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Lincoln Electric 355M User's Manual

1. 4 saat a Tm R97 R98 R99 R100 R101 R106 R29 R83 R122 R141 19400 1000_ RESISTOR MF 1 4W 100 196 R32 R33 R34 R48 R49 R50 S19400 1003 RESISTOR MF 1 4W 100K 1 R51 R62 R63 R74 R75 R85 R86 R87 R134 R135 R35 R52 R73 R84 519400 6191 RESISTOR MF 1 4W 6 19K 195 R36 R37 R123 519400 2213 1 4W 221K 1 R38 R40 R42 R45 R53 R59 519400 1002 RESISTOR MF 1 4W 10 0K 1 R66 R69 R70 R72 R80 R82 R142 R143 EN R41 R67 19400 4752_ RESISTOR MF 1 4W 47 5K 1 ND 3 R44 R68 T123009 _ RESISTOR WW 1W 1 0 1 16 PLACES i R46 R76 19400 3322_ RESISTOR MF 1 4W 33 2K 1 NB N G N M R47 R64 1519400 2000 RESISTOR MF 1 4W 200 1 5 PLACES R5 R6 R19 R26 R93 R105 519400 1001 RESISTOR MF 1 4W 1 00K 1 6 i f Return to Section TOC Return to Master TOC D R109 R128 R129 R55 R56 R57 R58 524376 3 RESISTOR WW 10W 100 5 R61 R77 519400 8251 RESISTOR MF 1 4W 8 25K 196 R65 R120 519400
2. PRIMARIES TRANSFORMER m EN 168 NEGATIVE NOTE 202 203 206 amp 207 BOLT ON WITH FILTER CAPS 207 INPUT RECTIFIER 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 355M 405M 6 10 ELECTRICAL DIAGRAMS G 10 PC BOARD ASSEMBLY SWITCH PC BOARD REQ D PART NO IDENTIFICATION C1 C23 520500 4 0047 1000 C10 C11 513490 130 CAPACITOR PCF 0 27 50V 596 C2 C24 S20500 7 CAPACITOR PPMF 047 1600V BOX 1096 C25 C26 T11577 57 CAPACITOR PEF 0 1 400V 1096 C3 C18 S13490 93 CAPACITOR TAEL 27 35V 10 C31 C32 S16668 7 __ CAPACITOR CEMO 820p 50V 5 C4 C21 520500 1 0 1 10007 10 C5 C6 C15 C16 516668 6 4700 50 10 C7 C12 C13 C14 C20 C27 C28 516668 5 022 50V 20 C29 C30 C8 C9 C22 516668 9 150 100V 596 CR1 CR2 514293 18 RELAY DPST 12VDC AG CDO D1 D4 D16 D17 T12705 59 IDIODE
3. J42 J41 J43 6 5 4 4 3 1211109 8 7 3 2 1 2 1 6 5 43 2 1 J42 J41 J43 k wasa c c 3 0000 TEST PROCEDURE Remove input power to the Power Wave 355M 405M 2 Using the 3 8 nut driver remove the case top 3 Perform the Capacitor Discharge 4 Locate the Power Board and plugs J42 and J43 Do not remove plugs or leads from the Power Board Refer to Figure F8 i 5 Carefully apply input power to the Power Wave 355M 405M A WARNING ELECTRIC SHOCK can kill High voltage is present when input power is applied to the machine 6 Turn on the Power Wave 355M 405M Carefully test for the correct voltages at the Power Board according to Table F 4 If either of the 40 VDC voltages is low or not present at plug J41 perform the DC Bus See the Wiring Diagram Also perform the 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 355M 405M LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC olo PJE c f i Sl gt om Bo ec 51 ele Return to Section TOC Return to Master TOC Return to Master TOC F 25 CHECK POINT LOCATION POWER BOARD C
4. N 71 1000F A 1A e O o Fle w PEN gt ele 5 o 1 GENERAL INF ORMAT IO LAST NO USED ELECTRICAL SYMBOLS PER E1537 22 MOV 2 CAPACITORS MFD UNLESS OTHERWISE SPECIFIED 17 LED 1 RESISTORS Ohms UNLESS OTHERWISE SPECIFIED 5 Dz 6 NOTES UNLESS OTHERWISE SPECIFIED SUPPLY VOLTAGE NET SINCE COMPONENTS OR CIRCUITRY ON A PRINTED CIRCUIT BOARD MAY CHANGE O Pow ies WITHOUT AFFECTING THE INTERCHANGEABILITY OF COMPLETE BOARD THIS DIAGRAM MAY NOT SHOW THE EXACT COMPONENTS OR CIRCUITRY OF CONTROLS HAVING COMMON CODE 57 COMMON CONNECTION E M19330_1BA F 1 1 FRAME CONNECTIO A THIS SHEET CONTAINS PROPRIETARY INFORMATION OWNED BY THE LINCOLN ELECTRIC CO EARTH GROUND CO AND IS NOT TO BE REPRODUCED DISCLOSED OR USED WITHOUT THE EXPRESS PERMISSION THE LINCOLN ELECTRIC CO UNLESS OTHERWISE SPECIFIED TOLERANCE Ch ge Sht No E ON HOLES SIZES PER 2055 THE LINCOLN ELECTRIC CO 5 MULTI SYSTEMS 40 VDC BUSS ON 2 PLACE DECIMALS E TYPE 0 AC SIMALS IS 02 DD 5 ON PLACE DECIMALS IS gt 002 CLEVELAND OHIO U S A suggecr POWER SUPPLY PCB SCHEMATIC ON ALL ANGLES IS 5 OF A DEGREE NONE 7 MATERIAL TOLERANCE t TO AGREE 6
5. ojo o E a gt INES 5 5 ply oO ajo Oe ED pee eel LUE cuoc EQUIPMENT TYPE INVERTER WELDERS En us ae SUBJECT SWITCH P C BOARD ASSEMBLY LS DRAWING J eee SCALE FULL_DATE 5 1 2000 DRAWN o G 3830 1 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 machine POWER WAVE 355M 405M e ELECTRICAL DIAGRAMS G 11 SCHEMATIC SNUBBER PC BOARD B40 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC C4 0047 1000V Fle s s gt 8 o 1 6 2 2000 NOTE This diagram is for reference only It may be accurate for all machines covered by this manual 4 POWER WAVE 355M 405M Return to Section TOC Return to Master TOC Gale ELECTRICAL DIAGRAMS G 12 PC BOARD ASSEMBLY SNUBBER PC B
6. i Switch PC Board Schematic L11487 1 G 9 Switch PC Board Assembly G3830 G 10 Snubber PC Board Schematic 524761 G 11 Snubber PC Board Assembly M19532 2 G 12 40 VDC Buss PC Board Schematic M19330 G 13 40 VDC Buss PC Board Assembly 111832 NOTE Many PC Board Assemblies are now totally encapsulated and are therefore considered to be unserviceable The Assembly drawings are provided for reference only ss 9 Return to Master POWER WAVE 355M 405M LINCOLN B G 2 ELECTRICAL DIAGRAMS n WIRING DIAGRAM POWER WAVE 355 405 RIGHT SIDE OF MACHINE FLAT SIDE OF LED ALIGNED WITH Return to Section TOC Return to Master BLACKLEAD La THERMAL 10021 1020 4103 5453 1104 YELLOW 01 1010 LED O OO KT LT J10 Jn STATUS RED GREEN CONTROL ory 180 J8 oP BOARD J 7 FLAT SIDE OF LED ALIGNED WITH WHITE LEAD PRIMARY RECONNECT EAA a REACTOR E lel CHOKE 1
7. olo PJE Sl Sl gt ec 5 2 2 c Return to Section TOC Return to Master TOC POWER WAVE 355M 405M LINCOLN B NOTES 60 WAVE 355 405 LINCOLN amp F 60 DOL J81Se N 01 DOL 181SEN 01 DOL J81Se N 01 DOL J81Se N 01 DOL uonoesg 0 uit DOL uonoesg 0 uit DOL uonoesg 0 uit DOL uonoesg 0 Return to Section TOC Return to Master TOC Return to Section TOC olo PJE Sl gt ol esc 5 2 ele Return to Section TOC Return to Master TOC Return to Master TOC F 61 TROUBLESHOOTING AND REPAIR DC BUS BOARD REMOVAL AND REPLACEMENT A 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 1 888 935 3877 DESCRIPTION The following procedure will aid the technician in removing the DC Bus Board for main tenance or replacement
8. 5 5 taie ee F 43 Replacement Procedures Control Board Removal and 47 E Main Switch Board Removal and 4 F 51 Snubber Board Removal and F 55 Power Board Removal and F 57 DC Bus Board Removal and 42 00 0 00000 00000 61 Input Rectifier Removal 65 Output Rectifier Modules Removal and F 69 Current Transducer Removal and 73 Retest after 2 eerte the cente Sia Hn Ae Rat si F 78 Return to Master TOC POWER WAVE 355M 405M LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC olo 5 5 gt ol 5 2 ele Return to Section TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING AND REPAIR HOW TO USE TROUBLESHOOTING GUIDE A WARNING Service and Repair should only be performed by Lincoln Electric Factory Trained Personnel
9. Return to Section Return to Master TOC s z 9 ARC GOUGING Gouging is basically removing metal to form a bevel or groove in a piece of steel with controlled forced air and a carbon rod The common procedures for Arc Gouging metal are Removing poor welds from a weldment so that new welds can be made Creating a welding groove or grooves in two pieces of steel butted together See Example below WELD GROOVES CREATED BY ARC GOUGING STEEL BUTTED TOGTHER Mode 9 in the POWER WAVE 355M is specifically for gouging Gouging can also be done in the stick soft and crisp modes Setting the output of the Stick Soft mode to 425 amps will enable the arc gouging mode The actual output current will depend on the size of carbon used The recommended maximum size carbon is 5 16 POWER MODE The Power Mode process was developed by Lincoln to maintain a stable and smooth arc at low procedure settings which are needed to weld thin metal without pop outs or burning through For Aluminum welding it provides excellent control and the ability to maintain constant arc length This results in improved welding performance in two primary types of applications Short Arc MIG at low procedure settings Aluminum MIG welding Ber OPERATION E Power Mode is a method of high speed regulation of the output power whenever an arc is established It provides a fast
10. GENERAL INFORMATION ELECTRICAL SYMBOLS PER E1537 CAPACITORS MFD 022 50V UNLESS OTHERWISE SPECIFIED RESISTORS Ohms 1 4W UNLESS OTHERWISE SPECIFIED LABELS ISOLATION BARRIER DIODES 1AA400V UNLESS OTHERWISE SPECIFIED SUPPLY VOLTAGE NET O POWER SUPPLY SOURCE POINT V COMMON CONNECTION 15 FILENAME 63789 10 JAH Free COBECTIN PROPRIETARY INFORMATION OWNED BY THE LINCOLN ELECTRIC EM DNO ie Wt TO BE REPRODUCED DIHCLOSED OR SED WITHOUT THE NPPSS FOGREXN OF THE LINCOLN ELECTRIC EARTH GROUND CONNECTION NOTES THE LINCOLN ELECTRIC co INVERTER WELDERS NU TENE CONPCRENITS OR CIRCUITRY GN A PRINTED BORN MAY CERE CLEVELAND a al suasect SCHEMATIC DIGITAL CONTROL WITHOUT AFFECTING THE INTERCHANGEABILITY OF A COMPLETE BOARD THIS DIAGRAM MAY 2 sag _NONE_ m NOT SHOW THE EXACT COMPONENTS OR CIRCUITRY OF CONTROLS HAVING A COMMON CODE pate 08 02 2000 cw SUP S D G No 3782 100 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 4 POWER WAVE 355M 405M Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC O o E 5 8 9S9 0 12 e 5 2 o ajo Return to Section TOC Return to Master TOC G 6 SCHEMATIC DIGITAL CONTROL PC BOARD 3 ELECTRICAL DIAGRAMS
11. LINCOLN B MASTER TABLE OF CONTENTS FOR ALL SECTIONS RETURN TO MAIN MENU Page Saf ly Ee ee eee ee RERUMS i vi Installation l lu E Section 660 8 2 52 554 55 D d Section Maintenance 222222 ku us Rex cw xm e xoxo v mox a a T RLW ee Seen DAL RUN A Ea Section D Theory of Operation 2 ee in n ae Section E Troubleshooting and Repair Section F Electrical Diagrams ull eee ees 22550 wh weds oe RR eed E M EOD ede wow eee eS Section G Parts Manual J u u a cd a se ata OR a S asw a P 418 Series POWER WAVE 355M 405M LINCOLN B Ai TABLE OF CONTENTS INSTALLATION SECTION 1 Installati n 1 D 5 gt 2 Technical Specifications 355M A 2 Technical Specifications 405M 4 4 A 3 PIECAUTIOMS y u uuu DEI MILII MI A 4 SLackitgusui foret cce LIII 4
12. SOLID EDGE EN 170 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 355M 405M ELECTRICAL DIAGRAMS 0 9 SCHEMATIC SWITCH PC BOARD V F CONVERTER 1 FAN A 300VDC CAP 5 89VDC AT VREF A 2 40KHZ CONTROL 1VDC CHANGE ON CAP 8HZ 6 mi 5 i VIVEVA 400V Zz POSITVE INPUT RECTIFIER 209 D 21 T 3 00 4 TRI 1 SUPPLY VOLTAGE POWER SUPPLY SOURCE POINT 57 COMMON CONNECTION R 143 X L DZ 21 A 2 7 7 FRAME CONNECTION LAST NO USED C 32 0 6 CR 2 Return to Master TOC i Return to Section TOC EARTH GROUND CONNECTION LR1 5 6 SWITCH SCHEMATIC CRI 3 4 SUBJECT RELAY SIGNAL ijfzvoc 1 12 0 FROM CONTROL CNY17 3V CAPACITOR BOARD PRECHARGE SOFT START 120 lt E CONTRO
13. EE CMT NERA IM Saa 4 Input Grounding CGOnnecUons l ULLA 4 Power Cord 4 D 3 Output Cables Connections and Limitations a A 5 Negative Electrode Polarity 5 2 eaae e e A AT E E A 5 Power Wave to Semi Automatic Wire Feeder A 6 Se eao uu uuu Z E A TAT P E T T A 7 System oeL uuu A 8 Multiple Group System a A 9 o g Single Group Multi Head System A 10 Welding with Multiple Power Waves A 11 gt Control Cable 11 5 E 1 0 Receptacle Specifications A 13 Dip Switch Settings Locations esssssssssssssseseeeseeeeenen nennen nennen ennt entrent rnnt A 13 E n 5 gt g POWER WAVE 355 405 LINCOLN B 2 INSTALLATION oe TECHNICAL SPECIFICATIONS POWER WAVE 355 INPUT AC VOLTAGE amp DC OUTPUT Product Ordering Input AC Rated DC
14. CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed Call 1 888 935 3877 POWER WAVE 355M 405M LINCOLN B Return to Section TOC Return to Master TOC r TROUBLESHOOTING AND REPAIR Observe Safety Guidelines detailed in the beginning of this manual PROBLEMS POSSIBLE AREAS OF RECOMMENDED SYMPTOMS MISADJUSTMENT S COURSE OF ACTION FUNCTION PROBLEMS 1 The machine may be trying to 1 deliver too much power When the average output current exceeds a maximum limit the machine will phase back to protect itself Adjust the proce dure or reduce the load to lower the current draw from the Power Wave machine Perform the Transducer Test 2 The control board may be faulty The machine often noodle welds with a particular procedure The output is limited to approximately 100 amps Return to Section TOC Return to Master TOC Excessively long and erratic arc Check for proper configuration and implementation of voltage sensing circuits Check the connections between the voltage sense receptacle and the control board See the Wiring Diagram Return to Section TOC Return to Master TOC The control board may be faulty olo 0 f i Sl gt EIS 5 2 ele
15. S s Sls ol To Control os Main Switch Board Board BIZ e Jo Z oc Positive Input Zu Output Input switch Rectifier Curent Terminal Sensor i Negative Reconnect R Output Switch 7 Terminal oF Primary ce Primary Current Feedback 2 Input Relay Control Soft Start Control 115VAC Fan Supply Auxiliary Output Voltage Sense Fan Control jeubig 1991 V F Capacitor Feedback 2 5 220 VAC Transformer ack 2 e G o Machine Control Supply Yelk nl w 40VDC Power 15VDO 15VDC 5VDC X mema wh LED e Board Control Board 4 RS232 Supply 5VDC 2 5 Supply 5VDC o c 5 1 40VDC R232 Connector Thermostats 2 Feeder OUTPUT RECTIFIER AND CHOKE The output rectifier receives the AC output from the main transformer secondary and rectifies it to a DC voltage level Since the output choke is in series with the negative leg of the output rectifier and also in series with the welding load a filtered DC output is applied to the machine s output terminals olo 0 a NE T olg Sl om ec Sla 2 c NOTE Unshaded areas of Block Logic Diagram are the subject of discussion P
16. 505 503 TRANSFORMER L2 SHE REACTOR oo t S M 1 R2 505 m 100 e5c66C 970 502 403A Return to Section TOC Return to Master TOC REAR OF MACHINE OUTPUT 0 DC BUS RECTIFIER 2 046 BOARD zm gg f j RECEPTACLE RECEPTACLE H1 H2 H3 H4 H5 H6 I 4 am WIRE FEEDER VOLTAGE SENSE J a E AUXILIARY 53 TRANSFORMER 220v coma 2 se Oh 5 ute ya 52 COLORS FOR PW405 1103 1104 p 4071410 dis E 412 411 408 901 n 2 CONTROL bad 903 LEGEND ALL MACHINES Ly OPTION A COMPONENT OUTLINE 98 ER FRONT VIEW OF MACHINE COLOR CODE mare 1 MODEL sss LEFT SIDE OF MACHINE R RED NOTES WZWHHE NA 1 FOR MACHINES WITH RED BLACK AND WHITE POWER CORDS NS ERO FOR SINGLE PHASE INPUT CONNECT GREEN LEAD TO GROUND PER NATIONAL ELECTRICAL B SINCE COMPONENTS OR CIRCUITRY OF A PRINTED CIRCUIT BOARD MAY CHANGE WITHOUT AFFECTING Y YELLOW CODE CONNECT BLACK AND WHITE LEADS TO SUPPLY CIRCUIT WRAP RED LEAD WITH TAPE THE INTERCHANGEABILITY OF A COMPLETE BOARD THIS DIAGRAM MAY NOT SHOW THE EXACT TO PROVIDE 600V INSULATION COMPONENTS OR CIRCUITRY HAVING A COMMON CODE NUMBER FOR THREE PHASE INPUT CONNECT GREEN LEAD TO GROUND PER NATIONAL ELECTRICAL
17. Return to Section Return to Master TOC oO 9 ET THEORY OF OPERATION FIGURE 7 TYPICAL IGBT OUTPUTS H 25 sec 50 psec 1 psec 1 psec 1 usec MINIMUM OUTPUT 1 psec 50 psec MAXIMUM OUTPUT PULSE WIDTH MODULATION The term Pulse Width Modulation is used to describe how much time is devoted to conduction in the posi tive and negative portions of the cycle Changing the pulse width is Known as modulation Pulse Width Modulation PWM 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 the cycle The top drawing in Figure E 7 shows the mini mum output signal possible over a 50 microsecond time period The positive portion of the signal represents one IGBT group conducting for one microsecond The negative portion is the other IGBT group The dwell time off time is 48 microseconds both IGBT groups off Since only two microseconds of the 50 microsecond time period is devoted to conducting the output power is minimized MAXIMUM OUTPUT By holding the gate signal on for 24 microseconds each and allowing only two microseconds of dwell time off time during the 50 microsecond cycle the output is maximized The darkened area under the top curve can
18. MATERIALS NEEDED 5 16 Nut Driver 3 8 Open End Wrench Flat Head Screwdriver Phillips Head Screwdriver POWER WAVE 355M 405M LINCOLN B F 61 Return to Section TOC Return to Master TOC Return to Section TOC olo 0 c f i Sl gt om so ec 5 2 ele Return to Section TOC Return to Master TOC Return to Master TOC F 62 PROCEDURE TROUBLESHOOTING AND REPAIR F 62 DC BUS BOARD REMOVAL AND REPLACEMENT continued 1 Remove input power to the POWER WAVE 6 355M 405M 2 Using a 5 16 nut driver remove the case wrap around cover 3 Perform the Input Filter Capacitor Discharge Procedure detailed earlier in this section 4 Locate the DC Bus Board See Figure F 27 5 Using a 5 16 nut driver remove the two screws from the bottom of the front of the machine See Figure F 28 Using a phillips head screwdriver remove the two screws and their washers from above and below the input power switch See Figure F 28 Using a phillips head screwdriver remove the four screws mounting the two welder output terminals on the front of the machine See Figure 28 The front of the machine may now gently be pulled forward to gain access to the DC Bus Board Note The front of the machine cannot be removed completely only pulled forward a few inches FIGURE F 27 DC BUS BOARD LOCATION DC BUS BOARD POWER WAVE 355M 405M LINCOLN B Return to Section TOC Retu
19. 0 2 gt lt x lt lt amp FREQUENCY gt SPRAY TRANSITION CURRENT POWER WAVE 355M 405M LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o 42 Return to Section Return to Master TOC s z 9 OPERATION ER 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 back ground 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 All 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 Contact to Work Distance is the distance from the contact ti
20. 7 Repeat the discharge procedure for the other three capacitors 8 Check the voltage across the terminals of all capacitors with a DC voltmeter Polarity of the capacitor terminals is marked on the PC board above the terminals Voltage should be zero If any voltage remains repeat this capacitor dis charge procedure FIGURE F 1 LOCATION OF INPUT FILTER CAPACITOR TERMINALS EIGHT CAPACITOR TERMINALS Neat 10 L 1L 1 INSULATED PLIERS Que 8 N 7 z Z POWER RESISTOR m 27 as INSULATED S Xa GLOVES POWER WAVE 355M 405M LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o 42 Return to Section Return to Master TOC s z 9 F 15 TROUBLESHOOTING AND REPAIR MAIN SWITCH BOARD TEST A 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
21. Move the A lead to the appropriate terminal POWER CORD CONNECTION A power cord is provided and wired into the machine Follow the power cord connection instructions Cord Length PW 355 10 Feet PW 405 5 Meters A CAUTION Incorrect connection may result in equipment damage Single Phase Input PW 355M Connect green lead to ground per National Electrical Code Connect black and white leads to power Wrap red lead with tape to provide 600V insulation Three Phase Input PW 355M Connect green lead to ground per National Electric Code Connect black red and white leads to power Lead Color Single Phase Three Phase Green Connect to Connect to ground per NEC ground per NEC Black White Power Lead Power Lead Power Lead Tape provide 600V insulation Single Phase Input PW 405M Connect green yellow lead to ground per National Electrical Code Connect blue and brown leads to power Wrap black lead with tape to provide 600V insulation Three Phase Input PW 405M Connect green yellow lead to ground per National Electric Code Connect black blue and brown leads to power POWER WAVE 355M 405M LINCOLN B Return to Section TOC Return to Master TOC o 42 Return to Section Return to Master TOC s z 9 AS INSTALLATION UNDERCARRIAGE MOUNTINGS OUTPUT CA
22. PJE c f i olg Sl g b om Bo ec 51 ele Return to Section TOC Return to Master TOC Return to Master TOC p OPERATION p FIGURE B 1 4 ss ER ee CASE FRONT LAYOUT POWER WAVE 355 405 5 Internal POWER CIRCUIT BREAKER Protects 115 volt AC circuit 6 LEAD CONNECTOR SENSE LEAD 7 DIAGNOSTIC CONNECTOR RS 232 8 WIRE FEEDER RECEPTACLE 5 PIN 9 NEGATIVE TWIST MATE TERMINAL 10 POSITIVE TWIST MATE TERMINAL NOMINAL PROCEDURES The Power Wave is designed to operate with 3 4 elec trode stick out for CV and Pulse processes FRINGE PROCEDURES Excessively short or long electrode stick outs may function only on a limited basis if at all MAKING A WELD A WARNING The serviceability of a product or structure utiliz ing the welding programs is and must be the sole responsibility of the builder user Many variables beyond the control of The Lincoln Electric Company affect the results obtained in applying these programs These variables include but are not limited to welding procedure plate chemistry and temperature weldment design fabrication methods and service requirements The available range of a welding program may not be suitable for all applications and the build user is and must be solely responsible for welding program selection The steps for operating the Power Wave will vary depending upon
23. STUD VOLTA SENSE CURRENT TRANSDUCER MAIN CHOKE THERMOSTAT olo 506 503 506 J505 STUD VOLTAG SENSE THERMAL LED 8J7 gt THERMAL LED 7J7 gt STATUS LED HI FOR RED 3 7 gt STATUS LED HIFOR GREEN 4J7 THERMOSTAT THERMOSTAT VOLTAGE FREQUENCY CONVERTER 2 VOLTAGE FREQUENCY CONVERTER 2 PRIMARY CURRENT SENSE 2 n PRIMARY CURRENT SENSE 2 GND a a SOFT START CONROL PULSE TRANSFORMER GATE DRIVE PULSE TRANSFORMER GATE DRIVE 15 a EE ee a FAN CONTROL J46 1 J46 2 x lt J46 3 J46 4 32A PW355 MODEL SEE BELOW FOR PW405 J52 1 1 5201 CB2 532 2 5A NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual J11 6 9 1 3 40VDC POWER gt J47 3 COMMON gt J47 6 gt 40VDC gt J47 8 gt FEEDER COMMON J47 1 gt DC BUS J8 J20 421 47 1 4 BOARD Sch M19330 555 oo o o o o J41 2 40 VDC lt J41 1 POWER machine 15 8 23421 POWERDOWN SIGNAL HIGH RUN POWER DOWN SIGNAL gt J42 4 45 a 4423 15V a 5V a GND a GND a J42 5 15 8 42 2 15 5 SPI b J43 3 15 SPI b J43 6 5V SPI b 15
24. 3 PRIMARY CURRENT SHUTDOWN 03 09 J9 STUP 1 lt Toor 62 995 asme x D e e ut Y seo sit a SEEN 1 74 1 74 1 74 3500 VOLTS ON CONNECTOR IDEAL VOLTAGE 2 6 20 70 09 035 4 51V 1 28 C35 0 3 Ve LINCOLN B AD_DATAIO AD_DATAIL AD DATAIZI AD DATAI3I AD DATAIAT AD DATAISI AD DATAI6 AD_DATAITI AD DATAIB AD_DATAISI AD_DATAILO AD_DATAI11 152 ica la ELI LL ELE 38 JBESESESEERES AD_DATAION 63 x 1 AD oATANaI J AD DATAI0 131 gt SHT 4 330740 Res CURRENT LIMIT Ve 15V Vi NOTES SINCE COMPONENTS OR CIRCUITRY ON A PRINTED CIRCUIT BOARD MAY CHANGE WITHOUT AFFECTING THE INTERCHANGEABILITY OF A COMPLETE BOARD THIS DIAGRAM MAY NOT SHOW THE EXACT COMPONENTS OR CIRCUITRY OF CONTROLS HAVING A COMMON CODE NUMBER m 9 IDEAL V RO A 25 70 ARCVOLTS Vc 1 lt GAIN lt 11 Ve THIS SHEET CONTAINS PROPRIETARY INFORMATION OWNED BY THE LINCOLN ELECTRIC AND 15 NOT TO BE REPRODUCED DISCLOSED OR USED WITHOUT THE EXPRESS PERMISSION OF THE LINCOLN ELECTRIC CO 57 ri 91 t c 50 SOV 01 50 xB X20 330740 css 330740 330740 01 01 01 sw sw sv Ve 15V GENERAL INFORMATION _ ELECTRICAL SYMBOL
