Lincoln Electric SVM159-A manual

SVM159-A December , 2003 Safety Depends on Y ou Lincoln arc welding and cutting equipment is designed and built with safety in mind. However , your overall safety can be increased by pr oper installation . . . and thoughtful operation on your part. DO NOT INST ALL, OPERA TE OR REP AIR THIS EQUIPMENT WITHOUT READ- ING THIS MANUAL AND THE SAFETY PREC[...]

Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC i SAFETY i FOR ENGINE powered equipment. 1.a. T urn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running. ____________________________________________________ 1.b. Operate engines in open, well-ventilated a[...]

Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ii SAFETY ii ARC RA YS 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 lens should conform to ANSI Z87. I standards. 4.b. U[...]

SAFETY iii iii POWER W A VE 355/405 Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC FOR ELECTRICALL Y powered equipment. 8.a. T urn off input power using the disconnect switch at the fuse box before working on the equipment. 8.b. Install equipment in accordance with the U.S. National Electrical Code, all local co[...]

SAFETY iv iv POWER W A VE 355/405 Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC PRÉCAUTIONS DE SÛRETÉ Pour votre propre protection lire et observer toutes les instructions et les précautions de sûreté specifiques qui parraissent dans ce manuel aussi bien que les précautions de sûreté générales suiv- [...]

INST ALLA TION v v POWER W A VE 355 Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC L10093 3-1-96H Conf or mance standard: EN 50 199 Electromagnetic Compatibility (EMC) Product Standard for Arc Welding Equipment. It All electrical equipment generates small amounts of electromagnetic emission. Electr ical emission[...]

INST ALLA TION vi vi POWER W A VE 355 Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC L10093 3-1-96H The size of the surrounding area to be considered will depend on the structure of the building and other activities Methods of Reducing Emissions Consideration should be giv en to shielding the supply cable of per[...]

MASTER T ABLE OF CONTENTS FOR ALL SECTIONS v v POWER W A VE 355/405 Page Safety .................................................................................................................................................i-iv Installation ...........................................................................................................[...]

SectionA-1 Section A-1 POWER W A VE 355/405 Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC T ABLE OF CONTENTS - INST ALLA TION SECTION - Installation T echnical Specifications 355 ................................................................................................... ...A-2 T echnical Specifications [...]

POWER W A VE 355/405 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC A-2 INST ALLA TION A-2 TECHNICAL SPECIFICA TIONS - POWER W A VE 355 INPUT AC VOL T AGE & DC OUTPUT Product Ordering Input AC Rated DC Output Output Weigh[...]

INST ALLA TION A-3 A-3 POWER W A VE 355/405 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TECHNICAL SPECIFICA TIONS - POWER W A VE 405 INPUT AC VOL T AGE & DC OUTPUT OUTPUT CABLES, CONNECTIONS AND LIMIT A TIONS Product O[...]

A-4 A-4 POWER W A VE 355/405 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC INST ALLA TION ELECTRIC SHOCK can kill . • TURN THE INPUT POWER OFF A T THE DISCONNECT SWITCH BEFORE A TTEMPTING T O CONNECT OR DIS- CONNECT INPUT [...]

INST ALLA TION A-5 A-5 POWER W A VE 355/405 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC 5.50 10.0 0 MOUNTING HOLE LOCATIONS M19527 1/4-20 NUT (4 PLAC ES) NOTE: MOUNTING SCREWS CA 4/01 N NOT PROTR UDE MORE THAN 0.5 IN CHES [...]

INST ALLA TION A-6 A-6 POWER W A VE 355/405 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Enable the voltage sense leads as follows: T ABLE A.1 Process Electrode V oltage Work V oltage Sensing 67 lead * Sensing 21 lead GMA W[...]

INST ALLA TION A-7 A-7 POWER W A VE 355/405 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC SYSTEM DESCRIPTION The POWER W A VE 355/405 and Power Feed 10/1 1 family of products utilize a digital communication sys- tem called L[...]

INST ALLA TION A-8 A-8 POWER W A VE 355/405 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC SYSTEM SET -UP Basic Rules • Each group is required to have one user interface. No group may have more than one user interface. • [...]

