10 0K R181 VV 10 0K R164 VV 10 0K R199 10 0K R200 VAS 10 0K 5V TE28FB00B5 Bo0 Vb R254 CRYSTAL 85 EXTAL XFC XTAL CLKOUT TE T 92 d Er 7650 Return to Master TOC Return to Section TOC ey lot CLIOEHENIBLIOELHBNN 077 BR CS0 142 7051 BG 81 3675 TSC BGACK 652 143 7052
115. GRAM DIODES 144000 UNLESS OTHERWISE SPECIFIED SUPPLY VOLTAGE NET NOT SHOW THE EXACT COMPONENTS OR CIRCUITRY OF CONTROLS HAVING A COMMON CODE 7 NUMBER O POWER SUPPLY SOURCE POINT i 57 COMMON CONNECTION 7 FRAME CONNECTION EARTH GROUND CONNECTION NA SINCE COMPONENTS OR CIRCUITRY ON A PRINTED CIRCUIT BOARD MAY CHANGE 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 EQUIPMENT Digital Systems DRAWN BY pueros SUBJECT Schematic Digital Power Supply pom SCALENONE DATE I 30 98 DRAWNGNo G 3631 Return to Section TOC Return to Master TOC NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual LINCOLN amp POWER WAVE 455 e ELECTRICAL DIAGRAMS BOARD ASSEMBLY DIGITAL POWER SUPPLY PART NUMBER x DESCRIPTION REFERENCE DESIGNATOR G3632 C POWER PC BOARD BLANK M19436 3 POTTING TRAY 58025 80 SELF TAPPING SCREW E2527 115g ENCAPSULATIOG RESIN E2861 AS REQ D ELECTRICAL INSULATING COMPOUND FOR ITEMS LISTED BELOW REFER TO ELECTRONIC COMPONENT DATABASE FOR COMPONENT SPECIFICATIONS DESCRIPTION REFERENCE PCB MTP DC POWER ASSY NP SDIO MURS120T3 NO PRINT D1 015 SRES 1 82K 1206 1 1 8W NP R14 R20 SRE
116. HC132 NP C64 65 69 C72 C75 C76 90 525069 35 1 19 SICS 28F800B5B90 FLASH 90 C77 C78 081 C82 91 525066 25 1 SICS AD7862 DUAL 12BIT 250KSPS 10 525024 85 5 10 11 17 18 80 SCAP 10UF TAN 6032 16V 10 TR NP 92 525057 35 1 xn SICS AD8403ARU10 DIGITAL POT NP 11 525020 135 2 613 16 ISCAP 150pF CER 0805 100V COG 5 TR NP 93 ___ 15105 95 1 12 SICS AD7945 12BIT PARALLEL 12 525024 55 6 23 C63 C66 C67 C68 C71 SCAP 4 7uF TAN 7343 35V 10 TRNP 94 815128 215 1 X13 SICS LT1016 COMPARATOR NP 13 525024 105 3 24 36 73 SCAP 22uF TAN 7343 25V 10 POLAR TR 95 515128 185 2 4 20 51 5 23074 0 5014 7 i4 52502025 1 les SCAP 0 022uF 0805 50V XTR 1035 oe m 8 SVD QUAD ORMANCE 1014 15 825020 105 3 040 042 044 ISCAP 4700pF_0805 50V X7R 10 T SST 1 95 16 525020 95 2 052579 5 47 0805 50 06 5 99 15203535 SICE ANB2527 CAN CONTROLLER PL 17 525020 155 3 55 058 083 ISCAP 22pF 0805 50V COG 5 TRIN 100 525065 25 17 09 SICS 74ACTS73 OCTAL TRANS LAT 18 152945991 2 _ 0002 PCF 63V 5 TR NP 101 520353 45 3 21 26 27 SICS MAX485 TRANSCEIVER NP 48 5184004179 1 1000UF ALU 35V 20 NP 102 525068 85 1 2 SICS 79L05 V REG 5V SO8 20 313480182 T 164 CAP 3300UF ALU 63V 20 NP 103 525068 65 2 X23X24 SICS 78L05 V REG 5V
117. HOOTING amp REPAIR GATEWAY PC BOARD REMOVAL AND REPLACEMENT CONTINUED FIGURE F 24 GATEWAY BOARD REMOVAL AND REPLACEMENT DEVICENET GATEWAY BOARD LOCATED BEHIND FRONT COVER REMOVAL PROCEDURE 1 Remove input power to the Power Wave 455 R 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 and remove the four molex plugs from the Gateway Board Using the 3 8 nut driver remove the self locking mounting nuts from the Gateway Board Carefully remove the board Refer to Figure F 24 lt PHILLIPS SCREW REPLACEMENT PROCEDURE 1 Install the Gateway Board to the case front cover with the self locking nuts Use the 3 8 nut driver Connect the four molex plugs to the Gateway Board Using the phillips head screw driver attach the cover to the case front POWER WAVE 455 R LINCOLN F 64 F 64 TROUBLESHOOTING amp REPAIR STT CURRENT TRANSDUCER REMOVAL AND REPLACEMENT WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty For your safety and to avoid electrical shock please observe all safety notes and precautions detaile
118. IARY TRANSFORMER NO 2 TEST TEST PROCEDURE 1 Remove the main input power to the Power 6 Wave 455 R machine 2 Remove any load that may be connected to the 115 VAC receptacle 3 Using the 3 8 nut driver remove the case top 2 4 Locate plugs P52 and P50 at the Auxiliary Transformer No 2 Refer to Figure F 17 5 Carefully apply the correct input power 9 A WARNING 10 ELECTRIC SHOCK can kill High voltage is present at both plugs 11 12 POWER WAVE 455 R LINCOLN H4 H3 H1 1 2 3 VIEWED FROM TRANSFORMER LEAD SIDE 4 35 36 H5 H6 H2 P50 350 352 12 VIEWED FROM TRANSFORMER LEAD END 3 4 33 P52 A Check for 115 VAC at plug P52 pins 1 and 4 leads 350 to 33A Check for 230 VAC at plug P52 pins 1 and 2 leads 350 to 352 If 115 VAC and 230 VAC are present Auxiliary Transformer No 2 is good If 115 is not present between pins 1 and 4 and 230 VAC is not present between pins 1 and 2 check the associated leads and plugs for loose or faulty connections Carefully test for the correct AC input volt age applied to the primary windings at plug P50 See the Wiring Diagram If the correct AC input voltage is applied to the primary of the Auxiliary Transformer No 2 and the secondary voltage is NOT correct the transformer may be faulty Replace Replace any cables ties and insulation removed earlier Install the
119. IGHT CT O CURRENT CURRENT FB STATUS THERMAL LIGHT LIGHT The Control Board also monitors and controls the STT Surface Tension Transfer circuitry incorporated in the Power Wave 4558 STT output currents and arc volt ages are monitored and the appropriated gate firing signals are applied or removed from the STT Chopper Board and switch boards to create a low spat ter low fume MIG welding process See GENERAL in this section In addition the Control Board monitors the ther mostats the main transformer primary currents and input filter capacitor voltages Depending on the fault condition the Control Board will activate the thermal and or the status light and will disable or reduce the machine output In some conditions the input contac tor will be de energized POWER WAVE 455 R LINCOLN 5 8 8 THEORY OPERATION olo ee FIGURE E 7 OUTPUT RECTIFIER OUTPUT CHOKE AND STT CHOPPER BOARD 5 5 8 4 POWER WAVE 455 R OUTPUT DIODES ELECTRODE 9 g 01 04 TERMINAL FEEDBACK LEFT 2 1 gt 8 SWITCH ORI RECTIFIER i me IGBT DRIVE STT CURRENT ELECTRODE Ed CONT STT CHOPPER TRANSDUCER TERMINAL Fu SWITCH CONTROL CURRENT BOARD TO CONTROL UR BOARD SIT SWITCH DRIVE CURRENT WORK FEEDBACK TRANSDUCER OUTPUT TERMINAL 67 v INPUT 51 O pee BOARD VOLT TO 67B SENSE VOLTAGE SE
120. IVLINOD 133HS SIHL ONTROL BD TO C 10K OVERVOLTAGE OTECTION PR Cw r t 1 C2 C5 EL EZ E ELECTRICAL DIAGRAMS 3 180 DHM 100 MHz 9 20 SCHEMATIC SWITCH PC BOARD 901 4 0 uunjeH DOL uonoes uumeg DOL uonoes C2 C3 C5 3 5 E2 E L TEST POINT 901 Je1Se A DOL Je1se N uunjeH DOL uonoeg uunjeg This diagram is for reference only It may not be accurate for all machines covered by this manual NOTE DOL Je1se N uunjeH DOL uonoeg oj uunjeg Return to Section Return to Master TOC Return to Section TOC O o 5 5 o PEN 9 gt 212 5 2 o Return to Section Return to Master TOC Return to Master TOC G 21 PC BOARD ASS
121. NSE CONTACTOR AND PRECHARGE BOARD OUTPUT CONTROL SIGNALS FROM CONTROL BOARD DEVICE VOLTAGE SENSE SELECT GATEWAY on 440 CONNECTION TO Return to Section TOC Return to Master TOC 2 FROM CONTROL AUGUE BOARD ROBOT 4 BOARD V AUX A RECONNECT IGBT TO FAN RELAY DRIVES CONTACTOR AND LINK PRECHARGE 115 VAC CONTROL SIGNALS THERMOSTATS 52 VAC EDO CONNECTION CDS RAX BUS BOARD DC POWER Se wonk T1 RECTIFIER BUS BOARD 35V 53 5232 ey LEFT SB CAP VIF RIGHT S B i CAP VIF ARC LINK CHOPPER WIRE BOARD LEFTCT RIGHT CT 6 WR CURRENT CURRENT rs STATUS THERMAL LIGHT LIGHT OUTPUT RECTIFIER OUTPUT CHOKE AND STT CHOPPER BOARD The output rectifier receives the AC output from the STT Chopper Board is in series with the STT out main transformer secondary and rectifies it to a DC put terminal and is used to interrupt the welding cur voltage level The output choke is in series with the rent for very short periods of time during the short arc negative leg of the output rectifier and also in series welding process The IGBT modules incorporat with the welding load Due to the current smoothing on this board receive their gate firing commands capability of the output choke a filtered DC output cur the Control Board rent is applied through machine output terminal
122. OLTAGE SENSE OUTPUT 67 CONTACTOR AND PRECHARGE 56 CONTROL SIGNALS FROM CONTROL BOARD FROM CONTROL BOARD AUX RECONNECT RELAY 115 VAC 52 VAC E 65 VDC X BUS BOARD DC RECTIFIER BUS BOARD 230 VAC WATER f COOLER T2 115 CONTROL BOARD The Control Board performs the primary interfacing functions to establish and maintain output control of the Power Wave 455R machine The function generator and weld files exist within the Control Board hardware and software Digital command signals and feedback information is received and processed at the Control Board Software within the Control Board processes the command and feedback information and sends the appropriate pulse width modulation PWM signals see PULSE WIDTH MODULATIONIin this section to the switch board IGBTs In this manner the digitally controlled high speed welding waveform is created 40 VDC 40 VDC ARC LINK WIRE 5 FEEDER ARC LINK CONNECTION 55 TO WIRE DRIVE 40 VDC BOARD 9 5 DEVICE NET To TO Lert RIGHT N S B GATEWAY connection ROBOT TO FAN RELAY DRIVES CONTACTOR AND PRECHARGE CONTROL SIGNALS ARC LINK 45V 85232 THERMOSTATS CONTROL BOARD 45 V ARC LINK 45V SPI 15V SPI 5V POWER BOARD S2 WORK O SENSE 3 RS232 LEFT S B CAP V F RIGHT S B 420 VDC VIF To CHOPPER BOARD LEFTCT R
123. ONTROL BOARD BOARD SIT EAE CURRENT TRANSDUCER CAP V F WORK FEEDBACK OUTPUT TERMINAL CHOKE olo CONTACTOR AND PRECHARGE BOARD SENSE 8 el CONTROL SIGNALS FROM DEVICE NET E 1 CONTROL BOARD VOLTAGE SENSE SELECT 1 GATEWAY connection 2 2 FROM CONTROL ACIS BOARD ae rd 40 VDC o gt AUX 40 VDC FAN RELAY 4 A DRIVES CONTACTOR AND RELAY ARC LINK PRECHARGE E E 115 VAC CONTROL SIGNALS 5 3 5V RS232 THERMOSTATS Y 45 V ARC LINK CONTROL 52 N 65 VDC CONNECTION or Dae f BUS BOARD DC DRIVE POWER 45V SPI O S2 WORK RECTIFIER Ti BUS BOARD BOARD 40 VDC 53 nese LEFT SB CAP V F 40 VDC 420 VDC RIGHT S B ES CAP VIF ARC LINK CHOPPER WIRE BOARD LEFTCT RIGHT CT FEEDER CURRENT CURRENT STATUS THERMAL LIGHT LIGHT SWITCH BOARDS AND MAIN TRANSFORMER There are two switch boards in the Power Wave 455 R Each switch board feeds current to a separate oppo machine Each contains an input capacitor and insu sitely wound primary winding in the Main Transformer lated gate bipolar transistor IGBT switching circuitry The reverse directions of current flow through the main Refer to Figure E 3 When the machine reconnect transformer primaries and the offset timing of the IGBT switches ar
124. PHOTO FET R1 R2 519400 4750 475 1 4W R3 18380 1 THERMISTOR PTC TP1 TP2 T13640 18 160J Return to Section TOC Return to Master TOC M19540 1 CAPACITORS MFD VOLTS RESISTORS OHMS INDUCTANCE HENRYS Return to Section TOC Return to Master TOC O 0 0 2 LLI 0 Lu lt H gt o 2 D E 5 9 o 5 COMMON DIGITAL CONTROLS VOLTAGE SENSE SELECT P C BD AS BLY 1 3 2000A M19540 1 Return to Section TOC Return to Master TOC NOTE Lincoln Electric assumes 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 Lincoln Electric This information is pro vided for reference only Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician Improper PC board repairs could result in damage to the LINCOLN amp ine LINCOLN machine POWER WAVE 455 R Return to Section Return to Master TOC Return to Section TOC Return to Master TOC
125. PI 64Kx8 S 15101 145 10 IC SMD CMOS MCU 32 BIT 2K RAM TPU 25M 525070 35 11 CPLD PROGRAMMABLE XC9536 44 PIN VQFP 525069 35 X13 IC SMD CMOS EEPROM FLASH 16 BIT 512K 517900 115 X14 IC SMD CMOS TRANCEIVER BUS 3 STATE OC 525069 45 15 RAM STATIC 16 BIT 128K 44 PIN TSOP 520353 55 16 18 IC CMOS CONTROLLER COMMUNICATION SERI 520353 45 17 22 IC CMOS SMD XCVR EIA485 SS 525068 45 X20 IC SMD TRANSCEIVER CAN UC5350 SOIC 8 517900 245 x23 IC SMD CMOS GATE NAND 2 INPUT QUAD SC 525065 25 31 IC SMD ACT LATCH OCTAL 3 STATE TSSOP 525082 15 1 CRYSTAL SMD QUARTZ 16MHZ UNLESS OTHERWISE SPECIFIED RESISTANCE OHMS 11 3 2000A L11046 1 POWER WAVE 455 R 10 ELECTRICAL DIAGRAMS G10 SCHEMATIC CONTROL PC BOARD BAV70LT 89 1 4401 X24 15 ved ee C105 C93 DDSYN 82 OE s VDDE 52 10K 100pF Tom O 1uF 0 1uF 5 5 VSSE 68332 MMBT4401 3 Kos 7 2 Jeza C18 2 57 MS i x10 16586 j 100pF Jd E To 44 AES X25 Mq V MMBT4401 LEZGZSINN TOF 9 WE
126. PI COMMON lt D 40VDC 24000uF 100V rs H2 5 5V lt 0VDC na 200 208 pae L 268A 4 343 lt SPI 5V Me t D C B U S B D CONTROL BOARD COMMON 10 4 CONTROL BOARD COMMON a 15V 314 lt 15V TRANSFORMER T2 zi P80 500 1 5 247 COMMON 5 411 45V ARCLINK m COMMON gt 547 gt 41941 lt 40 COMMON 55 DEVICENET Edi cr 352A 2 ARCLINK COMMON 10 43 273 8011 4 ARCLINK COMMON CONNECTOR LR a H5 40VDC POWER 7 47 gt lt 2041 lt 40V 440 460 CB2 5232 45V gt aysa gt _ _ 226 lt lt RS232 45V 2 24 06 i 10A COMMON gt 6147 gt lt 4 40V COMMON m 3 33 4 gt 33 5 RS232 COMMON gt 9443 228 5 lt RS232 COMMON 280 416 na lt 148 40VDC POWER gt 847 40V gt lt iis 49 H3A 2 gt 2514S lt 4 CAN H 220230 POS lt COMMON 147 gt 51 gt m NOTES 2 4 lt 5 mao 15H S4 REFERENCE ONLY ALL COMPONENTS CB1 110 FTN ARE NOT SHOWN NEG 446 is RECEPTACLE GO ch EP 200 208 BOARD COMPONENTS SHOWN FOR lt
127. POWER WAVE 455 For use with machines having Code Numbers 10675 10676 October 2001 Return to Master TOC View Safety Info Safety Depends on You Lincoln arc welding and cutting equipment is designed and built with safety in mind However your overall safety can be in creased by proper installation and thoughtful operation on your part DO NOT INSTALL OPERATE OR REPAIR THIS EQUIPMENT WITHOUT READING THIS MANUAL AND THE SAFETY PRECAUTIONS CONTAINED THROUGHOUT And most importantly think before you act and be careful Return to Master TOC View Safety Info w gt is o z EU gt 60974 1 SERVICE MANUAL O O E o 9 gt 5 View Safety Info LINCOLN Copyright 2001 Lincoln Global Inc World s Leader in Welding and Cutting Products Sales and Service through Subsidiaries and Distributors Worldwide Cleveland Ohio 44117 1199 U S A TEL 216 481 8100 FAX 216 486 1751 WEB SITE www lincolnelectric com Return to Master TOC SAFETY 8 A WARNING CALIFORNIA PROPOSITION 65 WARNINGS 8 Diesel engine exhaust and some of its constituents The engine exhaust from this product contains gt known to the State of California to cause can chemicals known to the State of California to cause cer birth defects and other reproductive harm cancer birth defects or other reproductiv