25. 8 5 lt 3 y Pa SHT 4 C SPLLATCH7 sm 2 5 88 sat lt sit 4 gt CEMPA se cs3 7 119 DATAI12 1906 ue narum SHT 2 RS232 TXD POST 118 DATAI13 sr 2 5 BS232 RX0 Td axo RITU VSTOBY 26 25 EBBESssssPESRSUD Ic H39 DATA 17 DATAI8 125 DATAI9 AA 124 DATAIL0 116 DATAILLI DATAILSI gt E B m Le BUD Ie t EDE 4 FPGA CS 5 FUNCEN 139 DATAIO 138 137 DATAI2 136 ADDRIBI 21 13 DATAI4 ADORITI 2i liz mrs m DATAIG 1 DATAN le ADDRIZI ADDRI1 b 88 BSEREESESERSES NOTES SINCE COMPONENTS OR CIRCUITRY ON PRINTED CIRCUIT BOARD MAY CHANGE WITHOUT AFFECTING THE INTERCHANGEABILITY GENERAL INFORMATION ELECTRICAL SYMBOLS PER E1537 FILENAME 63789 10 THIS SHEET CONTAINS PROPRIETARY INFORMATION OWNED BY THE LINCOLN ELECTRIC CO AND IS NOT TO BE REPRODUCED DISCLOSED OR USED WITHOUT THE EXPRESS OF THE LINCOLN ELECTRIC CO THE LINCOLN ELECTRIC CO CLEVELAND OHIO U S A PLACE 1 NONE COMPLETE BOARD THIS DIAGRAM MAY SCALE WERIAL TO NOT SHOW THE EXACT COMPONENTS OR CIRCUITRY OF CONTROLS HAVING A COMMON CODE NUMBER CAPACITORS 022 50V UNLESS OTHERW
26. 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 i SAFETY i 6 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 levage cables 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 10 Ne pas souder en pr sence de vapeurs de chlore provenant d op rations 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 fortement toxique ou autres produits irritants 11 Pour obtenir de plus amples renseignements
27. CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed Call 1 888 935 3877 POWER WAVE 355M 405M LINCOLN B Return to Section TOC Return to Master TOC Pa TROUBLESHOOTING AND REPAIR Observe Safety Guidelines detailed in the beginning of this manual PROBLEMS POSSIBLE AREAS OF RECOMMENDED SYMPTOMS MISADJUSTMENT S COURSE OF ACTION FUNCTION PROBLEMS Auxiliary receptacle is dead no Circuit breaker CB1 on case 1 Perform the Auxiliary auxiliary voltage front may have opened Reset Transformer Test Return to Section TOC Return to Master TOC Circuit breaker in recon nect area may have opened Reset On PW 405 models the circuit breaker 4 protects the 220VAC receptacle Reset if tripped A fault or error code is displayed See Fault Code Explanations 1 See Fault Code Explanations General degradation of the weld Check for feeding problems Perform the Voltage and performance bad connections excessive Current Calibration Procedure loops in cabling etc using the Power Wave software program Return to Section TOC Return to Master TOC Verify weld mode is correct for processes 2 Perform the Current The power source may require calibration 2 Perform the Output Diode Check the actua
28. Electrode Voltage Sense switch 6 reserved for future use 440vdc Switch 7 reserved for future use Ovdc Switch 8 work sense lead TABLE A 3 VOLTAGE SENSE RECEPTACLE switch 8 worksenselead LEAD FUNCTION work sense lead not connected 21A Work Voltage Sense work sense lead connected TABLE A 4 Factory setting for Switch 8 is OFF RS232 RECEPTACLE FIGURE A 7 iocus Transmit CONTROL BOARD DIP Switch Location Pin4 Pin20 Pin6 RS232 Common DIP SWITCH SETTINGS AND LOCATIONS DIP switches on the P C Boards allow for custom con figuration of the Power Wave To access the DIP switch es WARNING 1 Turn off power to the power source at the dis NOTE For PF10M Dual Boom Feeder set up and op connect switch eration The Power Wave 355M 405M control ES S A SS S A a E board dip switches must be set with 3 4 7 to 2 Remove the wrap around cover from the power the ON position Power Wave 355M 405M source input on off switch must be cycled to enable any change of dip switches 3 The control board is on the center assembly facing d d P the case front Locate the 8 position DIP switch and look for switch 8 of the DIP switch 4 Using a pencil or other small object slide the switch to the OFF position if the work sense lead is NOT connected Conversely slide the switch to the ON position if the work sense lead is present 5 Replace the wrap around and screws The PC board
29. The following procedure will aid the technician in removing the main switch board for maintenance or replacement MATERIALS NEEDED 5 16 Nut Driver Flathead Screwdriver 7 16 mm Socket 3 16 Allen Wrench 3 8 Nut Driver POWER WAVE 355M 405M LINCOLN B F 51 Return to Section TOC Return to Master TOC Return to Section TOC olo 0 c fia Sl AIS o S9 EIE 5 2 2 c Return to Section TOC Return to Master TOC Return to Master TOC diis TROUBLESHOOTING AND REPAIR dn MAIN SWITCH BOARD REMOVAL amp REPLACEMENT continued FIGURE F 21 MAIN SWITCH BOARD LEAD LOCATIONS 207 202 4 J2 PROCEDURE 1 Remove the input power to the POWER WAVE 5 Using a 3 8 nut driver remove the input lead 355 405 shield from the area at the bottom of the main switch board 2 Using a 5 16 nut driver remove the case wrap around cover 6 Using a 7 16 socket remove leads 201 202 203 204 205 206 207 208 209 from the 3 Perform the Input Filter Capacitor Discharge switch board Note lead terminal locations and Procedure detailed earlier in this section washer positions upon removal 7 Locate and disconnect the three harness plugs associated with the main switch board Plugs CAUTION J20 21 222 See Figure F 21 Locate the eight capacitor terminals and Observe static precautions detailed in remove the nuts using a 7 16 socket or nut
30. 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 Mar 95 Return to Master TOC Return to Master TOC n s gt 2 E Return to Master PRECAUTIONS DE SURETE Pour votre propre protection lire et observer toutes les instructions et les pr cautions de s ret specifiques qui parraissent dans ce manuel aussi bien que les pr cautions de s ret g n rales suiv antes Sdret 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 met allique 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
31. Will read the switch at power up and configure the work voltage sense lead appropriately 123 45 6 7 8 POWER WAVE 355 405 LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o 42 Return to Section Return to Master TOC s z 9 14 CABLE INDUCTANCE AND ITS EFFECTS ON PULSE WELDING For Pulse Welding processes cable inductance will cause the welding performance to degrade For the total welding loop length less than 50 ft 15 24m tradi tional welding cables may be used without any effects on welding performance For the total welding loop length greater than 50 ft 15 24m the K1796 Coaxial Welding Cables are recommended The welding loop length is defined as the total of electrode cable length A work cable length B work length C See Figure A 3 FIGURE A 3 For long work piece lengths a sliding ground should be considered to keep the total welding loop length less than 50 ft 15 24m See Figure A 4 FIGURE A 4 SLIDING WORK K1796 COAXIAL CABLE MEASURE FROM END zi OF OUTER JACKET OF CABLE INSTALLATION A 14 Most welding applications run with the electrode being positive For those applications connect the elec trode cable between the wire feed
32. contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 1 888 935 3877 TEST DESCRIPTION This test will help determine if the power section of the switch boards are functioning correctly This test will NOT indicate if the entire PC board is functional This resistance test is preferable to a voltage test with the machine energized because this board can be damaged easily In addition it is dangerous to work on this board with the machine ener gized MATERIALS NEEDED Analog Volt Ohmmeter 5 16 in Wrench 7 16 in Wrench POWER WAVE 355M 405M LINCOLN B F 15 16 TROUBLESHOOTING AND REPAIR MAIN SWITCH BOARD TEST continued FIGURE F 2 MAIN SWITCH BOARD LEAD LOCATIONS x 2 lt J22 Return to Section TOC Return to Master TOC Return to Master TOC o O IE 42 9 a olo a x HE TEST PROCEDURE 1 Remove input power to the POWER WAVE 4 Using a 7 16 wrench locate label and remove ele 355M 405M leads 201 202 203 204 205 206 207 and amp c 208 from the switch board Note lead and 2 Using 5 16 nut driver remove the case washer placement for reassembly Clear wraparound leads Perform the Input Filter Capacitor Discharge 5 Using the Analog ohmmeter perform the resis detailed earlier in this section tance tests detailed in Table F 1 Refer to
33. olo Oo 0 H SIG gt o S 5 Dio 2 c OUTPUT CABLES CONNECTIONS AND LIMITATIONS Select the output cable size based upon the following chart Cable sizes for Combined Length of Electrode and Work Cable Copper 75C rated DUTY CYCLE CURRENT LENGTH UP 61m 200 FT 61 76m 200 250 100 275 1 0 1 0 60 350 1 0 2 0 Return to Section Return to Master TOC POWER WAVE 355M 405M LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC olo 5 5 g ol 5 2 2 c Return to Section TOC Return to Master TOC Return to Master TOC INSTALLATION SAFETY PRECAUTIONS WARNING ELECTRIC SHOCK can kill e TURN THE INPUT POWER OFF AT THE DISCONNECT SWITCH BEFORE ATTEMPTING TO CONNECT OR DIS CONNECT INPUT POWER LINES OUTPUT CABLES OR CONTROL CABLES Only qualified personnel should perform this installation Connect the green yellow lead of the power cord to ground per U S National Electrical Code SELECT SUITABLE LOCATION In order to assure long life and reliable operation the owner of this machine should follow these sim ple preventative measures The machine must be located where there is free cir culation of clean air such that air movement in the back out the sides and bottom will not be restricted Dirt and dust that can be drawn into the
34. 8 SCALE SHT WITH PUBLISHED STANDARDS Date _09 01 99 CHK SUP S D G NO 19330 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 POWER WAVE 355 405
35. 9 To prevent accidentally starting gasoline engines while turning the engine or welding generator during maintenance work disconnect the spark plug wires distributor cap or magneto wire as appropriate 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 pur chase a copy of Safety in Welding amp Cutting ANSI Standard Z49 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 The Above For Gasoline Engines 1 h To avoid scalding do not remove the radiator pressure cap when the engine is hot 23 ELECTRIC AND ET MAGNETIC FIELDS may be dangerous m 2 Electric current flowing through any conductor causes localized Electric and Magnetic Fields EMF Welding current creates EMF fields around welding cables and welding machines EMF fields may interfere with some pacemakers and welders having a pacemaker should consult their physician before welding Exposure to EMF
36. 9 Apply a thin coat of Penetrox A 13 heatsink com 11 Reconnect the previously removed leads to their 9 Y pound to the point of contact between the input proper locations Torque to 31 inch pounds 2 2 rectifier and the mounting surface eS 12 Cover the input rectifier and its six terminals with 10 Secure the new input bridge into its proper silicon sealant alo tion with the two 3 16 in allen mounting screws e c previously removed Torque to 44 inch pounds 13 Replace the case wraparound cover FIGURE F 31 INPUT RECTIFIER CLOSE UP Small Lead H1 To Auxiliary Transformer 3 16 ALLEN BOLTS Return to Section TOC Return to Master TOC 209 olo 0 Sl gt om so ec 51 ele Small Lead A q FRONT To Circuit Breaker REAR Return to Section TOC Return to Master TOC POWER WAVE 355M 405M LINCOLN B NOTES 68 WAVE 355 405 LINCOLN amp F 68 DOL J81Se N 01 DOL 181SEN 01 DOL J81Se N 01 DOL J81Se N 01 DOL uonoesg 0 uit DOL uonoesg 0 uit DOL uonoesg 0 uit DOL uonoesg 0 F 69 TROUBLESHOOTING AND REPAIR co OUTPUT RECTIFIER MODULES REMOVAL AND REPLACEMENT A 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 y
37. AXLDS 3A 600V UFR D7 D8 D9 D12 D14 D18 D19 T12199 1 IDIODE AXLDS 1A 400V 020 021 DZ1 DZ2 DZ3 DZ5 DZ6 DZ15 T12702 29 ZENER DIODE 1W 15V 5 1N4744A DZ16 DZ18 DZ19 DZ23 DZ11 DZ22 T12702 4 ZENER DIODE 1W 20V 5 1N4747A DZ4 DZ7 DZ17 DZ20 T12702 40 DIODE 1W 6 2V 5 1N4735A DZ8 T12702 19 ZENER DIODE 1 12 5 1N4742A DZ9 DZ10 DZ12 DZ13 112702 45 ZENER DIODE 1W 18V 5 1 4746 J20 J21 524016 8 _ CONNECTOR MOLEX MINLPCB RT L 8 PIN J22 S24016 4 CONNECTOR MOLEX MINI PCB RT L 4 PIN OCI1 0CI2 0CI3 515000 22 OPTOCOUPLER PHOTO Q 70V CNY17 3 VDE OC 515000 29 OPTOCOUPLER TRIAC DRV RANDOM 600V CRIMP memes 02 03 04 05 12704 7 4 DIP 1A 100V RFD110 HEIGHT M NON COMPONENT 06 T1270469 TRANSISTOR PNP TO226 0 5A 40V 2N4403 SIDE R1 R2 R3 R4 R7 R8 R9 R10 14648 5 RESISTOR WW 5W 3 3K 5 SQ R124 R125 R126 R127 R130 EYELET DETAIL R131 R132 R133 R11 R12 R30 R31 S19400 1503_ RESISTOR MF 1 4W 150K 1 R13 R39 R43 R60 R81 R92 519400 3321 5 5 1 4 3 32 1 R137 S19400 3570_IRESISTOR MF 1 4W 357 1 R138 S19400 1500_ RESISTOR MF 1 4W 150 1 R139 S19400 4750 RESISTOR MF 1 4W 475 19 R14 R107 519400 1652 RESISTOR MF 1 4W 16 5K 196 ah R140 19400 39R2 RESISTOR MF 1 4W 39 2 1 BPLACES R15 R20 R21 R22 R27 R28 S19400 10R0 RESISTOR MF 1 4W 10 0 1 Return to Section TOC Return to Master TOC
38. COMMENTS Not Recommended below 200 WFS Not Recommended below 100 WFS Not Recommended below 200 WFS Not Recommended below 200 WFS POWER WAVE 355M 405M LINCOLN B Return to Master TOC Return to Master TOC ss z 9 c Return to Master v1 TABLE OF CONTENTS ACCESSORIES SECTION v1 ACCeSSOrIGS 3 5 5 5 u EE RR EX RR eS Name wita EFE EE NR EE RE EE ER NER E w C 1 Optional Eg ipimernti 2 Field Installed qasa al aaa 2 Compatible Lincoln Equibrmenmt U u uU 2 POWER WAVE 355 405 LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC olo PJE Sl gt ol esc 51 ele Return to Section TOC Return to Master TOC Return to Master TOC ACCESSORIES 6 2 OPTIONAL EQUIPMENT FACTORY INSTALLED None Available FIELD INSTALLED K940 Work Voltage Sense Lead Kit K1 764 1 Undercarriage K1838 1 Valet Style Undercarriage K1796 Coaxial Welding Cable Requires Adapter K2176 1 K2176 1 Twist mate to Lug Adapters Dual Cylinder Kit for K1764 1 is K1702 1 K2436 1 Ethernet Devicenet Communication Interface Welding Cable Connectors K852 70 1 0 2 0 CABLE K852 95 2 0 3 0 CABLE COMPATIBLE LINCOLN EQUIPMENT Any ARC Link compatible wire feeding equipment PF10M
39. DEMS ISE 02 DRAWN BY _ F Valencic SUBJECT ANGLES IS 5 OF DEGREE TONEN MACHINE SCHEMATIC FTE APPROVED 10 NONE PPROVAL 7502 ROET 336 VOLTAGE SENSE RECEPTACLE 143 lt 4 POWERWAVE 355 405 90000000 ob e ELECTRICAL SYMBOLS PER E1537 LEGEND ALL MACHINES OPTION COMPONENT OUTLINE THIS DOCUMENT CONTAINS PROPRIETARY INFORMATION OWNED BY LINCOLN GLOBAL INC AND MAY NOT BE DUPLICATED COMMUNICATED PROPRIETARY amp CONFIDENTIAL a OTHER PARTIES OR USED FOR ANY PURPOSE WITHOUT THE EXPRESS WRITTEN PERMISSION OF LINCOLN GLOBAL INC FT DESIGN INFORMATION JREFERENCE EQUIPMENT TYPE PAGE 1 OF SOLID EDGE POWER WAVE 355M 405M Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC 9 o g 3 Return to Section TOC Return to Master TOC o o o v z 2 tc G 4 SCHEMATIC DIGITAL CONTROL PC BOARD 1 ELECTRICAL DIAGRAMS 68LE9 THERMAL_LED SHT 4 gt ihe C25 031 z FAN 8 SHT gt FAN CONTROL 97 sur 9480 22 as V D T 18 100 EH a 22 40V LEVEL IN 0 5 s B 12 an 15V SHT 23 C SYS RESET PH
40. GMAW P The pulsed arc process is by definition a spray trans fer process wherein spray transfer occurs in pulses at regularly spaced intervals In the time between pulses the welding current is reduced and no metal transfer occurs Pulsed arc transfer is obtained by operating a power source between low and high current levels The high current level or pulse forces an electrode drop to the workpiece The low current level or background main tains the arc between pulses See Figure B 3 Pulsed MIG is an advanced form of welding that takes the best of all the other forms of transfer while mini mizing or eliminating their disadvantages Unlike short circuit pulsed MIG does not create spatter or run the risk of cold lapping The welding positions in pulsed MIG are not limited as they are with globular or spray and its wire use is definitely more efficient Unlike the spray arc process pulsing offers controlled heat input that allows better welding on thin materials Pulsing allows for lower wire feed speeds which leads to less distortion and improved overall quality and appear ance This is especially important with stainless nick el and other alloys that are sensitive to heat input In GMAW P mode arc control adjusts the background current and frequency of the wave When arc control goes up the frequency increases thus increasing the droplet transfer FIGURE B 3 EACH PULSE DELIVERS ONE DROPLET OF WELD MATERIAL
41. Output Output Weight Dimensions Name Information Voltage Amps Volts Duty Cycle Range with Cord HxWxD continuous Power 200 208 Wave K2152 1 220 240 350A 34V 60 355 380 415 1 amp 3 Phase 14 8 13 3 x 440 480 81 5 Ibs 27 8 575 37 0 kg 373 x 338 x 706 mm 60 50 HZ 300A 32V 100 Includes 1 amp 3 Phase Handles Overall Length Including Handle 21 6 549mm without handle POWER WAVE 355 INPUT CURRENT Recommended Fuse Sizes Base On The U S National Electrical Code And Maximum Machine Outputs input 50750 Hz 32Volts 10096 34Volts 6096 AWG Recommended Recommended 125A Note 2 230 69 Note 1 Note 1 ot 85 380 1 Not Not Recommended Recommended ot 64 Note 2 42 Recommended Recommended 41 Note 2 Note 2 Note 1 Not rated is indicated by 4 x s in the box on the rating plate 415 Note 2 When operating on these inputs the line cord should be changed to an input conductor of 6 AWG or larger 460 575 OUTPUT CABLES CONNECTIONS AND LIMITATIONS Select The output cable size based upon the following chart Cable sizes for Combined Length of Electrode and Work Cable Copper 75C rated DUTY CYCLE CURRENT LENGTH UP 200FT 61m 200 250 FT 61 76m Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC 1 1 2 1 4 5 H s S BA SIG gt os 5 2 ele 100 300 1 0 1 0 60 350 1 0 2 0 Lincoln El
42. PF15M PF25M series NOTE No Linc Net semi automatic wire feeding equip ment is compatible Specifically the semi automatic Power Feed family PF 10 PF 10X2 PF 11 will not work with a PW355M 405M POWER WAVE 355M 405M LINCOLN B Return to Master TOC Return to Master TOC ss z 9 c Return to Master D 1 51 STABLE OF CONTENTS MAINTENANCE SECTION Maintenance 2 c xk ere See eter NIRE EE RR tere E ERE ws sj ee eh Ww OW T EE WEN E E D 1 Safety PIecautloris u tu ha e s t tea ses D 2 Capacitor Discharge 4 D 2 Visual Inspection oet etit D 2 Routine poen eee qawa D 2 Periodic Malnterianee u Saa asa afar e D 2 Major Component D 3 POWER WAVE 355M 405M LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o 42 Return to Section Return to Master TOC s z 9 bre MAINTENANCE zs A WARNING Have qualified personnel do the maintenance work Always use the greatest care when working near moving parts Do not put your hands near
43. PLACE A LEAD ON APPROPRIATE CONNECTION FOR INPUT VOLTAGE CONNECTION SHOWN IS FOR 18120 CODE CONNECT BLACK RED amp WHITE LEADS TO SUPPLY CIRCUIT 550 575V OPERATION PW405 ONLY GO TO 415VAC J2 15 J11 iMi 2 FOR MACHINES WITH BROWN BLACK AND BLUE POWER CORDS D INPUT POWER LINE FILTER IS PRESENT ONLY ON PW405 CENTER 2 J46 J9 J42 FOR SINGLE PHASE INPUT CONNECT GREEN YELLOW LEAD TO GROUND PER NATIONAL E ON PW405 MOV S ARE IN THE INPUT POWER LINE FILTER PANEL 3 ELECTRICAL CODE CONNECT BLUE AND BROWN LEADS TO SUPPLY CIRCUIT WRAP BLACK F 220VWINDING IS ONLY PRESENT ON 405 FAN SHROUD CASE FRONT BASE ae Seen LEAD WITH TAPE TO PROVIDE 600V INSULATION PROTECTIVE BONDING CIRCUIT ae 5 FOR THREE PHASE INPUT CONNECT GREEN YELLOW GROUND PER NATIONAL ELECTRICAL e CODE CONNECT BLUE BLACK amp BROWN LEADS TO SUPPLY CIRCUIT CONNECTOR CAVITY NUMBERING SEQUENCE ELECTRICAL SYMBOLS PER E1537 VIEWEDFROM COMPONENT SIDE OF BOARD o Fle w PEN es 1 woe 4 1 4 64131 Return Section Return to Master 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 LINCOLN jo POWER W
44. REPLACEMENT continued 16 Replace the two 5 16 mounting screws to the bottom of the case front 17 Replace the case wraparound cover Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC olo PJE Sl gt ol esc 51 ele Return to Section TOC Return to Master TOC POWER WAVE 355M 405M LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC olo PJE Sl gt ol esc 5 2 ele Return to Section TOC Return to Master TOC Return to Master TOC F 65 TROUBLESHOOTING AND REPAIR INPUT RECTIFIER REMOVAL AND REPLACEMENT A 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 1 888 935 3877 DESCRIPTION The following procedure will aid the technician in removing the input rectifier for mainte nance or replacement MATERIALS NEEDED 3 16 A
45. 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 D ine LINCOLN machine POWER WAVE 355 405 on ELECTRICAL DIAGRAMS eus SCHEMATIC 40 VDC BUSS PC BOARD OEEG6TIA 40 VDC JN 8 57 45 120 VDC Return Section Return to Master a ne 1000V Work Lead Disconnect Protection Circuitry x E Return to Section TOC Return to Master TOC 14 CL 03 27 35V 600V
46. TEST POINT TERMINALS ANALOG METER X10 RANGE PROBE Acceptable Meter Readings A Greater than 1000 ohms B Greater than 1000 ohms C Greater than 1000 ohms A Greater than 1000 ohms B Greater than 1000 ohms C Greater than 1000 ohms A Less than 100 ohms B Less than 100 ohms C Less than 100 ohms 207 A Less than 100 ohms 207 B Less than 100 ohms 207 C Less than 100 ohms 207A A Less than 100 ohms 207A B Less than 100 ohms 207A C Less than 100 ohms 209 A Greater than 1000 ohms 209 B Greater than 1000 ohms 209 C Greater than 1000 ohms 9 If the input rectifier does not meet the acceptable readings outlined in Table F 2 11 If the input rectifier is faulty see the the component may be faulty Replace Input Rectifier Bridge Removal amp Replacement procedure Note Before replacing the input rectifier check the input power switch and recon 12 Replace the case wraparound cover nect switches Perform the Board Test Also check for leaky or faulty filter capacitors 10 If the input rectifier is good be sure to reconnect leads 207 207A and 209 to the correct terminals and torque to 31 inch Ibs Apply silicone sealant POWER WAVE 355M 405M LINCOLN B NOTES pee POWER WAVE 355M 405M LINCOLN F 22 DOL J81Se N 01 DOL 181SEN 01 DOL J81Se N 01 DOL J81Se N 01 DOL uonoesg 0 uit DOL uonoesg 0 uit DOL uonoesg 0 uit DOL uonoesg 0 Return to Section TOC Return to Master TOC Retu
47. be compared to the area under the bottom curve The more dark area that is under the curve indi cates that more power is present 1 IGBT group consists of two IGBT modules feed ing one transformer primary winding POWER WAVE 355M 405M LINCOLN F TABLE OF CONTENTS TROUBLESHOOTING AND REPAIR F o Troubleshooting and Repair F 1 gt g How to Use Troubleshooting F 2 PC Board Troubleshooting Procedures and 1 F 3 Troubleshooting uide ne cies asas ite cus E case n d F 4 Test Procedures Input Filter Capacitor Discharge eene nnne nnn F 13 Switch Board eiit i E Een ie HIE ens edocet e uie es ect ds fee F 15 Input Rectifier Test LEES F 19 E Power Board Iesu cati u A T E T E A T F 23 E DC eii ud i De Lib Lies F 27 5 2 Output Rectifier Modules Test 1 1 u F 31 Auxiliary Transformer Iest LLL ees eed ie EE F 35 Current Transducer Testa 39