INST ALLA TION A-9 A-9 POWER W A VE 355/405 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC FIGURE A.3 Multiple Group System No “FH0 Allowed! FIGURE A.4 Single Group Multi-Head System No “FH0 Allowed! The Dual Head option [...]

INST ALLA TION A-10 A-10 POWER W A VE 355/405 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC FIGURE A.5 Single Group Multi-Head System (Alternate Method) No “FH0 Allowed! When a standard User Interface is used in a group wi[...]

INST ALLA TION A-11 A-11 POWER W A VE 355/405 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC WELDING WITH MUL TIPLE POWER WA VES Special care must be taken when more than one Power W ave is welding simultaneously on a single [...]

INST ALLA TION A-12 A-12 POWER W A VE 355/405 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC I / O RECEPT ACLE SPECIFICA TIONS T ABLE A.2 WIRE FEEDER RECEPT ACLE PIN LEAD# FUNCTION A5 3 Communication Bus L B5 4 Communication [...]

Section B-1 Section B-1 POWER W A VE 355/405 T ABLE OF CONTENTS - OPERA TION SECTION - Operation ............................................................................................................................... Section B Safety Precautions ................................................................................................[...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC B-2 B-2 POWER W A VE 355/405 OPERA TION GENERAL DESCRIPTION The Power W ave semi-automatic power source is designed to be a part of a modular , multi-process weld- ing system. De[...]

OPERA TION B-3 B-3 POWER W A VE 355/405 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC POWER W A VE 355/405 – Semi-Automatic Operation Semi Automatic Power W aves can only be used with Linc-Net compatible Power Feed semi-au[...]

OPERA TION B-4 B-4 POWER W A VE 355/405 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC FIGURE B.1 10 4 6 1 3 2 5 7 8 9 CASE FRONT LA YOUT POWER W A VE 355/405 5. Internal POWER CIRCUIT BREAKER: Protects 1 15 volt AC circuit. [...]

OPERA TION B-5 B-5 POWER W A VE 355/405 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC In non-synergic modes, the WFS control behaves more like a conventional CV power source where WFS and voltage are independent adjustments.[...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC OPERA TION B-6 B-6 POWER W A VE 355/405 TIG GT A W The TIG mode features continuous control from 5 to 425 amps. The TIG mode can be run in either the T ouch Start TIG or Scratch [...]

INST ALLA TION B-7 B-7 POWER W A VE 355 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC PULSE WELDING (GMA W-P) The pulsed-arc process is, by definition, a spray trans- fer process wherein spray transfer occurs in pulses at re[...]

INST ALLA TION B-8 B-8 POWER W A VE 355 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC PULSE-ON-PULSE™ (GMA W-PP) Pulse on Pulse™ is a Lincoln process specifically designed for use in welding relatively thin (less than 1/[...]

C-1 C-1 POWER W A VE 355/405 Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC T ABLE OF CONTENTS - ACCESSORIES SECTION - Accessories ........................................................................................................................... Section C Optional Equipment .............................[...]

ACCESSORIES C-2 C-2 POWER W A VE 355/405 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC OPTIONAL EQUIPMENT F ACTOR Y INST ALLED None Available. FIELD INST ALLED K940-Work V oltage Sense Lead Kit K1764-1-Undercarriage* K1838-1[...]

Section D-1 Section D-1 POWER W A VE 355/405 T ABLE OF CONTENTS -MAINTENANCE- Maintenance ......................................................................................................................... Section D Capacitor Dischar ge Procedur e ................................................................................................[...]

MAINTENANCE D-2 D-2 POWER W A VE 355/405 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Have qualified personnel do the maintenance work. Always use the greatest care when working near moving parts. Do not put your hands near[...]

W ARNING W ARNING AVI SO DE PRECAUCION A TTENTION ! ! ! ! Lor em i psum dol or si t a me t cons ecte t ue r a di pi sci ng Lorem ipsum dolor sit amet consectetuer ad ipiscing e lit, ed d i am nonummy ni bh eui smod t i nc idun t ut elit, ed di am no nu mm y n ibh e uismod t incidunt ut lao re et dolore m agna aliq ua m e rat lao re et dol ore magn [...]

NOTES D-4 D-4 POWER W A VE 355/405 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC[...]

Section E-1 Section E-1 POWER W A VE 355/405 Theory of Operation ............................................................................................................. Section E General Description ....................................................................................................................E-2 Input Line V oltage, Auxi[...]

