Lincoln Electric Welder SVM159 A User Manual
RETURN TO MAIN INDEX  
SVM159-A  
December, 2003  
POWER WAVE 355/405  
For use with machine code numbers 10895, 10896  
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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 careful.  
V E 3 5 5  
W A  
W E R  
P O  
W
A
R
N
I
N
G
R
E
M
O
T
E
P
O
W
E
R
O
N
SERVICE MANUAL  
Copyright © 2003 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  
Download from Www.Somanuals.com. All Manuals Search And Download.  
ii  
ii  
SAFETY  
ARC RAYS can burn.  
ELECTRIC SHOCK can kill.  
3.a. The electrode and work (or ground) circuits  
are electrically “hot” when the welder is on.  
Do not touch these “hot” parts with your bare  
skin or wet clothing. Wear dry, hole-free  
gloves to insulate hands.  
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. Use suitable clothing made from durable flame-resistant  
material to protect your skin and that of your helpers from  
the arc rays.  
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.  
4.c. 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.  
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 cramped positions such as sitting,  
kneeling or lying, if there is a high risk of unavoidable or  
accidental contact with the workpiece or ground) use  
the following equipment:  
FUMES AND GASES  
can be dangerous.  
5.a. Welding may produce fumes and gases  
hazardous to health. Avoid breathing these  
• Semiautomatic DC Constant Voltage (Wire) Welder.  
• DC Manual (Stick) Welder.  
• AC Welder with Reduced Voltage Control.  
fumes and gases.When welding, keep  
your head out of the fume. Use enough  
ventilation and/or exhaust at the arc to keep  
3.c. In semiautomatic or automatic wire welding, the electrode,  
electrode reel, welding head, nozzle or semiautomatic  
welding gun are also electrically “hot”.  
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.  
3.d. 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.  
3.e. Ground the work or metal to be welded to a good electrical  
(earth) ground.  
3.f. Maintain the electrode holder, work clamp, welding cable and  
welding machine in good, safe operating condition. Replace  
damaged insulation.  
5.b. 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.  
3.g. Never dip the electrode in water for cooling.  
3.h. 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.  
5.c. 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.  
3.i. When working above floor level, use a safety belt to protect  
yourself from a fall should you get a shock.  
5.d. 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.  
3.j. Also see Items 6.c. and 8.  
5.e. Also see item 1.b.  
Mar ‘95  
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iii  
iii  
SAFETY  
WELDING SPARKS can  
cause fire or explosion.  
CYLINDER may explode  
if damaged.  
6.a. Remove fire hazards from the welding area.  
If this is not possible, cover them to prevent  
7.a. Use only compressed gas cylinders  
containing the correct shielding gas for the  
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.  
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.  
7.b. Always keep cylinders in an upright position securely  
chained to an undercarriage or fixed support.  
6.b. Where compressed gases are to be used at the job site,  
special precautions should be used to prevent hazardous  
situations. Refer to “Safety in Welding and Cutting” (ANSI  
Standard Z49.1) and the operating information for the  
equipment being used.  
7.c. Cylinders should be located:  
•Away from areas where they may be struck or subjected to  
physical damage.  
6.c. 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.  
•A safe distance from arc welding or cutting operations and  
any other source of heat, sparks, or flame.  
7.d. Never allow the electrode, electrode holder or any other  
electrically “hot” parts to touch a cylinder.  
6.d. 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).  
7.e. Keep your head and face away from the cylinder valve outlet  
when opening the cylinder valve.  
7.f. Valve protection caps should always be in place and hand  
tight except when the cylinder is in use or connected for  
use.  
7.g. Read and follow the instructions on compressed gas  
cylinders, associated equipment, and CGA publication P-l,  
“Precautions for Safe Handling of Compressed Gases in  
Cylinders,” available from the Compressed Gas Association  
1235 Jefferson Davis Highway, Arlington, VA 22202.  
6.e. Vent hollow castings or containers before heating, cutting or  
welding. They may explode.  
6.f. 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.  
FOR ELECTRICALLY  
powered equipment.  
6.g. Connect the work cable to the work as close to the welding  
area as practical. Work cables connected to the building  
framework or other locations away from the welding area  
increase the possibility of the welding current passing  
through lifting chains, crane cables or other alternate circuits.  
This can create fire hazards or overheat lifting chains or  
cables until they fail.  
8.a. Turn 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 codes and the manufacturer’s  
recommendations.  
6.h. Also see item 1.c.  
8.c. Ground the equipment in accordance with the U.S. National  
Electrical Code and the manufacturer’s recommendations.  
Mar ‘95  
POWER WAVE 355/405  
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iv  
iv  
SAFETY  
6. Eloigner les matériaux inflammables ou les recouvrir afin de  
PRÉCAUTIONS DE SÛRETÉ  
prévenir tout risque d’incendie dû aux étincelles.  