48. bon et s r tat defonc tionnement d 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 souder parce que la tension entre les deux pinces peut tre le total de la tension vide des deux machines Si on utilise la machine souder comme une source de courant pour soudage semi automatique ces precautions pour le porte lectrode s applicuent aussi au pistolet de soudage 2 Dans le cas de travail au dessus du niveau du sol se prot ger contre les chutes dans le cas ou on recoit un choc Ne jamais enrouler le c ble lectrode autour de n importe quelle partie du corps Un coup d arc peut tre plus s v re qu un coup de soliel donc a Utiliser un bon masque avec un verre filtrant appropri ainsi qu un verre blanc afin de se prot ger les yeux du rayon nement de l arc et des projections quand on soude ou quand on regarde l arc b Porter des v tements convenables afin de prot ger la peau de soudeur et des aides contre le rayonnement de l arc c Prot ger l autre personnel travaillant proximit au soudage l aide d crans appropri s et non inflammables 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 pan talons sans revers et chaussures montantes
49. electrical equipment generates small amounts of electromagnetic emission Electrical emission may be transmitted through power lines or radiated through space similar to a radio transmitter When emissions are received by other equipment electrical interference may result Electrical emissions may affect many kinds of electrical equipment other nearby welding equipment radio and TV reception numerical controlled machines telephone systems computers etc Be aware that interference may result and extra precautions may be required when a welding power source is used in a domestic establishment Installation and Use The user is responsible for installing and using the welding equipment according to the manufacturer s instructions If electromagnetic disturbances are detected then it shall be the responsibility of the user of the welding equipment to resolve the situation with the technical assistance of the manufacturer In some cases this remedial action may be as simple as earthing grounding the welding circuit see Note In other cases it could involve construction an electromagnetic screen enclosing the power source and the work complete with associated input filters In all cases electromagnetic disturbances must be reduced to the point where they are no longer troublesome Note The welding circuit may or may not be earthed for safety reasons according to national codes Changing the earthing arrangements should only be authorized by a perso
50. fields in welding may have other health effects which are now not known 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 them with tape when possible 2 d 2 Never coil the electrode lead around your body 2 d 3 Do not place your body between the electrode and work cables If the electrode cable is on your right side the work cable should also be on your right side Connect the work cable to the workpiece as close as possible to the area being welded Do not work next to welding power source Mar 95 LINCOLN B Return to Master TOC Return to Master TOC n s z 9 E Return to Master SAFETY ELECTRIC SHOCK 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 scaffolds when in cram
51. fig ure F 2 for test point locations Note Test using an Analog ohmmeter on the Rx1 range Make sure the test probes are making electri cal contact with the conductor surfaces on the PC board Return to Section TOC Return to Master TOC POWER WAVE 355M 405M LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC olo 916 c f tw 514 gt ol esc 51 ele Return to Section TOC Return to Master TOC F 17 7 TROUBLESHOOTING AND REPAIR 17 MAIN SWITCH BOARD TEST continued 6 If any test fails replace the switch board See 8 Main Switch Board Removal and Replacement If the switch board resistance tests are OK check connections on plugs J20 J21 J22 and all asso ciated wiring See wiring diagram Reconnect leads 201 202 203 204 205 206 207 and 208 to the switch board Ensure that the leads are installed in their proper locations Pre Torque all leads nuts to 25 inch 165 before tight ening them to 44 inch Ibs Replace the case wraparound cover using a 5 16 nut driver TABLE F 1 SWITCH BOARD RESISTANCE TEST APPLY POSITIVE TEST APPLY NEGATIVE TEST NORMAL PROBE TO TERMINAL PROBE TO TERMINAL RESISTANCE READING Greater than 1000 ohms Greater than 1000 ohms Greater than 1000 ohms Greater than 1000 ohms Less than 100 ohms Less than 100 ohms Less than 100 ohms Less than 100 ohms POWER WAVE 355M 405M LIN
52. is turned off Error Code interpretation through the Status light is detailed in the Service Manual Individual code digits are flashed in red with a long pause between digits The codes will be separated by a green light There may be more than one error code indicated To clear the error turn power source off and back on to reset Non recoverable hardware fault Generally indi cates nothing is connected to the POWER WAVE 355M 405M wire feeder receptacle See Trouble Shooting Section Not applicable POWER WAVE 355M 405M LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o O 42 Return to Section Return to Master TOC n Oo 9 rae TROUBLESHOOTING AND REPAIR nae ERROR CODES FOR THE POWER WAVE The following is a list of possible error codes that the POWER WAVE 355M 405M can output via the status light If connected to a PF 10 11 these error codes will generally be accompanied by an Err 006 or Err 100 on the user interface display Individual code digits are flashed in RED with a long pause between digits Complete codes are seprated by one GREEN light There may be more than one error code indicated Example Error code 31 Red red red pause red green Error codes 32 amp 34 Red red red pause Red red Green Red red red pause Red red red red Green Sequence wi
53. lens should conform to ANSI Z87 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 4 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 The operation of welding fume control equipment is affected by various factors including proper use and positioning of the equipment maintenance of the equipment and the specific welding procedure and application involved Worker exposure level should be checked upon installation and periodi
54. machine should be kept to a minimum Failure to observe these precautions can result in excessive operating temperatures and nuisance shutdown Keep machine dry Shelter from rain and snow Do not place on wet ground or in puddles 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 STACKING POWER WAVE 355M 405M cannot be stacked TILTING Place the machine directly on a secure level surface or on a recommended undercarriage The machine may topple over if this procedure is not followed INPUT AND GROUNDING CONNECTIONS Only a qualified electrician should connect the POWER WAVE 355M 405M Installation should be made in accordance with the appropriate National Electrical Code all local codes and the information detailed below When received directly from the factory multiple volt age machines are internally connected for the highest voltage Always double check connections before powering up the machine Initial 200VAC 415VAC and 575VAC operation will require an Input voltage panel setup Open the access panel on the rear of the machine For 200 or 230 Position the large switch to 200 230 For higher voltages Position the large switch to 380 575
55. 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 LINCOLN B 7 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 hoses 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 Oylinders 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
56. system is considered a separate node regardless of its physical location For example even though a UI and FH may be physically mounted together they are still viewed as separate pieces nodes by the network and can only communicate via Arclink The connection is generally made externally through the Linc Net Control Cable but can also be made internally as with the PF 10 bench model feeder The most common Arclink configuration called a sim ple system consists of one power source one user interface and one feeder Under these circumstances the group and feed head ID DIP switches are ignored and the system will function regardless of their posi tion The same is true for the minimum system consist ing of a power source and one UI Example a stick welding system FIGURE A 1 POWER WAVE 355M 405M LINCOLN B 8 INSTALLATION iii SYSTEM SET UP Basic Rules Each group is required to have one user interface No group may have more than one user interface Each group can have up to seven Feed Heads Exception Group 3 is limited to a maximum of six Feed Heads Return to Section TOC Return to Master TOC Each system has only one power source For network purposes the PS belongs to Group 3 which is why group 3 is only allowed 6 feed heads in addition to it s user interface No two feed heads can have identical Group and Feed Head numbers Group and Feed Head ID numbers must be set on the appropriate
57. the cooling blower fan If a problem cannot be corrected by following the instructions take the machine to the nearest Lincoln Field Service Shop ELECTRIC SHOCK can kill Do not touch electrically live parts or electrode with skin or wet clothing e insulate yourself from work and ground Always wear dry insulating gloves r a 2 EXPLODING PARTS can cause injury CMS Failed parts can explode or cause other parts to explode when power is applied Always wear a face shield and long sleeves when servicing See additional warning information throughout this Manual CAPACITOR DISCHARGE PROCEDURE 1 Obtain a power resistor 25 ohms 25 watts 2 Hold resistor body with electrically insulated glove DO NOT TOUCH TERMINALS Connect the resis tor terminals across the two studs in the position shown Hold in each position for 1 second Repeat for all four capacitors CAPACITOR TERMINALS 3 Use a DC voltmeter to check that voltage is not present across the terminals on all four capaci tors VISUAL INSPECTION Clean interior of machine with a low pressure air stream Make a thorough inspection of all compo nents Look for signs of overheating broken leads or other obvious problems Many problems can be uncovered with a good visual inspection ROUTINE MAINTENANCE 1 Every 6 months or so the machine should be cleaned with a low pressure airstream Keeping the machine clean
58. transformer 21 Lead Voltage Sense BERE Recp onnector develops three different secondary voltages The 115VAC is applied via the main switch board to the fan motor The 42VAC is rectified and filtered The 65VDC produced by the Bus board rectifier is used by the Bus board to provide 40VDC to the power board 40VDC is also applied to the wire feeder receptacle PW405 models an additional 220VAC winding that is connected to a 220 AC receptacle Thermostats 2 The input voltage is rectified by the input rectifier and the resultant DC voltage is applied to the switch board through the reconnect switch assembly located at the rear of the machine The reconnect switch connects the two pairs of input capacitors either in a parallel lower voltage or series higher voltage configuration to accommodate the applied input voltage During the precharge time the DC input voltage is applied to the input capacitors through a current limit ing circuit The input capacitors are charged slowly and current limited voltage to frequency converter circuit located on the switch board monitors the capacitor voltages This signal is coupled to the con trol board When the input capacitors have charged to an acceptable level the control board energizes the input relays that are located on the switch board making all of the input power without current limiting available to the input capacitors If the capacitors
59. types are used instead of the single pulse type normally used in GMAW P A number of high energy pulses are used to obtain spray transfer and transfer metal across the arc Such pulses are shown in the figure below After a number N of such pulses depending on the wire feed speed used an identical number N of low energy pulses are performed These low energy pulses shown in the figure below do not transfer any filler metal across the arc and help to cool the arc and keep the heat input low N PULSES N PULSES HIGH HEAT PULSES PEAK AMPS BACKGROUND AMPS The Peak Current Background Current and Frequency are identical for the high energy and low energy pulses In addition to cooling the weld down the major effect of the low energy pulses is that they form a weld ripple Since they occur at very regular time intervals the weld bead obtained is very uniform with a very consistent ripple pattern In fact the bead has its best appearance if no oscillation of the welding gun whipping is used See the figure below LOW HEAT PULSES WL TIME KCC OPERATION B 10 When Arc Control is used in the Pulse on Pulse modes it does the same things it does in the other pulsed modes decreasing the Arc Control decreases the droplet transfer and weld deposition rate Increasing the Arc Control increases the droplet trans fer and weld deposition rate Since Arc Control var
60. uonoesg 0 uit DOL uonoesg 0 uit DOL uonoesg 0 Return to Section TOC Return to Master TOC Return to Section TOC olo PJE Sl gt ol esc 5 2 ele Return to Section TOC Return to Master TOC Return to Master TOC F 13 TROUBLESHOOTING AND REPAIR INPUT FILTER CAPACITOR DISCHARGE PROCEDURE A 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 1 888 935 3877 TEST DESCRIPTION This procedure will drain off any charge stored in the four large capacitors that are part of the switch board assembly This procedure MUST be performed as a safety pre caution before conducting any test or repair procedure that requires you to touch inter nal components of the machine MATERIALS NEEDED 5 16 Nut Driver Insulated Pliers Insulated Gloves High Wattage Resistor 25 1000 ohms and 25 watts minimum DC Volt Meter POWER WAVE 355M 405M LIN
61. vu Operation 15Volts gt 750 Amp x lt lt Le T E Machine Control Shut Down ls a a Q rad 2 Ves DEF L gt P L 4 o 2 5 2 5 Return to Master TOC al 15Volts 100Amp 5 HE m gt i GE Le yo Se s s Undenotage Detect lt 30VDC I3 p 4 kL gt m i Los e asv E w 15Volts 250Amps SP 4 Overvoltage Shutdown gt 55VDC sm 1 T T T 4 ov un YE dos ds 5Volts 3 Amps re TETS bls ble Ee SPI xls J B fg gt gt b q S rir a 5Volts 100 Amp i T 7 7 5 ow 20Volts 2 g La 200 Amps 2 Th Rj Gate Drive 2 gt 5 gt gt EA ty B p 4 gt gt i 1
62. 05 8h yous vot r SHT 1 OUTPUT ON 149 1 0149 1 0176 176 DATAI101 SHT 1 SPLCS3 150 1 0150 1 0175 115 9 A 8 j j SK 152 1 0152 1 0172 172 ADORIAT SHT 1 5 51 159 1 0159 1 0171 171 DORIS IN DATAIAT SHT 1 SPLCSO 164 1 9161 10169 9 SHT 1 25 162 1 0162 1 0168 168 ADORI7 163 1 0163 170167 167_IACK SHT 1 016s Up 66 US sur 1 SHT aL gt AD DATAIO 131 AD_DATAI0 131 SHT 1 31 03 1 045 AD DATAIBI E xu 25 Vo ka AD DATAI61 J SS ae OSP_DI6 8 1 08 1 042 2 AD DATAISI 3 Li 0 8 Konko ao matan 1 037 AD_DATAIZI xe 0 9 o 8 3 Return to Master TOC pi 45V 5 isis p SHT 3 MSELEN o 5 mC 1 run 09 IE HH oT o mua o ae rele ipei m 5 5 DSP_READY DRY BIN Y EP x fia 453 gt 332 gt gt 332 a 25 gt gt 332 332 sv 5V GENERAL INFORMATION ELECTRICAL SYMBOLS PER E1537 CAPACITORS 022 50 UNLESS OTHERWISE SPECIFIED RESISTORS Ohms 1 4W UNLESS OTHERWISE SPECIFIED DIODES 1A 400
63. 2001 RESISTOR MF 1 4W 2 00K 196 R78 R79 516296 5 TRIMMER MT 1 2W 10K 10 LINEAR TM MANUFACTURED AS T 513000 46 _ TRANSFORMER PCB PAGES T2T3 M19612 CURRENT TRANSDUCER 125 TURN 1 11364024 MOV 175VRMS 120 20MM G3830 1B1 TRH 515161 27 _ TRIAC T220 8A 800V X1X4 515128 10 VOLTAGE REF ADJ PRECISION 431 2 3 515128 18 HIGH PERF 33074 IDENTIFICATION CODE P T PART NO NL pe NOTES NA CAUTION THIS DEVICE IS SUBJECT TO DAMAGE BY STATIC ELECTRICITY LINCOLN ELECTRIC TO SEE E2454 CAPACITORS MFDVOLTS BEFORE HANDLING INDUCTANCE HENRIES SNAP POWER TERMINALS INTO COMPONENT SIDE OF BOARD RESISTOR OHMS N C THIS AREA TO BE COVERED ON BOTH SIDES OF BOARD WHERE POSSIBLE WITH SEALANT PRIOR TO ENCAPSULATION ND INJECT SEALANT ITEM 8 THROUGH THE PC BOARD SEAL MODULE LEADS 16 PLACES AND ALL COMPONENT LEADS ON THE NONO COMPONENT T OF un BOARD THAT ARE COVERED BY MODULE CASE PARTNO DESCRIPTION N E FEMALE EYELET TO BE AGAINST THE NON COMPONENT SIDE AS SHOWN 63831 8 BOARD BLANK EYELET MUST NOT SPIN AFTER CLINCHING Mi610044 ELECTRONIC MODULE AT A2 N F SOLDER EYELET SO THAT SOLDER COVERS ENTIRE EYELET 523006 TERMINAL 8211 8218 8204 8205 8209 AND ALL AROUND EYELET COPPER SIDE ONLY M19612 CURRENT TRANSDU
64. 20Volts pe ow p 200 Amps S 5is r SVolts 00 Amp BW Gate Drive els z amp Z RS232 nil T olo c 5 2 4 4 gt GENERAL INFORMATION ELECTRICAL SYMBOLS PER E1537 CAPACITORS MFD 02250V UNLESS OTHERWISE SPECIFIED RESISTORS Ohms MW UNLESS OTHERWISE SPECIFIED LABELS DIODES UNLESS OTHERWISE SPECIFIED A SUPPLY VOLTAGE NET Nores SINGE COMPONENTS OR ORCUTRY ONAPRITED CRCUT BOARD AY CHANCE THE NTERCHANGEABLITY OF A COMPLETE BOARD S DIAGRAM MAY Not show THE EXACT COMPONENTS OR CINGUTRY OF CONTROLS HAVING A COMMON CODE Nees Power supptv source PONT 7 COMMON CONNECTION FRAME CONNECTION QE EARTH GROUND CONNECTION THIS SHEET OONTANS PROPRIETARY RFORVATON OWNED BY THE LNCOLN ELECTRIC COMPANY AND IS NOT TO EE REPRODUCED DISCLOSED OR USED WITHOUT TEETFESSWRTIENPERISSON OF THE LINCOLN ELECTRIC CONPANY CLEVELAND OHOUSA K INFO Chg Sheet No DESIGN INFORMATION REFERENCE EQUIPMENT TYPE Di ital 5 stems EDU DRAWN BY JPNK 9 n ENGNEER SUBIECT Schematic Digital Power Supply DATE TH30 98 DRAWNGNo G 3631 ACESS OTHERWISE SPECTIED TOLERANT MANUFACTURING TOLERANCE PER E2056 ON 2 PLACE DECIMALS IS 02 ON 3 PLACE DECIMALS IS 002 ON ALL ANGLES IS 5 OF A DEGREE MATERIAL TOLERANGE ll TO AGREE WITH PUBLISHED STANDARDS DO NOT SCALE THIS DRAWING
65. 32 Supply 5 VDC 5 Supply 5VDC n 1 y GENERAL DESCRIPTION The Power Wave semi automatic 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 and pulse welding modes The Power Wave power source is designed to be used with the semi automatic family of power feed wire feeders operating as a system Each component in the system has special circuitry to talk with the other system components so each component power source wire feeder user interface knows what the other is doing at all times These components com municate with Arc Link a digital communications sys tem The POWER WAVE 355M 405M is a high performance digitally controlled inverter welding power source capable of complex high speed waveform control Properly equipped it can support the GMAW GMAW P FCAW SMAW GTAW and CAC A processes It car ries an output rating of 350 Amps 34 Volts at 60 duty cycle and 300 Amps 32 volts at 100 duty cycle INPUT LINE VOLTAGE AUXILIARY TRANSFORMER amp PRECHARGE The POWER WAVE 355M 405M can be connected for a variety of three phase or single phase input volt ages The initial power is applied to the 355M 405M through a line switch located on the front of the machine Two phases of the input voltage are applied to the auxiliary transformer The auxiliary
66. AND SWITCHED PC BOARDS TO VERIFY PROBLEM will help avoid denial of legitimate PC board warranty claims POWER WAVE 355M 405M LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Q 42 Return to Section Return to Master TOC 5 s z 9 E F 4 TROUBLESHOOTING AND REPAIR Observe Safety Guidelines detailed in the beginning of this manual PROBLEMS POSSIBLE AREAS OF SYMPTOMS MISADJUSTMENT S Major physical or electrical damage is evident when the sheet metal cover is removed The machine is dead no output no LED s The main input fuses or breaker repeatedly fail OUTPUT PROBLEMS 1 Contact your local authorized Lincoln Electric Field Service Facility for technical assistance 1 Make sure the input line switch is in the ON position 2 Check the main input line fuses If open replace 3 Check the 15 amp circuit break er CB1 Reset if tripped Also check CB3 4 Make sure the reconnect switch and jumper lead is configured correctly for the applied input voltage 5 If the machine is being operated with single phase input voltage make sure the correct lead is not connected See th Installation 1 Make certain the fuses or break ers are sized properly 2 Make sure the reconnect switch and jumper lead is configured correctly for the applied i
67. AVE 355M 405M Return to Section TOC Return to Master TOC Return to Section TOC O o Fle PEN 212 o 1 Return Section Return to Master Return to Master TOC G 3 ELECTRICAL DIAGRAMS SCHEMATIC COMPLETE MACHINE IENGINEERING CONTROLLED CHANGE DETAIL Released from X EN 170 LINCOLN B MANUFACTURER INPUT SW G GREE GREENYELLOW COLOR FOR PW405 denn AUXILIARY TRANSFORMER H3 H5 CB2 2 5A RECONNECT SWITCH Lashed ines represent copper busconnecfons Shown connected for 200 240 Volt Input Voltage SWITCH BOARD R1 206 E N FAN CONTROL F J20 6 lt FAN POWER J22 2 k J22 1 K J22 3 lt J20 2 lt Sch L11487 MA 209 RELAY AIN VIF CONVERTER 2 PULSE TRANSFORMER J20 1 1 J20 5 15 J20 4 CONTROL BOARD Sch G3789 15V gt J21 7 gt 605 SNUBBER E a gt S 2 E BOARD Sch S24761 MAIN RELAY CONTROL VOLTAGE FREQUENCY CONVERTER 1 PRIMARY CURRENT SENSE 1 pores OUT lt J90 3 lt 15V J90 1 PRIMARY CURFENT SENSE 1 CURRENTFEEDBACK 4V 500A T 15V 90 2 GND lt J90 4 p mE CONTROL BOARD COMMON
68. BLES CONNECTIONS AND LIMITATIONS Connect a work lead of sufficient size and length 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 excessive lengths and do not coil excess cable CAUTION When using inverter type power sources like the Power Waves use the largest welding electrode and work cables that are practical At least 2 0 copper wire even if the average output current would not normally require it When pulsing the pulse current can reach very high levels Voltage drops can become excessive leading to poor weld ing characteristics if undersized welding cables are used Most welding applications run with the electrode being positive For those applications connect the elec trode cable between the wire feeder and the positive output Twist Mate terminal on the power source Connect the other end of the electrode cable to 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 con tact The electrode cable should be sized according to the specifications given in the output cable connections section Connect a work lead from the negative power source