FIGURE E.2 – INPUT VOL T AGE AND PRECHARGE Control Board Choke Positive Output T erminal Negative Output T erminal Board C urrent Feedback Reconnect Switch Output V oltage Sense Input switch Input Rectifier Auxiliary Transformer Fan Power Board 220 Receptacle RS232 Supply +5VDC Machine Control Supply +15VDC, -15VDC, +5VDC 40VDC 42V AC 220 V AC Ma[...]

SWITCH BOARD & MAIN TRANSFORMER There is one switch boar d in the POWER WA VE 355/405. This board incorporates two pairs of input capacitors, two insulated gate bipolar transistor (IGBT) switching circuits, a fan motor drive cir cuit, and a volt- age/frequency capacitor feedback cir cuit. The two capacitors in a pair are always in series with e[...]

THEOR Y OF OPERA TION E-4 E-4 POWER W A VE 355/405 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC FIGURE E.4 – POWER BOARD, CONTROL BOARD AND SERIAL PERIPHERAL INTERF ACE (SPI) COMMUNICA TIONS Control Board Choke Positive O[...]

OUTPUT RECTIFIER AND CHOKE The output rectifier r eceives 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. THEOR Y [...]

THERMAL PROTECTION Three normally closed (NC) thermostats pr otect the machine from excessive operating temperatur es. These thermostats are wir ed in series and are con- nected to the control boar d. 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[...]

INSULA TED GA TE BIPOLAR TRANSIST OR (IGBT) OPERA TION An IGBT is a type of transistor . IGBT are semiconduc- tors well suited 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, zer o volts relative to the source, and ther efore, no curr ent flow . The drain te[...]

PULSE WIDTH MODULA TION 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[...]

POWER W A VE 355/405 Section F-1 Section F-1 Tr oubleshooting & Repair Section ................................................................................. Section F How to Use T roubleshooting Guide ....................................................................................F-2 PC Board T roubleshooting Pr ocedures and Replacement[...]

HOW TO USE TROUBLESHOOTING GUIDE Service and repair should be performed by only Lincoln Electric Factory T rained Personnel. Unauthorized repairs performed on this equipment may r esult 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 safet[...]

POWER W A VE 355/405 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-3 F-3 Sometimes machine failures appear to be due to PC board failures. These problems can sometimes be traced to poor electr[...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC POWER W A VE 355/405 TROUBLESHOOTING & REP AIR F-4 F-4 Observe Safety Guidelines TROUBLESHOOTING GUIDE detailed in the beginning of this manual. CAUTION If for any reason you[...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC POWER W A VE 355/405 TROUBLESHOOTING & REP AIR F-5 F-5 TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginning of this manual. CAUTION If for any reason you[...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC POWER W A VE 355/405 TROUBLESHOOTING & REP AIR F-6 F-6 Observe Safety Guidelines TROUBLESHOOTING GUIDE detailed in the beginning of this manual. CAUTION If for any reason you[...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC POWER W A VE 355/405 TROUBLESHOOTING & REP AIR F-7 F-7 Observe Safety Guidelines TROUBLESHOOTING GUIDE detailed in the beginning of this manual. CAUTION If for any reason you[...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC POWER W A VE 355/405 TROUBLESHOOTING & REP AIR F-8 F-8 Observe Safety Guidelines TROUBLESHOOTING GUIDE detailed in the beginning of this manual. CAUTION If for any reason you[...]

F-9 F-9 POWER W A VE 355/405 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR USING THE ST A TUS LED TO TROUBLESHOOT SYSTEM PROBLEMS The Power W ave / Power Feed are best diagnosed as a system. Eac[...]

POWER W A VE 355/405 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-10 F-10 ST A TUS LED ERROR CODE T ABLE NOTE: The error code signal sequence is always pr eceded by a 2 second green light. If[...]

POWER W A VE 355/405 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-11 F-11 43 Capacitor delta error . The maximum voltage dif ference between the main capaci- tors has been exceeded. May be ac[...]

NOTES F-12 F-12 POWER W A VE 355/405 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC[...]