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-  
antes:  
7. Quand on ne soude pas, poser la pince à une endroit isolé de  
la masse. Un court-circuit accidental peut provoquer un  
échauffement et un risque d’incendie.  
8. S’assurer que la masse est connectée le plus prés 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  
éloignés de la zone de travail, on augmente le risque de voir  
passer le courant de soudage par les chaines de levage,  
câbles de grue, ou autres circuits. Cela peut provoquer des  
risques d’incendie ou d’echauffement des chaines et des  
câbles jusqu’à ce qu’ils se rompent.  
Sûreté Pour Soudage A L’Arc  
1. Protegez-vous contre la secousse électrique:  
a. Les circuits à l’électrode et à la piéce sont sous tension  
quand la machine à souder est en marche. Eviter toujours  
tout contact entre les parties sous tension et la peau nue  
ou les vétements mouillés. Porter des gants secs et sans  
trous pour isoler les mains.  
b. Faire trés 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 couché pour lesquelles une grande  
partie du corps peut être en contact avec la masse.  
c. Maintenir le porte-électrode, la pince de masse, le câble de  
soudage et la machine à souder en bon et sûr état defonc-  
tionnement.  
9. Assurer une ventilation suffisante dans la zone de soudage.  
Ceci est particuliérement important pour le soudage de tôles  
galvanisées plombées, ou cadmiées ou tout autre métal qui  
produit des fumeés toxiques.  
10. Ne pas souder en présence de vapeurs de chlore provenant  
d’opérations de dégraissage, nettoyage ou pistolage. La  
chaleur ou les rayons de l’arc peuvent réagir avec les vapeurs  
du solvant pour produire du phosgéne (gas fortement toxique)  
ou autres produits irritants.  
d.Ne jamais plonger le porte-électrode dans l’eau pour le  
refroidir.  
e. Ne jamais toucher simultanément les parties sous tension  
des porte-électrodes connectés à deux machines à souder  
parce que la tension entre les deux pinces peut être le total  
de la tension à vide des deux machines.  
11. Pour obtenir de plus amples renseignements sur la sûreté, voir  
le code “Code for safety in welding and cutting” CSA Standard  
W 117.2-1974.  
f. Si on utilise la machine à souder comme une source de  
courant pour soudage semi-automatique, ces precautions  
pour le porte-électrode s’applicuent aussi au pistolet de  
soudage.  
PRÉCAUTIONS DE SÛRETÉ POUR  
LES MACHINES À SOUDER À  
TRANSFORMATEUR ET À  
REDRESSEUR  
2. Dans le cas de travail au dessus du niveau du sol, se protéger  
contre les chutes dans le cas ou on recoit un choc. Ne jamais  
enrouler le câble-électrode autour de n’importe quelle partie du  
corps.  
3. Un coup d’arc peut être plus sévère qu’un coup de soliel, donc:  
a. Utiliser un bon masque avec un verre filtrant approprié ainsi  
qu’un verre blanc afin de se protéger les yeux du rayon-  
nement de l’arc et des projections quand on soude ou  
quand on regarde l’arc.  
1. Relier à la terre le chassis du poste conformement au code de  
l’électricité et aux recommendations du fabricant. Le dispositif  
de montage ou la piece à souder doit être branché à une  
bonne mise à la terre.  
b. Porter des vêtements convenables afin de protéger la peau  
de soudeur et des aides contre le rayonnement de l‘arc.  
c. Protéger l’autre personnel travaillant à proximité au  
soudage à l’aide d’écrans appropriés et non-inflammables.  
2. Autant que possible, I’installation et l’entretien du poste seront  
effectués par un électricien qualifié.  
3. Avant de faires des travaux à l’interieur de poste, la debranch-  
er à l’interrupteur à la boite de fusibles.  
4. Des gouttes de laitier en fusion sont émises de l’arc de  
soudage. Se protéger avec des vêtements de protection libres  
de l’huile, tels que les gants en cuir, chemise épaisse, pan-  
talons sans revers, et chaussures montantes.  
4. Garder tous les couvercles et dispositifs de sûreté à leur place.  
5. Toujours porter des lunettes de sécurité dans la zone de  
soudage. Utiliser des lunettes avec écrans lateraux dans les  
zones où l’on pique le laitier.  
Mar. ‘93  
POWER WAVE 355/405  
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v
v
INSTALLATION  
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 50 199 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 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 constructing 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 person who is competent to  
assess 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 equipment.  
Assessment of Area  
Before installing welding equipment the user shall make an assessment of potential electromagnetic problems 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.  
3-1-96H  
L10093  
POWER WAVE 355  
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vi  
vi  
INSTALLATION  
ELECTROMAGNETIC COMPATIBILITY (EMC)  
The size of the surrounding area to be considered will depend on the structure of the building and other activities  
that are taking 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 recommendations.  
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 equipment 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 the floor level.  