69. CER 12 T3 NO ICICLES OR SOLDER BLOBS PERMITTED 524866 POWER TERMINAL B201 B208 N G AFTER SOLDERING INSPECT POWER TERMINAL CONNECTIONS T9147 11 EYELET FEMALE TO ENSURE SOLDER HAS PROPERLY WET COMPONENT SIDE PAD TTE EYELET MALE ON A MINIMUM OF 3 OF THE 4 LEGS OF THE POWER TERMINAL N H BAR MUST FREE OF ENCAPSULATION MATERIAL ON BOTH SURFACES AROUND MOUNTING HOLES AND ENTIRE LENGTH OF MOUNTING SURFACE ENCAPSULATION MATERIAL MUST NOT EXTEND BEYOND THE MOUNTING SURFACE PLANE 2 PLACES DO NOT COAT WITH ENCAPSULATION MATERIAL TOP AND BOTTOM 80 05 DIA PC BOARD HOLES BE FREE OF ENCAPSULATION MATERIAL AND SEALANT MAKE PER E1911 FOR A DIAMETER OF 50 FOR THE LARGER HOLES AND 25 FOR THE SMALLER NN J HOLES BOTH SIDES OF BOARD 4 PLACES ENCAPSULATE WITH E1844 3 COATS 2 PLACES L THIS AREA TO BE COVERED ON COMPONENT SIDE OF BOARD WITH SEALANT PRIOR TO ENCAPSULATION MATERIAL MUST BE APPLIED FROM TOP TO COMPLETELY FIL TO UNDERSIDE OF DEVICE THEN APPLY SEALANT AROUND TEST PER E3817 SW N M THIS AREA TO BE COVERED ON OPPOSITE COMPONENT SIDE OF BOARD WITH ITEM 8 PRIOR TO ENCAPSULATION DO NOT COAT WITH ENCAPSULATION MATERIAL ON THE TOP SURFACES NOR THE THREADS N N THESE SURFACES MUST BE MAINTAINEDCO PLANAR WITHIN 010 THROUGH ENTIRE SOLDERING AND SEALING PROCESS N P SEALANT HEIGHT BETWEEN MODULES NOT TO EXCEED 17
70. COLN B F 13 Return to Section TOC Return to Master TOC Return to Section TOC olo PJE Sl gt om Bo esc 5 2 2 c Return to Section TOC Return to Master TOC Return to Master TOC F 14 TROUBLESHOOTING AND REPAIR F 14 INPUT FILTER CAPACITOR DISCHARGE PROCEDURE continued VU AR ATTN ELECTRIC SHOCK can kill e Have an electrician install and service this equipment e Turn the input power off at the fuse box before working on equipment Do not touch electrically hot parts e Prior to performing preventative maintenance perform the following capacitor discharge procedure to avoid electric shock DISCHARGE PROCEDURE 1 Remove the input power to the POWER WAVE 355M 405M 2 Using the 5 16 wrench remove the screws from the case wraparound cover 3 Be careful not to make contact with the capacitor terminals located at the top and bottom of the switch board 4 Obtain a high resistance and high wattage resistor 25 1000 ohms and 25 watts minimum This resistor is not with the machine NEVER USE A SHORTING STRAP FOR THIS PROCEDURE 5 Locate the eight capacitor terminals shown in fig ure 1 6 Using electrically insulated gloves and pliers hold the body of the resistor with the pliers and con nect the resistor leads across the two capacitor terminals Hold the resistor in place for 10 sec onds DO NOT TOUCH CAPACITOR TERMINALS WITH YOUR BARE HANDS
71. COLN B NOTES POWER WAVE 355 405 LINCOLN amp F 18 DOL J81Se N 01 DOL 181SEN 01 DOL J81Se N 01 DOL J81Se N 01 DOL uonoesg 0 uit DOL uonoesg 0 uit DOL uonoesg 0 uit DOL uonoesg 0 Return to Section TOC Return to Master TOC Return to Section TOC olo PJE Sl gt ol esc 5 2 ele Return to Section TOC Return to Master TOC Return to Master TOC F 19 TROUBLESHOOTING AND REPAIR INPUT RECTIFIER TEST A 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 1 888 935 3877 TEST DESCRIPTION This test will help determine if the input rectifier has shorted or open diodes MATERIALS NEEDED Analog Voltmeter Ohmmeter Multimeter 5 16 Nut Driver Phillips Head Screwdriver Wiring Diagram POWER WAVE 355M 405M LINCOLN B F 19 Return to Section TOC Return to Master TOC Retu
72. DC Bus Board 3 Perform the 4 Perform the Power Board 5 Perform the Module Test 6 The control board may be faulty 7 The input filter capacitors may be faulty Check and replace if necessary 1 Perform the Output Rectifier 2 Perform the Main Switch 3 Perform the 4 Perform the Current Transducer Test 5 The control board may be faulty CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed Call 1 888 935 3877 POWER WAVE 355M 405M LINCOLN B F TROUBLESHOOTING AND REPAIR r Observe Safety Guidelines detailed in the beginning of this manual PROBLEMS POSSIBLE AREAS OF RECOMMENDED SYMPTOMS MISADJUSTMENT S COURSE OF ACTION FUNCTION PROBLEMS The machine regularly overheats 1 The welding application may 1 The 115VAC fan motor is con and the yellow thermal light is ON be exceeding the recommended trolled by the control board vi indicating a thermal overload duty cycle of the POWER WAVE the main switch board Perform 355M 405M Fan Motor And Control Test Dirt and dust may have clogged est the cooling channels inside the 1 A thermostat or associated cir machine cuitry may be faulty See the wiring diagram One normall closed thermostat is located on the output choke one on the DC Bus Board a
73. H VOLTAGE IS PRESENT AT THE SWITCH BOARD If the 115VAC is NOT present in the previous step then proceed to the fan control test FAN CONTROL TEST PROCEDURE 1 Locate plug J20 on the switch board Do not remove the plug from the switch board See Figure 4 F46 Energize the weld output terminals Select Weld Terminals ON and carefully check for 15VDC at plug J20 pin 6 to J20 pin 2 leads 715 to 716 See Figure F 16 If the 15VDC is present and the fan is not running then the switch board may be faulty If the 15VDC is not present when the weld terminals are energized then the control board may be faulty Also check plugs J20 J7 and all asso ciated leads for loose or faulty connections See the Wiring Diagram WARNING HIGH VOLTAGE IS PRESENT AT THE SWITCH BOARD Remove the input power to the POWER WAVE 355M 405M Note The fan motor may be accessed by the removal of the rear panel detailed in Current Transducer Removal Replacement Procedure 4 Replace the case wrap around cover FIGURE F 16 PLUG J20 Lead 716 Lead 715 Plug J20 POWER WAVE 355M 405M LINCOLN B F 45 NOTES PAG POWER WAVE 355M 405M LINCOLN F 46 DOL J81Se N 01 DOL 181SEN 01 DOL J81Se N 01 DOL J81Se N 01 DOL uonoesg 0 uit DOL uonoesg 0 uit DOL uonoesg 0 uit DOL uonoesg 0 Return to Section TOC Return to Master TOC Retur
74. ISE SPECIFIED RESISTORS Ohms 1 40 UNLESS OTHERWISE SPECIFIED 010065 1A 400V UNLESS OTHERWISE SPECIFIED EQUIP TYPE SUBJECT R 267 X 33 L 1 00 4 LABELS SUPPLY VOLTAGE NET INVERTER WELDERS SCHEMATIC DIGITAL CONTROL SUP S D G pare 98 02 2000 cu NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual far G3789 100 POWER WAVE 355M 405M ELECTRICAL DIAGRAMS 0 5 SCHEMATIC DIGITAL CONTROL BOARD 2 681 9 Return Section Return to Master lt 2 SVRS232 10VRS232 MC1454070W 5VRS232 Return to Section TOC Return to Master TOC 10VRS232 ee ee ee 2 25 2 smi ua USACRU 5 25 CONTROL BOARD an VOLTAGE SUPPLIES D om P24 p23 fe STATUS 22 5 o F 5 8 9S9 0 12 g 2 5 3 o ajo airs STATUS 1 __ gt SANS Miwmp27 p2i pe ANT P26 P202 4 00 br ADORISI 2 ral im TRF ra 07 BUSS H JN ARI me B matano EU apo bd ang sca bs aB u ADORIEI d pa amp 2 0 A D sQ Dali mum Bz DATALAD E M Aim E E DATADAS er V ecan ASV CAN COMMUNICATION CIRCUITRY
75. 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 111 119 575 60 olo PJE Sl olz om po ec 51 2 c Return to Section TOC Return to Master TOC POWER WAVE 355M 405M LINCOLN B e TABLE OF CONTENTS DIAGRAM SECTION e E 5 Electrical Diagrams 2 2 2 2 2 2 22 2224 2 4 lt 24 G 1 gt E WirmaDiagram GAIS D ses uu u LT iQ au ass Pacte or Dad alay Nd and Dp AP c d G 2 Entire Machine Schematic 604132 1 G 3 Control PC Board Schematic 1 G3789 1D0 1 ananasa anaana G 4 Control PC Board Schematic 2 G3789 1D0 2 G 5 Control PC Board Schematic 3 G3789 1D0 3 G 6 i Control PC Board Schematic 4 G3789 1D0 4 G 7 Control PC Board Assembly S25385 for 355 S25425 for 405 3 Digital Power Supply PC Board Schematic 603631 G 8 E Digital Power Supply PC Board Assembly 3632
76. January 2008 POWER WAVE 355M 4D5M For use with machine code numbers 11141 11142 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 increased by proper installation and thoughtful operation on your part DO NOT INSTALL OPERATE OR REPAIR THIS EQUIPMENT WITHOUT READ ING THIS MANUAL AND THE SAFETY PRECAUTIONS CON TAINED THROUGHOUT And most importantly think before you act and be carelul Return to Master TOC View Safety Info Pe Xs 5 oz se gt 0 2 gt View Safety Info NCOLN Copyright 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 Return to Master TOC Return to Master TOC 0o s z 9 E Return to Master SAFETY A WARNING Diesel engine exhaust and some of its constituents are known to the State of California to cause can cer birth defects and other reproductive harm A CALIFORNIA PROPOSITION 65 WARNINGS A The engine exhaust from this product contains chemicals known to the State of California to cause cancer birt
77. L 181SEN 01 DOL J81Se N 01 DOL J81Se N 01 DOL uonoesg 0 uit DOL uonoesg 0 uit DOL uonoesg 0 uit DOL uonoesg 0 Return to Section TOC Return to Master TOC Return to Section TOC olo PJE Sl gt ol esc 5 2 ele Return to Section TOC Return to Master TOC Return to Master TOC F 73 TROUBLESHOOTING AND REPAIR CURRENT TRANSDUCER REMOVAL AND REPLACEMENT A 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 1 888 935 3877 DESCRIPTION The following procedure will aid the technician in removing the current transducer for maintenance or replacement MATERIALS NEEDED 5 16 Nut Driver 1 4 Nut Driver 1 2 Nut driver 3 8 Nut Driver Channel Locks Flathead Screwdriver Phillips Head Screwdriver Hammer Crescent Wrench Pliers POWER WAVE 355M 405M LINCOLN B F 73 TROUBLESHOOTING AND REPAIR r CU
78. L BOARD lt 3 Es 1 4W UNLESS OTHERWISE SPECIFIED UNLESS OTHERWISE SPECIFIED 06 22 00 L11487_1C MFD 022 50V UNLESS OTHERWISE SPECIFIED Ohms DATE 1A 400V RECONNECT 206 CLEVELAND OHIO U S A FILENAME THE LINCOLN ELECTRIC CO GENERAL INFORMATION ELECTRICAL SYMBOLS PER E1537 CAPACITORS RESISTORS DIODES R9 33K SW R10 Return to Section TOC Return to Master TOC 13K c 206 FILTER CAPACITOR gt THE LINCOLN ELECTRIC 022 x3 2 33074A 5 33074A H 11 e PRIMARIES TRANSFORMER 33K SW Z FOW FILTER 28 CAPACITOR Yo 171 pg Tt DRIVE RECONNECT 203 PWM DRIVE 14 12 THE LINCOLN ELECTRIC IN 6 2 2000 NO u lt 619 V F CONVERTER 2 2915VDC CA
79. OARD Return to Section TOC Return to Master TOC REQD PARTNO DESCRIPTION ITEM PART NO DESCRIPTION m M19532 A P C BOARD BLANK vdOXxoa 13157 16 TERMINAL o T9147 11 EYELET FEMALE vdoxos8 4 T9147 15 EYELET MALE 4 B1 x 5 NOTES N A FEMALE EYELET TO BE AGAINST THE COPPER SIDE AS SHOWN EYELET MUST NOT SPIN AFTER CLINCHING N B SOLDER EYELET SO THAT SOLDER COVERS ENTIRE EYELET AND ALL AROUND EYELET ON COPPER SIDE ONLY NO ICICLES OR SOLDER BLOBS PERMITTED Return to Section TOC Return to Master TOC HEIGHT COPPER SIDE EYELET DETAIL MANUFACTURED AS SNUBBER ENCAPSULATE WITH E1844 2 COATS TEST PER E3817 SN PER E1911 M19532 1A0 IDENTIFICATION CODE Return to Section TOC Return to Master TOC 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 OHIO U S A MANUFACTURING TOLERANCE PER E2056 ON 2 PLACE DECIMALS IS 02 6 2 2000 EQUIPMENT TYPE INVERTER WELDERS ON 3 PLACE DECIMALS IS 002 MATERIAL TOLERANCE rt TO AGREE ENGINEER JOU BIECT SNUBBER P C BOARD ASSEMBLY APPROVEB SCALENONE X DATEIO 6 99 DRAWINGNon 19532 1 Return to
80. ONNECTOR 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 CONNECTOR PLUG J43 TROUBLESHOOTING AND REPAIR POWER BOARD TEST CONTINUED TABLE F 3 POWER BOARD VOLTAGE CHECKS TEST CONNECTOR LEAD NO OR DESCRIPTION PLUG PIN NO IDENTITY CHECK 40 VDC INPUT FROM DC BUS BOARD CHECK 15 VDC SUPPLY FROM POWER BOARD CHECK 5 VDC SUPPLY FROM POWER BOARD CHECK 15 VDC SUPPLY FROM POWER BOARD CHECK 5 VDC ARCLINK SUPPLY FROM POWER BOARD CHECK 5 VDC RS 232 SUPPLY FROM POWER BOARD CHECK 5 VDC SPI SUPPLY FROM POWER BOARD POWER WAVE 355M 405M LINCOLN B F 25 NORMAL ACCEPTABLE VOLTAGE READING 38 42 VDC NOTES 355 405 LINCOLN amp F 26 DOL J81Se N 01 DOL 181SEN 01 DOL J81Se N 01 DOL J81Se N 01 DOL uonoesg 0 uit DOL uonoesg 0 uit DOL uonoesg 0 uit DOL uonoesg 0 Return to Section TOC Return to Master TOC Return to Section TOC olo PJE Sl gt ol esc 51 ele Return to Section TOC Return to Master TOC Return to Master TOC F 27 TROUBLESHOOTING AND REPAIR DC BUS BOARD TEST A WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel Unauthorized repairs performed on this equip
81. OWER WAVE 355M 405M LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC olo PJE ojeg Sl gt ol esc 51 ele Return to Section TOC Return to Master TOC ES 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 switch board one is located on the output choke and the third thermostat is located on the DC Bus Board Excessive tempera tures may be caused by a lack of cooling air or oper ating the machine beyond its duty cycle or output rat ing 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 air intake louvers are obstructed then the power must be removed from the machine and the fan problem or air obstruction corrected PROTECTIVE CIRCUITS Pro
82. P 5 89VDC VREF B 1 000KHZ 400V 4 1VDC CHANGE ON CAP 6H2 1 R40 10 0K o Fle 5 PEN gt 8 o 1 NOT SHOW THE EXACT COMPONENTS OR CIRCUITRY OF CONTROLS HAVING A COMMON CODE WITHOUT AFFECTING THE INTERCHANGEABILITY OF COMPLETE BOARD THIS DIAGRAM MAY NUMBER SINCE COMPONENTS OR CIRCUITRY ON A PRINTED CIRCUIT BOARD MAY CHANGE ON HOLES SIZES PER E 2056 ON 2 PLACE DECIMALS IS 02 WITH PUBLISHED STANDARDS N A ON 3 PLACE DECIMALS 1S 002 ON ALL ANGLES IS 5 OF A DEGREE AND IS NOT TO BE REPRODUCED DISCLOSED OR USED WITHOUT THE EXPRESS PERMISSION OF THIS SHEET CONTAINS PROPRIETARY INFORMATION OWNED BY UNLESS OTHERWISE SPECIFIED TOLERANCE MATERIAL TOLERANCE TO AGREE l CAPACITOR k 24 X on s NS AL ee 1 R127 Le 3K 5 33 Sw eo R26 Let RIZ Le L 9047 33K 5W 33K 5W 5 X OHN 5 5 CAPACITOR ZUM Oom pot pr eue n
83. ROL BOARD LOCATION Control Board PROCEDURE 1 3 Remove input power to the POWER WAVE 4 355M 405M Using a 5 16 nut driver remove the case wrap around cover Perform the Input Filter Capacitor Discharge Procedure Hetailed earlier in this section Locate the control board behind the front panel of the machine See Figure F 17 Using a 5 16 nut driver remove the two screws from the bottom of the front of the machine See Figure F 18 FIGURE F 18 CASE FRONT SCREW REMOVAL Lj status THERMAL 9 999900009099 5 00000000000 Phillips Head Screws Phillips Head Screws 5 16 Mounting Screws POWER WAVE 355M 405M LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC olo PJE Sl olz o S9 ec 5 2 c Return to Section TOC Return to Master TOC Return to Master TOC F4 TROUBLESHOOTING AND REPAIR pM CONTROL BOARD REMOVAL AND REPLACEMENT continued FIGURE F 19 CONTROL BOARD ALL PLUG LOCATIONS 8 CAUTION Observe static precautions detailed in 9 Board Troubleshooting Procedures at the beginning of this section 6 Using a phillips head screwdriver remove the two 10 screws and their washers from above and below the input power switch See Figure F 18 7 Using a phillips head s
84. RRENT TRANSDUCER REMOVAL AND REPLACEMENT continued PROCEDURE 1 Remove input power to the POWER WAVE 4 Using a 5 16 nut anver remove the four screws 355M 405M from the bottom and right side of the rear assem bly See Figure F 34 2 Using a 5 16 nut driver remove the case wrap around cover 3 Perform the Input Filter Capacitor Discharge detailed earlier in this section Return to Section TOC Return to Master TOC FIGURE F 34 CASE BACK SCREW LOCATIONS REAR Return to Section TOC Return to Master TOC olo PJE Sl gt om so ec 51 ele Plastic C Nut 5 16 Mounting Screws Return to Section TOC Return to Master TOC POWER WAVE 355M 405M LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC olo PJE Sl gt om so ec 51 ele Return to Section TOC Return to Master TOC E TROUBLESHOOTING AND REPAIR rm CURRENT TRANSDUCER REMOVAL AND REPLACEMENT continued 5 Label and remove the four leads connected to the 9 Using a hammer and a flathead screwdriver firmly reconnect panel Pliers may be necessary tap the metal nut from the bottom of one of its ribs This tapping will loosen the nut Note Be sure to 6 Label and remove the two leads connected to the tap
85. S PER E1537 CAPACITORS 022 50V UNLESS OTHERWISE SPECIFIED RESISTORS Ohms 1 4W UNLESS OTHERWISE SPECIFIED 0100 5 1A400V UNLESS OTHERWISE SPECIFIED LAST NO USED LABELS SUPPLY VOLTAGE NET POWER SUPPLY SOURCE POINT V COMMON CONNECTION 77 FRAME CONNECTION QC EARTH GROUND CONNECTION FILENAME 63789 10 Ch os Sht No X INFO UNLESS OTHERWISE SPECIFIED TOLERANCE ON PLACE DECIMALS IS 2 d 6 2 2000 zz ON 3 PLACE DECIMALS IS 002 ON ALL ANGLES IS 5 OF A DEGREE MATERIAL TOLERANCE 7 TO AGREE WITH PUBLISHED STANDARDS 8 4 2000 NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual THE LINCOLN ELECTRIC CO PG scaE _ a aim INVERTER WELDERS sueJecr SCHEMATIC DIGITAL CONTROL R 3789 109 CLEVELAND OHIO U S A 03 NONE FM SUP S D G POWER WAVE 355M 405M ELECTRICAL DIAGRAMS 857 SCHEMATIC DIGITAL CONTROL BOARD 4 5 5 68159 5 o SHT gt DATAI0 15 s 5 gt sat D a _ _ sv gt olo c amp ev c SHT 2 5 5 c 139 0139 Votes 185 DATAI6I 51 si 100184118 Sr 551 SHT 1 rr 2 10142 01811181 RAW shr 1 ojo 5 1 05 0101 mia 100190180 ADORI1 OSP_0191 org 101791079 101 A SHT 2 15501 155 1 05 _08 17 yo147 101781178 ADORI A AD_DATAI0
86. Suppl Primary Current Feedback 2 o Input Relay Control E Z Auxiliary Soft Start Control 5 c s 220 VAC Transformer S V F Capacitor Feedback 2 o 8 40VDC Machine Control Supply Yellow 3 15VDC 15VDC 5VD Power 48 90 15VDC 2pVDCS yu Board Control Board RS232 Supply 5VDC M Can Supply 5VDC Li x 40VDC R232 Connector Thermostats 2 POWER WAVE 355M 405M LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC olo gt 0 15 514 Sla 2 c Return to Section TOC Return to Master TOC ES THEORY OF OPERATION Ee FIGURE E 2 GENERAL DISCRIPTION mani poaru Input Input switch Rectifier Reconnect Fan Control swith NA Primary Current Feedback 2 115VAC Fan Suppl ppy Input Relay Control Soft Start Control Positive Output Terminal Negative Output Terminal Primary Current Sensor 1991 Output Voltage Sense 120515 Yellow Thermal LED Control Board Status Red Green LED gt Bus 40VDC E VIF Capacitor Feedback 2 w e c Machine Control Supply W 40VDC 15VDC 15VDC 5VDC 2 d RS2
87. T switching circuits When welding output is required the Insulated Gate Bipolar Transistors switch the DC power from the input capacitors on and off thus supplying a pulsed DC current to the main transformer primary windings IGBT Operation Discussion and Diagrams in this section Each IGBT switching circuit feeds current to a separate oppositely wound primary winding in the main transformer The reverse directions of current flow through the main transformer primaries and the offset timing of the IGBT switching circuits induce an olo F i To Control 5 Main Switch Board Board HE off Positive cle Input a Output 15 Input switch Rectifier L Terminal 5 Sensor E _ Negative oc Reconnect Output M pf Switch Terminal LL gt Primary 2 5 emis O 8 D KS 115VAC Fan iM Primary Current Feedback 2 15 IHE Fn eey Input Relay Control E 2 Auxiliary 8 Soft Start Control 5 5 220 VAC Transformer amp Capacitor Feedback 2 2 a x O Machine Control Supply Yell olo w 40VDC 415VDC 15VDC 5VDC Thema I V Power LED cl e Board Control Board Stat 9 4 RS232 Supply 5VDC gt Rm olg 5 Can Supply 5VDC LED lz o e n DC olo Bus Board 40VDC Connector Thermostats c yo 2 AC square wave output signal at the secondary of the main transformer The two cu
88. To Control Main Switch Board Board Positive Input e Output Input switch Rectifier Lo Enos Terminal Sensor 5 2 Negative Reconnect Output J P Switch Terminal 2 Current 5 Sensor e e D 8 115VAC Fan 24 Primary Current Feedback 2 o SEG SH E Input Relay Control Si Auxiliary 8 Soft Start Control 8 Capacitor Feedback 2 2 3 220 VAC Transformer S 5 8 Machine Control Supply Yellow w 40VDC J 15VDC 15VDC 5VDC Thermal LED e Board Control Board Status 4 RS232 Supply 5VDC Jesi 5 Can Supply 5VDC LED n 1 L 5 y 40VDC R232 Connector Thermostats 2 DC BUS BOARD POWER BOARD AND CONTROL BOARD DC BUS 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 40VDC is applied to the Power Board and the wire feed receptacles POWER BOARD The power board utilizing a switching power supply processes the 40VDC input and develops several reg ulated positive and negative DC supplies Three DC supplies are fed to the control board for machine con trol supplies A 5VDC is used for the RS232 connec tion supply Another 5
89. Troubleshooting Procedures Jit the beginning of driver Note the position of the washers behind each nut for replacement this section Failure to do so can result in perma nent damage to equipment 4 Locate the main switch board and all associat ed plug and lead connections See figure F 21 See Wiring Diagram POWER WAVE 355M 405M LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC olo PJE Sl gt om so ec 5 2 ele Return to Section TOC Return to Master TOC Return to Master TOC F 53 9 TROUBLESHOOTING AND REPAIR MAIN SWITCH BOARD REMOVAL amp REPLACEMENT continued FIGURE 22 3 16 ALLEN BOLT LOCATION 1 L o o c O 9 4 Jr IKEE 5 3 16 ALLEN BOLTS _ ce 9 cK O O Using 3 16 allen wrench remove four allen bolts and washers as shown in Figure F 22 At this point the board is ready for removal Carefully maneuver the board out of the machine Apply a thin coat of Penetrox A 13 to the IGBT heatsinks on the back of the new switch boards mating surfaces Note Keep compound away from the mounting holes Replace the four allen bolts and washers previously removed Replace the eight capacitor terminal nuts washers and necessary leads previously removed Reconnect the three harness plugs previous ly remove
90. UBBER BOARD LEADS CLOSE UP olo PJE c f i olg 514 gt om so ec 51 ele Lead 10 Return to Section TOC Return to Master TOC POWER WAVE 355M 405M LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC olo PJE Sl gt ol esc 51 ele Return to Section TOC Return to Master TOC Return to Master TOC F 57 TROUBLESHOOTING AND REPAIR POWER BOARD REMOVAL AND REPLACEMENT A 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 1 888 935 3877 DESCRIPTION The following procedure will aid the technician in removing the power board for mainte nance or replacement MATERIALS NEEDED 5 16 Nut Driver 3 8 Nut Driver POWER WAVE 355M 405M LINCOLN B F 57 pos TROUBLESHOOTING AND REPAIR dns POWER BOARD REMOVAL AND REPLACEMENT continued FIGURE F 25 POWER BOARD LOCATION Power Bo
91. UXILIARY TRANSFORMER TEST continued olo 5 FIGURE 10 Auxiliary Transformer m Auxiliary al Transformer HE ojo Secondary Lead Plugs P52 o O IE 42 9 m Return to Master TEST PROCEDURE 1 Remove input power to the POWER WAVE 4 Locate the auxiliary transformer See Figure olo 355M 405M F 10 O 2 Using a 5 16 nut driver remove the case 5 Locate the secondary leads and plug P52 6 wraparound cover See Figure F 10 and F 11 o 9 3 3 Perform the Input Capacitor Discharge e s Procedure detailed earlier in this section 2 FIGURE F 11 Plug Lead Connections Viewed From Transformer Lead Side of Plug amp c PW405 Only 220V 532 115V SEN Plug 52 O FTE 6 5 L I 52 oe Com 2 ele 31 5 5 2 2 POWER WAVE 355 405 LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC olo PJE Sl gt ol esc 5 2 ele Return to Section TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING AND REPAIR AUXILIARY TRANSFORMER TEST continued TABLE F 5 LEAD IDENTIFICATION 42 TO COM 1A quick connects Carefully apply the correct input voltage to the POWER WAVE 355M 405M and check for the correct secondary voltages per table F5 Make sure the reconnect jumper lead and switch are con