W ARNING Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-13 F-13 POWER W A VE 355/405 INPUT FIL TER CAP ACITOR DISCHARGE PROCEDURE Service and repair should be performed by only Lincoln Electric[...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-14 F-14 POWER W A VE 355/405 ELECTRIC SHOCK can kill. • Have an electrician install and service this equipment. • T urn the input power off at[...]

MAIN SWITCH BOARD TEST Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may r esult 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 [...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-16 F-16 POWER W A VE 355/405 MAIN SWITCH BOARD TEST (continued) FIGURE F .2 MAIN SWITCH BOARD LEAD LOCA TIONS TEST PROCEDURE 1. Remove input power[...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-17 F-17 POWER W A VE 355/405 MAIN SWITCH BOARD TEST (continued) T ABLE F .1. SWITCH BOARD RESIST ANCE TEST 6. If any test fails r eplace the switc[...]

NOTES F-18 F-18 POWER W A VE 355/405 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC[...]

TROUBLESHOOTING & REP AIR F-19 F-19 POWER W A VE 355/405 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC INPUT RECTIFIER TEST Service and repair should be performed by only Lincoln Electric factory trained personnel. Unaut[...]

TEST PROCEDURE 1. Remove input power to the POWER WA VE 355/405 machine. 2. Using a 5/16” nut driver , remove the case wraparound cover . 3. Perform the Capacitor Discharge Procedur e detailed earlier in this section. 4. Locate the input r ectifier and associated leads. See Figure F .3. 5. Carefully r emove the silicone sealant from leads 207, 20[...]

TROUBLESHOOTING & REP AIR F-21 F-21 POWER W A VE 355/405 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC 9. If the input r ectifier does not meet the acceptable readings outlined in T able F .2 the component may be faulty [...]

NOTES F-22 F-22 POWER W A VE 355/405 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC[...]

F-23 F-23 POWER W A VE 355/405 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR POWER BOARD TEST Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthori[...]

TROUBLESHOOTING & REP AIR F-24 F-24 POWER W A VE 355/405 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC POWER BOARD TEST (CONTINUED) J42 J41 J43 FIGURE F .4 – POWER BOARD TEST TEST PROCEDURE 1. Remove input power to the[...]

POWER BOARD CONNECTOR PLUG J41 POWER BOARD CONNECTOR PLUG J42 POWER BOARD CONNECTOR PLUG J42 POWER BOARD CONNECTOR PLUG J42 POWER BOARD CONNECTOR PLUG J43 POWER BOARD CONNECTOR PLUG J43 POWER BOARD CONNECTOR PLUG J43 CHECK 40 VDC INPUT FROM DC BUS BOARD CHECK +15 VDC SUPPL Y FROM POWER BOARD CHECK +5 VDC SUPPL Y FROM POWER BOARD CHECK -15 VDC SUPPL[...]

NOTES F-26 F-26 POWER W A VE 355/405 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC[...]

TROUBLESHOOTING & REP AIR F-27 F-27 POWER W A VE 355/405 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC DC BUS BOARD TEST W ARNING Service and repair should be performed by only Lincoln Electric factory trained personnel.[...]

TROUBLESHOOTING & REP AIR F-28 F-28 POWER W A VE 355/405 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC DC BUS BOARD W A R N IN G R E M O T E P O W E R O F F O N STATUS THERMAL LINCOLN ELECTRIC FIGURE F .5 – DC BUS POWE[...]

TROUBLESHOOTING & REP AIR F-29 F-29 POWER W A VE 355/405 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC DC BUS BOARD TEST (CONTINUED) 6. Check the DC Bus Board input and output voltages according to T able F .4. See Figur[...]

NOTES F-30 F-30 POWER W A VE 355/405 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC[...]

OUTPUT DIODE MODULES TEST Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may r esult 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 a[...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-32 F-32 POWER W A VE 355/405 OUTPUT DIODE MODULES TEST (continued) TEST PROCEDURE 1. Remove input power to the POWER W A VE 355/405. 2. Locate the[...]

TROUBLESHOOTING & REP AIR F-33 F-33 POWER W A VE 355/405 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC OUTPUT DIODE MODULES TEST (continued) 5. If 200 ohms is measur ed then the output diodes are not “shorted”. NOTE:[...]

TROUBLESHOOTING & REP AIR OUTPUT DIODE MODULES TEST (continued) F-34 F-34 POWER W A VE 355/405 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Figure F .9 Snubber and Output Diode Locations LEFT SIDE Snubber Board Output D[...]