Equipotential Bonding  
Bonding of all metallic 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 connection 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  
1
interference. Screening of the entire welding installation may be considered for special applications.  
1
Portions of the preceding text are contained in EN50199: "Electromagnetic Compatibility (EMC) product standard for  
arc welding equipment."  
3-1-96H  
L10093  
POWER WAVE 355  
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v
v
MASTER TABLE OF CONTENTS FOR ALL SECTIONS  
RETURN TO MAIN INDEX  
Page  
Safety.................................................................................................................................................i-iv  
Installation.............................................................................................................................Section A  
Operation...............................................................................................................................Section B  
Accessories...........................................................................................................................Section C  
Maintenance .........................................................................................................................Section D  
Theory of Operation .............................................................................................................Section E  
Troubleshooting and Repair.................................................................................................Section F  
How to Use Troubleshooting Guide............................................................................................F-2  
Troubleshooting Guide................................................................................................................F-4  
Test Procedures ........................................................................................................................F-15  
Replacement Procedures .........................................................................................................F-47  
Electrical Diagrams..............................................................................................................Section G  
Parts Manual....................................................................................................................P-401 Series  
POWER WAVE 355/405  
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SectionA-1  
Section A-1  
TABLE OF CONTENTS  
- INSTALLATION SECTION -  
Installation  
Technical Specifications 355......................................................................................................A-2  
Technical Specifications 405......................................................................................................A-3  
Safety Precautions......................................................................................................................A-4  
Stacking......................................................................................................................................A-4  
Tilting ..........................................................................................................................................A-4  
Input Grounding Connections ....................................................................................................A-4  
Power Cord Connection.............................................................................................................A-4  
Output Cables, Connections and Limitations ............................................................................A-5  
Negative Electrode Polarity ........................................................................................................A-5  
Voltage Sensing..........................................................................................................................A-5  
Power Wave to Semi-Automatic Wire Feeder............................................................................A-6  
System Description ....................................................................................................................A-7  
System Set-up............................................................................................................................A-8  
Multiple Group System...............................................................................................................A-9  
Single Group Multi-Head System.............................................................................................A-10  
Welding with Multiple Power Waves ........................................................................................A-11  
Control Cable Specifications....................................................................................................A-11  
I/0 Receptacle Specifications...................................................................................................A-12  
Dip Switch Settings and Locations ..........................................................................................A-12  
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A-2  
A-2  
INSTALLATION  
TECHNICAL SPECIFICATIONS - POWER WAVE 355  
INPUT AC VOLTAGE & DC OUTPUT  
Product Ordering  
Input AC  
Rated DC Output  
Output  
Range  
(continuous)  
Weight  
with Cord  
Dimensions  
HxWxD  
Name Information Voltage Amps/Volts/Duty Cycle  
200-208  
220-240  
380-415  
440-480  
575  
Power  
Wave  
355  
350A / 34V / 60%  
1 & 3 Phase  
K2152-1  
14.8” x 13.3” x  
27.8”*  
(373 x 338 x  
706*)mm  
*Includes  
Handles  
AMPS  
5-425  
(81.5 lbs.)  
(37.0 kg.)  
300A / 32V / 100%  
1 & 3 Phase  
60/50 HZ  
* 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 50/60 Hz Output Recommended  
Line Cord  
300Amps @ Fuse size  
Notes  
Voltage  
200  
Phases  
350Amps @  
34Volts(60%)  
Not  
32Volts(100%)  
Not  
AWG  
Note 1  
1
---  
Recommended Recommended  
Note 2  
Note 2  
Note 1  
208  
230  
380  
1
1
1
76  
69  
Not  
94  
85  
Not  
2
4
125A  
125A  
---  
Recommended Recommended  
Not Not  
Recommended Recommended  
Note 1  
Note 2  
400  
1
---  
---  
415  
460  
575  
1
1
1
41  
36  
31  
64  
42  
37  
6
8
8
80A  
70A  
50A  
Note 2  
Note 2  
200  
208  
230  
380  
400  
415  
460  
575  
3
3
3
3
3
3
3
3
41  
39  
36  
23  
22  
22  
19  
16  
50  
50  
42  
28  
27  
26  
23  
18  
6
6
8
8
8
8
8
8
80A  
80A  
70A  
50A  
50A  
50A  
50A  
35A  
Note 1. Not rated is indicated by 4-x’s in the box on the rating plate.  
Note 2. When operating on these inputs, the line cord should be changed to an input conductor of 6 AWG or larger.  
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  
100%  
CURRENT  
300  
LENGTH UP 200FT.(61m)  
200-250 FT. (61-76m)  
1/0  
1/0  
1/0  
2/0  
60%  
350  
*Lincoln Electric recommends using a minimum of 2/0 welding cable for pulse welding.  