128. PUT K1 761 1 450A 38V 100 70 65 35 208 230 460V 60HZ 570A 43V 60 87 82 48 400A 36V 100 64 58 32 200 220 440 50 2 500 940 60 79 74 41 400 Watts 88 K1761 2 450 38V 100 58 53 25 22 MAX 208 230 460 575V 60HZ 570 43V 60 82 78 37 31 400 36V 100 49 45 23 200 220 440 50HZ 500A 40V 60 67 61 31 PULSE AND AUXILIARY POWER CIRCUIT RANGE FREQUENCY VOLTAGE BACKGROUND PARAMETERS CIRCUIT BREAKER VOLTAGE TIME RANGE PROTECTED 75 VDC 5 570 0 15 1000 2 5 55 VDC 100 MICRO 40 325 AMPS 40 VDC 10 AMPS 3 3 SEC 115VAC 10 AMPS PROCESS CURRENT RANGES DC CURRENT MIG MAG 50 570 Average Amps FCAW 40 570 Average Amps SMAW 30 570 Average Amps Pulse 5 750 Peak Amps STT 40 325 Average Amps RECOMMENDED INPUT WIRE AND FUSE SIZES INPUT INPUT AMPERE TYPE 75 C TYPE 75 C TYPE 75 C VOLTAGE RATING ON COPPER WIRE GROUND WIRE SUPER LAG FREQUENCY NAMEPLATE IN CONDUIT IN CONDUIT OR BREAKER 0 89 MIN Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC K1761 1 208 230V 60HZ 450 100 460V 60HZ 450 100 200 220V 50HZ 400 100 440V 50HZ 400 100 208 230V 60HZ 570 6096 110 110 460V 60HZ 570 6096 70 200 220V 50HZ 500 6096 100 100 440V 50HZ 500 6096 K1761 2 208 230V 60HZ 450 100 460V 60HZ 450 100 575V 60HZ 450 100 200 220V 50HZ 400 100 440V 50HZ 400 10
129. ROLS FEED HEAD PC BOARD ASSEMBLY 4 20 2001C L11087 2 Lincoln Electric assumes 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 Lincoln Electric This information is pro vided for reference only Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician Improper PC board repairs could result in damage to the POWER WAVE 455 R machine G 17 6 18 9 18 SCHEMATIC INPUT PC BOARD 80961 N ELECTRICAL DIAGRAMS Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC PRE CHARGE CONNECTIONS CONTACTOR OUTP 4 461 2 660V J 8 B2 e 250J F n is 1A 1 ocli 5 CONTACTOR COIL CONNECT CONTACTOR CONTROL 13V FROM CONTROL BOARD PRE CHARGE CONTROL 13V A us CNY17 3V v 2 6 4 SINGLE PHASE DETECT J60 CENTER LEG TO OUTSIDE LEG OF INPUT D1 olo o e S L8 PEN 2 o
130. RS160 1A 600V FAST RECO D2 D3 D6 D7 D8 D9 SICS TL4311D LIN V REF 36V 40 1 2 SICS PWM CONTROLLER I MODE NP X5 5 78 05 100 5 x6 X7 17 3 HSS MTP VERT MOUNT TO220 NP 01 02 HEATSINKS RES THERMISTOR PTC POS TEMP TR R40 RES THERMISTOR NTC NEG TEMP NP R55 CAP 1uF PEMF 200V 10 NP C13 C26 TFM L 5763 3 FLYBACK NP 1 TFM L 5764 3 FLYBACK NP T2 TRA BUZ30A NMF 21A 200V T0220 Q1 02 CON 4P TIN MINI NP J41 CON 6P TIN MINI NP J42 CON 12P TIN MINI NP J43 SCREW N A WASHER N A SDIO MURS360T3 NP D19 1500pF 200V MET POLYPROP C12 31 ISCAP 0 022uF 50v X7R C49 ISCAP 330pF 0805 50V 5 COG C52 SRES 47 5 1210 5 1 2W TR NP R6 R7 R57 R58 SRES 10 TKF 0805 1 1 10W R9 R60 R61 ISRES 30 1 FXD 1210 5 1 2W TR R35 R36 STRA 78M15C DPACK xs ISTRA 7815C DPACK xB STRA 79M15C DPACK 29 5 5 2 49 1210 5 1 2 R19 R23 ISRES 1 21K 1210 5 1 2W TR NP R46 R48 R37 ISRES 150 1210 5 1 2W TR NP R25 R44 ISRES 475 1206 R8 5 55 2 0263 8 016 HEATSINKS THERMAL JOINT COMPOUND SCAP 0 1uF 0805 50V X7R 10 TR C53 ISRES 75K TKF 1206 1 1 8W TR R31 SRES 150 1210 5 1 2W TR NP R62 R63 R64 PART NUMBER PCLIN 503 3 707W04095 A262564400 A262566900 A262569000 A262576200 A262577900 SM100 035 SM100 444 SM100 411 SM100 420 SM100 440 SM100 441 SM100 443 SM100 445 SM100 446 SM100 447 SM100 448 3
131. Return to Section Return to Master TOC Return to Section TOC Return to Master TOC 515 gt 218 JE 2 1 Return to Section Return to Master TOC E 5 E 5 THEORY OF OPERATION FIGURE E 4 DC BUS BOARD POWER BOARD FEED HEAD BOARD GATEWAY BOARD AND VOLTAGE SENSE BOARD IGBT DRIVE FROM CONTROL POWER WAVE 455 R CT CURRENT soe TRANSFORMER MAIN ELECTRODE TERMINAL FEEDBACK 1 RECTIFIER POWER BOARD CURRENT SI ELECTRODE RECONNECT SELDRVE STT CHOPPER TRANSDUCER TERMINAL SWITCH 52651 CURRENT BOARD L TO GONIHOE z ole SW1 e STT Le CAP V F DRIVE CURRENT WORK FEEDBACK TRANSDUCER OUTPUT TERMINAL CHOKE 67 INPUT E AAO BOARD VOLT CONTACTOR AND PRECHARGE SENSE VOUIAGE SENSE S CONSORS CRAS LEON BOARD DEVICE NET T VOLTAGE SENSE SELECT GATEWAY connection 2 FROM CONTROL adl BOARD ROBOT 4 BOARD AUX TO FAN RELAY DRIVES CONTACTOR AND RELAY 59 115 VAC 52 VAC A 65 VDC 9 X BUS BOARD DC RECTIFIER BUS BOARD ARC LINK WIRE FEEDER RECP DC BUS BOARD POWER BOARD FEED HEAD BOARD GATEWAY BOARD AND VOLTAGE SENSE BOARD The DC Bus Board receives approximately 65VDC from the Bus Board rectifier The DC Bus Board regu lates that 65VDC to a 40VDC supply This regulated 40VD
132. S 5 62K 1206 1 1 8W TR NP_ R12 R28 R45 5 5 10 1206 1 1 4 09 007 R4 R13 R22 R2 R27 R56 SRES 56 2K 1206 196 1 8W NP 500 R38 R39 SRES 100K TKF 1206 1 1 8W TR R5 R10 R21 R29 SRES 330 1206 5 1 4W R41 R53 SRES 249 1206 1 1 4W TR NP R33 SRES 221K 1206 1 1 8W TR NP R34 R52 SRES 20 1206 1 1 8W TR NP R32 SRES 0 05 1 2W TR NP R11 R30 SRES 1K 5 2W TR NP R26 SRES 33 2 1206 1 1 4W TR NP R15 R16 R43 SRES 43 2K 1206 1 1 4W TR NP R18 R49 SRES 44 2K 1206 1 1 4W TR NP R42 R51 SRES THERMISTOR POS TEMP TR NP R50 SRES THERMISTOR POS TEMP TR NP R17 R24 C1 C10 C17 C18 C19 C20 C24 SCAP 4 7uF TAN 35V 20 TR NP C33 C38 C6 SCAP 150pF 0805 50V COG 5 TR C27 C45 C46 SCAP 1uF TAN 3528 35V TR NP C23 C29 C30 C40 C47 SCAP 820pF 0805 50V COG 5 TR C8 SCAP 2700pF 0805 5OV X7R 5 6 TR C16 C42 C2 C5 C7 C9 C14 C21 C22 C25 SCAP 0 1uF 0805 50V X7R 1096 TR C34 C39 C44 SCAP 10pF CER 0805 100V 5 TR C28 C32 SCAP 33uF TAN 7343 25V 10 TR LOW ESR 11 SCAP 100uF TAN 7343 10V 20 6 TR C35 C36 C37 C41 C43 SDIO 1A 400V DO 214BA GLS NP_ 010 012 013 014 017 024 025 SLED RED 1206 TR NP LED1 LED2 SDIO MURD620CT 6A 200V ULTRA F 04 018 016 SDIO MBRA130LT3 1A 30V SCHOTTK 020 021 022 023 ISDIO MURB1620CT 16A 200V D16 SDIO 1SMB5934BT3 24V 3W 021 SDIO MMSZ5254BT1 0 5W 27V 596 T 022 023 SDIO 1SMB5913BT3 3W 3 3V 5 6 TR 024 SDIO 1SMB5931BT3 3W 18V 5 TR DZ7 028 ISRES 15K FXD 1206 1 1 8W TR R1 ISRES 6 19K 1206 1 1 8W TR NP R3 SDIO MU
133. SISTOR SMD METAL FILM 1 10W 4 75K 1 525000 10015 R18 R37 R41 R65 R68 R100 RESISTOR SMD METAL FILM 1 10W 1 00K 1 525001 10025 R27 R28 RESISTOR SMD 10K 1 4W 1206 1 TR 525000 15015 R30 RESISTOR SMD METAL FILM 1 10W 1 50K 1 525001 33205 R31 R32 R33 R46 R47 R72 RESISTOR SMD 3320HMS 1 4W 1206 1 TR 525000 75005 R36 R44 R76 RESISTOR SMD METAL FILM 1 10W 7500HMS 525001 12115 R48 R49 RESISTOR SMD 1 21K 1 4W 1206 1 TR 525001 26705 R50 R51 R52 R53 R57 R58 R59 RESISTOR SMD 2670HMS 1 4W 1206 1 TR 525000 10005 R54 R55 R56 R80 R81 R82 RESISTOR SMD METAL FILM 1 10W 1000HMS 525001 24895 R73 R74 R75 RESISTOR SMD 24 90HMS 1 4W 1206 1 TR 525001 20005 R77 R78 R79 RESISTOR SMD 2000HMS 1 4W 1206 1 TR 518380 5 R83 THERMISTOR PTC 0 5 1 17 OHMS 0 5A 519869 8 51 52 SWITCH DIP SPST 8 CIRCUITS 520375 8 T1 TRANSFORMER PCB PWM FLYBACK 520353 15 2 IC SMD CMOS DRIVER RECEIVER EIA232 14 515128 255 X3 IC SMD VOLTAGE REGULATOR FIXED POSITI 525068 65 4 24 IC SMD VOLT REG FIXED 3 T 0 1A 5V 515128 55 x5 IC VOLT REG SMD FIXED 3 T 1A 5V 824841 1 6 IC MODULE CONVERTER DC DC 5V 3A OUT 525068 75 7 9 IC SMD CMOS UNDERVOLT SENSING RESET M 525069 25 8 IC SMD CMOS EEPROM SERIAL S
134. STOR IGBT OPERATION An IGBT is a type of transistor IGBTs are semicon ductors well suited for high frequency switching and high current applications Drawing A shows an IGBT in a passive mode There is no gate signal zero volts relative to the source and therefore no current flow The drain terminal of the IGBT may be connected to a voltage supply but since there is no conduction the circuit will not supply current to components connected to the source The circuit is turned off like a light switch in the OFF position lt DRAIN DRIFT REGION POSITIVE VOLTAGE 15 APPLIED GATE BODY REGION lt DRAIN DRIFT REGION __ opem _ Burren LAYER INJECTING LAYER DRAIN B ACTIVE Drawing B shows the IGBT in an active mode When the gate signal a positive DC voltage relative to the source is applied to the gate terminal of the IGBT it is capable of conducting current A voltage supply connected to the drain terminal will allow the IGBT to conduct and supply current to circuit components cou pled to the source Current will flow through the con ducting IGBT to downstream components as long as the positive gate signal is present This is similar to turning ON a light switch POWER WAVE 455 R LINCOLN 5 Return to Section Return to Master TOC Return to Section TOC Return to Master TOC Q BS 5 2 Return to Section R
135. Section 0 1 Section 0 1 TABLE CONTENTS ELECTRICAL DIAGRAMS SECTION 2 Electrical DIagrams e pe edite Era e Section G 8 Wiring Diagram Code 10675 024240 0 112000400 eene tnr nnne nennen nnn G 2 9 Wiring Diagram Code 10676 0 0020400440 00000 nentes nnns G 3 Schematic Complete Machine Code 10675 G 4 Schematic Complete Machine Code 10676 G 5 Schematic Chopper PC 2 4 nnne G 6 PC Board Assembly Chopper PC G 7 Schematic DeviceNet Gateway PC G 8 PC Board Assembly DeviceNet Gateway PC G 9 Schematic Control PC Board nennen rennen nnns G 10 Board Assembly Control PO Board 9 11 5 Schematic Digital Power Supply PC G 12 3 PC Board Assembly Digital Power Supply PC Board G 13 9 Schematic FeedHead PC G 14 Schematic FeedHead PC Board 2 G 15 2 Schematic FeedHead PC Board
136. TOC Return to Master TOC Q BS 5 2 Return Section Return to Master 2 2 5 TROUBLESHOOTING amp REPAIR HOW TO USE TROUBLESHOOTING GUIDE WARNING Service and repair should be performed by only Lincoln Electric Factory Trained Personnel Unauthorized repairs performed on this equipment may result in danger to the technician and machine operator and will invalidate your factory warranty For your safety and to avoid Electrical Shock please observe all safety notes and precautions detailed throughout this manual This Troubleshooting Guide is provided to help you locate and repair possible machine malfunc tions Simply follow the three step procedure listed below Step 1 LOCATE PROBLEM SYMPTOM Look under the column labeled PROBLEM SYMP TOMS This column describes possible symp toms that the machine may exhibit Find the list ing that best describes the symptom that the machine is exhibiting Symptoms are grouped into two main categories Output Problems and Function Problems Step 2 PERFORM EXTERNAL TESTS The second column labeled POSSIBLE AREAS OF MISADJUSTMENT S lists the obvious external possibilities that may contribute to the machine symptom Perform these tests checks in the order listed In general these tests can be con ducted without removing the case cover Ste
137. TV sealant may have to be 455 R removed from the input rectifier termi nals RTV should be replaced 2 Using the 3 8 nut driver remove the case when test is complete top 5 With the phillips head screw driver remove 3 Perform the Capacitor Discharge the positive and negative leads from the rec Procedure tifier 4 Locate the Input Rectifier and lead locations Refer to Figure F 4 Return to Section TOC Return to Master TOC POWER WAVE 455 R LINCOLN Return to Section Return to Master TOC Return to Section TOC Return to Master TOC Q BS 5 2 Return Section Return to Master TOC 2 2 5 F 16 F 16 TROUBLESHOOTING amp REPAIR INPUT RECTIFIER TEST CONTINUED 6 Use the analog ohmmeter to perform the 9 tests detailed in Table F 2 7 If the input rectifier does not meet the acceptable readings outlined in the table the component may be faulty Replace 10 NOTE Before replacing the input rectifier per form the Switch Board Test and the 11 Input Contactor Test 8 When installing a new input rectifier see Input Rectifier Removal and Replacement procedure If the input rectifier is good be sure to reconnect the positive and negative leads to the correct terminals and torque to 31 in lbs See the Wiring Diagram Replace any seala
138. This 13 15 VDC will remain for approximately 6 sec onds and then be removed The Relay is controlled by the Control Board See the Wiring Diagram This is the DC Coil Voltage for the Control Relay Normally this DC Voltage will be present approxi mately 12 seconds after Input Switch SW1 is activated The Relay is controlled by the Control PC Board See the Wiring Diagram 30 30 TROUBLESHOOTING amp REPAIR STT CHOPPER BOARD TEST WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty For your safety and to avoid electrical shock please observe all safety notes and precautions detailed throughout this manual Return to Section TOC Return to Master TOC 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 before you proceed Call 1 800 833 9353 WELD TEST DESCRIPTION This test will help determine if the STT Chopper Board is receiving the necessary voltages to function and if the related circuitry is correct Return to Section TOC Return to Master TOC MATERIALS NEEDED 3 8 Nut driver Volt ohmmeter Wiring Diagram This procedure should take approximately 30 m
139. VE 455 R Return to Section Return to Master TOC Return to Section TOC Return to Master TOC o 2 2 3 Q 5 D E 6 3 WIRING DIAGRAM POWER WAVE 455 CODE 10676 WORK 05 600V S5 DEVICENET CONNECTOR TO S1 93 A4 WIRE 892 FEEDER 891 56 WIREDRIVE INTERFACE RECEPTACLE 841 52 844 VOLTAGE 842 SENSE 545 RECEPTACLE 846 3 CONDUCTOR 847 TWISTED SHIELDED SHIELD GROUND TO CASE 67B TO 539 8 53 vs RS232 CONNECTOR e 521 1 10A CIRCUIT BREAKER 5 lt 0 z rx rommoouo 57 12 CONNECTOR S4 851 115V 852 RECEPTACLE 853 854 855 856 12 862 GND B lt 2 a 500 2 10A CIRCUIT BREAKER NA N 4 TO J7 2s ow NA 7 52 Hn 5 Te AAA T TH 50 ELECTRODE TP6 VOLTAGE SENSE 682 SELECT WORK ELECTRODE 31 0 33 STATUS LED R G THERMAL LED Y TOJ7 ELECTRICAL DIAGRAMS POWER WAVE 455 WIRING DIAGRAM CONTROL BOARD 1 14 FEED HEAD BOARD E T 1 BON
140. aster TOC Return to Section TOC Return to Master TOC Q BS 5 2 Return to Section Return to Master TOC 2 2 5 SAFETY PRECAUTIONS Read this entire section of operating instructions before operating the machine A WARNING ELECTRIC SHOCK can kill Unless using cold feed feature when feeding with gun trigger the electrode and drive mechanism are always electrically energized and could remain energized several seconds after the welding ceases Do not touch electrically live parts or electrodes with your skin or wet clothing Insulate yourself from the work and ground Always wear dry insulating gloves FUMES AND GASES can be dangerous Keep your head out of fumes 40 e Use ventilation or exhaust to remove fumes from breathing zone SE WELDING SPARKS can cause or explosion Keep flammable material away Do not weld on containers that have held combustibles ARC RAYS can burn 4 Wear eye ear and body protection Observe additional guidelines detailed in the beginning of this manual POWER WAVE 455 R LINCOLN 5 B 3 B 3 OPERATION GRAPHIC SYMBOLS THAT APPEAR ON THIS MACHINE OR IN THIS MANUAL o 2 Return to Master TOC INPUT POWER T SMAW ON G
141. ble to perform the test repairs safely contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed Call 1 800 833 9353 POWER WAVE 455 R LINCOLN 5 Return to Section Return to Master TOC Return to Section TOC Return to Master TOC Q BS 5 2 Return to Section Return to Master TOC 9 2 5 7 TROUBLESHOOTING amp REPAIR TROUBLESHOOTING GUIDE PROBLEMS SYMPTOMS The machine often noodle welds when running a particular process The output is limited to approxi mately 100 amps Observe Safety Guidelines detailed in the beginning of this manual POSSIBLE AREAS OF MISADJUSTMENT S FUNCTION PROBLEMS The machine may be trying to deliver too much power When the average output current exceeds 570 amps 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 455R machine RECOMMENDED COURSE OF ACTION 1 Perform the Transducer Test The Control faulty Board may be The Power Wave 455R will not pro duce full output The input voltage may be too low limiting the output capability of the machine Make certain the input voltage is correct for the machine and the reconnect panel configuration Make sure all three phases of