92. 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 malfunctions Simply follow the three step procedure listed below Step 1 LOCATE PROBLEM SYMPTOM Look under the column labeled PROBLEM SYMPTOMS This column describes pos sible symptoms that the machine may exhib it Find the listing that best describes the symptom that the machine is exhibiting Symptoms are grouped into the following categories output problems function prob lems wire feeding problems and welding problems Step 2 PERFORM EXTERNAL TESTS The second column labeled POSSIBLE AREAS MISADJUSTMENT S lists the obvious external possibilities that may con tribute to the machine symptom Perform these tests checks in the order listed In general these tests can be conducted with out removing the case wrap around cover Step 3 RECOMMENDED COURSE OF ACTION The last column labeled Recommended Course of Action lists the most likely com ponents that may have failed in your machine It also specifies the appropriate test procedure to verify that the subject com ponent is either good or bad If there are a number of possible com
93. V b POWER SUPPLY SPI GND b J43 12 R2 10 Ohms GND SPI b 5V RS232 5 RS232 RS232 e J43 4 GND e SUPPLY GND e gt J43 9 244841 gt 20 0 2442 8 gt CHOPPER TOPPER GND c gt J43 2 J9 6 s SUPPLY 20 d 5J43 7 gt GND d 43 1 gt lt J9 4 lt lt J11 1 lt lt J11 2 J11 4 VOLTAGE SENSE LINCNET LINCNET 5 gt J43 5 GND 43 10 lt J11 3 lt VOLTAGE FREQUENCY CONVERTER 1 FLAT SIDE OF LED ALIGNED WITH BLACK LEAD THERMAL YELLOW LED STATUS RED GREEN lt LED L FLAT SIDE OF LED ALIGNED WITH WHITE LEAD Jo 15 53 A LINCNET 54 67 52 WIRE FEEDER RECEPTACLE lt B LINCNET lt C ELECTRODE SENSE D 40 VDC 51 E OVDC o 45 6 58 CONNECTOR NUMBERING SEQUENCE VIEWED FROM COMPONEN SIDE OF BOARD PC BOARD CONPONENTS SHOWN FOR REFERENCE NOTES 4 2 21 ONLY ALL COMPONENTS ARE NOT SHOWN B INPUT LINE FILTER IS PRESENT ONLY ON PW405 ON PW405 MOV s AFE IN THE INPUT POWR LINE FILTER PLACE A LEAD ONAPPROPRIATE CONNECTIONFOR INPUT VOLTAGE CONNECTION SHOWN 8 FOR 550 575 OPERATION PW405 ONLY GO TO 415 ACT TOLERANCE PER E206 t DECIMALS IS 02 ON SPACE
94. V UNLESS OTHERWISE SPECIFIED TMS320F 240 1 FILENAME 63789 10 THIS SHEET CONTAINS PROPRIETARY INFORMATION OWNED BY THE LINCOLN ELECTRIC CO AND 15 NOT TO BE REPRODUCED DISCLOSED OR USED WITHOUT THE EXPRESS PERMISSION OF LINCOLN ELECTRIC CO 50 tess oreet THE LINCOLN ELECTRIC FP INVERTER WELDERS NOTES ON 2 PLACE DECIMIS IS 2 02 CLEVELAND OHIO U S A SCHEMATIC DIGITAL CONTROL SINCE COMPONENTS OR CIRCUITRY ON A PRINTED CIRCUIT BOARD MAY CHANGE ON 3 PLACE DECIMALS 18 002 04 WITHOUT AFFECTING THE INTERCHANGEABILITY OF A COMPLETE BOARD THIS DIAGRAM MAY ON ALL ANGLES IS 5 OF A DEGREE ste _ SHT NOT SHOW THE EXACT COMPONENTS OR CIRCUITRY OF CONTROLS HAVING A COMMON CODE FM pate 08 02 2000 SUP S D G na 63789 100 NUMBER 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 rae POWER WAVE 355M 405M ae ELECTRICAL DIAGRAMS G 8 SCHEMATIC POWER SUPPLY PRINTED CIRCUIT BOARD Return to Section TOC Return to Master TOC H fa 20 une 5Volts 750 Amp 10 55 VDC w
95. VDC supply is utilized by the CAN digital communication circuitry An over or under input voltage detection and shutdown circuit is also part of the power board s circuitry Feeder CONTROL BOARD The Control Board performs the primary interfacing functions to establish and maintain output control of the POWER WAVE 355 405 The function genera tor and weld files exist within the Control Board hard ware and software Digital command signals received from the user interface feed head and feedback infor mation received from the current sensor and output voltage sensing leads are 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 Sed PULSE WIDTH MODULATION n this section to the switch board IGBT s In this manner the digitally controlled high speed welding waveform is created 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 s output NOTE Unshaded areas of Block Logic Diagram are the subject of discussion POWER WAVE 355M 405M LINCOLN B THEORY OPERATION FIGURE E 5 OUTPUT RECTIFIER AND CHOKE
96. anual PROBLEMS POSSIBLE AREAS OF SYMPTOMS MISADJUSTMENT S The machine does not have weld ing output The POWER WAVE 355M 405M will not produce full output OUTPUT PROBLEMS 1 Make sure the reconnect switch is configured correctly for the input voltage applied 2 Primary current limit has been exceeded Possible short in output circuit Turn machine off Remove all loads from the output of the machine Turn back on If condition persists turn power off and contact an authorized Lincoln Electric Field Service Facility 3 This problem will normally be accompanied by an error code Error codes are displayed as a series of red and green flashes by the status LED 4 If an error code is displayed If thermal light is on wait for machine to cool 1 The input voltage may be too low limiting the output capabili ty of the machine Make cer tain the input voltage is correct for the machine and the recon nect switch and jumper lead configuration are correct 2 The output current or voltage may not be calibrated correctly Check the values displayed on the Power Feed 10 11 versus readings on an external voltage and ammeter 3 The welding current may be too high The machine will fold back to 100 amps if the weld ing current exceeds 450 amps RECOMMENDED COURSE OF ACTION 1 Check the reconnect switch and associated leads for loose or faulty connections See the wiring diagram 2 Perform the
97. ard Return to Section TOC Return to Master TOC o O IE 42 9 m Return to Master LEFT SIDE olo e E 912 Bia o 2 coe Be e S 3 dle PROCEDURE 3 Perform the Input Filter Capacitor Discharge 1 E power to the POWER WAVE Procedure detailed earlier in this section 4 Locate the power board See Figure F 25 2 Using a 5 16 nut driver remove the case wrap around cover Return to Section TOC Return to Master TOC POWER WAVE 355M 405M LINCOLN da TROUBLESHOOTING AND REPAIR dnd POWER BOARD REMOVAL AND REPLACEMENT continued 7 Remove the three nuts at the corners of the board CAUTION using a 3 8 nut driver Board is ready for removal 8 Replace the power board Observe static precautions detailed in 9 Secure the new power board into its proper posi Board Troubleshooting Procedures at the tion with the three 3 8 nuts previously removed beginning of this section Return to Section TOC Return to Master TOC 10 Reconnect the three plugs previously removed Plugs J41 J42 and J43 5 Locate the three plug connections J41 J42 and J43 on the Power Board See figure F 26 11 Replace the case wraparound cover 6 Carefully disconnect the three plugs from the Power Board FIGURE F 26 POWER BOARD LEAD LOCATION Return to Section TOC Return to Master TOC J42 J41 M
98. ated behind the snubber board See figure F 32 Before the output rectifier modules can be reached the Snubber Board Removal Procedure must be performed TROUBLESHOOTING AND REPAIR F0 OUTPUT RECTIFIER MODULES REMOVAL AND REPLACEMENT con t 6 After the snubber board is removed remove the four leads connected to the modules using a 3 16 allen wrench These leads are X4 X2 20 40 Note their positions for reassembly Remove the copper plates from the tops of the modules NOTE Any instructions that are packaged with the replacement part will supercede these instruc tions FIGURE F 32 OUTPUT RECTIFIER MODULE LEAD LOCATIONS Modules Snubber Board LEFT SIDE POWER WAVE 355M 405M LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC olo PJE olg Sl gt om Bo esc 5 2 ele Return to Section TOC Return to Master TOC Return to Master TOC F 71 10 11 12 9 64 Allen Under the copper plate previously removed there is an allen bolt Remove it using a 9 64 allen wrench See Figure F 33 Using a 7 16 socket remove the mounting bolts at the top and bottom of the modules See Figure F 33 The output rectifier modules are ready for removal and or replacement Before replacing the diode module apply a thin even coat of Penetrox A 13 heatsink compound to the bottom surface of the diode modul
99. become under or over voltage the control board will de energize the input relays and the 355M 405M out put will be disabled Other possible faults may also cause the input relays to drop out NOTE Unshaded areas of Block Logic Diagram are the subject of discussion POWER WAVE 355M 405M LINCOLN B E 3 FIGURE SWITCH BOARD amp MAIN TRANSFORMER olo O 919 c nx olg Sl gt om Bo ec Sla 2 c Return to Section TOC Return to Master TOC SWITCH BOARD amp MAIN TRANSFORMER There is one switch board in the POWER WAVE 355M 405M This board incorporates two pairs of input capacitors two insulated gate bipolar transistor IGBT switching circuits a fan motor drive circuit and a voltage frequency capacitor feedback circuit The two capacitors in a pair are always in series with each other When the reconnect switch is in the lower volt age position the capacitor pairs are in parallel that is two series capacitors in parallel with two series capac itors When the reconnect switch is in the high voltage position the two capacitor pairs are in series or four capacitors in series This is required to accommodate the higher input voltages When the input capacitors are fully charged they act as power supplies for the IGB
100. board Replace any previously removed cable ties Replace plugs J2 J4 J5 J6 J7 28 J9 J10B and J10A previously removed Replace the two screws and their washers from above and below the input power switch 19 20 21 Replace the four screws from around the two welder output terminals on the front of the machine Replace the two case front mounting screws at the bottom of the front of the machine Replace the case wraparound cover POWER WAVE 355M 405M LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC olo PJE Sl gt ol esc 5 2 ele Return to Section TOC Return to Master TOC Return to Master TOC F 51 TROUBLESHOOTING AND REPAIR MAIN SWITCH BOARD REMOVAL amp REPLACEMENT A 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 1 888 935 3877 DESCRIPTION
101. c components in the welding installation and adjacent to it should be considered However metallic components bonded to the work piece will increase the risk that the operator could receive a shock by touching these metallic components and the electrode at the same time The operator should be insulated from all such bonded metallic components Earthing of the Workpiece Where the workpiece is not bonded to earth for electrical safety not connected to earth because of its size and position e g ships hull or building steelwork a connection bonding the workpiece to earth may reduce emissions in some but not all instances Care should be taken to prevent the earthing of the workpiece increasing the risk of injury to users or damage to other electrical equipment Where necessary the con nection of the workpiece to earth should be made by a direct connection to the workpiece but in some countries where direct connection is not permitted the bonding should be achieved by suitable capacitance selected according to national regulations Screening and Shielding Selective screening and shielding of other cables and equipment in the surrounding area may alleviate problems of interference Screening of the entire welding installation may be considered for special applica tions 1 Portions of the preceding text are contained in 60974 10 Electromagnetic Compatibility EMC product standard for arc welding equipment 110093 3 1 96
102. cables can influence the voltage apparent at the studs of the welder Voltage sense leads improve the accuracy of the arc conditions and can have a dramatic effect on performance Sense Lead Kits K940 10 25 or 50 are available for this purpose CAUTION If the voltage sensing is enabled but the sense leads are missing improperly connected or if the electrode polarity switch is improperly configured extremely high welding outputs may occur The ELECTRODE sense lead 67 is built into the con trol cable and is automatically enabled for all semi automatic processes The WORK sense lead 21 con nects to the Power Wave at the four pin connector By default the WORK voltage is monitored at the output stud in the POWER WAVE 355 405 For more informa tion on the WORK sense lead 21 sed Work Voltage Sensing in the following paragraph POWER WAVE 355M 405M LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o 42 Return to Section Return to Master TOC n s z 9 iis INSTALLATION 256 Enable the voltage sense leads as follows TABLE A 1 Electrode Voltage Sensing 67 lead 67 lead required 67 lead required 67 lead required Voltage sense at studs Voltage sense at studs 67 lead required Voltage sense at studs Work Voltage Sensing 21 lead 21 lead optional 21 lead opt
103. cally thereafter to be certain it is within applicable OSHA PEL and ACGIH TLV limits 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 prod ucts Shielding gases 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 Also see item 1 b Aug 06 Return to Master TOC Return to Master TOC n s z 9 E Return to Master SAFETY y Z WELDING SPARKS 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 6 b Where compressed gases are to be used at the job site special precautions shou
104. check for 115VAC at plug J22 pin 2 machine to J22 pin 3 leads 32A to 31B C See Figure 15 WARNING HIGH VOLTAGE IS PRE SENT AT THE MAIN SWITCH BOARD FIGURE F 15 PLUG J22 olo 0 Sl gt om so ec 51 ele Fan Lead Lead 32A Lead 31B C Fan Lead Plug J22 Return to Section TOC Return to Master TOC POWER WAVE 355M 405M LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC olo C PJE c f w Si gt om Bo esc 5 2 2 c Return to Section TOC Return to Master TOC Return to Master TOC F 45 T TROUBLESHOOTING AND REPAIR FAN CONTROL AND MOTOR TEST continued If the 115VAC is low or not present check cir cuit breaker CB2 located on the front panel If the circuit breaker is OK perform Check plug J22 circuit breaker CB2 and associated leads for loose or faulty connections See the Wiring Diagram Energize the weld output terminals with the PW 355M 405M in mode 200 This mode can be accessed using a wire feeder placed in mode 200 or a laptop computer and the appro priate software Carefully check for 115VAC at plug J22 pin 1 to J22 pin 4 fan leads Figure F 15 If the 115VAC is present and the fan is not running then the fan motor may be faulty Also check the associated leads between plug J22 and the fan motor for loose or faulty connections See the Wiring Diagram WARNING HIG
105. coln wire feeders cannot be used All welding programs and procedures are selected through the Power Feed semi automatic user interface REQUIRED EQUIPMENT Any Arclink compatible semi automatic wire feeding equipment Specifically the semi automatic Power Feed family PF10M Series Power Feed 15M and Power Feed 25M LIMITATIONS Only Arclink compatible Power Feed semi automatic wire feeders and users interfaces may be used Other Lincoln wire feeders or non Lincoln wire feed ers cannot be used POWER WAVE 355M 405M Output Limitations The POWER WAVE 355M 405M will support maxi mum average output current of 350 Amps 60 duty cycle DUTY CYCLE AND TIME PERIOD The duty cycle is based upon a ten minute period A 60 duty cycle represents 6 minutes of welding and 4 minutes of idling in a ten minute period 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 2 STATUS LIGHT A two color light that indicates sys tem errors Normal operation is a steady green light Error conditions are indicated per table B 1 NOTE The POWER WAVE 355M 405M 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 normally with wire
106. crewdriver remove the four 11 screws from around the two welder output termi nals on the front of the machine See Figure F 18 The front of the machine may now gently be pulled forward to gain access to the Control Board Note The front of the machine cannot be removed completely only pulled forward a few inches Beginning at the right side of the control board remove plugs J10A and J10B Note Be sure to label each plugs position upon removal See Figure F 19 Working your way across the top of the board from right to left label and remove plugs J9 J8 J7 J6 and J5 See Figure F 19 Working your way down the left side of the board label and remove plugs J4 and J2 See Figure F 19 POWER WAVE 355M 405M LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC olo PJE Sl 514 om so ec 5 2 ele Return to Section TOC Return to Master TOC Return to Master TOC F 50 12 13 15 16 17 18 TROUBLESHOOTING AND REPAIR F 50 CONTROL BOARD REMOVAL AND REPLACEMENT continued Using a 3 8 nut driver remove the two mounting nuts from the top two corners of the control board See Figure F 20 Cut any necessary cable ties 14 Replace the control board FIGURE F 20 CONTROL BOARD MOUNTING SCREW LOCATION Mounting Nuts 3 8 Replace the two 3 8 mounting nuts at the top two corners of the control
107. d 15 16 17 18 19 Reconnect the nine leads 8201 4209 that were previously removed Replace any necessary cable ties previously removed Pre torque all screws to 25 inch Ibs before tightening to 44 inch Ibs Replace the input lead shield previously removed Replace the case wraparound cover NOTE Any instructions that are packaged with the replacement board will supercede these instructions POWER WAVE 355M 405M LINCOLN B F 53 NOTES E94 POWER WAVE 355M 405M LINCOLN amp F 54 DOL J81Se N 01 DOL 181SEN 01 DOL J81Se N 01 DOL J81Se N 01 DOL uonoesg 0 uit DOL uonoesg 0 uit DOL uonoesg 0 uit DOL uonoesg 0 Return to Section TOC Return to Master TOC Return to Section TOC olo PJE Sl gt ol esc 5 2 ele Return to Section TOC Return to Master TOC Return to Master TOC F 55 TROUBLESHOOTING AND REPAIR SNUBBER BOARD REMOVAL AND REPLACEMENT A 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 perfo
108. dip switches at each node Consult the PF 10 11 Instruction Manual for specific details regarding dip switch settings Feed head 0 not allowed Exception Simple sys tem ignores all ID numbers therefore FHO will func tion Return to Section TOC Return to Master TOC Each node must be connected to the Linc Net com munication network The order of connection is not important as each node is identified by it s unique Group and Feed Head ID number as defined on it s dip switches See Figures A 2 thru A 5 Simple System FIGURE A 2 olo PJE Sl gt ol esc 51 ele Power Wave Group and Feed Head ID numbers are ignored in a simple system Return to Section TOC Return to Master TOC POWER WAVE 355M 405M LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Q o 42 Return to Section Return to Master TOC ss z 9 9 Multiple Group System Power Wave Single Group Multi Head System INSTALLATION FIGURE A 3 FIGURE A 4 POWER WAVE 355M 405M LINCOLN B A 9 No FHO Allowed No FHO Allowed The Dual Head option allows the ability to maintain 2 sets of procedures If more then 2 heads are used odd s use FH1 settings even s use FH2 settings Return to Section TOC Return to Master TOC R
109. djust the grid load to obtain 300 amps on the 12 Replace the control box top and any cable ties external ammeter and check feedback volt previously removed ages pet lable Ee 13 Install the case wraparound cover using the A Pin 1 lead 801 to Pin 6 lead 806 should 5 16 nut driver read 2 4 VDC machine loaded to 300 amps 9 If for any reason the machine cannot be loaded to 300 amps Table shows what feedback voltage is produced at various cur rent loads olo 0 c f i Sl gt om so ec 51 ele 10 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 Return to Section TOC Return to Master TOC POWER WAVE 355M 405M LINCOLN B NOTES POWER WAVE 355 405 LINCOLN amp F 42 DOL J81Se N 01 DOL 181SEN 01 DOL J81Se N 01 DOL J81Se N 01 DOL uonoesg 0 uit DOL uonoesg 0 uit DOL uonoesg 0 uit DOL uonoesg 0 Return to Section TOC Return to Master TOC Return to Section TOC olo PJE Sl gt ol esc 51 ele Return to Section TOC Return to Master TOC Return to Master TOC F 43 TROUBLESHOOTING AND REPAIR FAN CONTROL AND MOTOR TEST A WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel Unauthorized repairs
110. dures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 1 888 935 3877 TEST DESCRIPTION This test will help determine if any of the output diodes are shorted MATERIALS NEEDED Analog Voltmeter Ohmmeter Wiring Diagram POWER WAVE 355M 405M LINCOLN B F 31 TROUBLESHOOTING AND REPAIR nee OUTPUT RECTIFIER MODULES TEST continued FIGURE F 7 Machine Output Terminals 299990020090 6 A 00000000000 Return to Section TOC Return to Master TOC o O IE 42 9 m Return to Master LL oO o NEGATIVE POSITIVE OUTPUT OUTPUT amp s TERMINAL TERMINAL S 9148 olz ole TEST PROCEDURE E 1 Remove input power to the POWER WAVE 4 Using the analog ohmmeter test for more 2 E 355M 405M than 200 ohms resistance between positive and negative output terminals Positive test 2 Locate the output terminals on the front lead to the positive terminal i Negative test panel of the machine See Figure F7 lead to the negative terminal 3 Remove any output cables and load from the output terminals NOTE The polarity of the test leads is most important If the test leads polarity is not cor rect the test will have e
111. e Note Keep the compound away from the mounting holes Press the module firmly against the sink while aligning the mounting holes Insert each outer screw through a spring washer and then a plain washer and into the holes Start threading all three screws into the heat sink 2 or 3 turns by hand TROUBLESHOOTING AND REPAIR OUTPUT RECTIFIER MODULES REMOVAL AND REPLACEMENT con t 13 14 15 16 15 16 17 F 71 The screw threads may catch on the threads of the heat sink so be sure to get the face of the screw into contact with the surface of the module using just hand torque Using a 7 16 socket tighten each mounting bolt to between 5 and 10 inch pounds Tighten the center allen screw to between 12 and 18 inch pounds Tighten each mounting bolt again 30 to 40 inch pounds this time Replace leads X2 X4 20 40 to their original terminals in their proper positions Torque bolts to 30 40 Inch Pounds Perform the Snubber Board Replacement Procedure detailed earlier in this section Replace the case wraparound cover FIGURE F 33 OUTPUT RECTIFIER MODULE MOUNTING BOLT LOCATIONS Mounting 40 20 Bolts 3 16 Allen Bolts Bolts Mounting Bolts POWER WAVE 355M 405M LINCOLN B NOTES r POWER WAVE 355 405 LINCOLN amp F 72 DOL J81Se N 01 DO
112. e the output diode heatsink assembly pre viously removed using a 3 8 wrench Note Be sure to place insulation in its original location Replace leads X2 20 X4 40 previously removed from the two output diode modules Torque to 30 40 inch Ibs Perform the Snubber Board Replacement Procedure 29 30 31 32 33 34 35 36 The rear of the machine may now be placed back into its original position Using 3 8 wrench replace leads 202 203 206 and 207A previously removed from the reconnect switches Tighten the metal nut previously removed from the inside of the rear wall on the back of the machine Channel locks may be necessary Replace the large plastic nut from around input power line located at the back of the machine Replace the four leads to the reconnect panel in their proper locations Replace the two CB2 circuit breaker leads previ ously removed Using a 5 16 nut driver replace the four screws from the rear assembly Replace the case wraparound cover POWER WAVE 355M 405M LINCOLN B pm TROUBLESHOOTING AND REPAIR s 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