POWER WAVE 355/405  
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A-3  
A-3  
INSTALLATION  
TECHNICAL SPECIFICATIONS - POWER WAVE 405  
INPUT AC VOLTAGE & DC OUTPUT  
Product  
Ordering Input AC  
Rated DC Output  
Output  
Range  
(continuous)  
Weight  
with Cord  
Dimensions  
HxWxD  
Name Information Voltage Amps/Volts/Duty Cycle  
350A / 34V / 60%  
14.7”x12.5”x  
27.8”*  
(373x318x  
706*)mm  
Power  
Wave  
405  
200-208 /  
3 Phase  
K 2152-2  
220-240/ 320A / 33V / 60%  
AMPS  
5-425  
86.5lbs  
(37.4 kg)  
380-415/  
3/50/60  
1 Phase  
60/50 Hz 275A / 31V /100%  
1 Phase  
300A / 32V / 100%  
3 Phase  
* Includes  
handles  
* Overall Length Including Handle, 21.6” (549mm) 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  
300Amps@  
Voltage  
Phases  
350Amps@  
34Volts(60%)  
Line Cord  
Size Fuse Size  
Notes  
32Volts(100%)  
Size mm2  
200  
220  
380  
400  
415  
3
3
3
3
3
41  
37  
23  
22  
22  
48  
48  
28  
27  
26  
16  
16  
10  
10  
10  
80A  
80A  
50A  
50A  
50A  
Note 2  
Note 2  
Voltage  
Phases  
31Volts(100%)  
275Amps@  
33Volts(60%)  
320Amps@  
Line Cord  
Fuse Size  
Notes  
Size mm2  
200  
220  
380  
400  
415  
1
1
1
1
1
Not Recommended Not Recommended  
---  
20  
16  
10  
10  
-----  
Note 1  
Note 2  
Note 2  
64  
44  
40  
38  
82  
55  
50  
48  
125A  
80A  
80A  
80A  
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.  
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  
100%  
CURRENT  
275  
350  
LENGTH UP 61m (200 FT)  
61-76m (200-250 FT)  
1/0  
1/0  
1/0  
2/0  
60%  
POWER WAVE 355/405  
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A-4  
A-4  
INSTALLATION  
• Open the access panel on the rear of the machine.  
• For 200 or 230: Position the large switch to 200-  
230.  
SAFETY PRECAUTIONS  
WARNING  
ELECTRIC SHOCK can kill.  
For higher voltages: Position the large switch to  
380-575.  
• Move the "A" lead to the appropriate terminal.  
• TURN THE INPUT POWER OFF AT  
THE DISCONNECT SWITCH BEFORE  
POWER CORD CONNECTION  
ATTEMPTING TO CONNECT OR DIS-  
CONNECT INPUT POWER LINES, OUTPUT  
CABLES, OR CONTROL CABLES.  
A power cord is provided and wired into the machine.  
Follow the power cord connection instructions.  
Machine  
Cord Length  
• Only qualified personnel should perform this  
installation.  
• Connect the green/yellow lead of the power  
cord to ground per U.S.National Electrical Code.  
----------------------------------------------------------------------  
PW 355  
PW 405  
10 Feet  
5 Meters  
CAUTION  
SELECT SUITABLE LOCATION  
•Incorrect connection may result in equipment  
damage.  
In order to assure long life and reliable operation,  
the owner of this machine should follow these sim-  
ple preventative measures:  
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A
A
M
P
S
V
• 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.  
V
O
L
T
S
A
O
U
T
L
P
U
IN  
E
T
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L
W
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O
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N
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R
M
C
IN  
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R
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R
N
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CT  
G
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E
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T
E
E
C
V
3
5
0
-
P
R
O
W
E
R
O
N
• Dirt and dust that can be drawn into the machine  
should be kept to a minimum. Failure to observe  
these precautions can result in excessive operating  
temperatures and nuisance shutdown.  
Single Phase Input (PW 355)  
Connect green lead to ground per National Electrical  
Code.  
• Keep machine dry. Shelter from rain and snow. Do  
not place on wet ground or in puddles.  
• DO NOT MOUNT OVER COMBUSTIBLE SURFACES.  
Connect black and white leads to power.  
Wrap red lead with tape to provide 600V insulation.  
Three Phase Input (PW 355)  
Connect green lead to ground per National Electric  
Code.  
Where there is a combustible surface directly under  
CAUTION  
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.  
Connect black, red and white leads to power.  
Lead Color Single Phase Three Phase  
Connect to  
ground per NEC  
Connect to  
ground per NEC  
Green  
STACKING  
POWER WAVE 355/405 cannot be stacked.  
Black  
White  
Red  
Power Lead  
Power Lead  
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.  
Power Lead  
Power Lead  
Power Lead  
Tape, provide  
600V insulation  
INPUT AND GROUNDING CONNECTIONS  
• Only a qualified electrician should connect the  
POWER WAVE 355/405. Installation should be  
made in accordance with the appropriate National  
Electrical Code, all local codes and the information  
detailed below.  