142. ctions The port is divided into three groups Trigger group Cold Inch Group and Shutdown Group Because the Power Wave is a slave on the DeviceNet network the Trigger and Cold Inch Groups are disabled when the DeviceNet Gateway is active The Shutdown Group is always enabled Shutdown 2 is used for signaling low flow in the water cooler Unused shutdowns must be jumpered Machines from the fac tory come with the shutdowns already jumpered See Figure A 4 FIGURE INPUT PORT CONNECTIONS 15 for Cold Inch Group Reserved for future use Cold Inch Forward 2 o 2 lt 2 gt te T Trigger Input Dual Procedure Input 4 Step Input Cold Inch Reverse Gas Purge Input 15 for shutdown group Shutdown1 input Shutdown input POWER WAVE 455 R LINCOLN 5 10 10 INSTALLATION DIP SWITCH SETTINGS AND LOCATIONS CONTROL BOARD DIP SWITCH 5 5 DIP switches the PC boards allow for custom con switch 1 reserved for future use a d figuration of the Power Wave Access the DIP switch switch 2 reserved for future use es as follows switch 3 reserved for future use g switch 4 reserved for future use EIE switch 5 reserved for future use 5 9 WARNING switch 6 reserved for future use ELECTRIC SHOCK CAN KILL switch 7 reserved for future use e switch 8 work sense lead Do not touch electrically live part
143. d throughout this manual Return to Section TOC Return to Master TOC 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 before you proceed Call 1 800 833 9353 WELD oio 6 5 DESCRIPTION zl 8 This procedure will aid the technician in the removal and replacement of the STT Current olg Transducer 8 8 2 MATERIALS NEEDED 3 8 Nut driver 5 16 Open end wrench 5 16 Socket wrench with extension Universal adapter 3 4 Wrench Phillips head screw driver Wire cutters Wiring Diagram This procedure should take approximately 25 minutes to perform Ojo 515 gt 218 5 2 Return to Section Return to Master TOC POWER WAVE 455 R LINCOLN Return to Section Return to Master TOC Return to Section TOC Return to Master TOC 5 5 gt 218 5 2 Return to Section Return to Master TOC F 65 F 65 TROUBLESHOOTING amp REPAIR STT CURRENT TRANSDUCER REMOVAL AND PLACEMENT CONTINUED FIGURE 25 CURRENT TRANSDUCER REMOVAL AND REPLACEMENT PROCEDURE ASSEMBLY CURRENT RESISTOR STT OUTPUT TERMINAL TOP RIGHT TRANSDUCER REMOVAL PROCEDURE 1 Remove input power to the Power Wav
144. e 5 Label and remove the leads to the resistor 455 R assembly See Figure F 25 Using the 5 16 socket wrench extension and univer 2 Using the 3 8 nut driver remove the case sal adapter remove the resistor assembly top and right side It may be necessary to remove the glastic 3 Perform the proce high voltage protection shield Use the dure 3 8 nut driver It may also be necessary to use 5 16 open end wrench to remove the 4 Using the wire cutters cut all cable ties to inside screws Carefully swing the resistor the transducer lead harness Unplug the assembly aside harness and swing it aside POWER WAVE 455 R LINCOLN Return to Section Return to Master TOC Return to Section TOC Return to Master TOC o 5 B Return to Section Return to Master TOC o 2 2 5 66 10 66 TROUBLESHOOTING amp REPAIR STT CURRENT TRANSDUCER REMOVAL AND REPLACEMENT CONTINUED With the 5 16 open end wrench remove the small screw from the STT output termi nal Label and remove the small leads See the Wiring Diagram Using the 3 4 wrench remove the bolt lock washer and flat washer from the STT output terminal Remove the double heavy output leads Cut any necessary cable ties Using the phillips head screw driver remove the screws and lock washers that hold the t
145. e configured for a lower input voltage switch boards induce an AC square wave output signal below 300VAC the input capacitors are connected at the secondary of the main transformer Current parallel When the machine is configured for higher transformers located on the switch boards monitor the input voltages 300VAC and above the input capaci primary currents If the primary currents become tors are connected in series abnormally high the Control Board will shut off the IGBTs thus disabling the machine s output The DC current flow through each primary winding is clamped back to each respective input capacitor when the 0 cic Sia When the input capacitors are fully charged they act as power supplies for the IGBT switching circuits The insulated gate bipolar transistors switch the DC power EN from the input capacitors on and off thus supplying IGBTs are turned off This is needed due to the induc pulsed DC current to the main transformer primary tance of the transformer primary windings The firing of windings See IGBT OPERATION DISCUSSION AND the two switch boards occurs during halves of a 50 DIAGRAMSlin this section microsecond interval creating a constant 20 KHZ out NOTE Unshaded areas of Block Logic Diagram are the subject of discussion Return to Section TOC Return to Master TOC POWER WAVE 455 R LINCOLN 5
146. e harm 2 The Above For Diesel Engines The Above For Gasoline Engines oc ARC WELDING can be hazardous PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY 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 strongly recommended that you purchase copy of Safety in Welding amp Cutting ANSI Standard 249 1 from the American Welding Society P O Box 351040 Miami Florida 33135 or CSA Standard W117 2 1974 A Free copy of Arc Welding Safety booklet E205 is available from the Lincoln Electric Company 22801 St Clair Avenue Cleveland Ohio 44117 1199 BE SURE THAT ALL INSTALLATION OPERATION MAINTENANCE AND REPAIR PROCEDURES ARE PERFORMED ONLY BY QUALIFIED INDIVIDUALS FOR ENGINE 842 1 avoid scalding do not remove the radiator pressure cap when the engine is powered equipment y e hot 1 a Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running 3 SX 1 b Operate engines in open well ventilated areas or vent the engine exhaust fumes outdoors Return to Master TOC ELECTRIC AND 3 Ss MAGNETIC FIELDS 1 c Do not add the fuel near an open flame weld S may be dangerous ing arc or when the engine is running Stop the engine and allow it to cool before refuel 2 a Electric curre
147. e input power OFF at the dis connect switch or fuse box before working on this equipment Turn off the input power to any other equip ment connected to the welding system at the discon nect switch or fuse box before working on the equip ment Do not touch electrically hot parts e Always connect the Power Wave grounding lug located inside the reconnect input access door to a proper safety Earth ground SELECT SUITABLE LOCATION Do not use Power Waves in outdoor environments The Power Wave power source should not be subjected to falling water nor should any parts of it be submerged in water Doing so may cause improper operation as well as pose a safety hazard The best practice is to keep the machine in a dry sheltered area Place the welder where clean cooling air can freely cir culate in through the rear louvers and out through the case sides and bottom Dirt dust or any foreign mate rial that can be drawn into the welder should be kept at a minimum Do not use air filters on the air intake because the air flow will be restricted Failure to observe these precautions can result in excessive operating temperatures and nuisance shutdowns Machines above code 10500 are equipped with F A N fan as needed circuitry The fan runs whenever the output is enabled whether under loaded or open circuit conditions The fan also runs for a period of time approximately 5 minutes after the output is disabled to ensure all com
148. e machine and the fan condi tion or air obstruction corrected On later production machines above code 10500 the cooling fan runs only when necessary The F A N fan as needed sys tem is controlled by the Control Board via a solid state relay PROTECTIVE CIRCUITS 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 average current exceeds 570 amps the peak cur rent will be limited to 100 amps until the average cur rent decreases to under 50 amps or the system is re triggered UNDER OVER VOLTAGE PROTECTION A protective circuit is included on the Control Board to monitor the voltage across the input capacitors In the event that a capacitor voltage is too high too low or becomes unbalanced side to side the protection cir cuit will de energize the input contactor Machine out put will be disabled and the soft start mode will be repeated The protection circuit will prevent output if any of the following circumstances occur 1 Capacitor conditioning is required This may be required if the machine has been off for a long peri od of time and is connected for high input voltage operation 2 Voltage across a capacitor exceeds 390 volts This could result from high line surges or improper input voltage connections 3 Voltage across a capacitor is under 70 volts This
149. ed output cover and along the channels formed into the base of the Power Wave out the back of the channels and then to the wire feeder Output connections on some Power Waves are made via 1 2 13 threaded output terminals located beneath the spring loaded output cover at the bottom of the case front On machines which carry the CE mark out put connections are made via Twist Mate receptacles also located beneath the spring loaded output cover at the bottom of the case front A work lead must be run from the negative power source output connection to the work piece The work piece connection must be firm and secure especially if pulse welding is planned CAUTION Excessive voltage drops at the work piece connection often result in unsatisfactory pulse welding perfor mance CONTROL CABLE SPECIFICATIONS It is recommended that genuine Lincoln control cables be used at all times Lincoln cables are specifically designed for the communication and power needs of the Power Wave Power Feed system CAUTION The use of non standard cables especially lengths greater than 25 feet can lead to communication prob lems system shutdowns poor motor acceleration poor arc starting and low wire driving force wire feed ing problems Lincoln control cables are copper 22 conductor cable in a SO type rubber jacket EXTERNAL I O CONNECTOR The Power Wave is equipped with a port for making sim ple input signal conne
150. er comme une source de courant pour soudage semi automatique ces precautions pour le porte lectrode s applicuent aussi au pistolet de soudage Dans le cas de travail au dessus du niveau du sol se pro t ger contre les chutes dans le cas ou on recoit un choc Ne Toujours porter des lunettes de s curit dans la zone de soudage Utiliser des lunettes avec crans lateraux dans les zones o l on pique le laitier Eloigner les mat riaux inflammables ou les recouvrir afin de pr venir tout risque d incendie d aux tincelles Quand on ne soude pas poser la pince une endroit isol de la masse Un court circuit accidental peut provoquer un chauffement et un risque d incendie S assurer que la masse est connect e le plus pr s possible de la zone de travail qu il est pratique de le faire Si on place la masse sur la charpente de la construction ou d autres endroits loign s de la zone de travail on augmente le risque de voir passer le courant de soudage par les chaines de lev age c bles de grue ou autres circuits Cela peut provoquer des risques d incendie ou d echauffement des chaines et des c bles jusqu ce qu ils se rompent Assurer une ventilation suffisante dans la zone de soudage Ceci est particuli rement important pour le soudage de t les galvanis es plomb es ou cadmi es ou tout autre m tal qui produit des fume s toxiques Ne pas souder en pr sence de vapeurs de chlore provenant d op ra
151. es resulting from board level troubleshooting PC Board repairs will invalidate your factory warranty Individual Printed Circuit Board Components not available from Lincoln Electric This information is vided for reference only Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician Improper PC board repairs could result in damage to the machine POWER WAVE 455 R LINCOLN amp ELECTRIC 9 12 ELECTRICAL DIAGRAMS SCHEMATIC DIGITIAL POWER SUPPLY BOARD Machine Control Power Supply 13 sov 5Volts 750 Amp 10 55 VDC Return to Section Return to Master TOC 022 im E 21 15Volts x 750 DC Input s gt gt Machine Control Shut Down Capacitor i DC Input 7 15Volts 100
152. es used for arc welding can displace air and cause injury or death Always use enough ventilation especially in confined areas to insure breathing air is safe Read and understand the manufacturer s instructions for this equipment and the consumables to be used including the material safety data sheet MSDS and follow your employer s safety practices MSDS forms are available from your welding distributor or from the manufacturer Mar 95 Return to Master Return to Master TOC Return to Master TOC Return to Master TOC i WELDING SPARKS can gt cause fire or explosion 6 a Remove fire hazards from the welding area 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 adjacent areas Avoid welding near hydraulic lines Have a fire extinguisher readily available Where compressed gases are to be used at the job site special precautions should be used to prevent hazardous situations Refer to Safety in Welding and Cutting ANSI Standard Z49 1 and the operating information for the equipment being used When not welding make certain no part of the electrode circuit is touching the work or ground Accidental contact can cause overheating and create a fire hazard Do not heat cut or weld tanks drums or containers until the proper steps have been taken to
153. eturn to Master TOC 2 D 2 5 12 12 THEORY OF OPERATION FIGURE E 10 TYPICAL IGBT OUTPUTS 1u sec gt _ 24 25 sec _ gt lt usec 50 sec lusec MINIMUM OUTPUT 14sec gt 24 4 sec 5 14sec 50 TZ MAXIMUM OUTPUT PULSE WIDTH MODULATION The term PULSE WIDTH MODULATION PWM is used to describe how much time is devoted to conduc tion in the positive and negative portions of the cycle Changing the pulse width is known as MODULATION Pulse Width Modulation is the varying of the pulse width over the allowed range of a cycle to affect the output of the machine MINIMUM OUTPUT By controlling the duration of the gate signal the IGBT is turned on and off for different durations during a cycle The top drawing below shows the minimum out put signal possible over a 50 microsecond time period IGBT group consists of the sets of IGBT modules grouped onto one switch board The shaded portion of the signal represents one IGBT group conducting for 1 microsecond The negative por tion is the other IGBT group The dwell time off time is 48 microseconds both IGBT groups off Since only 2 microseconds of the 50 microsecond time period are devoted to conducting the output power is minim