113. ecommended Welding Procedures for Power Mode TABLE B 2 MATERIAL Aluminum 4043 Aluminum 5356 Mild Steel Mild Steel Mild Steel Mild Steel Mild Steel Mild Steel Stainless Steel Stainless Steel WIRE E4043 E5356 L56 L56 L56 L56 L56 L56 E308L E308L WIRE SIZE 0 035 0 035 0 030 0 035 100 Agr 100 Agr 100 75 25 gt 100 75 25 Ar CO gt 100 75 25 Ar CO gt Tri mix Tri mix Not Not recommended 008 recommended 9010 120 1 0 120 1 0 100 0 7 100 1 0 80 1 5 50 0 5 olo 0 G f ie 514 om Bo EIS 5 2 ele 140 17 140 1 5 110 1 5 110 1 5 100 2 5 100 2 5 110 2 0 110 2 0 190 2 0 190 2 0 125 2 0 125 2 0 125 3 0 125 3 0 140 2 5 130 2 7 400 2 0 400 2 5 260 3 0 260 3 0 160 2 3 160 2 3 160 3 8 160 3 5 210 3 0 190 3 5 330 5 0 330 4 5 230 3 5 230 3 5 200 5 0 200 4 5 270 5 0 230 6 0 z M 5 E ES x x lt gt 500 7 0 500 7 0 300 6 0 300 6 0 240 6 5 240 7 0 325 6 5 300 7 0 WFS POWER MODE SETTING 570 90 600 7 8 400 7 5 400 7 0 700 9 1 700 8 5 Not Not Recommended Recommended below 400 below 400 WFS WFS COMMENTS Return to Section TOC Return to Master TOC POWER WAVE 355M 405M LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC 2 42
114. ection TOC Return to Master TOC Current flow from Arc 2 affects sense lead 1 Source Neither sense lead picks up the correct work voltage causing starting and welding arc instability BETTER Sense 1 is only affected by weld current from Arc 1 Return to Section TOC Return to Master TOC Sense 2 is only affected by weld current from Arc 2 Due to voltage drops across work piece Arc voltage may be low causing need for deviation from standard procedures Power Source BEST Both Sense leads are out of the current paths 5 s gt 2 Both Sense leads detect arc voltage accurately i 2 o 42 Source No voltage drop between Arc and Sense lead Best starts best arcs most reliable results Return to Section TOC Return to Master TOC POWER WAVE 355M 405M LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC olo olg 88 gt ol 5 2 ele Return to Section TOC Return to Master TOC Return to Master TOC O RECEPTACLE SPECIFICATIONS CONTROL BOARD DIP SWITCH TABLE 2 switch 1 reserved for future use WIRE FEEDER RECEPTACLE switch 2 reserved for future use LEAD FUNCTION switch 3 reserved for future use Communication Bus L switch 4 reserved for future use Communication Bus H switch 5 reserved for future use
115. ectric recommends using a minimum of 2 0 welding cable for pulse welding Return to Section TOC Return to Master TOC POWER WAVE 355M 405M LINCOLN B Return to Section TOC Return to Master TOC A3 INSTALLATION TECHNICAL SPECIFICATIONS POWER WAVE 405 INPUT AC VOLTAGE amp DC OUTPUT Rated DC Output Weight Amps Volts Duty Cycle with Cord Ordering Information Voltage Output Range continuous 86 5lbs 87 4 kg Dimensions HxWxD 14 7 x12 5 x 2068 373x318x 706 mm Includes handles 350A 34V 60 Power 200 208 3 Phase Wave 2152 2 220 240 320A 33V 60 405 380 415 3 50 60 60 50 Hz 275A 31V 10096 1 Phase 300A 32V 100 3 Phase Overall Length Including Handle 21 6 b49mm without handle POWER WAVE 405 INPUT CURRENT Recommended Fuse Sizes Based On The U S National Electrical Code And Maximum Machine Outputs Input 50 60 Hz Output Recommended Voltage Phases 300Amps 350Amps Line Cord Size Fuse Size 32Volts 100 34Volts 60p6 Size mm 200 80A 220 80A 50A 50A Notes Return to Section TOC Return to Master TOC Note 2 Note 2 275Amps 33Volts 60 Not Recommended Line Cord Size mm Not Recommended 320Amps Fuse Size 31Volts 100 1 Not rated is indicated by 4 x s in the box on the rating plate 2 When operating on these inputs the line cord should be changed to an input conductor of 6 AWG or larger
116. el correspondingly to main tain similar arc characteristics throughout the WFS range Non Synergic CV This type of CV mode behaves more like a convention al CV power source Voltage and WFS are independent adjustments Therefore to maintain the arc characteris tics the operator must adjust the voltage to compen sate for any changes made to the WFS All CV Modes Arc Control often referred to as wave control adjusts the inductance of the wave shape The wave control adjustment is similar to the pinch function in that it is inversely proportional to inductance Therefore increasing wave control greater than 0 0 results in a harsher colder arc while decreasing the wave control to less than 0 0 provides a softer hotter arc See Figure B 2 FIGURE B 2 att CURRENT WAVE FORM CV te ita Aara Atanan POWER WAVE 355M 405M LINCOLN B TIG GTAW NOTE Later versions of weld software In SMAW STICK mode the arc control adjusts the arc force It can be set to the lower range 0 to 10 for io DE a soft and less penetrating arc characteristic or to the short circuit TIG touch f current is maintained at higher range 0 to 10 for a crisp and more penetrat approximately 25 amps independent of the preset ing arc Normally when welding with cellulosic types of current When the tungsten is lifted an arc is initiated electrodes E6010 E7010 E601 1 a higher energy and the output is regulated at t
117. er and the positive output Twist Mate terminal on the power source Connect the other end of the electrode cable to 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 con tact The electrode cable should be sized according to the specifications given in the output cable connec tions section Connect a work lead from the negative power source output Twist Mate terminal to the work piece The work piece connection must be firm and secure especially if pulse welding is planned For additional Safety information regarding the elec trode and work cable set up See the standard SAFE TY INFORMATION located in the front of the Instruction Manuals POWER WAVE 355M 405M LINCOLN B Return to Master TOC Return to Master TOC 9 Return to Master TABLE OF CONTENTS OPERATION SECTION B PERO cm B 1 oatetyPrecautloris E temer qu E h asss e B 2 General Description cane eee aE i AAA RORA S AA sakha sasa AEA SAARE ra B 2 Recommended Processes and 201 0 B 2 Required 04 u LU 3 Lin A cat s
118. er to the Power o Wave 355M 405M 5 Turn on the Power Wave 355M 405M The ele LED on the DC Bus Power Supply PC Board EIS should light o 2 ole 2 FIGURE F 6 DC BUS POWER SUPPLY POWER SUPPLY PC BOARD tc J47 447 475 51 Rectifier lt 477 52 Jy H E 9 E J46 J COR Thermostat P m Ka Z Y s 66 65 LJ 918 A ele J46 e 2 2 POWER WAVE 355 405 LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC olo ale Sl olz om Bo ec 51 2 c Return to Section TOC Return to Master TOC Return to Master TOC F 29 TROUBLESHOOTING AND REPAIR F 29 DC BUS BOARD TEST CONTINUED 6 Check the DC Bus Board input and outp voltages according to Table F 4 See Figure K6hnd the Wiring Diagram A WARNING ELECTRIC SHOCK can kill High voltage is present at the ter minals of Capacitor C3 near where testing is to be done 7 If all the voltages are correct the DC Bus Board is operating properly 8 If any of the output voltages are not correct and the input voltage is correct the DC Bus Board may be faulty 9 If the input voltage is not correct check the leads between the DC Bus Board and the Bus Rectifier See the Wiring Diagram 10 When finished testing replace the case wraparound cover TABLE F 4 DC BUS POWER SUPPLY PC BOARD VOLTAGE TABLE Positive Mete
119. es appear to be due to 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 Ifthe problem persists replace the suspect PC board using standard practices to avoid static electrical damage and electrical shock Read the warning 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 ohm resistive cord connected to a grounded part of the equipment frame ATTENTION Static Sensitive If you don t have a wrist strap touch an un painted grounded part of the equipment frame Keep touching the frame to prevent static build up Be sure not to touch any electrically live parts at the same time Devices Handle only at Static Safe Workstations 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
120. eturn to Master TOC Return to Section TOC Return to Master TOC o 42 Return to Section Return to Master TOC s z 9 INSTALLATION SYSTEM DESCRIPTION The POWER WAVE 355M 405M and Power Feed 10 11 family of products utilize a digital communication system called Arclink Simply put Arclink allows large amounts of information to be passed at very high speeds between components nodes in the system The system requires only two wires for communication and because of its bus like structure the components may be connected to the network in any order thus simplifying the system set up Each system must contain only one power source The power source may be connected to a maximum of four feeder groups Each group containing one user interface Ul and up to seven Feed Heads FH SEE FIGURE A 1 The UI controls all of the FH s of that group The Ul s and FH s are assigned to groups by setting a code on the DIP switches mounted on their individual control boards For example all of the FH s to be controlled by a given UI must have their Group ID switches set to the same group number as the Ul In addition each FH must be assigned a separate FH number within that group See the system set up sec tion for further details System Model Maximum Configuration Power Wave 455 From a network perspective each component in the
121. eturn to Section TOC Return to Master TOC o 42 Return to Section Return to Master TOC s z 9 10 INSTALLATION Single Group Multi Head System Alternate Method FIGURE A 5 f Power Wave POWER WAVE 355M 405M LINCOLN B No FHO Allowed When a standard User Interface is used in a group with multi ple Feed Heads all of the Feed Heads use a single set of proce dures Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC 42 Return to Section Return to Master TOC s z 9 11 WELDING WITH MULTIPLE POWER WAVES CAUTION Special care must be taken when more than one 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 stud 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 below 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 When these parameters are identical the puls ing freq
122. f the machine Thermal error Indicates over temperature Usually accompanied by ther mal LED Check fan operation Be sure process does not exceed duty cycle limit of the machine WELL Capacitor precharge failed Usually accompanied by codes 32 35 Secondary overcurrent error The secondary weld current limit has been exceeded When this occurs the machine output will phase back to 100 amps typically resulting in a condition referred to as noodle welding NOTE The secondary limit is 570 for the standard stud and 325 amps for all single phase operation POWER WAVE 355M 405M LINCOLN B FH TROUBLESHOOTING AND REPAIR Pn Capacitor delta error The maximum voltage difference between the main capaci tors has been exceeded May be accompanied by errors 32 35 Check the output diodes Error codes that contain three or four digits are defined as fatal errors These codes generally indicate internal errors on the Control Board If cycling the input power on the machine does not clear the error try reloading the operating system If this fails replace the Control Board Return to Section TOC Return to Master TOC Return to Section TOC o IE P 2 m tc Return to Section TOC POWER WAVE 355M 405M LINCOLN B NOTES POWER WAVE 355 405 LINCOLN amp F 12 DOL J81Se N 01 DOL 181SEN 01 DOL J81Se N 01 DOL J81Se N 01 DOL uonoesg 0 uit DOL
123. feeder and its components if other feeder amp components show they are powered up Occurs during a reset and indicates the POWER WAVE 355M 405M is mapping identifying each component in the system Normal for first 1 10 seconds after power is turned on or if the system configuration is changed during operation Non recoverable system fault If the PW Status light is flashing any combination of red and green errors are present in the POWER WAVE 355M 405M Read the error code before the machine is turned off Error Code interpretation thro light is detailed in the Individual code digits are flashed in red with a long pause between digits If more than one code is present the codes will be sepa rated by a green light To clear the error turn power source off and back on to reset Non recoverable hardware fault Generally indicates nothing is connected to the POWER WAVE 355M 405M wire feeder receptacle See Trouble Shooting Section Steady Red Blinking Red Not applicable 3 HIGH TEMPERATURE LIGHT thermal overload A yellow light that comes on when an over temper ature situation occurs Output is disabled and the fan continues to run until the machine cools down When cool the light goes out and output is enabled 4 CB1 WIRE FEEDER CIRCUIT BREAKER Protects 40 volt DC wire feeder power supply POWER WAVE 355M 405M LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC olo
124. figure the work voltage sense lead appropriately ELECTRODE VOLTAGE SENSING Enabling or disabling electrode voltage sensing is auto matically configured through software The 67 elec trode sense lead is internal to the cable to the wire feeder and always connected when a wire feeder is present PF10M feeder has user preference features to select voltage senses temporarily for testing sense leads CAUTION Important The electrode polarity must be config ured at the feed head for all semi automatic processes Failure to do so may result in extreme ly high welding outputs POWER WAVE TO SEMI AUTOMATIC POW ERFEED WIRE FEEDER INTERCONNEC TIONS The POWER WAVE 355M 405M and semi automatic Power Feed family communicate via a 5 conductor control cable K1543 The control cable consists of two power leads one twisted pair for digital communica tion and one lead for voltage sensing The cables are designed to be connected end to end for ease of exten sion The output receptacle on the POWER WAVE 405M is on the case front The input receptacle on the Power Feed is typically located at the back of the feed er or on the bottom of the user interface Due to the flexibility of the platform the configuration may vary The following is a general description of the system For specific configuration information consult the semi automatic Power Feed instruction manual POWER WAVE 355M 405M LINCOLN Return to Section TOC R
125. figured correctly for the input voltage being applied sure circuit breaker CB3 is functioning properly NOTE The secondary voltages will vary if the input line voltage varies If the correct secondary voltages are present the auxiliary transformer is functioning proper ly If any of the secondary voltages are miss ing or low check to make certain the primary is configured correctly for the input voltage applied See Wiring Diagram NORMAL EXPECTED VOLTAGE COM 2 31 TO 115V 532 115 VAC 42 VAC F 37 WARNING High voltage is present at primary of Auxiliary Transformer If the correct input voltage is applied to the primary and the secondary voltage s are not correct the auxiliary transformer may be faulty 10 Remove the input power to the POWER WAVE 11 355 405 Install the case wraparound cover using 5 16 nut driver POWER WAVE 355M 405M LINCOLN B NOTES 38 355 405 LINCOLN amp F 38 DOL J81Se N 01 DOL 181SEN 01 DOL J81Se N 01 DOL J81Se N 01 DOL uonoesg 0 uit DOL uonoesg 0 uit DOL uonoesg 0 uit DOL uonoesg 0 Return to Section TOC Return to Master TOC Return to Section TOC olo PJE Sl gt ol esc 51 ele Return to Section TOC Return to Master TOC Return to Master TOC F 39 TROUBLESHOOTING AND REPAIR CURRENT TRANSDUCER TEST A WARNING Ser
126. figured with many different options your system may not have all of the following adjustments Regardless of availability all controls are described below For further information consult the Power Feed wire feeder instruction manual e WFS AMPS In synergic welding modes synergic CV pulse GMAW WFS wire feed speed is the dominant control para meter controlling all other variables The user adjusts WFS according to factors such as weld size penetra tion requirements heat input etc The Power Wave then uses the WFS setting to adjust its output charac teristics output voltage output current according to pre programmed settings contained in the Power Wave POWER WAVE 355M 405M LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC C 42 Return to Section Return to Master TOC 5 s z 9 OPERATION BN In non synergic modes the WFS control behaves more like a conventional CV power source where WFS and voltage are independent adjustments Therefore to maintain the arc characteristics the operator must adjust the voltage to compensate for any changes made to the WFS In constant current modes stick TIG this control adjusts the output current in amps VOLTS TRIM In constant voltage modes synergic CV standard CV the control adjusts the welding voltage In pulse sy
127. from the bottom so the nut loosens in a counter CB2 circuit breaker clockwise fashion if viewed from the front of the machine 7 Using a crescent wrench remove the large plastic nut from around the input power line located at bot 10 Using a 3 8 nut driver label and remove leads tom of the rear assembly See Figure 5 202 203 206 207A from the reconnect switches See Figure F 35 8 Locate the steel nut located directly on the other side of the rear assembly behind the plastic nut that was previously removed See Figure F 35 FIGURE F 35 LEAD LOCATIONS POWER WAVE 355M 405M LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC olo 0 c f i Sl gt om so ec 51 ele Return to Section TOC Return to Master TOC Return to Master TOC F 76 Perform The back of the machine may now gently be pulled away to gain access to the current trans ducer Note The rear of the machine cannot be removed completely Carefully swing the rear of the machine open to the left while facing the rear of the machine the Procedure Snubber Board Removal Remove leads X2 and 20 from the output diode module Remove leads X4 and 40 from the other output diode module TROUBLESHOOTING AND REPAIR CURRENT TRANSDUCER REMOVAL AND REPLACEMENT continued 16 17 18 19 20 F 76 Usi
128. g place The surrounding area may extend beyond the boundaries of the premises Methods of Reducing Emissions Mains Supply Welding equipment should be connected to the mains supply according to the manufacturer s recommenda tions If interference occurs it may be necessary to take additional precautions such as filtering of the mains supply Consideration should be given to shielding the supply cable of permanently installed welding equipment in metallic conduit or equivalent Shielding should be electrically continuous throughout its length The shielding should be connected to the welding power source so that good electrical contact is maintained between the conduit and the welding power source enclosure Maintenance of the Welding Equipment The welding equipment should be routinely maintained according to the manufacturer s recommendations All access and service doors and covers should be closed and properly fastened when the welding equip ment is in operation The welding equipment should not be modified in any way except for those changes and adjustments covered in the manufacturers instructions In particular the spark gaps of arc striking and stabilizing devices should be adjusted and maintained according to the manufacturer s recommendations Welding Cables The welding cables should be kept as short as possible and should be positioned close together running at or close to floor level Equipotential Bonding Bonding of all metalli
129. h Board and Main IranstOrmor ocio cerei ime la 3 DC Bus Board Power board and Control E 4 Output and 5 esses E 6 Protociivo CICUS f URDU E 6 Over curen POLE CHON i E 6 Under Over Voltage Protection i vec eoa 6 Insulated Gate Bipolar Transistor IGBT Operation 10 0 7 Pulse Width Modulalie ll E 8 Minimum Maximum eg ene ed e thin PRENNE ak 8 lt 20 OA 0 lt 5 0 07 FIGURE E 1 BLOCK LOGIC DIAGRAM To Control Main Switch Board Board gt 22 NZ Positive Input Output Input switch Rectifier Cane Terminal Sensor O Negative Reconnect Output b Switch S Terminal y pa 2 Fan V XL Sensor o 771 ri O 115VAC Fan
130. h defects or other reproductive harm Above For Diesel Engines PERFORMED ONLY BY QUALIFIED INDIVIDUALS FOR ENGINE powered equipment 1 Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running hy h 1 b Operate engines in open well ventilated areas or vent the engine exhaust fumes outdoors 1 c Do not add the fuel near an open flame weld ing arc or when the engine is running Stop the engine and allow it to cool before refuel ing to prevent spilled fuel from vaporizing on contact with hot engine parts and igniting Do not spill fuel when filling tank If fuel is spilled wipe it up and do not start engine until fumes have been eliminated 1 d Keep all equipment safety guards covers and devices in posi tion 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 In some cases it may be necessary to remove safety guards to perform required maintenance Remove guards only when necessary and replace them when the maintenance requiring their removal is complete Always use the greatest care when working near moving parts 1 f Do not put your hands near the engine fan Do not attempt to override the governor or idler by pushing on the throttle control rods while the engine is running
131. he preset value set arc is required to maintain arc stability This is usually ting of 0 results in the most positive arc initiation A indicated when the electrode sticks to the work piece setting of 10 reduces the start procedure to start the or when the arc pops out during manipulative tech weld and from there to ramp to the welding proce hique For low hydrogen types of electrodes E7018 dure over a specified amount of time E8018 E9018 etc a softer arc is usually desirable and the lower end of the Arc Control suits these types of electrodes In either case the arc control is available to increase or decrease the energy level delivered to the arc Cy x E The TIG mode features continuous control from 5 to e rea 2 2 425 TIG mode either the m mode an on y allow 8 amp Touch Start TIG or Scratch start mode Touch Start operation e 2 cle The Arc Control level selects the starting mode SMAW 5 5 2 2 Between 10 0 the Touch Start TIG mode is selected The OCV is controlled below 10V and the A setting above 0 selects a Scratch Start Full OCV is available when the arc initiates the output is regulated to the preset value Typically starting procedure on a higher setting is known as a Hot Start Setting a starting procedure on a lower setting is known as a Cold Start Return to Section TOC Return to Master TOC R