Single Phase Input (PW 405)  
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.  
• 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.  
Three Phase Input (PW 405)  
Connect green/yellow lead to ground per National  
Electric Code.  
Connect black, blue and brown leads to power.  
POWER WAVE 355/405  
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A-5  
A-5  
INSTALLATION  
UNDERCARRIAGE MOUNTINGS  
CAUTION  
Excessive voltage drops caused by poor work  
piece connections often result in unsatisfactory  
welding performance.  
MOUNTING HOLE LOCATIONS  
NOTE: MOUNTING SCREWS CAN NOT PROTR  
UDE MORE THAN  
CHES INSIDE THE MACHINE.  
0.5 IN  
3.50  
-----------------------------------------------------------------------  
NEGATIVE ELECTRODE POLARITY  
When negative electrode polarity is required, such as  
in some Innershield applications, reverse the output  
connections at the power source (electrode cable to  
the negative (-) Twist-Mate terminal, and work cable  
to the positive (+) Twist-Mate terminal.  
1/4-20 NUT (4 PLACES)  
5.50  
10.00  
4/01  
11.8  
4
M19527  
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.  
OUTPUT CABLES, 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.  
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 cables can influence the  
voltage apparent at the studs of the welder. Voltage  
sense leads improve the accuracy of the arc condi-  
tions and can have a dramatic effect on performance.  
Sense Lead Kits (K940-10, -25 or -50) are available for  
this purpose.  
CAUTION  
When using an inverter type power source like the  
PowerWaves, 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  
welding characteristics, if undersized welding  
cables are used.  
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.  
------------------------------------------------------------------------  
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 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.  
------------------------------------------------------------------------  
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 infor-  
mation on the WORK sense lead (21), see"Work  
Voltage Sensing” in the following paragraph.  
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 355/405  
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A-6  
A-6  
INSTALLATION  
5. Replace the wrap around and screws. The PC board  
will “read” the switch at power up, and configure the  
work voltage sense lead appropriately.  
Enable the voltage sense leads as follows:  
TABLE A.1  
Process Electrode Voltage Work Voltage  
Sensing 67 lead *  
GMAW 67 lead required  
GMAW-P 67 lead required  
FCAW 67 lead required  
GTAW Voltage sense at studs Voltage sense at studs  
GMAW Voltage sense at studs Voltage sense at studs  
Sensing 21 lead  
21 lead optional  
21 lead optional  
21 lead optional  
ELECTRODE VOLTAGE SENSING  
Enabling or disabling electrode voltage sensing is  
automatically configured through software. The 67  
electrode sense lead is internal to the cable to the wire  
feeder and always connected when a wire feeder is  
present.  
SAW  
67 lead required  
21 lead optional  
CAC-C Voltage sense at studs Voltage sense at studs  
CAUTION  
* The electrode voltage 67 sense lead is integral to the  
control cable to the wire feeder.  
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.  
Work Voltage Sensing  
The standard POWER WAVE 355/405 default to the  
work stud (work sense lead disabled)  
------------------------------------------------------------------------  
POWER WAVE TO SEMI-AUTOMATIC  
POWERFEED WIRE FEEDER INTERCON-  
NECTIONS  
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:  
The POWER WAVE 355/405 and semi-automatic  
PowerFeed family communicate via a 5 conductor con-  
trol 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 405  
is on the case front. The input receptacle on the Power  
Feed is typically located at the back of the feeder, or on  
the bottom of the user interface.  
WARNING  
• Do not touch electrically live parts or  
electrodes with your skin or wet  
clothing.  
• Insulate yourself from the work and  
ground.  
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.  
• Always wear dry insulating gloves.  
1. Turn off power to the power source at the disconnect  
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.  
O
N
1
2
3
4
5
6
7
8
POWER WAVE 355/405  
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A-7  
A-7  
INSTALLATION  
From a network perspective, each component in the  
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 Linc-Net. The Linc-Net  
connection is generally made external through the  
Linc-Net Control Cable, but can also be made internal-  
ly, as with the PF-10 bench model feeder.  
SYSTEM DESCRIPTION  
The POWER WAVE 355/405 and Power Feed 10/11  
family of products utilize a digital communication sys-  
tem called Linc-Net. Simply put, Linc-Net 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.  
The most common Linc-Net configuration (called a  
simple 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 con-  
sisting of a power source and one UI (Example: a stick  
welding system).  
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 (UI), and up to seven Feed Heads (FH). SEE  
FIGURE A.1. The UI controls all of the FH’s of that  
group. The UI’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 UI. In  
addition, each FH must be assigned a separate FH  
number within that group. See the system set-up sec-  
tion for further details.  
FIGURE A.1  
System Model  
Maximum  
Configuration  
POWER WAVE 355/405  
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A-8  
A-8  
INSTALLATION  
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.  