154. eturn to Master TOC o 2 2 E 5 Return to Master TOC SAFETY PRECAUTIONS DE SURETE gt Pour votre propre protection lire et observer toutes les instructions et les pr cautions de s ret specifiques qui parraissent dans manuel aussi bien que les pr cautions de s ret g n rales suiv antes S ret Pour Soudage A L Arc 1 Protegez vous contre la secousse lectrique Les circuits l lectrode et la pi ce sont sous tension quand la machine souder est en marche Eviter toujours tout contact entre les parties sous tension et la peau nue ou les v tements mouill s Porter des gants secs et sans trous pour isoler les mains Faire tr s attention de bien s isoler de la masse quand on soude dans des endroits humides ou sur un plancher metallique ou des grilles metalliques principalement dans les positions assis ou couch pour lesquelles une grande partie du corps peut tre en contact avec la masse Maintenir le porte lectrode la pince de masse le c ble de soudage et la machine souder en bon et s r tat defonctionnement Ne jamais plonger le porte lectrode dans l eau pour le refroidir Ne jamais toucher simultan ment les parties sous tension des porte lectrodes connect s deux machines soud er parce que la tension entre les deux pinces peut tre le total de la tension vide des deux machines Si on utilise la machine soud
155. ffect the operation of RF controlled equipment which may result in bodily injury or damage to the equipment POWER WAVE 455 R LINCOLN 5 Return to Section Return to Master TOC Return to Section TOC 515 gt 218 5 2 Return to Section Return to Master TOC Return to Master TOC A 5 A 5 INSTALLATION FIGURE A 1 K1761 1 CONNECTION DIAGRAM ON CONNECTION INPUT ACCESS DOOR INPUT SUPPLY CONNECTION DIAGRAM Disconnect input power before inspecting or servicing machine Do not operate with covers removed ELECTRIC SHOCK CAN KILL Do not touch electrically live parts Only qualified persons should install use or service this equipment VOLTAGE 220 230V INPUT SUPPLY CONNECTION DIAGRAM A WARNING Disconnect input power before inspecting or servicing machine Do not operate with covers removed ELECTRIC not touch electrically live parts SHOCK Only qualified persons should install CAN KILL use or service this equipment VOLTAGE 220 230V 200 208V 220 230 440 460V 550 575 VOLTAGE 200 208V
156. h the machine energized because these boards can be damaged easily In addition it is dangerous to work on these boards with the machine energized MATERIALS NEEDED 3 8 Nut driver 3 8 Wrench Analog volt ohmmeter Wiring Diagram This procedure should take approximately 20 minutes to perform POWER WAVE 455 R LINCOLN F 11 Return to Section Return to Master TOC Return to Section TOC Return to Master TOC o 5 B Return to Section Return to Master TOC o 2 2 5 F 12 F 12 TROUBLESHOOTING amp REPAIR SWITCH BOARD TEST CONTINUED FIGURE F 2 RECONNECT SWITCHES TEST PROCEDURE 1 Perform the Remove input power to the Power Wave 455 R Using the 3 8 nut driver remove the case top and sides apacitor Discharge Procedure Locate label and remove leads 19C and 19D from the reconnect switches with the 3 8 wrench Note lead placement for reassem bly Clear leads Refer to Figure F 2 POWER WAVE 455 R LINCOLN 19D RECONNECT SWITCHES 5 Using the Analog ohmmeter perform the resistance tests detailed in Table F 1 Refer to Figure F 3 for the test points If any test fails replace both switch boards See witc Replacement If the switch board res
157. 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 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 assembly and individual rectifier module replacement This procedure takes approximately 35 minutes to remove and replace the output rectifi er 5 minutes to remove the STT Chopper Board and 5 minutes to remove and replace the rectifier module MATERIALS NEEDED 3 8 Nut driver 7 16 Wrench 9 16 Wrench 9 64 Allen wrench 3 16 Allen wrench Needle nose pliers Slot head screwdriver Penetrox A13 Thermal Joint Compound Wiring Diagram This procedure should take approximately 45 minutes to perform POWER WAVE 455 R LINCOLN 71 71 TROUBLESHOOTING amp REPAIR OUTPUT RECTIFIER STT CHOPPER BOARD AND RECTIFIER MODULE REMOVAL AND REPLACEMENT CONTINUED FIGURE 27 OUTPUT RECTIFIER STT CHOPPER BOARD AND RECTIFIER MODULE REMOVAL AND REPLACEMENT Return to Section TOC Return to Master TOC RECTIFIER THERMOSTAT LEAD 287 LEADS 291 amp 292 SNUBBER LEAD 289B DIODE STT SNUBBER CAPACITOR PLUG J10 TRANSFORMER LEADS 9 RECTIFIER MODULE Return to Section TOC Ret
158. iablilities resulting from board level troubleshooting PC Board repairs will invalidate your factory warranty Individual Printed Circuit Board Components not available from Lincoln Electric This information is pro vided for reference only Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician Improper PC board repairs could result in damage to the machine POWER WAVE 455 R 9 20 004 58 HILIMS JILVNW3H3S NOLLOSNNO 19 HLY NOLLO3NNO2 ALY LIN 09170 Add 1389 031319345 SSIMYSHLO SSS INN 031519345 3SIMH3H10 553731 05 220 MHI 10 80 50 3190 av W HOr 3NON 31925 dd 10 2 757 OIHO ONV 134319 719 13 N TOINI 3H 031412348 351 702 2918123 13 JHL A00TVI 530010 SUYO 590151533 SHOLIOUdv2 LESTI H3d 5708 5 79218123713 NOILVAHOJNI TV33N39 3Hl0 5531 0 30 NOISSIWH3d SS3tdX3 02 218123 13 100 17 AHL LOVX3 3H 2 SIHL 29 0 33449 Y NO AHLIDOHIO HO SINSNOdWOI 3ONIS HO 0350710510 Q39ndosd3s 38 01 LON ST ONY NOLLUWHOJNI AHUL3IHdOBd SN
159. id electrical shock please observe all safety notes and precautions detailed throughout this manual Return to Section TOC Return to Master TOC 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 before you proceed Call 1 800 833 9353 WELD olo 515 DESCRIPTION 8 This procedure will aid the technician the removal and replacement of auxiliary trans olg former No 1 5 MATERIALS NEEDED 3 8 Nut driver Wire cutters Wire splicer or soldering equipment This procedure should take approximately 25 minutes to perform 515 gt 218 5 2 Return to Section Return to Master TOC POWER WAVE 455 R LINCOLN Return to Section Return to Master TOC Return to Section TOC Return to Master TOC 5 5 gt 218 5 2 Return to Section Return to Master TOC F 53 F 53 TROUBLESHOOTING amp REPAIR AUXILIARY TRANSFORMER NO 1 REMOVAL AND REPLACEMENT PROCEDURE CONTINUED FIGURE F 20 AUXILIARY TRANSFORMER NO 1 REMOVAL AND REPLACEMENT RECONNECT X3 X5 B 1 TERMINALS gt H2 B4 5 MOTOR LEADS gt gt 2 ys E POWER
160. idate your factory warranty For your safety and to avoid electrical shock please observe all safety 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 Service Department for electrical trou bleshooting assistance before you proceed Call 1 800 833 9353 WELD TEST DESCRIPTION This test will determine if the DC Bus Power Supply PC Board is receiving and process ing the proper voltages MATERIALS NEEDED 3 8 Nut driver Volt ohmmeter Wiring Diagram This procedure should take approximately 30 minutes to perform POWER WAVE 455 R LINCOLN F 20 Return to Section Return to Master TOC Return to Section TOC Return to Master TOC Q BS 5 2 Return to Section o 2 2 5 Return to Master TOC F 21 F 21 TROUBLESHOOTING amp REPAIR DC BUS POWER SUPPLY PC BOARD TEST CONTINUED FIGURE F 7 DC BUS POWER SUPPLY POWER SUPPLY PC BOARD LED nA A DC BUS me BOARD REN _ ny 2 A Be BV J46 C3 CAUTION
161. iliary A lead is placed in the wrong position there are two possible results If the lead is placed in a position higher than the applied line voltage the welder may not come on at all If the auxiliary A lead is placed in a position lower than the applied line volt age the welder will not come on and 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 CAUTION Special care must taken when more than Power Wave is welding simultaneously on a single part Arc blow and arc interference may occur or be magnified Each power source requires a work lead from the work terminal to the welding fixture Do not combine all of the work leads into one lead The welding travel directions should be in the direction moving away from the work lead as shown in Figure A 2 Connect all of the work sense leads from each power source to the work piece at the end of the weld For the best results when pulse welding set the wire size and wire feed speed the same for all the Power Waves FIGURE A 2 MULTIPLE POWER WAVE CONNECTIONS TWO POWER WAVES e e BS O o E o 9 4 zi ENS 8 4 EL 5 EA 0 9 ele 818 2 c ELECTRO
162. ily without water flow ing Recommend practice is to install a water flow sensor such as on the water return line of the torch When fully integrated into the welding system the sensor will prevent welding if no water flow is pre sent Dual Cylinder Undercarriage K1570 1 Coaxial Welding Cable K1796 The Dual Cylinder Undercarriage 1570 1 is not compatible in combination with the Power Wave Water Cooler K1767 1 POWER WAVE 455 R LINCOLN 5 Section D 1 Section D 1 TABLE OF CONTENTS MAINTENANCE SECTION Section Safety Precautiofis avis fence evades shades be aspera D 2 Routine and Periodic D 2 Main Assembly Exploded View nennen nnn then sinere nnns D 3 Return to Master TOC Return to Master TOC o o gt 0 iv z o 4 c tc Return to Master TOC POWER WAVE 455 R LINCOLN 5 Return to Section Return to Master TOC Return to Section TOC Return to Master TOC Q BS 5 2 Return Section Return to Master TO
163. input power are being applied to the machine If using output terminal be aware that the STT output is limited to 325 amps 1 Perform the Output Rectifier 2 Perform the 3 Perform the Power Board Test 4 The Control faulty Board may be If using the output terminal the STT Chopper Board may be faulty See the Wiring Diagram CAUTION 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 troubleshooting assistance before you proceed Call 1 800 833 9353 POWER WAVE 455 R LINCOLN 5 Return to Section Return to Master TOC Return to Section TOC Return to Master TOC Q BS 5 2 Return to Section Return to Master TOC 9 2 5 F 8 F 8 TROUBLESHOOTING amp REPAIR Observe Safety Guidelines detailed in the beginning of this manual PROBLEMS SYMPTOMS The Auxiliary Receptacle is dead The 120VAC is not present at the receptacle POSSIBLE AREAS OF MISADJUSTMENT S FUNCTION PROBLEMS Check the 10 amp circuit break er CB2 located on the case front Reset if necessary Check the 6 amp circuit breaker CB4 located in the reconnect area Reset if necessary Make sure all three phases of input power are being
164. insure that such procedures will not cause flammable or toxic vapors from substances inside They can cause an explosion even though they have been cleaned For information purchase Recommended Safe Practices for the Preparation for Welding and Cutting of Containers and Piping That Have Held Hazardous Substances AWS F4 1 from the American Welding Society see address above Vent hollow castings or containers before heating cutting or welding They may explode Sparks and spatter are thrown from the welding arc Wear oil free protective garments such as leather gloves heavy shirt cuffless trousers high shoes and a cap over your hair Wear ear plugs when welding out of position or in confined places Always wear safety glasses with side shields when in a welding area Connect the work cable to the work as close to the welding area as practical Work cables connected to the building framework or other locations away from the welding area increase the possibility of the welding current passing through lifting chains crane cables or other alternate circuits This can create fire hazards or overheat lifting chains or cables until they fail 6 h Also see item 1 c SAFETY LINCOLN 8 CYLINDER may explode 22584 gt if damaged 7 a Use only compressed gas cylinders containing the correct shielding gas for the process used and properly operating regulators designed for the gas and pressure used All h
165. inutes to perform 515 gt 218 5 2 Return to Section Return to Master TOC POWER WAVE 455 R LINCOLN Return to Section Return to Master TOC Return to Section TOC Return to Master TOC Q BS 5 2 Return to Section Return to Master TOC o 2 2 5 31 31 TROUBLESHOOTING amp REPAIR STT CHOPPER BOARD TEST CONTINUED FIGURE F 10 CHOPPER BOARD TEST DETAILS CONTROL PC BOARD POWER PC BOARD J7 J43 J7 123 45 67 8 9 10 11 12 1331415 16 748 9 10 11 12 4W 4R 345 STT OUTPUT TERMINAL POWERWAVE OUTPUT TERMINAL 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 F 10 3 Perform the following resistance tests probe on the STT output terminal probe on the Power Wave output ter minal The reading should be approximately 300 000 ohms POWER WAVE 455 R LINCOLN probe on the Power Wave output ter minal probe on the STT
166. istance tests check the molex pin connections and asso ciated wiring from the switch boards to the control board See the Wiring Diagram 13 13 TROUBLESHOOTING amp REPAIR SWITCH BOARD TEST CONTINUED FIGURE SWITCH BOARD TEST POINTS Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC SWITCH BOARD 8 Reconnect leads 19 19D to the recon 9 Install the right and left case sides and top nect switches Ensure that the leads are using the 3 8 nut driver installed in the same location they were removed from Ojo 5 5 gt 218 5 2 TABLE F 1 SWITCH BOARD RESISTANCE TEST APPLY POSITIVE TEST APPLY NEGATIVE TEST RESISTANCE READING PROBE TO TERMINAL NORMAL PROBE TO TERMINAL 19 11 12 OR 15 16 Greater than 1000 ohms 19 13 14 OR 17 18 Greater than 1000 ohms 11 12 OR 15 16 20 Greater than 1000 ohms 13 14 OR 17 18 20 Greater than 1000 ohms 11 12 OR 15 16 Less than 100 ohms 20 13 14 OR 17 18 Less than 100 ohms 11 12 OR 15 16 19 Less than 100 ohms 13 14 OR 17 18 19 Less than 100 ohms Return to Section TOC Return to Master TOC POWER WAVE 455 R LINCOLN 14 14 TROUBLESHOOTING amp REPAIR INPUT RECTIFIER TEST WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel Unauthori
167. iver Wiring Diagram This procedure should take approximately 30 minutes to perform 515 gt 218 5 2 Return to Section Return to Master TOC POWER WAVE 455 R LINCOLN Return to Section Return to Master TOC Return to Section TOC Return to Master TOC 5 5 gt 218 5 2 44 lt gt X2 POWER BOARD RECTIFIER BRIDGE F 44 TROUBLESHOOTING amp REPAIR AUXILIARY TRANSFORMER NO 1 TEST CONTINUED FIGURE F 16 AUXILIARY TRANSFORMER NO 1 TEST X3 X5 FAN MOTOR LEADS TEST PROCEDURE 1 Remove the main input power to the Power Wave 455 R machine Using the 3 8 nut driver remove the case top and sides Perform the Capacitor Discharge proce dure Locate secondary leads X1 and X2 at power board rectifier bridge Refer to Figure F 16 INPUT CONTACTOR Locate secondary leads X3 and 5 fan motor leads Locate secondary lead X4 at main contac tor Return to Section TOC Return to Master TOC POWER WAVE 455 R LINCOLN Return to Section Return to Master TOC Return to Section TOC Return to Master TOC Q BS 5 2 Return Section Return to Master TOC 2 2 5