AUXILIAR Y TRANSFORMER TEST Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may r esult 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[...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-36 F-36 POWER W A VE 355/405 AUXILIAR Y TRANSFORMER TEST (continued) TEST PROCEDURE 1. Remove input power to the POWER WA VE 355/405. 2. Using a 5[...]

TROUBLESHOOTING & REP AIR AUXILIAR Y TRANSFORMER NO.1 TEST (continued) F-37 F-37 POWER W A VE 355/405 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC 7. Car efully apply the correct input voltage to the POWER WA VE 355/405[...]

NOTES F-38 F-38 POWER W A VE 355/405 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC[...]

TROUBLESHOOTING AND REP AIR F-39 F-39 POWER W A VE 355/405 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC CURRENT TRANSDUCER TEST Service and repair should be performed by only Lincoln Electric factory trained personnel. Unau[...]

TROUBLESHOOTING AND REP AIR CURRENT TRANSDUCER TEST (continued) F-40 F-40 POWER W A VE 355/405 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TEST PROCEDURE 1. Remove input power to the POWER W A VE 355/405. 2. Using the 5/16[...]

TROUBLESHOOTING AND REP AIR CURRENT TRANSDUCER TEST (continued) F-41 F-41 POWER W A VE 355/405 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC 8. Check the feedback voltage fr om the current transducer using a resistive load b[...]

NOTES F-42 F-42 POWER W A VE 355/405 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC[...]

TROUBLESHOOTING AND REP AIR F-43 F-43 POWER W A VE 355/405 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC F AN CONTROL AND MOTOR TEST Service and repair should be performed by only Lincoln Electric factory trained personnel. [...]

TROUBLESHOOTING AND REP AIR F AN CONTROL AND MOTOR TEST (continued) F-44 F-44 POWER W A VE 355/405 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TEST PROCEDURE 1. Remove the input power to the POWER W A VE 355/405 machine. 2[...]

Plug J20 Lead 715+ 1 2 3 4 7 8 6 5 Lead 716- TROUBLESHOOTING AND REP AIR F AN CONTROL AND MOTOR TEST (continued) F-45 F-45 POWER W A VE 355/405 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC 7. If the 115V AC is low or not pr[...]

NOTES F-46 F-46 POWER W A VE 355/405 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC[...]

CONTROL BOARD REMOV AL AND REPLACEMENT 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 sa[...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC POWER W A VE 355/405 TROUBLESHOOTING & REP AIR F-48 F-48 PROCEDURE 1. Remove input power to the POWER WA VE 355/405. 2. Using a 5/16” nut driver remove the case wrap- aroun[...]

Observe static precautions detailed in PC Board T roubleshooting Procedures at the beginning of this section. 6. Using a phillips head screwdriver r emove the two screws and their washers fr om above and below the input power switch. See Figure F .18. 7. Using a phillips head screwdriver r emove the four screws fr om around the two welder output te[...]

POWER W A VE 355/405 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC 12. Using a 3/8” nut driver remove the two mounting nuts from the top two corners of the control board. See Figur e F .20. 13. Cut any necessary cable ties[...]

MAIN SWITCH BOARD REMOV AL AND REPLACEMENT Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may r esult in danger to the technician or machine operator and will invalidate your factory warranty . For your safety and to avoid electrical shock, please observe a[...]

PROCEDURE 1. Remove the input power to the POWER WA VE 355/405. 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. Observe static precautions detailed in PC Board Tr oubleshooting Procedures at the beginning of this section. Failure to do so [...]

POWER W A VE 355/405 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-53 F-53 FIGURE F.22 – 3/16” ALLEN BOLT LOCATION - + - + - + - + 3/16" ALLEN BOL TS MAIN SWITCH BOARD REMOV AL & [...]

NOTES F-54 F-54 POWER W A VE 355/405 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC[...]

SNUBBER BOARD REMOV AL AND REPLACEMENT Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may r esult 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 s[...]

PROCEDURE 1. Remove input power to the POWER WA VE 355/405. 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 snubber board.. See Figur e F .23. 5. Remove small lead #B1 from the boar d. See Figure F .24. 6. Remove the four bol[...]