• 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 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 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 “FH0” will func-  
tion.  
• 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  
Group and Feed  
Head ID numbers are  
ignored in a simple  
system.  
POWER WAVE 355/405  
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A-9  
A-9  
INSTALLATION  
Multiple Group System  
No “FH0 Allowed!  
FIGURE A.3  
Single Group Multi-Head System  
FIGURE A.4  
No “FH0 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.  
POWER WAVE 355/405  
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A-10  
Single Group Multi-Head System (Alternate Method)  
A-10  
INSTALLATION  
No “FH0 Allowed!  
When standard  
FIGURE A.5  
a
User Interface is used  
in a group with multi-  
ple Feed Heads, all of  
the Feed Heads use a  
single set of proce-  
dures.  
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A-11  
A-11  
INSTALLATION  
CONTROL CABLE SPECIFICATIONS  
WELDING WITH MULTIPLE POWER  
WAVES  
It is recommended that genuine Lincoln control cables  
be used at all times. Lincoln cables are specifically  
designed for the communication and power needs of  
the Power Wave / Power Feed system.  
CAUTION  
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.  
CAUTION  
The use of non-standard cables, especially in  
lengths greater than 25 feet, can lead to communi-  
cation problems (system shutdowns), poor motor  
acceleration (poor arc starting) and low wire dri-  
ving 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.  
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 frequency will be the same, helping to stabilize the  
arcs.  
Every welding gun requires a separate shielding gas  
regulator for proper flow rate and shielding gas cover-  
age.  
Do not attempt to supply shielding gas for two or more  
guns from only one regulator.  
If an anti-spatter system is in use then each gun must  
have its own anti-spatter system. (See Figure A.6)  
FIGURE A.6  
POWER WAVE 355/405  
POWER WAVE 355/405  
TWO POWER WAVES  
Travel  
Direction  
Connect All Work  
Sense Leads at the End  
of the Joint  
Connect All Welding  
Work Leads at the  
Beginning of the Joint  
POWER WAVE 355/405  
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A-12  
A-12  
INSTALLATION  
CONTROL BOARD DIP SWITCH:  
switch 1 = reserved for future use  
switch 2 = reserved for future use  
switch 3 = reserved for future use  
switch 4 = reserved for future use  
switch 5 = reserved for future use  
switch 6 = reserved for future use  
switch 7 = reserved for future use  
switch 8* = work sense lead  
I / O RECEPTACLE SPECIFICATIONS  
TABLE A.2  
WIRE FEEDER RECEPTACLE  
PIN  
A
B
C
D
LEAD#  
53  
54  
67A  
52  
FUNCTION  
Communication Bus L  
Communication Bus H  
Electrode Voltage Sense  
0vdc  
E
51  
+40vdc  
TABLE A.3  
VOLTAGE SENSE RECEPTACLE  
switch 8*  
work sense lead  
off  
on  
work sense lead not connected  
work sense lead connected  
PIN  
3
LEAD#  
21A  
FUNCTION  
Work Voltage Sense  
*Factory setting for Switch 8 is OFF.  
TABLE A.4  
RS232 RECEPTACLE  
PIN  
2
3
LEAD#  
253  
254  
#
FUNCTION  
RS232 Receive  
RS232 Transmit  
Pin5  
FIGURE A.7  
CONTROL BOARD (DIP Switch Location)  
4
5
#
Pin4  
6
20  
7
# #  
# #  
251  
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  
switches:  
WARNING  
1. Turn off power to the power source at the dis-  
connect 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.  
O
N
1
2
3
4
5
6
7
8
5. Replace the wrap around and screws. The PC board  
will “read” the switch at power up, and configure the  
work voltage sense lead appropriately.  
POWER WAVE 355/405  
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Section B-1  
Section B-1  
TABLE OF CONTENTS  
- OPERATION SECTION -  
Operation...............................................................................................................................Section B  
Safety Precautions......................................................................................................................B-2  
General Description....................................................................................................................B-2  
Recommended Processes and Equipment................................................................................B-2  
Required Equipment...................................................................................................................B-3  
Limitations...................................................................................................................................B-3  
Duty Cycle and Time Period.......................................................................................................B-3  
Case Front Controls....................................................................................................................B-3  
Making a Weld ............................................................................................................................B-4  
Welding Adjustments..................................................................................................................B-4  
Constant Voltage Welding ..........................................................................................................B-5  
Tig (GTAW) ..................................................................................................................................B-6  
Special Welding Processes Available.........................................................................................B-6  
Power Mode ...............................................................................................................................B-6  
Pulse Welding (GMAW-P)...........................................................................................................B-7  
Pulse-on-Pulse (GMAW-PP).......................................................................................................B-8  
Benefits of Pulse-on-Pulse Welding...........................................................................................B-8  
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B-2  
B-2  
OPERATION  
SAFETY PRECUATIONS  
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.  
Read this entire section of operating instructions  
before operating the machine.  