168. ized MAXIMUM OUTPUT By holding the gate signals on for 24 microseconds each and allowing only 2 microseconds of dwell or off time one microsecond during each half cycle during the 50 microsecond cycle the output is maximized The dark ened area under the minimum output curve can be com pared to the area under the maximum output curve The more darkened area the more power is present POWER WAVE 455 R LINCOLN 5 Section F 1 Section F 1 TABLE OF CONTENTS TROUBLESHOOTING amp REPAIR SECTION 5 Troubleshooting amp Repair Section F 3 How to Use Troubleshooting Guide ennt nennen F 2 9 Board Troubleshooting PEOGSOHEBS tma ed v an Sta F 3 Troubleshooting rette 4 2 Test uci x dae dette ad he deed 9 Input Filter Capacitor Discharge Procedure F 9 Switch Board MI pm F 11 put Recunor e viens F 14 Contactor 17 DC Bus Power Supply PC Board F 20 Power Board 23 5 Board v F 26 3 Chopper Board F 30 9 Power Wave Current Transducer Test
169. ke approximately 25 minutes to perform POWER WAVE 455 R LINCOLN F 37 Return to Section Return to Master TOC Return to Section TOC Return to Master TOC 515 gt 218 5 2 Return to Section Return to Master TOC F 38 F 38 TROUBLESHOOTING amp REPAIR STT CURRENT TRANSDUCER TEST CONTINUED FIGURE F 13 STT CURRENT TRANSDUCER TEST CONTROL BOARD J8 813 12 3M 516 7 8 811 816 812 J8 CURRENT TRANSDUCER TEST PROCEDURE WARNING 1 Remove input power to the Power Wave 455 R _ ELECTRIC SHOCK can kill 2 Using the 3 8 nut driver remove the case High voltage is present when top and the control box cover input power is applied to the 3 Locate the STT current transducer leads at machine Control Board plug J8 See Figure F 13 4 Carefully apply input power to the Power Wave 455 R POWER WAVE 455 R LINCOLN Return to Section Return to Master TOC Return to Section TOC Return to Master TOC 5 5 gt 218 5 2 Return to Section Return to Master TOC F 39 TROUBLESHOOTING amp REPAIR STT CURRENT TRANSDUCER TEST CONTINUED FIGURE F 14 RECEPTACLE 57 TRIGGERED RECEPTACLE S7
170. ll the case top sides and input access panel using the 3 8 nut driver POWER WAVE 455 R LINCOLN 50 50 TROUBLESHOOTING amp REPAIR INPUT CONTACTOR REMOVAL AND REPLACEMENT WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty For your safety and to avoid electrical shock please observe all safety notes and precautions detailed throughout this manual Return to Section TOC Return to Master TOC 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 before you proceed Call 1 800 833 9353 WELD TEST DESCRIPTION This procedure will aid the technician in the removal and replacement of the input con tactor Return to Section TOC Return to Master TOC MATERIALS NEEDED 3 8 nut driver 5 16 nut driver Phillips head screwdriver This procedure should take approximately 15 minutes to perform 515 gt 218 5 2 Return to Section Return to Master TOC POWER WAVE 455 R LINCOLN Return to Section Return to Master TOC Return to Section TOC Return to Master TOC
171. m 515 gt 218 5 2 Return to Section Return to Master TOC POWER WAVE 455 R LINCOLN 42 42 TROUBLESHOOTING amp REPAIR OUTPUT RECTIFIER TEST CONTINUED FIGURE F 15 OUTPUT RECTIFIER TEST Return to Section TOC Return to Master TOC POWERWAVE 455 R e e NEGATIVE 2222 OUTPUT STT OUTPUT TERMINAL Of TERMINAL Es 5 _ M POSITIVE TERMINAL 42 5 Return to Master TOC e o TEST PROCEDURE 5 8 1 Remove main input supply power to the IMPORTANT The positive meter probe 9 2 Power Wave 455 R must be attached to the positive output ter 2 2 minal the negative meter probe must be 8 8 2 Remove the case top and sides and perform attached to the negative output terminal the Input Filter Capacitor Discharge pro 313 cedure 6 If the reading is more than 200 ohms the output rectifier modules not shorted If 3 Using the 5 16 wrench remove and insu the reading is less than 200 ohms one or late lead 202A from the negative output ter more of the rectifier modules are shorted minal Refer to the Output Rectifier Module 4 Remove any output load that may be con Replacement
172. m Using the needle nose pliers remove leads 292 and 291 from the rectifier ther mostat the STT Chopper Board With the 7 16 wrench remove lead 287 from the STT Snubber Diode D5 With the 7 16 wrench remove lead 289B from the STT Snubber Capacitor C10 Using the 7 16 wrench remove the four nuts and associated washers from the heat sink mounting bolts The heat 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 clean bench surface Using a slot head screw driver remove the two nylon screws holding the board to the heat sink Save the standoffs for reassem bly Using the 7 16 wrench remove the two bolts lock washers and flat washers Save the standoffs for reassembly POWER WAVE 455 R LINCOLN 4 Using the 3 16 allen wrench remove the four screws and lock washers holding the board to the heat sink 5 Carefully remove the STT Chopper Board REPLACEMENT PROCEDURE 1 2 Position the new board on the heat sink using the standoffs for the slot head nylon screws and the allen head screws Install the four 3 16 allen head screws and lock washers 3 Install the two nylon slot head screws 4 nstall the two 7 16 bolts lock washers and flat washers Return to Section Return to Master TOC Ret
173. n Return to Master TOC Return to Section TOC Return to Master TOC 5 5 gt 2 2 EIS 2 1 Return to Section Return to Master TOC SVM ERROR REPORTING FORM We need to know if there are errors in our manuals We also value any suggestions as to additional tests or procedures that would make this SVM a better tool for you If you discover new or different Problems or Symptoms that are not covered in the three col umn troubleshooting chart please share this information with us Please include the machine s code number and how the problem was resolved Thank You Technical Services Group Lincoln Electric Co 22801 St Clair Ave Cleveland Ohio 44117 1199 FAX 216 481 2309 SVM Number Page Number if necessary Your Company Your Name Please give detailed description below SD287 01 99 LINCOLN 5
174. n to Section Return to Master TOC NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual LINCOLN POWER WAVE 455 R G 11 ELECTRICAL DIAGRAMS
175. n to Section Return to Master TOC o 2 2 5 49 F 49 TROUBLESHOOTING amp REPAIR INPUT RECTIFIER REMOVAL AND REPLACEMENT CONTINUED FIGURE F 18 INPUT RECTIFIER REMOVAL AND REPLACEMENT RECTIFIER REMOVAL PROCEDURE 1 Remove input power to the Power Wave 455 R Using the 3 8 nut driver remove the case top sides and input access panel Perform the Capacitor Discharge proce dure Locate and remove the RTV sealant from the input rectifier connection terminals See Figure F 18 Label and using the phillips head screwdriv er carefully remove the five leads from the input rectifier terminals Note placement for reassembly See Figure F 18 Using the 3 16 allen wrench remove the two mounting screws and washers from the rectifier module Carefully remove the input rectifier module INPUT POS REPLACEMENT PROCEDURE 1 Clean heat sink surfaces 2 Apply an even coating of joint compound Penetrox A 13 to both the heat sink and module mounting surfaces The joint com pound should be 0 002 0 005 in thick per surface 3 Mount the module to the heat sink and even ly torque the mounting screws with wash ers to 44 in Ibs 4 Assemble the leads to the correct module terminals and torque to 26 in lbs See Figure F 18 5 Apply RTV sealant to the rectifier connection terminals 6 Insta
176. nch une bonne mise la terre Autant que possible l installation et l entretien du poste seront effectu s par un lectricien qualifi Avant de faires des travaux l interieur de poste la debrancher l interrupteur la boite de fusibles Garder tous les couvercles et dispositifs de s ret leur place Mar 93 MASTER TABLE CONTENTS FOR ALL SECTIONS RETURN TO MAIN MENU Page SMOG i iv Section GU TT NETTE Section B Accessories SCHON Maintenance Section D Theory of Operation ettet Section E Troubleshooting and Repair SCHON F Electrical 2224 2 2 22222 202 202 2 2 00 Section G Parts POWER WAVE 455 R LINCOLN 5 Section TABLE CONTENTS INSTALLATION SECTION 5 mes RT Section 8 Specifications intret rera teer a K A 2 9 Safety Precautions M 4 Select Sutrtable LOCatlon rnt t tren ett t eitis er de o LE Ee eR ex ERR A 4 c ITI EDEN 4 SLACKING uM MAE 4 Machine Grounding o 4 High Frequency Protection ccc 4 COMMECHON 5 Inpu
177. nect plugs P50 and P52 6 Disconnect leads 33 and 32 to circuit breaker CB2 and the 115 V receptacle Using the 3 8 nut driver remove the two transformer mounting screws Return to Section Return to Master TOC Return to Section TOC Return to Master TOC 5 5 gt 218 5 2 Return to Section Return to Master TOC F 57 TROUBLESHOOTING amp REPAIR AUXILIARY TRANSFORMER NO 2 REMOVAL AND REPLACEMENT PROCEDURE CONTINUED 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 Connect leads 33 and 32 to circuit breaker CB4 and the 115 V receptacle 4 Connect plugs P50 and P52 5 Reposition any wire leads and install cable ties as necessary 6 Install the case back using the 3 8 nut driver 7 Install the case top sides and input access panel using the 3 8 nut driver POWER WAVE 455 R LINCOLN F 57 Return to Section Return to Master TOC Return to Section TOC Return to Master TOC Q BS 5 2 Return to Section Return to Master TOC 2 2 5 58 TROUBLESHOOTING amp REPAIR CONTROL FEED HEAD OR VOLTAGE SENSE PC BOARD REMOVAL AND REPL
178. nslated by the Gateway Board to ArcLink compatible messages The following block diagram Figure E 5 depicts the flow of communica tion information NOTE Unshaded areas of Block Logic Diagram are the subject of discussion POWER WAVE 455 R LINCOLN 5 Return to Section Return to Master TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Master TOC THEORY OF OPERATION FIGURE E 5 POWER WAVE 455 R COMMUNICATIONS Translator Robot Controller POWER WAVE 455 R LINCOLN 5 E 6 THEORY OPERATION FIGURE E 6 CONTROL BOARD Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC O10 515 gt 218 5 oO Return to Section Return to Master TOC IGBT DRIVE FROM CONTROL POWER WAVE 455 R CAP V F FEEDBACK CR1 INPUT SWITCH RECTIFIER IGBT DRIVE FROM CONTROL CURRENT BOARD TO CONTROL BOARD RECONNECT gt SWITCH 4 CAP V F FEEDBACK 67A SWITCH VOLT CT CURRENT TO CONTROL MAIN TRANSFORMER ELECTRODE OUTPUT DIODES D1 D4 TERMINAL gt 20 VDC FROM POWER BOARD STT ELECTRODE TERMINAL CURRENT TRANSDUCER STT DRIVE CURRENT WORK TRANSDUCER OUTPUT RU CHOKE SENSE BOARD VOLTAGE SENSE SELECT V
179. nt flowing through any conductor causes ing to prevent spilled fuel from vaporizing on localized Electric and Magnetic Fields EMF Welding contact with hot engine parts and igniting Do current creates EMF fields around welding cables and not spill fuel when filling tank If fuel is spilled welding machines wipe it up and do not start engine until fumes have been eliminated EMF fields may interfere with some pacemakers and welders having a pacemaker should consult their physician Keep all equipment safety guards covers before welding and devices in position and in good repair Keep hands hair clothing and tools away from V belts gears fans and all other moving parts when starting operating or repairing equipment Exposure to EMF fields in welding may have other health effects which are now not known o o P 0 iv gt c tc All welders should use the following procedures in order to minimize exposure to EMF fields from the welding circuit 2 d 1 Route the electrode and work cables together Secure 1 6 some cases it may be necessary to remove safety them with tape when possible guards to perform required maintenance Remove guards only when necessary and replace them when the maintenance requiring their removal is complete 2 4 2 Never coil the electrode lead around your body Always use the greatest care when working near moving parts 2 d 3 Do not place you
180. nt previously removed Install the case top TABLE F 2 INPUT RECTIFIER TEST POINTS AND ACCEPTABLE READINGS TEST POINT TERMINALS ANALOG METER X100 RANGE Probe Probe Acceptable Meter Readings NEG NEG NEG POS POS POS A B POWER WAVE 455 R LINCOLN Greater than 1000 ohms Greater than 1000 ohms Greater than 1000 ohms Approx 500 ohms Approx 500 ohms Approx 500 ohms Approx 500 ohms Approx 500 ohms Approx 500 ohms Greater than 1000 ohms Greater than 1000 ohms Greater than 1000 ohms 17 17 TROUBLESHOOTING amp REPAIR INPUT CONTACTOR TEST WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty For your safety and to avoid electrical shock please observe all safety notes and precautions detailed throughout this manual Return to Section TOC Return to Master TOC 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 before you proceed Call 1 800 833 9353 WELD TEST DESCRIPTION This test will help determine if the input contactor is functional and if the contacts are functioning correctly Return to Section TOC Re
181. o Section TOC Return to Master TOC Q BS 5 2 Return to Section Return to Master TOC 2 2 5 INSTALLATION VOLTAGE SENSING The best arc performance occurs when the Power Wave has accurate data about the arc conditions Depending upon the process inductance within the electrode and work lead cables can influence the volt age apparent at the terminals of the welder Voltage sense leads improve the accuracy of the arc conditions and can have a dramatic effect on performance A CAUTION If the voltage sensing is enabled but the sense leads are missing or improperly connected extremely high welding outputs may occur Do not tightly bundle the work sense lead to the work lead The sense leads connect to the Power Wave at the four pin connector located underneath the output ter minal cover Lead 67 senses 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 lead optional GMAW P 67 lead required 21 lead optional FCAW 67 lead required 21 lead optional STT 67 lead required 21 lead required GTAW Voltage sense at Voltage sense at terminals terminals SAW 67 lead required 21 lead optional The electrode voltage 67 sense lead is integral to the con t
182. om the current transducer The current feedback voltage can be read at plug J8 on the Control Board A Pin 1 lead 211 to pin 6 lead 216 should read 2 0 VDC machine loaded to 250 amps 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 E 5 5 gt 8 EIS 2 6 If both of the supply voltages are low or missing check the associated leads between plug J8 and current transducer plug P91 and the Control Board Return to Section TOC Return to Master TOC POWER WAVE 455 R LINCOLN Return to Section Return to Master TOC Return to Section TOC Return to Master TOC Q BS 5 2 Return to Section Return to Master TOC 2 2 5 F 36 F 36 TROUBLESHOOTING amp REPAIR POWER WAVE CURRENT TRANSDUCER TEST CONTINUED 8 If for any reason the machine cannot be loaded to 250 amps Table F 6 shows what feedback voltage is produced at various cur rent loads If the correct supply voltages are applied to the current transducer and with the machine loaded the feedback voltage is missing or not correct the current transducer may be faulty Also make certain that lead 211 plug J8 pin 1 has continuity zero ohms between the current