132. ies weld droplet transfer rate the Arc Control can be used to vary the ripple spacing in the weld bead BENEFITS OF PULSE ON PULSE FROM LINCOLN ELECTRIC Excellent appearance of the weld bead Improved cleaning action Reduced porosity Table B 3 shows WFS and Trim settings for common aluminum types and wire sizes when welding with Pulse on Pulse The welds made to obtain the values in the table were fillet welds in the flat position The val ues in the table can be helpful as a starting point to establish a welding procedure From there adjust ments need to be made to set the proper procedure for each specific application out of position other types of joints etc The comments on the table below show values of WFS below which it is not recommended to weld The rea son is that below these values the weld transfer will change from a spray arc to a short arc which is not advisable when welding aluminum TABLE WELDING PROCEDURES FOR PULSE ON PULSE MATERIAL Aluminum 4043 Aluminum 4043 Aluminum 5356 Aluminum 5356 GAS 100 Ar 100 Ar 100 Ar 100 Ar WIRE E4043 E4043 E5356 E5356 WIRE SIZE 0 035 3 64 0 035 3 64 14 ga 250 0 200 0 230 0 225 0 10 ga 400 0 280 0 42510 400 0 3 16 MATERIAL THICKNESS 550 0 340 0 670 0 500 0 ARC CONTROL WFS 1 4 600 0 400 0 700 0 550 0
133. ional 21 lead optional Voltage sense at studs Voltage sense at studs 21 lead optional Voltage sense at studs The electrode voltage 67 sense lead is integral to the control cable to the wire feeder Work Voltage Sensing The standard POWER WAVE 355M 405M default to the work stud work sense lead disabled For processes requiring work voltage sensing connect the 21 work voltage sense lead K940 from the Power Wave work sense lead receptacle to the work piece Attach the sense lead to the work piece as close to the weld as practical but not in the return current path Enable the work voltage sensing in the Power Wave as follows A WARNING Do not touch electrically live parts or electrodes with your skin or wet clothing e e Insulate yourself from the work and ground e Always wear dry insulating gloves switch 2 Remove the wrap around cover from the power source 3 The control board is on the center assembly facing the case front Locate the 8 position DIP switch and look for switch 8 of the DIP switch 4 Using a pencil or other small object slide the switch to the OFF position if the work sense lead is NOT connected Conversely slide the switch to the ON position if the work sense lead is present 123 45 67 8 gt zo 5 Replace the wrap around and screws The PC board will read the switch at power up and con
134. isted Gash A t DeL as LA B 3 Duty Cycle and Time Period u Lu irme e inda ir S Lego sensi Eee o HEX seats B 3 GaSe MEE B 3 Making ael 5 stie toute coat seca esc EEREDAR E Ee ULL PILLE B 4 Wel le Tero evo Siglo iz u u REPRE B 4 Constant Voltage Welding eesseeeseseseeseeeseeeeseeeeenn sensn tenen nr B 5 TIOGTAW MM EN 6 Special Welding Processes u uu uuu B 6 Power C uu sassa aa sasa B 7 Pulse Welding GMAW P r B 8 Pulse on Pulse a B 10 Benefits of Pulse on Pulse 8 8 4 10 POWER WAVE 355 405 LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC olo ale f i olg Sl gt om ec 51 ele Return to Section TOC Return to Master TOC Return to Master TOC He OPERATION P SAFETY PRECAUTIONS Read this entire section of operating instructions before operating the machine WARNING ELECTRIC SHOCK can kill Unless using cold feed feature when feeding with gun trigger the elec trode and drive mechanism are always electrically energized and co
135. l current dis played on the Power Feed 10 5 The control board may be vs actual current measured via faulty external meter Check the actual voltage dis played on the Power Feed 10 vs actual voltage measured via external meter olo ale G f i Sl om po EIS 5 2 ele Check the actual WFS displayed on the Power Feed 10 vs actual WFS measured via external meter CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed Call 1 888 935 3877 POWER WAVE 355M 405M LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Section TOC olo 916 c f i olg PIE g b ol 5 2 ele Return to Section TOC Return to Master TOC Return to Master TOC USING THE STATUS LED TO TROUBLESHOOT SYSTEM PROBLEMS The Power Wave Power Feed are best diagnosed as a system Each component power source user interface and feed head has a status light and when a problem occurs it is important to note the condition of each In addition errors displayed on the user interface in most cases indicate only that a problem exists in the power source not what the problem may be Therefore prior to cycling power to the sys tem check the power so
136. ld 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 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
137. ld read 15 VDC If either of the supply voltages are low or miss 4 Locate plug J8 on the control board Do not ing the control board may be faulty remove the plug from the P C Board 5 Apply the correct input power to the POWER WAVE 355 405 FIGURE 13 Plug J8 Viewed From Lead Side of Plug 802 804 olo PJE Sl gt om so ec 51 ele 801 O 9 9 O Plug J8 Return to Section TOC Return to Master TOC POWER WAVE 355M 405M LINCOLN p TROUBLESHOOTING AND REPAIR AUXILIARY TRANSFORMER TEST continued TABLE F 6 EXPECTED TRANSDUCER FEEDBACK OUTPUT LOAD CURRENT VOLTAGE Return to Section TOC Return to Master TOC e 0 2 S 1 7 8 Check the feedback voltage from the current Before replacing the current transducer check p transducer using a resistive load bank and the leads and plugs between the control board ala with the POWER WAVE 355 405 in mode 08 and the current transducer J90 See The 200 Mode 200 is constant current test Wiring Diagram For access to plug J90 and the current transducer refer to Transducer Removal Replacement mode This mode can be accessed using a wire feeder placed in mode 200 or a laptop computer and the appropriate software Apply the grid load across the output of the POWER gt WAVE 355M 405M Set machine output to 22 300 amps and enable WELD TERMINALS A
138. ll repeat continuously STATUS LED ERROR CODE TABLE CAN communication bus off Probably due to excessive number of communication errors User interface time out error Ul is no longer responding to the Power Source The most likely cause is fault bad connection the communication leads or control cable 21 Unprogrammed weld mode Contact the service department for instructions on reloading the Welding Software 22 Empty weld table Contact the service department for instructions on reloading the Welding Software 23 Weld table checksum error Contact the service department for instructions on reloading the Welding Software 31 Primary overcurrent error Excessive Primary current present May be related to a short in the main transformer or output rectifier Capacitor A under voltage Low voltage on the main capacitors May be caused by improper input configuration Capacitor B under voltage When accompanied by an overvoltage error on the same side it indicates no capacitor voltage present on that side and is usually the result of an open or short in the primary side of the machine Capacitor A overvoltage Excessive voltage on the main capacitors May be caused by improper input configuration Capacitor B overvoltage When accompanied by an under voltage error on the same side it indicates no capacitor voltage present on that side and is usually the result of an open or short in the primary side o
139. llen wrench 5 16 Nut Driver Flathead Screwdriver Penetrox A 13 Heatsink Compound Silicon Sealant POWER WAVE 355M 405M LINCOLN B F 65 r 66 TROUBLESHOOTING AND REPAIR F 09 INPUT RECTIFIER REMOVAL AND REPLACEMENT continued all leads and their positions upon removal 2 Using a 5 16 nut driver remove the case Figure F 31 wraparound cover e o e 5 5 PROCEDURE 5 9 5 1 Remove input power to the POWER WAVE 6 Remove the six screws from the terminals using a 355M 405M flathead screwdriver Carefully note the position of HE 2 2 7 Using 3 16 in allen wrench remove the two 3 Perform the nput Filter Capacitor Discharge mounting screws and washers from the input Procedure detailed earlier in this section bridge See Figure 1 4 Locate the input rectifier See figure F 30 8 Remove the input bridge 5 Carefully remove the silicon sealant insulating the NOTE Any instructions that are packaged with the six input rectifier terminals replacement board will supercede these instructions FIGURE F 30 INPUT RECTIFIER LOCATION INPUT RECTIFIER Return to Section TOC Return to Master TOC olo 0 c f i Sl gt om esc 51 2 c Return to Section TOC Return to Master TOC POWER WAVE 355M 405M LINCOLN B ind TROUBLESHOOTING AND REPAIR ind INPUT RECTIFIER REMOVAL AND REPLACEMENT continued olo e sls
140. ment 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 1 888 935 3877 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 POWER WAVE 355M 405M LINCOLN B F 27 din TROUBLESHOOTING AND REPAIR E28 DC BUS BOARD TEST CONTINUED FIGURE F 5 DC BUS POWER SUPPLY POWER SUPPLY PC BOARD DC BUS BOARD Return to Section TOC Return to Master TOC o O IE 42 9 m Return to Master TEST PROCEDURE A WARNING 1 Remove input power to the machine ELECTRIC SHOCK can kill 2 Using the 3 8 nut driver remove the wrap High voltage is present when around cover input power is applied to the 3 Locate the DC Bus Board See Figure F 5 machine ale 4 Carefully apply input pow
141. n trol Properly equipped it can support the GMAW GMAW P FCAW SMAW GTAW and CAC A process es It carries an output rating of 350 Amps 34 Volts at 60 duty cycle and 300 Amps 32 volts at 100 duty cycle RECOMMENDED PROCESSES AND EQUIPMENT RECOMMENDED PROCESSES The POWER WAVE 355M 405M can be set up in a number of configurations some requiring optional equipment or welding programs Each machine is fac tory preprogrammed with multiple welding procedures typically including GMAW GMAW P FCAW GTAW and CAC A for a variety of materials including mild steel stainless steel cored wires and aluminum The POWER WAVE 355M 405M is recommended for semi automatic welding and may also be suitable for basic hard automation applications This Power Wave is not recommended for processes other than those listed POWER WAVE 355M 405M LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC olo 0 f i S gt 5 2 2 c Return to Section TOC Return to Master TOC B OPERATION E POWER WAVE 355M 405M Operation Semi Automatic Semi Automatic Power Waves can only be used with Arclink compatible Power Feed semi automatic wire feeders In addition the Power Feed semi automatic wire feeders may require optional equipment to access certain weld modes in the Power Wave Other models of Lincoln feeders or any models of non Lin
142. n to Master TOC olo PJE Sl gt ol esc 51 ele Return to Section TOC Return to Master TOC POWER WAVE 355M 405M LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC olo PJE Sl gt ol esc 5 2 ele Return to Section TOC Return to Master TOC Return to Master TOC F 35 TROUBLESHOOTING AND REPAIR AUXILIARY TRANSFORMER TEST A 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 1 888 935 3877 TEST DESCRIPTION This procedure will determine if the correct voltage is being applied to the primary of aux iliary transformer and also if the correct voltage is being induced on the secondary wind ings of the transformer MATERIALS NEEDED Volt ohmmeter Multimeter 5 16 Nut Driver Wiring Diagram POWER WAVE 355M 405M LINCOLN B F 35 TROUBLESHOOTING AND REPAIR Een A
143. n to Section TOC olo PJE Sl gt ol esc 51 ele Return to Section TOC Return to Master TOC Return to Master TOC F 47 TROUBLESHOOTING AND REPAIR CONTROL BOARD REMOVAL AND REPLACEMENT A 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 1 888 935 3877 DESCRIPTION The following procedure will aid the technician in removing the control board for mainte nance or replacement MATERIALS NEEDED 5 16 Nut Driver 3 8 Nut Driver Flathead Screwdriver Phillips Head Screwdriver POWER WAVE 355M 405M LINCOLN B F 47 Return to Section TOC Return to Master TOC Return to Section TOC olo C 916 ojeg ofe gt ol esc 5 2 ele Return to Section TOC Return to Master TOC Return to Master TOC F 48 CONTROL BOARD REMOVAL AND TROUBLESHOOTING AND REPAIR F 48 REPLACEMENT continued FIGURE F 17 CONT
144. n who is competent to access whether the changes will increase the risk of injury e g by allowing parallel welding current return paths which may damage the earth circuits of other equip ment Assessment of Area Before installing welding equipment the user shall make an assessment of potential electromagnetic prob lems in the surrounding area The following shall be taken into account a other supply cables control cables signaling and telephone cables above below and adjacent to the welding equipment b radio and television transmitters and receivers c computer and other control equipment d safety critical equipment e g guarding of industrial equipment e the health of the people around e g the use of pacemakers and hearing aids f equipment used for calibration or measurement g the immunity of other equipment in the environment The user shall ensure that other equipment being used in the environment is compatible This may require additional protection measures h the time of day that welding or other activities are to be carried out 110093 3 1 96 LINCOLN B Return to Master TOC Return to Master TOC o s z 9 E Return to Master vi SAFETY Electromagnetic Compatibility The size of the surrounding area to be considered will depend on the structure of the building and other activities that are takin
145. nd the other is located on the main switch board heat sink See the wiring diagram Return to Section TOC Return to Master TOC Air intake and exhaust louvers may be blocked due to inade quate clearance around the machine Make certain the fan as needed is operating properly The fan should operate when The Main Switch Board welding voltage is present Removal Procedure will be and or when there is an over required to gain access to temperature condition the heat sink thermostat Return to Section TOC Return to Master TOC An attached wire feeder will not Make certain the wire feeder 1 Check for 40 VDC on D function correctly Apparently the control cable is connected to and pin E at the Power Wave wire feeder is not being powered the wire feeder receptacle See wire feeder receptacle See up the Wiring Diagram Wiring Diagram If 40 volts DC is Not present at the Power Wave wire feeder receptacle perform the Board Test The wire feeder or control cable 2 Check the DC Bus Board rectifi may be faulty er See Wiring Diagram 3 Perform the T1 Auxiliary trans If the 40 volts DC is present at the Power Wave wire feeder receptacle the problem is in the control cable or the wire drive control box Check the two circuit breakers located at the front of the machine Reset if tripped olo 0 G NE T Sl gt om Be EIS 5 2 ele
146. nergic welding modes pulse GMAW only the user can change the Trim setting to adjust the arc length It is adjustable from 0 500 to 1 500 A Trim set ting of 1 000 is a good starting point for most condi tions WELDING MODE May be selected by name CV MIG CC Stick Crisp Gouge etc or by a mode number 10 24 71 etc depending on the Control Box options Selecting a welding mode determines the output characteristics of the Power Wave power source A more complete description of all modes can be found in this section ARC CONTROL Also known as Inductance or Wave Control Allows operator to vary the arc characteristics from soft to harsh in all weld modes It is adjustable from 10 0 to 10 0 with a nominal setting of 00 0 The nominal set ting of 00 0 may be displayed as OFF on some Power Feed wire feeder control panels See the Welding Mode descriptions for a more detailed explanations of how the Arc Control affects each mode A m m Pe Current _ _ _ _ _ PS m wt T at m CONSTANT VOLTAGE WELDING Synergic CV For each wire feed speed a corresponding voltage is preprogrammed into the machine through special soft ware at the factory The nominal preprogrammed volt age is the best average voltage for a given wire feed speed but may be adjusted to preference When the wire feed speed changes the Power Wave automati cally adjusts the voltage lev
147. ng a 3 8 wrench remove the three mounting screws from the output diode heatsink assembly Take note placement of insulation for reassembly See Figure F 36 Cut any necessary cable ties and carefully remove the heavy lead from the diode heatsink using a 1 2 nut driver Remove the output diode heatsink assembly through the rear of the machine Remove plug J90 from the current transducer Using a 3 8 nut driver remove the two mounting nuts from the current transducer FIGURE F 36 OUTPUT HEATSINK MOUNTING SCREW LOCATION 3 8 MOUNTING POWER WAVE 355M 405M LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Q O 42 Return to Section Return to Master TOC 5 s z 9 F 77 TROUBLESHOOTING AND REPAIR F 77 CURRENT TRANSDUCER REMOVAL AND REPLACEMENT continued 21 22 23 24 25 26 27 28 Replace the current transducer Replace the two 3 8 mounting nuts previously removed Reconnect plug J90 to the current transducer Replace any necessary cable ties previously cut From the rear of the machine replace the heavy flex lead to the bottom of the output diode heatsink assembly using a 1 2 wrench Note Don t forget to include all washers Replac
148. nput voltage 3 The welding procedure may be drawing too much input current or the duty cycle may be too high Reduce the welding cur rent and or reduce the duty cycle F 4 RECOMMENDED COURSE OF ACTION 1 Contact the Lincoln Electric Service Department 1 888 935 3877 1 Perform the Auxiliary Trans 2 Perform the DC Bus Board Test 2 Perform the Power Board Test 3 The Bus Board rectifier and o associated filter capacitor C5 may be faulty Check anc replace as necessary 4 The Control Board may be faulty 1 Check the reconnect switches and associated wiring See the Wiring Diagram 2 Perform the Input Rectifier 3 Perform the Main Switch Board 4 Perform the Output Diode Module Test 5 The Input Filter Capacitors may be faulty Check and if any are faulty replace all four CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed Call 1 888 935 3877 POWER WAVE 355M 405M LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o 42 Return to Section Return to Master TOC 5 n s z 9 E pu TROUBLESHOOTING AND REPAIR p Observe Safety Guidelines detailed in the beginning of this m
149. 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 shield ing bag If the PC board uses protective shorting jumpers don t remove them until installation is complete 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 symptom has been corrected by the replacement PC board NOTE It is desirable to have a spare known good PC board available for PC board troubleshooting NOTE Allow the machine to heat up so that all electrical components can reach their operating temperature 5 Remove the replacement PC board and substitute it with the original PC board to recreate the original problem a If 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 terminal 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 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
150. our 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 1 888 935 3877 DESCRIPTION The following procedure will aid the technician in removing the output rectifier modules for maintenance or replacement MATERIALS NEEDED Return to Section TOC Return to Master TOC 3 16 Allen wrench 9 64 Allen wrench 5 16 Nut Driver 7 16 Wrench Flathead Screwdriver Penetrox A 13 Heatsink Compound Thin Knife Screwdriver olo PJE Sl gt ol esc 5 2 ele Return to Section TOC Return to Master TOC POWER WAVE 355M 405M LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC olo 0 c f i Sl gt om so ec 5 2 ele Return to Section TOC Return to Master TOC Return to Master TOC F 70 PROCEDURE 1 Output Diode Remove input power to the POWER WAVE 355M 405M Using a 5 16 nut driver remove the case wrap around cover Perform the Input Filter Capacitor Discharge Procedure detailed earlier in this section Locate the output diode modules loc
151. output Twist Mate terminal to the work piece The work piece connection must be firm and secure especially if pulse welding is planned For additional Safety information regarding the elec trode and work cable set up See the standard SAFE TY INFORMATION located in the front of the Instruction Manuals glo CAUTION MOUNTING HOLE LOCATIONS P E NOTE MOUNTING SCREWS CAN NOT PROTRUDE MORE THAN Excessive voltage drops caused by poor work 2 05 INCHES INSIDE THE en piece connections often result in unsatisfactory f 5 gt fo 275 350 578 welding performance c N NEGATIVE ELECTRODE POLARITY 2 2 Itl Edd sg When negative electrode polarity is required such as mm THE in some Innershield applications reverse the output o HMHI ef connections at the power source electrode cable to NS WEN acc the negative Twist Mate terminal and work cable to the positive Twist Mate terminal re 11 84 401 19527 When operating with electrode polarity negative the Electrode Sense Polarity DIP switch must be set to the Negative position on the Wire Drive Feed Head PC Board The default setting of the switch is positive electrode polarity Consult the Power Feed instruction manual for further details VOLTAGE SENSING The best arc performance occurs when the PowerWaves have accurate data about the arc condi tions Depending upon the process inductance within the electrode and work lead
152. p to the work piece The Power Wave wave forms 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 reaching physical limitations of the welding process Arc Control often referred to as wave control in pulse programs usually adjusts the focus or shape of the arc Wave control values greater than 0 0 increase the pulse frequency while decreasing the background cur rent resulting in a tight stiff arc best for high speed sheet metal welding Wave control values less than 0 0 decrease the pulse frequency while increasing the background current for a soft arc good for out of posi tion welding FIGURE B 3 CURRENT WAVE FORM PULSE Current Wave Control 10 0 Wave Control 0 0 I d Wave Control 410 0 Time POWER WAVE 355M 405M LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC C 42 Return to Section Return to Master TOC 5 0o s z 9 10 PULSE ON PULSE GMAW PP Pulse on Pulse is a Lincoln process specifically designed for use in welding relatively thin less than 1 4 thick aluminum See the table below It gives weld beads with very consistent uniform ripple In Pulse on Pulse modes two distinct pulse