WARNING  
ELECTRIC SHOCK can kill.  
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 commu-  
nicate with Linc-Net.  
• Unless using cold feed feature, when  
feeding with gun trigger, the elec-  
trode and drive mechanism are  
always electrically energized and  
could remain energized several sec-  
onds after the welding ceases.  
• Do not touch electrically live parts or electrodes  
with your skin or wet clothing.  
The POWER WAVE 355/405 is a high performance,  
digitally controlled inverter welding power source capa-  
ble of complex, high-speed waveform control. Properly  
equipped, it can support the GMAW, GMAW-P, FCAW,  
SMAW, GTAW, and CAC-A processes. It carries an  
output rating of 350 Amps, 34 Volts at 60% duty cycle  
and 300 Amps, 32 volts at 100% duty cycle.  
• Insulate yourself from the work and ground.  
• Always wear dry insulating gloves.  
-----------------------------------------------------------  
FUMES AND GASES can be dangerous.  
• Keep your head out of fumes.  
• Use ventilation or exhaust to remove  
fumes from breathing zone.  
RECOMMENDED PROCESSES AND  
EQUIPMENT  
-----------------------------------------------------------  
WELDING SPARKS can cause fire or  
explosion.  
RECOMMENDED PROCESSES  
The POWER WAVE 355/405 can be set up in a num-  
ber of configurations, some requiring optional equip-  
ment or welding programs. Each machine is factory  
preprogrammed with multiple welding procedures, typ-  
ically including GMAW, GMAW-P, FCAW, GTAW, and  
CAC-A for a variety of materials, including mild steel,  
stainless steel, cored wires, and aluminum.  
• Keep flammable material away.  
• Do not weld on containers that have  
held combustibles.  
-----------------------------------------------------------  
The POWER WAVE 355/405 is recommended for  
semi-automatic welding, and may also be suitable for  
basic hard automation applications.  
ARC RAYS can burn.  
• Wear eye, ear, and body protection.  
• This Power Wave is not recommended for processes  
other than those listed.  
Observe additional guidelines detailed in the  
beginning of this manual.  
POWER WAVE 355/405  
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B-3  
B-3  
OPERATION  
POWER WAVE 355/405  
Operation  
–
Semi-Automatic  
NOTE: The POWER WAVE 355/405 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.  
Semi Automatic Power Waves can only be used with  
Linc-Net 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-Lincoln wire  
feeders, cannot be used.  
TABLE B.1  
Light  
Condition  
Meaning  
Steady Green System OK. Power source communicating normal-  
ly with wire feeder and its components.  
All welding programs and procedures are selected  
through the Power Feed semi-automatic user interface  
Blinking  
Green  
Occurs during a reset, and indicates the  
POWER WAVE 355/405 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  
REQUIRED EQUIPMENT  
Any Linc-Net compatible semi-automatic wire feeding  
equipment. Specifically, the semi-automatic Power  
Feed family (PF-10, PF-10X2, PF-11).  
Alternating Non-recoverable system fault. If the PW  
Green  
Red  
and Status light is flashing any combination of  
red and green, errors are present in the  
POWER WAVE 355/405. Read the error  
code before the machine is turned off.  
LIMITATIONS  
• Only Linc-Net compatible Power Feed semi-automat-  
ic wire feeders and users interfaces may be used.  
Other Lincoln wire feeders or non-Lincoln wire feed-  
ers cannot be used.  
Error Code interpretation through the Status  
light is detailed in the LED Status Chart.  
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.  
• POWER WAVE 355/405 Output Limitations  
The POWER WAVE 355/405 will support maximum  
average output current of 350 Amps @ 60% duty  
cycle.  
To clear the error, turn power source off, and  
back on to reset.  
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.  
Non recoverable hardware fault. Generally  
Steady Red  
Blinking Red  
indicates nothing is connected to the  
POWER WAVE 355/405 wire feeder recep-  
tacle. See Trouble Shooting Section.  
CASE FRONT CONTROLS  
All operator controls and adjustments are located on  
the case front of the Power Wave. (See Figure B.1)  
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.  
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.  
4. CB1 WIRE FEEDER CIRCUIT BREAKER:  
Protects 40 volt DC wire feeder power supply.  
POWER WAVE 355/405  
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B-4  
B-4  
OPERATION  
The steps for operating the Power Wave will vary  
depending upon 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.  
FIGURE B.1  
2
3
7
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.)  
4
1
6
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.  
8
9
10  
5
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.  
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  
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.  
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  
Because the Control Box can be configured 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 manu-  
al.  
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.  
------------------------------------------------------------------------  
• WFS / AMPS:  
In synergic welding modes (synergic CV, pulse  
GMAW) WFS (wire feed speed) is the dominant control  
parameter, controlling all other variables. The user  
adjusts WFS according to factors such as weld size,  
penetration requirements, heat input, etc. The Power  
Wave then uses the WFS setting to adjust its output  
characteristics (output voltage, output current) accord-  
ing to pre-programmed settings contained in the Power  
Wave.  