183. oses fittings etc should be suitable for the application and maintained in good condition Always keep cylinders in an upright position securely chained to an undercarriage or fixed support Cylinders should be located Away from areas where they may be struck or subjected to physical damage safe distance from arc welding or cutting operations and any other source of heat sparks or flame Never allow the electrode electrode holder or any other electrically hot parts to touch a cylinder Keep your head and face away from the cylinder valve outlet when opening the cylinder valve Valve protection caps should always be in place and hand tight except when the cylinder is in use or connected for use Read and follow the instructions on compressed gas cylinders associated equipment and CGA publication Precautions for Safe Handling of Compressed Gases in Cylinders available from the Compressed Gas Association 1235 Jefferson Davis Highway Arlington VA 22202 FOR ELECTRICALLY powered equipment 8 a Turn off input power using the disconnect switch at the fuse box before working on the equipment Install equipment in accordance with the U S National Electrical Code all local codes and the manufacturer s recommendations Ground the equipment in accordance with the U S National Electrical Code and the manufacturer s recommendations Return to Master R
184. otes and precautions detailed throughout this manual Return to Section TOC Return to Master TOC 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 before you proceed Call 1 800 833 9353 WELD TEST DESCRIPTION This procedure will aid the technician in the removal and replacement of the switch board s and or filter capacitor s Return to Section TOC Return to Master TOC MATERIALS NEEDED 3 8 Nut driver 7 16 Wrench 3 16 Allen wrench Slot head screwdriver Penetrox A13 thermal joint compound This procedure should take approximately 25 minutes to perform E 515 gt 2 2 5 2 Return to Section Return to Master TOC POWER WAVE 455 R LINCOLN Return to Section Return to Master TOC Return to Section TOC Return to Master TOC E 5 5 gt 2 2 5 2 Return to Section Return to Master TOC F 75 F 75 TROUBLESHOOTING amp REPAIR SWITCH BOARD AND FILTER CAPACITOR REMOVAL AND REPLACEMENT CONTINUED FIGURE F 28 SWITCH BOARD AND FILTER CAPACITOR REMOVAL AND REPLACEMENT REMOVAL PROCEDURE NOTE Observe all static electricity precautions 4 Lead and plug references below use a slash to indica
185. ow speed gear BEHIND CASE CONTROL 3 3 FRONT BOX BEHIND on high speed gear o o OS CASE FRONT cc DEVICENET con BOARD i lt CASE FRONT LOCATED BEHIND FRONT E lt OPENING de3 CASE FRONT 55 COVER e si olo LEFT RIGHT 5 d t Oo olg gt 23 0 POWER WAVE 455 R LINCOLN 5 Return to Section Return to Master TOC Return to Section TOC Return to Master TOC o 5 B Return to Section Return to Master TOC 2 2 5 Mui INSTALLATION DEVICENET GATEWAY BOARD DIP SWITCH BANK S2 switch 1 2 configure the baud rate for DeviceNET Prior to 524958 6 software switch 1 switch 2 baud rate off off on off 125K off on 250K on on 500 524958 6 and later software switch 1 switch 2 baud rate off off 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 use switch 8 reserved for future use POWER WAVE 455 R LINCOLN 5 A 11 12 5 POWER WAVE 455 R LINCOLN E A 12 901 Je1Se A 0 uunjeH 901 Je1Se A 0 uunjeH 901 J91Se
186. p REPAIR PC BOARD TROUBLESHOOTING PROCEDURES A WARNING ELECTRIC SHOCK can kill Have an electrician install and service this equipment Turn the machine OFF before working on equipment Do not touch electrically hot parts Sometimes machine failures appear to be due to PC board failures These problems can sometimes be traced to poor electrical connections To avoid prob lems when troubleshooting and replacing PC boards please use the following procedure 1 Determine to the best of your technical ability that the PC board is the most likely component causing the failure symptom 2 Check for loose connections at the PC board to assure that the PC board is properly connected 3 If the problem persists replace the suspect PC board using standard practices to avoid static elec trical damage and electrical shock Read the warn ing inside the static resistant bag and perform the following procedures PC Board can be damaged by static electricity Remove your body s static charge before opening the static shielding bag Wear an anti static wrist strap For safety use a 1 Meg re Static Sensitive ohm resistive cord connected to a Devices grounded part of the equipment Handle only at frame Static Safe f you don t have a wrist strap Workstations touch an unpainted grounded part of the equipment frame Keep touching the frame to prevent sta tic build up Be
187. p 3 PERFORM COMPONENT TESTS The last column labeled Recommended Course of Action lists the most likely components that may have failed in your machine It also specifies the appropriate test procedure to verify that the sub ject component is either good or bad If there are a number of possible components check the components in the 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 at the end of this section Refer to the Troubleshooting and Repair Table of Contents to locate each specific Test Procedure All 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 locate the appropriate diagram A CAUTION 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 troubleshooting assistance before you proceed Call 1 800 833 9353 POWER WAVE 455 R LINCOLN 5 Return to Section Return to Master TOC Return to Section TOC Ojo 515 gt 218 5 2 Return to Section Return to Master TOC Return to Master TOC F 3 F 3 TROUBLESHOOTING am
188. piece The work piece connection must be firm and secure especially if pulse welding is planned CAUTION Excessive voltage drops caused by poor work piece connections often result in unsatisfactory welding per formance When welding with the STT process use the positive output connection labeled STT for STT welding If desired other welding modes can be used on this ter minal however their average output current will be lim ited to 325 amps For non STT processes use the positive output connection labeled Power Wave so that the full output range of the machine is available CAUTION Do not connect the STT and Power Wave terminals together Paralleling the terminals will bypass STT cir cuitry and severely deteriorate STT welding perfor mance NEGATIVE ELECTRODE POLARITY When negative electrode polarity is required such as in some Innershield applications reverse the output connections at the power source electrode cable to the negative terminal and work cable to the positive terminal When operating with electrode polarity negative the Dip switch 7 must be set to ON on the Wire Feed Head PC Board The default setting of the switch is OFF to represent positive electrode polarity To set the Negative Polarity switch on Wire Feed Head PC board refer to the section DIP SWITCH SETTINGS AND LOCATIONS POWER WAVE 455 R LINCOLN 5 Return to Section Return to Master TOC Return t
189. ponents 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 leads 444 and X3A together at the output of the solid state fan control relay located on the back of the Control PC board enclosure See the Wiring Diagram CAUTION DO NOT MOUNT OVER COMBUSTIBLE SURFACES Where there is a combustible surface directly under stationary or fixed electrical equipment that surface shall be covered with a steel plate at least 06 1 6mm thick which shall extend not less than 5 90 150mm beyond the equipment on all sides LIFTING Lift the machine by the lift bail only The lift bail is designed to lift the power source only Do not attempt to lift the Power Wave with accessories attached to it STACKING Power Wave machines can be stacked a maximum of three high CAUTION 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 MACHINE GROUNDING The frame of the welder must be grounded A ground terminal marked with the symbol is located inside the reconnect input access door for this purpose See your local and national electrical codes for proper grounding methods HIGH FREQUENCY PROTECTION Locate the Power Wave away from radio controlled machinery CAUTION The normal operation of the Power Wave adverse ly a
190. put Board through the input line switch SW1 are connected 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 resultant DC voltage is applied through the reconnect switches to the input capacitors located on the right and left switch boards The Control Board monitors the voltage across the capacitors When the capacitors have charged to an acceptable level the Control Board signals the Input Board to energize the main input contactor making all three phases of input power without current limiting available to the input capacitors At this point the Power Wave 455 R is in the Run Mode of operation If the capacitors become undervoltaged overvoltaged or unbalanced the Control Board will signal the Input Board to de energize the main input contactor and the Power Wave 455 R will be disabled Figure E 2 POWER WAVE 455 R LINCOLN 5 4 4 THEORY OPERATION SWITCH 5 FIGURE SWITCH BOARDS AND MAIN TRANSFORMER 8 MEC s 9 3 POWER WAVE 455 R ur diis o 2 OUTPUT DIODES ELECTRODE olo Pe Ne TERMINAL FEEDBACK aa d 20 VDC FROM RECTIFIER POWER BOARD CURRENT SIT ELECTRODE RECONNECT 581 STT CHOPPER TRANSDUCER TERMINAL FROM CONTROL CURRENT SWITCH BOARD TOC
191. r Use K1796 coaxial welding cables wherever possible Minimum work and electrode cables sizes are as follows TABLE A 1 Current 60 Duty Cycle MINIMUM COPPER WORK CABLE SIZE AWG Up To 100 Ft Length 30 m 400 Amps 2 0 67 mm 500 Amps 3 0 85 mm 600 Amps 3 0 85 mm When using an inverter type power source like the Power Wave use the largest welding electrode and ground cables that are practical At least 2 0 copper wire even if the average output current would not nor mally require it CAUTION When pulsing the pulse current can reach very high levels Voltage drops can become excessive leading to poor welding characteristics if undersized welding cables are used Most welding applications run with the electrode being positive For those applications connect one end of the electrode cable to the positive output terminal on the power source located beneath the spring loaded output cover near the 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 be against the feed plate Be sure the connection to the feed plate makes tight metal to metal electrical contact The electrode cable should be sized according to the specifications given in Table A 1 Connect a work lead from the negative power source output terminal to the work
192. r body between the electrode and work cables If the electrode cable is on your right Do not put your hands near the engine fan Do not attempt to side the work cable should also be on your right side override the governor or idler by pushing on the throttle con trol rods while the engine is running 2 d 4 Connect the work cable to the workpiece as close as possible to the area being welded To prevent accidentally starting gasoline engines while turning the engine or welding generator during maintenance 2 d 5 Do not work next to welding power source work disconnect the spark plug wires distributor cap or magneto wire as appropriate Return to Master TOC LINCOLN 5 Return to Master TOC Return to Master TOC o o P 0 iv gt c tc Return to Master TOC SAFETY ELECTRIC SHOCK can kill 3 a The electrode and work or ground circuits are electrically hot when the welder is on Do not touch these hot parts with your bare skin or wet clothing Wear dry hole free gloves to insulate hands 3 b Insulate yourself from work and ground using dry insulation Make certain the insulation is large enough to cover your full area of physical contact with work and ground In addition to the normal safety precautions if welding must be performed under electrically hazardous conditions in damp locations or while wearing wet clothing on metal structures such as floors gratings or
193. ransducer to the front panel Remove the STT current transducer care fully feeding the output leads through it Remove the standoffs from the transducer and save them for reassembly with the new transducer REPLACEMENT PROCEDURE 1 2 Attach the standoffs to the transducer Position the transducer on the back of the front panel and attach it with the two phillips screws and lock washers Feed the output leads through the transducer POWER WAVE 455 R LINCOLN Attach the double heavy leads to the STT output terminal with the 3 4 bolt lock wash er and flat washer Attach the small leads to the STT output ter minal with the 5 16 screw Install the resistor assembly using the 5 16 socket wrench extension and universal adapter Install the glastic high voltage pro tection shield with the 3 8 nut driver Replace all cable ties cut during removal Install the case top and right side using the 3 8 nut driver 67 67 TROUBLESHOOTING amp REPAIR POWER WAVE CURRENT TRANSDUCER REMOVAL AND REPLACEMENT WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty For your safety and to avoid electrical shock please observe all safety notes and precautions detailed throughout this manual
194. ration is a steady green light Error conditions are indicated per Table B 1 NOTE The robotic Power Waves status light will flash green and sometimes red and green for up to one minute when the machine is first turned on This is a normal situation as the machine goes through a self test at power up TABLE B 1 Light Condition Meaning Steady System OK Power source Green communicating normally with wire feeder and its components Blinking Normal for first 1 10 seconds Green after power is turned on Alternating Non recoverable system fault Green Must turn power source off find and Red source of error and turn power back on to reset See Troubleshooting Guide Steady See Troubleshooting Guide Red HIGH TEMPERATURE LIGHT thermal overload A yellow light that comes on when an over tem perature situation occurs Output is disabled until the machine cools down When cool the light goes out and output is enabled 10 AMP WIRE FEEDER CIRCUIT BREAKER Protects 40 volt DC wire feeder power supply 10 AMP AUXILIARY POWER CIRCUIT BREAKER Protects 115 volt AC case front receptacle auxil iary supply LEAD CONNECTOR S2 SENSE LEAD 5 PIN ARC LINK 1 5 PIN DEVICENET CONNECTOR S5 1 O CONNECTOR NEGATIVE OUTPUT TERMINAL INTERFACE CONNECTOR S6 STT TERMINAL POSITIVE OUTPUT TERMINAL AUXILIARY OUTPUT FIGURE B 1 POWER WAVE CASE FRONT CONTROLS