153. ped 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 Manual Stick Welder 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 B Sf ARC RAYS can burn 4 a Use a shield with the proper filter and cover plates to protect your eyes from sparks and the rays of the arc when welding or observing open arc welding Headshield and filter
154. 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 1 888 935 3877 TEST DESCRIPTION This test will help determine if the fan motor control board switch board or associated leads and connectors are functioning correctly MATERIALS NEEDED Voltmeter 5 16 Nut Driver POWER WAVE 355M 405M LINCOLN B F 43 p TROUBLESHOOTING AND REPAIR FM FAN CONTROL AND MOTOR TEST continued e o ole cls TEST PROCEDURE 9 E 1 Remove the input power to the POWER WAVE Perform the Input Filter Capacitor Discharge d s 355M 405M machine els 2 Using the 5 16 nut driver remove the case 4 Locate plug J22 on the main switch board Do a wraparound cover not remove the plug from the board See cic Figure F 14 FIGURE F 14 PLUG J22 LOCATION C ides 3 Return to Section TOC Return to Master TOC J21 R 5 Carefully apply the correct input power to the 6 Carefully
155. perly with inverter sup plies Try an analog type meter and calibrate around 300 amps 30V loading in all cases POWER WAVE 355M 405M LINCOLN B D MAINTENANCE ils FIGURE D 1 MAJOR COMPONENT LOCATIONS 1 Center Panel Use parts page exploded views to also help iso 2 Case Back late and identify smaller parts Parts page num bers can be found on the Master Table of 3 Case Front 4 Base Assembly 5 Case Wraparound Contents in the front of this manual Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC olo PJE ojeg Sl gt om so ec 51 ele Return to Section TOC Return to Master TOC POWER WAVE 355M 405M LINCOLN B D 4 NOTES POWER WAVE 355M 405M LINCOLN amp D 4 DOL J81Se N 01 DOL 181SEN 01 DOL J81Se N 01 DOL J81Se N 01 DOL uonoesg 0 uit DOL uonoesg 0 uit DOL uonoesg 0 uit DOL uonoesg 0 Return to Master TOC Return to Master TOC s 2 E Return to Master E 1 TABLE OF CONTENTS THEORY OF OPERATION SECTION E Theory of Operation eo ew raises Ste saat a tee S Qala E 1 Generalileschptior UN esuada c a 2 Input Line Voltage Auxiliary Transformer and 100000 2 Switc
156. ponents 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 chapter Refer to the Troubleshooting and Repair Table of Contents to locate each specific Test Procedure All of the specified test points components terminal strips etc can be found on the referenced electrical wiring diagrams and schematics Refer to the Electrical Diagrams Section Table of Contents to locate the appropriate diagram CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed Call 1 888 935 3877 POWER WAVE 355M 405M LINCOLN B F 2 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o 42 Return to Section Return to Master TOC s z 9 E TROUBLESHOOTING AND REPAIR PS PC BOARD TROUBLESHOOTING PROCEDURES WARNING LM e ELECTRIC SHOCK can kill Have an electrician install and service this equipment Turn the input power OFF at the fuse box before working on equipment Do not touch electrically hot parts CAUTION Sometimes machine failur
157. r Probe Test Point Negative Meter Probe Test Point Approximate Voltage Reading Conditions Comments Plug P46 Pin 1 Lead 65 Plug P46 Pin Lead 66 65 75 VDC Should be same as the Bus Rectifier Plug P47 Pin 8 Lead 52 Plug P47 Pin 1 Lead 51 38 0 42 0 VDC Supply to the Wire Feeder Receptacle Plug P47 Pin 3 Lead 477 Plug P47 Pin 6 Lead 475 38 0 42 0 VDC POWER WAVE 355M 405M LINCOLN B Supply to Power Board NOTES Fst POWER WAVE 355M 405M LINCOLN F 30 DOL J81Se N 01 DOL 181SEN 01 DOL J81Se N 01 DOL J81Se N 01 DOL uonoesg 0 uit DOL uonoesg 0 uit DOL uonoesg 0 uit DOL uonoesg 0 Return to Section TOC Return to Master TOC Return to Section TOC olo PJE Sl gt ol esc 5 2 ele Return to Section TOC Return to Master TOC Return to Master TOC F 31 TROUBLESHOOTING AND REPAIR OUTPUT RECTIFIER MODULES TEST A 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 proce
158. response to changes in the arc The higher the Power Mode Setting the longer the arc If a welding procedure is not established the best way to determine the Power Mode Setting is by experimenta tion until the desired output result is established In the Power Mode variables need to be set Wire Feed Speed Output Arc Control Setting up a Power Mode procedure is similar to set ting a CV MIG procedure Select a shielding gas appropriate for a short arc process For steel use 75 25 Ar CO2 shield gas For Stainless select a Helium blend Tri Mix For Aluminum use 100 Ar Start by setting the wire feed speed based upon mate rial thickness and appropriate travel speed Then adjust the Output knob as follows For steel listen for the traditional frying egg sound of a good short arc MIG procedure to know you have the process set correctly For aluminum simply adjust the Output knob until the desired arc length is obtained Note the Volts display is simply a relative number and DOES NOT correspond to voltage Some Power Mode procedure recommendations appear ir Table B 2 POWER WAVE 355M 405M LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC olo PJE Sl gt om so ec 51 ele Return to Section TOC Return to Master TOC Return to Master TOC ig OPERATION Pg SPECIAL WELDING PROCESSES AVAILABLE ON THIS MACHINE PULSE WELDING
159. rm the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 1 888 935 3877 DESCRIPTION The following procedure will aid the technician in removing the snubber board for main tenance or replacement MATERIALS NEEDED 5 16 Nut Driver 7 16 Socket or Nut Driver POWER WAVE 355M 405M LINCOLN B F 55 P26 TROUBLESHOOTING AND REPAIR bon SNUBBER BOARD REMOVAL AND REPLACEMENT continued PROCEDURE 1 Remove input power to the POWER WAVE 3 Perform the Input Filter Capacitor Discharge 355M 405M Procedure detailed earlier in this section 2 Using a 5 16 nut driver remove the case wrap 4 Locate the snubber board See Figure F 23 around cover Return to Section TOC Return to Master TOC FIGURE F 23 SNUBBER BOARD LOCATION Snubber Board Return to Section TOC Return to Master TOC LEFT SIDE 5 Remove small lead B1 from the board See 8 Replace the snubber board Figure F 24 9 Replace the bolts leads and washers previously 6 Remove the four bolts using a 7 16 socket Two removed Torque bolt to 30 40 Inch Lbs of these bolts have leads 30 and 10 connected to them Note the position of all leads and associ 10 Reconnect small lead B1 previously removed ated washers upon removal 11 Replace the case wraparound cover 7 Carefully remove the snubber board FIGURE F 24 SN
160. rn to Master TOC Return to Section TOC olo PJE Sl gt om esc 51 2 c Return to Section TOC Return to Master TOC Return to Master TOC Eps TROUBLESHOOTING AND REPAIR 63 DC BUS BOARD REMOVAL AND REPLACEMENT continued FIGURE F 28 CASE FRONT SCREW REMOVAL Lj status THERMAL 9 999990009009 00000000000 O 9 ZG Phillips Head Phillips Head Screws Screws u ZU 9 ZF H e e 5 16 Mounting Screws 9 Label and remove two thermostat leads and four 13 Reconnect previously removed leads to their prop leads from the bus rectifier er locations 10 Using a 3 8 open end wrench remove the three 14 Replace the four head screws mounting DC Bus Board mounting nuts See Figure F 29 the two welder output terminals to the front of the machine 11 Replace the DC Bus Board 15 Replace the two phillips head screws from above 12 Secure the new DC Bus Board in its proper loca and below the input power switch tion using the 3 8 mounting nuts FIGURE F 29 CASE FRONT SCREW REMOVAL J47 p x Rectifier 3 8 Mounting Nuts 1 820111 Thermostat POWER WAVE 355M 405M LINCOLN B F 64 TROUBLESHOOTING AND REPAIR o DC BUS BOARD REMOVAL AND
161. rn to Section TOC olo 0 c f i Sl gt om esc 51 2 c Return to Section TOC Return to Master TOC Return to Master TOC F 20 TROUBLESHOOTING AND REPAIR F 20 INPUT RECTIFIER TEST CONTINUED TEST PROCEDURE 1 Remove input power to the POWER 6 Using a phillips head screwdriver WAVE 355M 405M machine remove leads 207 207A and 209 from the input rectifier 2 Using a 5 16 nut driver remove the case wraparound cover 7 Usethe analog ohmmeter to perform the tests detailed in Table 2 See the 3 Perform the Capacitor Discharge Wiring Diagram Procedure Hetailed earlier in this section Visually inspect the three MOV S for 4 Locate the input rectifier and associated damage TP1 TP2 TP3 Replace if leads See Figure F 3 essary 5 Carefully remove the silicone sealant from leads 207 207A and 209 Figure F 3 Input Rectifier Small Lead H1 To Auxiliary Transformer 3 16 ALLEN BOLTS 207 207A 209 Small Lead A r FRONT To Circuit Breaker REAR POWER WAVE 355M 405M LINCOLN B ger Return to Section TOC Return to Section TOC Return to Master TOC olo C 9 c f ia Sl gt om Bo esc 5 2 2 c Return to Section TOC Return to Master TOC Return to Master TOC FI TROUBLESHOOTING AND REPAIR Pal INPUT RECTIFIER TEST CONTINUED Table F 2 Input Rectifier Test Points
162. rn to Section TOC olo PJE Sl gt ol esc 51 ele Return to Section TOC Return to Master TOC Return to Master TOC F 23 TROUBLESHOOTING AND REPAIR POWER BOARD TEST A 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 1 888 935 3877 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 Volt Ohmmeter 3 8 Nut Driver Wiring Diagram POWER WAVE 355M 405M LINCOLN B F 23 Return to Section TOC Return to Master TOC Return to Section TOC olo 0 c f i Sl olz om Bo eE 512 2 c Return to Section TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING AND REPAIR F 24 FIGURE F 4 POWER BOARD TEST
163. rrent transformers CT located on the switch board monitor these primary currents If the primary currents become abnormally high the control board will shut off the IGBTs thus dis abling the machine output The DC current flow through each primary winding is clamped back to each respective input capacitor when the IGBTs are turned off This is needed due to the inductance of the transformer primary winding The firing of the two switch boards occurs during halves of a 50 microsec ond interval creating a constant 20 KHZ output In some low open circuit Tig modes the firing frequency is reduced to 5KHZ The POWER WAVE 355M 405M has F A N fan as needed circuit The fan operates when the welding output terminals are energized or when a thermal over temperature condition exists Once the fan is activat ed it will remain on for a minimum of five minutes The fan driver circuit is housed on the switch board but it is activated by a signal from the control board NOTE Unshaded areas of Block Logic Diagram are the subject of discussion POWER WAVE 355M 405M LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o 42 Return to Section Return to Master TOC s z 9 4 THEORY OF OPERATION E 4 FIGURE E 4 POWER BOARD CONTROL BOARD AND SERIAL PERIPHERAL INTERFACE SPI COMMUNICATIONS
164. rroneous results Return to Section TOC Return to Master TOC POWER WAVE 355M 405M LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC olo PJE SI gt om Bo ec 51 2 c Return to Section TOC Return to Master TOC Return to Master TOC F 33 TROUBLESHOOTING AND REPAIR OUTPUT RECTIFIER MODULES TEST continued Figure F 8 Terminal Probes If 200 ohms is measured then the output diodes are not shorted NOTE There is a 250 ohm resistor across the welding output terminals If less than 200 ohms is measured one or more diodes or the snubber board may be faulty Perform the Filter Capacitor Discharge Procedure detailed in the maintenance sec tion Locate the output diode modules and snub ber board See Figure F 9 Test all output diode modules individually Test for open diodes also NOTE This may require the disassembly of the leads and the snubber board from the diode modules Refer to the Output Rectifier Modules Removal Replacement Procedure for detailed instructions POWER WAVE 355M 405M LINCOLN B F 33 Faa TROUBLESHOOTING AND REPAIR ot Figure F 9 Snubber and Output Diode Locations Return to Section TOC Return to Master TOC Output Diode Modules Snubber Board LEFT SIDE Return to Section TOC Retur
165. sur la s ret voir le code Code for safety in welding and cutting CSA Standard W 117 2 1974 PR CAUTIONS DE S RET POUR LES MACHINES SOUDER TRANSFORMATEUR ET REDRESSEUR 1 Relier la terre le chassis du poste conformement au code de l lectricit et aux recommendations du fabricant Le dispositif de montage ou la piece souder doit tre branch 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 debranch er l interrupteur la boite de fusibles 4 Garder tous les couvercles et dispositifs de s ret leur place Mar 93 LINCOLN B Return to Master TOC Return to Master TOC o s z 9 E Return to Master SAFETY Electromagnetic Compatibility EMC Conformance Products displaying the CE mark are in conformity with European Community Council Directive of 3 May 1989 on the approximation of the laws of the Member States relating to electromagnetic compatibility 89 336 EEC It was manufactured in conformity with a national standard that implements a harmonized standard EN 60974 10 Electromagnetic Compatibility EMC Product Standard for Arc Welding Equipment It is for use with other Lincoln Electric equipment It is designed for industrial and professional use Introduction All
166. tective circuits are designed into the POWER WAVE 355M 405M to sense trouble and shut down the machine before damage occurs to the machine s internal components OVER CURRENT PROTECTION If the average current exceeds 450 amps for one sec ond then the output will be limited to 100 amps until the load is removed If the peak current exceeds 600 amps for 150 ms the output will be limited to 100 amps until the load is removed UNDER OVER VOLTAGE PROTECTION Protective circuits are included on the switch and con trol boards to monitor the voltage across the input capacitors In the event that a capacitor pair voltage is too high or too low the machine output will be dis abled The protection circuits will prevent output if any of the following conditions exist 1 Voltage across a capacitor pair exceeds 467 volts High line surges or improper input voltage connections 2 Voltage across a capacitor pair is under 190 volts Due to improper input voltage connections 3 Any major internal component damage POWER WAVE 355M 405M LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o 42 Return to Section Return to Master TOC s z 9 ET THEORY OF OPERATION ET INSULATED GATE BIPOLAR TRANSISTOR OPERATION An IGBT is a type of transistor IGBT are semiconduc tors well s
167. the options installed in the user inter face control box of the welding system The flexibility of the Power Wave system lets the user customize operation for the best performance First consider the desired welding process and the part to be welded Choose an electrode material diam eter shielding gas and process GMAW GMAW P etc Second find the program in the welding software that best matches the desired welding process The stan dard software shipped with the Power Waves encom passes a wide range of common processes and will meet most needs If a special welding program is desired contact the local Lincoln Electric sales repre sentative To make a weld the Power Wave needs to know the desired welding parameters The Power Feed PF family of feeders communicate settings to the Power Wave through control cable connection Arc length wire feed speed arc control etc are all communicated digitally via the control cable WELDING ADJUSTMENTS All adjustments are made on the system component known as the User Interface Control Box which con tains the switches knobs and digital displays neces sary to control both the Power Wave and a Power Feed wire feeder Typically the Control Box is supplied as part of the wire feeder It can be mounted directly on the wire feeder itself the front of the power source or mounted separately as might be done in a welding boom installation Because the Control Box can be con
168. uency 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 anti spatter system is in use then each gun must have its own anti spatter system See Figure A 6 INSTALLATION A 11 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 A CAUTION The use of non standard cables especially in lengths greater than 25 feet can lead to communi cation problems such as system shutdowns poor motor acceleration poor arc starting and low wire driving force wire feeding problems The K1543 series of control cables can be connected end to end for ease of extension Do not exceed more than 100 feet 30 5 m total control cable length FIGURE A 6 TWO POWER WAVES Travel Direction POWER WAVE 355 405 Connect All Work Sense Leads at the End of the Joint Connect All Welding Work Leads at the Beginning of the Joint POWER WAVE 355M 405M LINCOLN B INSTALLATION 12 MULTIPLE UNSYNCHRONIZED SENSE LEAD WORK LEAD PLACEMENT GUIDELINES P Source BAD Current flow from Arc 1 affects sense lead 2 Return to S
169. uited for high frequency switching and high current applications Example A in Figure E 6 shows an IGBT in passive mode There is no gate signal zero volts relative to the source and therefore no current flow The drain ter minal of the IGBT may be connected to a voltage sup ply 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 Example 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 con nected to the drain terminal will allow the IGBT to con duct and supply current to the circuit components coupled to the source Current will flow through the conducting IGBT to downstream components as long as the positive gate signal is present This is similar to turning ON a light switch FIGURE E 6 IGBT GATE SOURCE BODY REGION DRAIN DRIFT REGION BUFFER LAYER p INJECTING LAYER DRAIN A PASSIVE POSITIVE VOLTAGE cipue GATE BODY REGION lt DRAIN DRIFT REGION BUFFER LAYER lt INJECTING LAYER DRAIN B ACTIVE POWER WAVE 355M 405M LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o 42
170. uld remain energized several sec onds after the welding ceases e Do not touch electrically live parts or electrodes with your skin or wet clothing e Insulate yourself from the work and ground Always wear dry insulating gloves 2 FUMES AND GASES can be dangerous E A Keep your head out of fumes Use ventilation or exhaust to remove fumes from breathing zone WELDING SPARKS can cause T fire or explosion Keep flammable material away Do not weld containers that held combustibles ARC RAYS can burn 4 Wear eye ear body protection ME Observe additional guidelines detailed in the beginning of this manual GENERAL DESCRIPTION The Power Wave semi automatic power source is designed to be a part of a modular multi process weld ing system Depending on configuration it can support constant current constant voltage and pulse welding modes The Power Wave power source is designed to be used with the semi automatic family of Power Feed M wire feeders operating as a system Each component in the System has special circuitry to talk with the other sys tem components so each component power source wire feeder user interface knows what the other is doing at all times These components communicate with Arclink The POWER WAVE 355M 405M is a high perfor mance digitally controlled inverter welding power source capable of complex high speed waveform co
171. urce status light for error sequences as noted below This is especially important if the user interface displays Err 006 or Err 100 Included in this section is information about the LIGHT CONDITION Status LED is solid green no blinking Status LED is blinking green Status LED is blinking red and green Status LED is solid red no blinking Status LED is blinking red F3 TROUBLESHOOTING AND REPAIR p power source Status LED and some basic trou bleshooting charts for both machine and weld perfor mance The STATUS LIGHT is a two color light that indicates System errors Normal operation is a steady green light Error conditions are indicated in the following chart NOTE The POWER WAVE 355M 405M 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 INDICATION System OK Power source communicating nor mally with wire feeder and its components Occurs during a reset and indicates the POWER WAVE 355M 405M is mapping identi fying each component in the system Normal for first 1 10 seconds after power is turned on or if the system configuration is changed during operation Non recoverable system fault If the PS Status light is flashing any combination of red and green errors are present in the POWER WAVE 355M 405M Read the error code before the machine
172. vice 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 1 888 935 3877 TEST DESCRIPTION This test will help determine if the current transducer and associated wiring are function ing correctly MATERIALS NEEDED Volt ohmmeter 5 16 Nut Driver Grid Bank External DC Ammeter POWER WAVE 355M 405M LINCOLN B F 39 FU TROUBLESHOOTING AND REPAIR Pag CURRENT TRANSDUCER TEST continued FIGURE F 12 Metal Plate Removal amp Plug J8 Location Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC TEST PROCEDURE 6 Check for the correct DC supply voltages to the current transducer at plug J8 See Figure 1 Remove input power to the POWER WAVE 12 355 405 A Pin 2 lead 802 to pin 6 lead 806 2 Using the 5 16 nut driver remove the case should read 15 VDC wraparound cover r C Pin 4 lead 804 to 6 lead 806 Perform the shou
173. will result in cooler operation and higher reliability Be sure to clean these areas All printed circuit boards Power switch Main transformer Input rectifier Auxiliary Transformer Reconnect Switch Area Fan Blow air through the rear louvers 2 Examine the sheet metal case for dents or breakage Repair the case as required Keep the case in good condition to insure that high voltage parts are protected and correct spacings are maintained All external sheet metal screws must be in place to insure case strength and electrical ground continuity PERIODIC MAINTENANCE Calibration of the POWER WAVE 355M 405M is critical to its operation Generally speaking the calibration will not need adjustment However neglected or improper ly calibrated machines may not yield satisfactory weld performance To ensure optimal performance the cali bration of output Voltage and Current should be checked yearly Calibration is accomplished with our Diagnostic Utility software found on the Lincoln Electric Service Navigator CD or on our web site at www lincoln electric com If a welder has difficulty in being calibrated some things to look for proper configuration of the sense leads Make sure your meter is measuring at the same point as the power source local studs or remote feeder All meters used for calibration checks must be calibrat ed and traceable to National Standards Some digital meters may not function pro

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