POWER BOARD REMOV AL AND REPLACEMENT Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may r esult 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 saf[...]

PROCEDURE 1. Remove input power to the POWER WA VE 355/405. 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 power board. See Figur e F .25. TROUBLESHOOTING & REP AIR F-58 F-58 POWER W A VE 355/405 Return to Section TOC Re[...]

TROUBLESHOOTING & REP AIR POWER BOARD REMOV AL AND REPLACEMENT (continued) F-59 F-59 POWER W A VE 355/405 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Observe static precautions detailed in PC Board T roubleshooting Pro[...]

NOTES F-60 F-60 POWER W A VE 355 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC[...]

F-61 F-61 POWER W A VE 355 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC DC BUS BOARD REMOV AL AND REPLACEMENT Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs p[...]

TROUBLESHOOTING & REP AIR F-62 F-62 POWER W A VE 355 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC PROCEDURE 1. Remove input power to the POWER WA VE 355/405. 2. Using a 5/16” nut driver remove the case wrap- around co[...]

TROUBLESHOOTING & REP AIR F-63 F-63 POWER W A VE 355 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC 9. Label and remove two thermostat leads and four leads from the bus r ectifier . 10. Using a 3/8” open end wr ench, re[...]

16. Replace the two 5/16” mounting scr ews to the bottom of the case front. 17. Replace the case wrapar ound cover . TROUBLESHOOTING & REP AIR DC BUS BOARD REMOV AL AND REPLACEMENT (Continued) F-64 F-64 POWER W A VE 355 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Maste[...]

TROUBLESHOOTING & REP AIR F-65 F-65 POWER W A VE 355/405 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC INPUT RECTIFIER REMOV AL AND REPLACEMENT Service and repair should be performed by only Lincoln Electric factory trai[...]

PROCEDURE 1. Remove input power to the POWER WA VE 355/405. 2. Using a 5/16” nut driver remove the case wraparound cover . 3. Perform the Input Filter Capacitor Discharge Procedure detailed earlier in this section. 4. Locate the input rectifier . See figure F .30. 5. Carefully r emove the silicon sealant insulating the six input rectifier termina[...]

9. Apply a thin coat of Penetrox A-13 heatsink com- pound to the point of contact between the input r ectifier and the mounting surface. 10. Secure the new input bridge into its proper posi- tion with the two 3/16”in. allen mounting screws previously r emoved. T orque to 44 inch pounds. 11. Reconnect the pr eviously removed leads to their proper [...]

NOTES F-68 F-68 POWER W A VE 355/405 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC[...]

F-69 F-69 POWER W A VE 355/405 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR OUTPUT RECTIFIER MODULES REMOV AL AND REPLACEMENT Service and repair should be performed by only Lincoln Electric fac[...]

PROCEDURE 1. Remove input power to the POWER WA VE 355/405. 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 output diode modules located behind the snubber board. See figur e F .32. 5. Before the output rectifier modules can [...]

8. Under the copper plate pr eviously removed, ther e is an allen bolt. Remove it using a 9/64” allen wrench. See Figur e F .33. 9. Using a 7/16” socket remove the mounting bolts at the top and bottom of the modules. See Figure F .33. 10. The output rectifier modules are r eady for removal and/or replacement. 11. Before replacing the diode modu[...]

NOTES F-72 F-72 POWER W A VE 355/405 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC[...]

F-73 F-73 POWER W A VE 355/405 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR CURRENT TRANSDUCER REMOV AL AND REPLACEMENT Service and repair should be performed by only Lincoln Electric factory t[...]

PROCEDURE 1. Remove input power to the POWER WA VE 355/405. 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. Using a 5/16” nut driver remove the four scr ews from the bottom and right side of the r ear assem- bly . See Figur e F .34. T[...]

5. Label and remove the four leads connected to the r econnect panel. Pliers may be necessary . 6. Label and remove the two leads connected to the CB2 circuit br eaker . 7. Using a crescent wr ench, remove the lar ge plastic nut from ar ound the input power line located at bot- tom of the rear assembly . See Figure F .35. 8. Locate the steel nut lo[...]

11. 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 r emoved completely . 12. Carefully swing the r ear of the machine open to the left while facing the rear of the machine. 13. Perform the Snubber Board Removal Procedure . 14. Remove leads #X2 and #20 from t[...]