195. rc welding Headshield and filter lens should conform to ANSI 787 standards Use suitable clothing made from durable flame resistant material to protect your skin and that of your helpers from the arc rays Protect other nearby personnel with suitable non flammable screening and or warn them not to watch the arc nor expose themselves to the arc rays or to hot spatter or metal 23 FUMES AND GASES can be dangerous 5 a Welding may produce fumes and gases hazardous to health Avoid breathing these fumes and gases When welding keep your head out of the fume Use enough ventilation and or exhaust at the arc to keep fumes and gases away from the breathing zone When welding with electrodes which require special ventilation such as stainless or hard facing see instructions on container or MSDS or on lead or cadmium plated steel and other metals or coatings which produce highly toxic fumes keep exposure as low as possible and below Threshold Limit Values TLV using local exhaust or mechanical ventilation In confined spaces or in some circumstances outdoors a respirator may be required Additional precautions are also required when welding on galvanized steel Do not weld in locations near chlorinated hydrocarbon vapors coming from degreasing cleaning or spraying operations The heat and rays of the arc can react with solvent vapors to form phosgene a highly toxic gas and other irritating products Shielding gas
196. rect check the leads between the DC Bus Power Supply PC Board and the Power PC Board Rectifier See the Wiring Diagram 10 When finished testing replace the case top TABLE F 3 DC BUS POWER SUPPLY PC BOARD VOLTAGE TABLE Positive Meter Probe Test Point Negative Meter Probe Test Point Approximate Voltage Conditions Comments Reading Plug P46 Pin 1 Plug P46 Pin Should be same as the Power PC Board Rectifier 65 75 VDC Plug P47 Pin 7 Plug P47 Pin 6 38 0 42 0 VDC Supply to Power PC Board Plug P47 Pin 8 Plug P47 Pin 6 Plug P47 Pin 4 Plug P47 Pin 2 Plug P47 Pin 3 Plug P47 Pin 1 38 0 42 0 VDC Supply to Power PC Board 38 0 42 0 VDC Supply to Feed Head PC Board 38 0 42 0 VDC Supply to 61 Wire Feeder Receptacle POWER WAVE 455 R LINCOLN Return to Section Return to Master TOC Return to Section TOC Return to Master TOC Q BS 5 2 Return to Section Return to Master TOC 2 2 5 23 TROUBLESHOOTING amp REPAIR POWER BOARD TEST WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty For
197. refully pinch the three plastic standoffs Remove the Voltage Sense Board POWER WAVE 455 R LINCOLN COMPARTMENT REPLACEMENT PROCEDURE 1 3 Install either the Control or the Feed Head Board to the back of the control box with the self locking nuts Use the 3 8 nut driver Connect the molex plugs to the Control Board and the Feed Head Board Be sure the lead harnesses are securely and proper ly positioned Secure the rear of the control box in place using two screws and the 3 8 nut driver 61 61 TROUBLESHOOTING amp REPAIR CONTROL FEED HEAD OR VOLTAGE SENSE PC BOARD REMOVAL AND REPLACEMENT CONTINUED 3 Secure the rear of the control box in place using two screws and the 3 8 nut driver Return to Section TOC Return to Master TOC 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 Return to Section TOC Return to Master TOC E 5 5 gt 2 2 5 2 Return to Section Return to Master TOC POWER WAVE 455 R LINCOLN Return to Section Return to Master TOC Return to Section TOC Return to Master TOC Q BS 5 2
198. rm 22 pin to 14 pin 10 ft K1804 1 Control Cables for use on FANUC robot arm 22 pin to 14 pin 18 in K1805 1 Control Cables for use on FANUC robot arm 22 pin to 14 pin 18 in K1804 2 LIMITATIONS The Power Wave 455 R is not suitable for SMAW CAC A or other processes not listed Power Waves are not to be used in outdoor environ ments Only ArcLink Power Feed wire feeders and user interfaces may be used Other Lincoln wire feeders or non Lincoln wire feeders cannot be used DUTY CYCLE AND TIME PERIOD The Power Feed wire feeders are capable of welding at a 10096 duty cycle continuous welding The power source will be the limiting factor in determining system duty cycle capability Note that the duty cycle is based upon a ten minute period A 6096 duty cycle represents 6 minutes of welding and 4 minutes of idling in a ten minute period POWER WAVE 455 R LINCOLN 5 Return to Section Return to Master TOC Return to Section TOC Return to Master TOC o BS 5 2 Return to Section Return to Master TOC o 2 2 5 CASE FRONT CONTROLS All operator controls and adjustments are located on the case front of the Power Wave See Figure B 1 1 POWER SWITCH Controls input power to the Power Wave STATUS LIGHT A two color light that indicates sys tem errors Normal ope
199. rol cable to the wire feeder FIGURE A 3 DIP SWITCH LOCATION REMOVE FRONT COVER WIRE FEED CONTROL HEAD BOARD BOARD ON RIGHT ON LEFT POWER WAVE 455 R LINCOLN 5 Return to Section Return to Master TOC Return to Section TOC 515 gt 218 5 2 Return to Section Return to Master TOC Return to Master TOC A 9 INSTALLATION WORK VOLTAGE SENSING The Power Wave is shipped from the factory with the work sense lead enabled For processes requiring work voltage sensing connect the 21 work voltage sense lead from the Power Wave to the work Attach the sense lead to the work as close to the weld as practical To enable the work voltage sensing in the Power Wave refer to the section DIP ELECTRODE VOLTAGE SENSING Enabling or disabling electrode voltage sensing is auto matically configured through software Electrode sense lead 67 must be connected at the wire feeder POWER WAVE POWER FEED WIRE FEEDER INTERCONNECTIONS Connect the control cable between the power source and wire feeder The wire feeder connection on the robotic Power Wave is located under the spring loaded output cover near the bottom of the case front The control cable is keyed and polarized to prevent improp er connection For convenience sake the electrode and control cables can be routed behind the left or right strain reliefs under the spring load
200. s or electrodes with your skin or wet cloth ing Insulate yourself from the work and switch 8 work sense lead around off work sense lead not connected 9 Always wear dry insulating gloves 9 Turn off power at the disconnect switch FEED HEAD BOARD DIP SWITCH o Remove the top four screws securing the front access switch 1 reserved for future use 2 2 panel switch 2 reserved for future use ES switch 3 reserved for future use 2 EE E the bottom switch 4 reserveditor tuture use cc O SOIOWS TAL switch 5 reserved for future use Open the access panel allowing the weight of the switch 6 reserved for future use panel to be carried by the bottom two screws Make switch 7 negative polarity switch sure to prevent the weight of the access panel from switch 8 high speed gear hanging on the harness Adjust the DIP switches as necessary Using a pen switch 7 electrode polarit cil or other small object slide the switch left for the le ON position or to the right for the OFF position as off positive appropriate negative 5 5 Replace the panel and screws and restore power lt witch wire driv r CONTROL BOARD E HEAD switch 8 e drive gea LOCATED CONTROL BOX LOCATED IN off l
201. s to the welding arc Ojo 515 gt 218 JE 2 1 Return Section Return to Master POWER WAVE 455 R LINCOLN 5 Return to Section Return to Master TOC Return to Section TOC 5 5 gt 218 5 2 Return to Section Return to Master TOC Return to Master TOC E 9 E 9 THEORY OF OPERATION THERMAL PROTECTION Three normally closed NC thermostats protect the machine from excessive operating temperatures These thermostats are wired in series and are con nected to the control board One of the thermostats is located on the heat sink of the output rectifier one on the DC bus and one on the output choke Excessive temperatures may be caused by a lack of cooling air or by operating the machine beyond its duty cycle or out put rating If excessive operating temperatures should occur the thermostats will prevent output from the machine The yellow thermal light located on the front of the machine will be illuminated The thermostats are self resetting once the machine cools sufficiently If the thermostat shutdown was caused by excessive output or duty cycle and the fan is operating normally the power switch may be left on and the reset should occur within a 15 minute period If the fan is not turn ing or the intake air louvers are obstructed the power must be removed from th
202. scaffolds when in cramped positions such as sitting kneeling or lying if there is a high risk of unavoidable or accidental contact with the workpiece or ground use the following equipment Semiautomatic DC Constant Voltage Wire Welder DC Manual Stick Welder AC Welder with Reduced Voltage Control In semiautomatic or automatic wire welding the electrode electrode reel welding head nozzle or semiautomatic welding gun are also electrically hot Always be sure the work cable makes a good electrical connection with the metal being welded The connection should be as close as possible to the area being welded Ground the work or metal to be welded to a good electrical earth ground Maintain the electrode holder work clamp welding cable and welding machine in good safe operating condition Replace damaged insulation Never dip the electrode in water for cooling Never simultaneously touch electrically hot parts of electrode holders connected to two welders because voltage between the two can be the total of the open circuit voltage of both welders When working above floor level use a safety belt to protect yourself from a fall should you get a shock Also see Items 6 c and 8 LINCOLN 8 Also see item 1 b ARC RAYS can burn 4 a Use a shield with the proper filter and cover Z plates to protect your eyes from sparks and the rays of the arc when welding or observing open a
203. sembly in place with the mounting bolts Assemble the nuts and associated wash ers to the mounting bolts Using the 7 16 wrench tighten the four nuts on the mounting bolts Replace leads 292 and 291 to the ther mostat Connect plug J10 to the STT Chopper Board With the 7 16 wrench attach lead 4287 from the STT Snubber Diode D5 With the 7 16 wrench attach lead 289 from the STT Snubber Capacitor C10 Connect the eight transformer leads to the correct rectifier modules Tighten the screws with two flat washers and one lock washer to between 30 and 40 in lbs Do not stress the terminals when making these connections Apply a thin coat of Penetrox A13 to the heat sink where the Power Wave positive output lead and the STT output lead attach Attach the Power Wave positive output lead to the heat sink using the 9 16 wrench Attach the STT output lead to the heat sink using the 7 16 wrench Install the case top and sides using the 3 8 nut driver F 74 F 74 TROUBLESHOOTING amp REPAIR SWITCH BOARD AND FILTER CAPACITOR REMOVAL AND REPLACEMENT WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty For your safety and to avoid electrical shock please observe all safety n
204. sing the 3 16 allen wrench carefully remove the four cap screws that mount the switch board to the heat sink Carefully remove the switch board from the heat sink If the filter capacitor is to be removed care fully slide it out of the mounting bracket REPLACEMENT PROCEDURE 1 If the filter capacitor is to be replaced care fully slide the new capacitor into the mount ing bracket Position the capacitor so the correct polarity terminal is lined up with the correct hole on the switch board All heat sink and IGBT mounting surfaces must be clean Apply a thin coat of thermal compound Penetrox A13 0 005 to 0 010 inches thick to the mating surfaces Do not apply around mounting holes Apply a thin coat of Penetrox A13 to the Capacitor terminals Be careful not to apply compound to screw threads or threaded area of terminals 10 11 12 13 POWER WAVE 455 R LINCOLN Mount the new switch board and tighten the four cap head screws in the following manner Tighten all until snug Tighten all from 24 to 28 in lbs Tighten all from 40 to 48 in lbs Make sure the capacitor is positioned cor rectly Connect leads 19C D and 20C D to the correct terminals Tighten to 55 in Ibs Position and mount the two nylon screws fiber spacers and washers Torque from 4 to 8 in Ibs Connect leads 11 12 or 15 16 to the correct terminal Connect leads 13 14 or 17 18 to the
205. t Fuse and Supply Wire 5 Input Voltage Change Over For Multiple Input Voltage Machines Only A 6 5 Welding with Multiple Power A 6 3 Electrode and Work Cable Connections sse eere nnne nnne A 7 9 Negative Electrode 7 E Voltage Sensing eap E A 8 c Work Voltage 5 9 Electrode Voltage 9 Power Wave Power Feed Wire Feeder A 9 Control Cable nnne nnn A 9 External l O COonfnector nt retta e ra uds A 9 Dip Switch Settings and Locations sssssssssssssssseeeeeeen nennen A 10 Control Board Dip Switch A 10 5 Feed Head Board Dip Switch sivi Gaston A 10 8 Devicenet Gateway Board Dip Switch Bank 52 A 11 g E o d z g E 2 o POWER WAVE 455 8 LINCOLN 5 2 2 INSTALLATION TECHNICAL SPECIFICATIONS POWER WAVE 455 K1761 1 K1761 2 INPUT AT RATED OUTPUT THREE PHASE ONLY INPUT OUTPUT INPUT IDLE POWER FACTOR VOLTS CONDITIONS RATED OUTPUT RATED OUT
206. t may result in danger to the technician or machine operator and will invalidate your factory warranty For your safety and to avoid electrical shock please observe all safety 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 Service Department for electrical trou bleshooting assistance before you proceed Call 1 800 833 9353 WELD TEST DESCRIPTION This test will help determine if the Input Board is sending the correct voltages and also if the Input Board is regulating and producing the correct DC voltages MATERIALS NEEDED 3 8 Nut driver Volt ohmmeter Wiring Diagram This procedure should take approximately 30 minutes to perform POWER WAVE 455 R LINCOLN F 26 27 27 TROUBLESHOOTING amp REPAIR olo O10 INPUT BOARD TEST CONTINUED 912 9 8 FIGURE 9 INPUT CONTACTOR CR1 o 0 8 cle 2 J60 J61 1234 12345 o Rt 2 5 Return to Master TOC CONTACTOR 5 6 7 8 6 7 8 9 10 J60 J61 ojo 2 55 PEN 15 0 2 5 5 5 E TEST PROCEDURE WARNING E 1 Remove input po
207. te machine right side left side wire number differences 5 1 Remove input power to the Power Wave 455 R 6 2 Using the 3 8 nut driver remove the case top and sides 3 Perform the Capacitor Discharge proce dure POWER WAVE 455 R LINCOLN MOLEX PLUG MOUNTING CREW 4X Using the 5 16 nut driver remove the three screws mounting the glastic high voltage protective shield Remove the shield Remove molex plug J40 J50 from the top of the switch board Refer to Figure F 28 Remove the mylar insulating shield covering leads 13 14 or 17 18 Cut the cable tie Return to Section Return to Master TOC Return to Section TOC Return to Master TOC o 5 B Return to Section Return to Master TOC o 2 2 5 F 76 10 11 12 13 F 76 TROUBLESHOOTING amp REPAIR SWITCH BOARD AND FILTER CAPACITOR REMOVAL AND REPLACEMENT CONTINUED Using the 7 16 wrench remove leads 13 14 or 17 18 from the switch board Using the 7 16 wrench remove leads 11 12 or 15 16 from the switch board Using the 7 16 wrench remove leads 19C D and 20C D from the switch board capacitor connection bolts With the slot head screwdriver remove the two nylon mounting screws at the bottom of the switch board Note placement of the shake proof washers and fiber spacers U
208. tions de d graissage nettoyage ou pistolage La chaleur ou les rayons de l arc peuvent r agir avec les vapeurs du solvant pour produire du phosg ne gas forte ment toxique ou autres produits irritants Pour obtenir de plus amples renseignements sur la s ret voir le code Code for safety in welding and cutting CSA Standard W 117 2 1974 jamais enrouler le c ble lectrode autour de n importe quelle PR CAUTIONS DE S RET POU R partie du corps LE S MACHINES SOUDER Un coup d arc peut tre plus s v re qu un coup de soliel TRANSFORMATEUR ET REDRESSEUR donc Utiliser un bon masque avec un verre filtrant appropri 1 ainsi qu un verre blanc afin de se prot ger les yeux du rayonnement de l arc et des projections quand on soude ou quand on regarde l arc Porter des v tements convenables afin de prot ger la peau de soudeur et des aides contre le rayonnement de l arc Prot ger l autre personnel travaillant proximit au soudage l aide d crans appropri s et non inflamma bles 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 gants en cuir chemise paisse pantalons sans revers et chaussures montantes LINCOLN 8 Relier la terre le chassis du poste conformement au code de l lectricit et aux recommendations du fabricant Le dis positif de montage ou la piece souder doit tre bra
209. turn to Master TOC MATERIALS NEEDED 3 8 Nut driver Volt ohmmeter External 24 VAC supply This procedure should take approximately 17 minutes to perform 515 gt 218 5 2 Return to Section Return to Master TOC POWER WAVE 455 R LINCOLN 18 18 TROUBLESHOOTING amp REPAIR INPUT CONTACTOR TEST CONTINUED FIGURE F 5 INPUT CONTACTOR COIL INPUT CONTACTOR Return to Section TOC Return to Master TOC o o 42 5 Return to Master TOC ojo EIE 5 8 ols TEST PROCEDURE cle 1 Remove input power to the Power Wave 4 Using the external 24 VAC supply apply 24 412 455 R VAC to the terminals of the input contactor 2 coil If the contactor does NOT activate the 2 Using the 3 8 nut driver remove the input input contactor is faulty Replace access panel and case top 3 Locate mark and remove the two leads 601 X4 that are connected to the input contactor coil Refer to Figure F 5 Return to Section TOC Return to Master TOC POWER WAVE 455 R LINCOLN Return to Section Return to Master TOC Return to Section TOC Return to Master TOC o 5 B Return to Section Return to Master TOC o 2 2 5 19
210. ty Also make certain that lead 811 plug J8 pin 5 has continuity zero ohms between the current transducer and the control board See the Wiring Diagram If the correct supply voltages are applied to 10 Install the right side case cover using the the current transducer and with the machine loaded the feedback voltage is missing or not correct the current transducer may be POWER WAVE 455 R LINCOLN 3 8 nut driver F 41 F 41 TROUBLESHOOTING amp REPAIR OUTPUT RECTIFIER TEST WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty For your safety and to avoid electrical shock please observe all safety notes and precautions detailed throughout this manual Return to Section TOC Return to Master TOC 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 before you proceed Call 1 800 833 9353 WELD TEST DESCRIPTION The test will help determine if any of the output rectifiers are shorted MATERIALS NEEDED Analog Volt Ohmmeter 3 8 Nut driver 5 16 Wrench Return to Section TOC Return to Master TOC This procedure should take approximately 20 minutes to perfor
211. unicate with other industri al machines via DeviceNET protocol The result is a highly intrigated and flexible welding cell The Power Wave 455 R is a high performance digital ly controlled inverter welding power source capable of complex high speed waveform control Properly equipped it can support the GMAW GMAW P FCAW GTAW and STT processes It carries an output rating of either 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 cycle If the duty cycle is exceeded a thermostat will shut off the output until the machine cools to a reasonable operating temperature DESIGN FEATURES AND ADVANTAGES Designed to the IEC 974 1 Standard Power Wave 455 multiple process output ranges 5 570 amps Easy access for input connections Connections are simple strip and clamp no lugs required F A N Fan As Needed Cooling fan runs only when necessary above Code 10500 only and all STT machines Modular construction for easy servicing Thermostatically protected Electronic over current protection Input over voltage protection Utilizes digital signal processing and microprocessor control Simple reliable input voltage change over All system components communicate and transfer information Auto device recognition simplifies accessory cable connections
212. up to 325 amps at a 100 GMAW GMAW P FCAW GTAW and STT Surface duty cycle Ojo 515 gt 218 2 NOTE Unshaded areas of Block Logic Diagram are the subject of discussion Return to Section TOC Return to Master TOC POWER WAVE 455 R LINCOLN 5 Return to Section Return to Master TOC Return to Section TOC 5 5 gt 218 5 2 Return to Section Return to Master TOC Return to Master TOC E 3 E 3 THEORY OF OPERATION INPUT VOLTAGE AND PRECHARGE The Power Wave 455 R can be connected for a variety of three phase input voltages Refer to Figure E 2 The initial input power is applied to the Power Wave 455 R through a line switch located on the front of the machine Two phases of the three phase input power are applied to the Input Board and both auxiliary trans formers The various secondary voltages developed by transformer T1 are applied to the Input Board the fan motor via a control relay and the Bus Board recti fier The 65VDC produced from the Bus Board rectifi er is used by the Bus Board to provide various DC volt ages for the Power Board the Feed Head Board and the wire feeder receptacle The 115 230VAC devel oped on the secondary of auxiliary transformer T2 is applied to the 115VAC receptacle and to the water cooler receptacle The two phases that are connected to the In
213. urn to Master TOC POSITIVE OUTPUT LEAD MOUNT BOLTS 4X HEATSINK RECTIFIER ASSEMBLY REMOVAL PROCEDURE 5 5 gt 218 5 2 1 Remove input power to the Power Wave 5 Using the 7 16 wrench remove the STT 455 R output lead from the rectifier heat sink Note fastener hardware for reassembly Refer to 2 Using th 3 Using the 3 8 nut driver remove the case Figure 27 top and sides 3 Perform the Capacitor Discharge proce 6 Using the 7 16 wrench 15 ne eight transformer leads from the rectifier modules dure Label the leads and take note of lead place 4 Using the 9 16 wrench remove the Power ment for reassembly Note that each screw Wave positive output lead from the rectifier has two flat washers and one lock washer heat sink Note fastener hardware for reassembly Refer to Figure F 27 Return to Section TOC Return to Master TOC POWER WAVE 455 R LINCOLN Return to Section Return to Master TOC Return to Section TOC Return to Master TOC o E 5 B Return to Section Return to Master TOC o 2 2 5 72 F 72 TROUBLESHOOTING amp REPAIR OUTPUT RECTIFIER STT CHOPPER BOARD AND RECTIFIER MODULE REMOVAL AND REPLACEMENT CONTINUED 10 11 Disconnect plug J10 fro
214. urn to Section TOC Return to Master TOC Q BS 5 2 Return Section Return to Master TOC o 2 2 5 F 73 F 73 TROUBLESHOOTING amp REPAIR OUTPUT RECTIFIER STT CHOPPER BOARD AND RECTIFIER MODULE REMOVAL AND REPLACEMENT CONTINUED RECTIFIER MODULE REMOVAL AND RECTIFIER ASSEMBLY REPLACE REPLACEMENT PROCEDURE 1 2 2 Using the 7 16 wrench remove the two mounting bolts and associated washers 3 from the rectifier module to be replaced 3 Remove the faulty module 4 4 This module requires special mounting con siderations to prevent warping of the base 5 plate The heat sink surfaces must be clean and flat Apply a thin even coating of ther mal compound Penetrox A13 0 004 to 6 0 010 inches thick Keep the compound away from the area of the mounting holes 7 5 Press the new module firmly against the heat sink while aligning the mounting holes 8 Start all three screws two to three 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 Ibs 9 8 Tighten each of the outer screws again this time to between 30 and 40 in Ibs 10 11 12 POWER WAVE 455 R Using the 9 64 allen wrench remove the cap screw from the center of the rectifier module that is to be replaced LINCOLN MENT PROCEDURE 1 Position the as
215. ut 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 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 WARNING ELECTRIC SHOCK can kill High voltage is present when input power is applied to the machine 6 Turn on the Power Wave 455 R Carefully test for the correct voltages at the Power Board according to Table F 4 7 If either of the 40 VDC voltages is low or not present at plug J41 perform the DC Bus iring Diagram Also perform the T1 Auxiliary Transformer Test 8 If any of the DC voltages are low or not pre sent at plugs J42 and or 43 the Power Board may be faulty 9 Install the case top using the 3 8 nut driver POWER WAVE 455 R LINCOLN Return to Section Return to Master TOC Return to Section TOC Return to Master TOC Q BS 5 2 Return to Section Return to Master TOC 2 2 5 25 CHECK POINT LOCATION POWER BOARD CONNECTOR PLUG J41 POWER BOARD CONNECTOR PLUG J42 POWER BOARD CONNECTOR PLUG J42 POWER BOARD CONNECTOR PLUG J42 POWER BOARD CONNECTOR PLUG J43 POWER BOARD CONNECTOR PLUG J43 POWER BOARD
216. ut voltage If the Thermal light is lit the unit may be overheated Let the machine cool and adjust weld ing load and or duty cycle to coincide with the output limits of the machine TROUBLESHOOTING GUIDE RECOMMENDED COURSE OF ACTION 1 Perform the Input Contactor 2 Perform the nput Board Test 3 Perform the 71 Auxiliar Transformer Test 4 Perform the Input Rectifier 5 Perform the Switch Board Test 6 Perform the Power Board Test 7 The Control Board may be faulty The thermal light is lit machine regularly overheats The The welding application may be exceeding the recommended duty cycle and or current limits of the machine Dirt and dust may have clogged the cooling channels inside the machine Refer to the Maint enance Section of this manual Air intake and exhaust louvers may be blocked due to inade quate clearance around the machine Make sure the fan is functioning correctly Machines above code 10500 are equipped with F A N fan as needed circuitry The fan runs whenever the output is enabled whether under load or open circuit conditions The fan also runs for a period of time approximately 5 minutes after the output is disabled One of the thermostats may be faulty Also check associated wiring for loose or faulty con nections See the Wiring Diagram CAUTION If for any reason you do not understand the test procedures or are una
217. v Sour iur coe M scx eav X30 16v vss 1 1 EEPROM AT25128N 10S1 lt i O o 5 5 PEN 2 cic 5 2 o ADDRE1 193 LM2576HVS 5 0 VIN BN 1561 12816 20 TI BANK1 MCT9L0SABD MURSIGDT3 T x22 GENERAL INFORMATION LAST NO USED ELECTRICAL SYMBOLS PER E1537 m CAPACITORS MFD 022 50V UNLESS OTHERWISE SPECIFIED E SWITCHING POWER SUPPLY RESISTORS Ohms LABELS 0 DIODES 1AA400V UNLESS OTHERWISE SPECIFIED SUPPLY VOLTAGE NET POWER SUPPLY SOURCE POINT COMMON CONNECTION 777 FRAME CONNECTION EARTH GROUND CONNECTION THIS SHEET CONTAINS PROPRIETARY INFORMATION OWNED BY LINCOLN ELECTRIC CO AND IS NOT TO BE REPRODUCED DISCLOSED OR WITHOUT THE EXPRESS PERMISSION OF LINCOLN ELECTRIC CO NOTES LESS oeme wawo THE LINCOLN ELECTRIC CO COMMONDIGITAL CONTROLS SINCE COMPONENTS OR CIRCUITRY ON A PRINTED CIRCUIT BOARD MAY CHANGE ON 3 PLACE DECIMALS 15 3 D 113 2000 CLEVELAND OHIO 58 sussect FEEDHEAD PC BOARD SCHEMATIC WITHOUT AFFECTING THE
218. wer to the Power Wave 455 N ELECTRIC SHOCK kill 2 Using the 3 8 nut driver remove the case High voltage is present when top input power is applied to the 3 Remove lead X4 from the coil terminal of machine main input contactor CR1 Insulate lead X4 Refer to Figure F 9 5 Turn on the Power Wave 455 R Carefully ejo 4 Carefully apply input power to the Power test for the correct voltages according to Wave 455 8 Table F5 EIE 5 5 POWER WAVE 455 8 LINCOLN F 28 F 28 TROUBLESHOOTING amp REPAIR oio INPUT BOARD TEST CONTINUED 918 9 d 6 Remove input power to the Power Wave 9 Turn on the Power Wave 455 R Check for 455 R If any of the voltages are low or not the presence of 24 VAC from lead X4 to o resent perform Contactor Test lead 601 See Figure 9 If the voltage EIE that choke out the Input Board may by is not present the 5 1 9 faulty Transformer 1 Test 7 Reconnect lead X4 to the main input contac This 24 VAC is the coil voltage for main tor CR1 coil terminal input contactor CR1 It will normally be present approximately 12 seconds after 8 Carefully apply the correct input voltage to input line switch SW1 is activated the Power Wave 455 R 10 When the test is completed remove input A WARNING power from the Power Wave 455 R 11 Install the case top using the 3 8
219. zed repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty For your safety and to avoid electrical shock please observe all safety notes and precautions detailed throughout this manual Return to Section TOC Return to Master TOC 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 before you proceed Call 1 800 833 9353 WELD TEST DESCRIPTION This test will help determine if the input rectifier has shorted or open diodes MATERIALS NEEDED Analog volt ohmmeter Phillips head screw driver Wiring Diagram 3 8 Nut driver Return to Section TOC Return to Master TOC This procedure should take approximately 15 minutes to perform Ojo 515 gt 218 5 2 Return to Section Return to Master TOC POWER WAVE 455 R LINCOLN 15 15 TROUBLESHOOTING amp REPAIR e INPUT RECTIFIER TEST CONTINUED 9192 9 8 FIGURE F 4 INPUT RECTIFIER TEST olz INPUT alz RECTIFIER eic o o 42 5 Return to Master TOC ojo ate 5 8 8 gt TEST PROCEDURE c 1 Remove input power to the Power Wave NOTE Some R

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