21. Replace the current transducer . 22. Replace the two 3/8” mounting nuts previously re moved. 23. Reconnect plug #J90 to the current transducer . 24. Replace any necessary cable ties previously cut. 25. From the rear of the machine, r eplace the heavy flex lead to the bottom of the output diode heatsink assembly using a 1/2” wrench. Note: Do[...]

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. OR If you repair or replace any electrical components. INPUT IDLE AMPS AND W A TTS MAXIMUM OUTPUT V OL T A GES TROUBLESHOOTING & REP AIR F-78 F-78 POWER W A VE 355/405 Return to Secti[...]

G-1 ELECTRICAL DIAGRAMS G-1 T ABLE OF CONTENTS -ELECTRICAL DIAGRAMS SECTION- ELECTRICAL DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION G WIRING DIAGRAM (G4131) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-2 ENTIRE[...]

ELECTRICAL DIAGRAMS G-2 POWERW A VE 355/405 WIRING DIAGRAM - POWERW A VE 355/405 - G4131 NOTES : N.A. 1. FO R MA CHI NE S WIT H RE D, BL ACK AN D W HITE POW ER C ORD S- FOR SINGL E P HAS E IN PUT: CON NE CT G RE EN L EAD T O G RO UND PER NATI ON AL EL ECT RIC AL CO DE. CO NNE CT BL ACK AN D W HITE L EA DS T O SU PPL Y CI RCUIT. WRA P R ED L EAD WIT[...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ELECTRICAL DIAGRAMS G-3 POWERW A VE 355/405 SCHEMA TIC - COMPLETE MACHINE EN-170 G4132 PO WE RW AV E 355/ 405 MACHINE SC HEM ATI C NON E G4093 F.Valencic L.Petrila J.O'Conn [...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ELECTRICAL DIAGRAMS G-4 POWERW A VE 355/405 SCHEMA TIC - DIGIT AL CONTROL PC BOARD #1 G-4 NOTE: This diagram is for reference only . It may not be accurate for all machines cover[...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ELECTRICAL DIAGRAMS G-5 POWERW A VE 355/405 SCHEMA TIC - DIGIT AL CONTROL PC BOARD #2 G-5 NOTE: This diagram is for reference only . It may not be accurate for all machines cover[...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ELECTRICAL DIAGRAMS G-6 POWERW A VE 355/405 SCHEMA TIC - DIGIT AL CONTROL PC BOARD #3 G-6 NOTE: This diagram is for reference only . It may not be accurate for all machines cover[...]

ELECTRICAL DIAGRAMS G-7 POWERW A VE 355/405 SCHEMA TIC - DIGIT AL CONTROL PC BOARD #4 G-7 NOTE: This diagram is for reference only . It may not be accurate for all machines covered by this manual. Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Re[...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ELECTRICAL DIAGRAMS G-8 POWERW A VE 355/405 SCHEMA TIC - POWER SUPPL Y PRINTED CIRCUIT BOARD ¬¥ ’· ± ’Ò ‰  ü ØØ —± ¬Õÿ ¨ Œ¬»± ± µ ¥ ¥÷ ±’ Ÿ?[...]

ELECTRICAL DIAGRAMS G-9 POWERW A VE 355/405 SCHEMA TIC - SWITCH PC BOARD G-9 NOTE: This diagram is for reference only . It may not be accurate for all machines covered by this manual. Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Maste[...]

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 troub[...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ELECTRICAL DIAGRAMS G-11 POWERW A VE 355/405 SCHEMA TIC - SNUBBER PC BOARD S24761 6-2-2000 G-11 NOTE: This diagram is for reference only . It may not be accurate for all machines[...]

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 troub[...]

ELECTRICAL DIAGRAMS G-13 POWERW A VE 355/405 SCHEMA TIC - 40 VDC BUSS PC BOARD G-13 NOTE: This diagram is for reference only . It may not be accurate for all machines covered by this manual. Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return t[...]

SVM ERROR REPORTING FORM We need to know if there are errors in our manuals. We also value any suggestions as to additional tests or procedures that would make this SVM a better tool for you. If you discover new or different “Problems or Symptoms” that are not covered in the three col- umn troubleshooting chart, please share this information wi[...]