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B-5  
B-5  
OPERATION  
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.  
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 level correspondingly to main-  
tain similar arc characteristics throughout the WFS  
range.  
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.  
Non Synergic CV:  
This type of CV mode behaves more like a conven-  
tional CV power source. Voltage and WFS are inde-  
pendent adjustments. Therefore to maintain the arc  
characteristics, the operator must adjust the voltage to  
compensate for any changes made to the WFS.  
In pulse synergic 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.  
All CV Modes:  
• WELDING MODE  
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)  
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. For a more complete  
description of the welding modes available in the  
Power Wave, see the explanation below.  
• 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, below, for detailed explanations of  
how the Arc Control affects each mode.  
FIGURE B.2  
CURRENT WAVE FORM (CV)  
Current  
Time  
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B-6  
B-6  
OPERATION  
Power Mode™ is a method of high speed regulation of  
the output power whenever an arc is established. It  
provides a fast 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.  
TIG GTAW  
The TIG mode features continuous control from 5 to  
425 amps. The TIG mode can be run in either the  
Touch Start TIG or Scratch start mode.  
The Arc Control level selects the starting mode.  
In the Power Mode variables need to be set:  
Between –10 and 0, the Touch Start TIG mode is  
selected. The OCV is controlled below 10V and the  
short circuit "TIG touch" current is maintained at  
approximately 25 amps, independent of the preset cur-  
rent. When the tungsten is lifted, an arc is initiated and  
the output is regulated at the preset value. A setting of  
0, results in the most positive arc initiation. A setting of  
-10 reduces hot start.  
• 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.  
Between 0 and 10, the Scratch starting TIG mode is  
selected. In this range, the OCV of the machine is con-  
trolled between 50 and 70 volts.  
• For steel, use 75/25 Ar/CO2 shield gas.  
• For Stainless, select a Helium blend Tri-Mix.  
• For Aluminum, use 100% Ar.  
SPECIAL WELDING PROCESSES  
AVAILABLE ON THIS MACHINE  
Start by setting the wire feed speed based upon mate-  
rial thickness and appropriate travel speed. Then  
adjust the Output knob as follows:  
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.  
• 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.  
• Short Arc MIG at low procedure settings.  
• Aluminum MIG welding.  
Note the Volts display is simply a relative number and  
DOES NOT correspond to voltage.  
Some procedure recommendations appear in the table  
below.  
Recommended Welding Procedures for Power Mode  
Aluminum 4043  
E4043  
Aluminum 5356  
E5356  
Mild Steel  
L56  
Mild Steel  
L56  
Mild Steel  
L56  
Mild Steel  
L56  
Mild Steel  
L56  
Mild Steel  
L56  
Stainless Steel  
E308L  
Stainless Steel  
E308L  
MATERIAL  
WIRE  
WIRE SIZE  
GAS  
0.035  
0.035  
0.025  
0.025  
0.030  
0.030  
0.035  
0.035  
0.030  
0.035  
100% Ar.  
125 / 2.25  
100% Ar.  
125 / 1.75  
100% CO2  
Not Recommended  
75/25% Ar/CO2  
100 / 0.8  
100% CO2  
Not Recommended  
75/25% Ar/CO2  
90 / 1.0  
100% CO2  
75/25% Ar/CO2  
Tri-mix  
Tri-mix  
22 ga.  
20 ga.  
18 ga.  
16 ga.  
150 / 2.5  
200 / 3.75  
300 / 7.75  
150 / 2.3  
200 / 3.0  
300 / 6.85  
120 / 1.0  
140 / 1.7  
120 / 1.0  
140 / 1.5  
100 / 0.7  
110 / 1.5  
100 / 1.0  
110 / 1.5  
80 / 1.5  
110 / 2.0  
140 / 2.5  
50 / 0.5  
110 / 2.0  
130 / 2.7  
100 / 2.5  
125 / 3.0  
100 / 2.5  
125 / 3.0  
190 / 2.0  
260 / 3.0  
330 / 5.0  
190 / 2.0  
260 / 3.0  
330 / 4.5  
125 / 2.0  
160 / 2.3  
230 / 3.5  
300 / 6.0  
125 / 2.0  
160 / 2.3  
230 / 3.5  
300 / 6.0  
14 ga.  
12 ga.  
10 ga.  
400 / 9.0  
450 / 9.5  
400 / 7.5  
450 / 8.0  
160 / 3.8  
200 / 5.0  
240 / 6.5  
160 / 3.5  
200 / 4.5  
240 / 7.0  
210 / 3.0  
270 / 5.0  
325 / 6.5  
190 / 3.5  
230 / 6.0  
300 / 7.0  
500 / 10.0  
500 / 8.5  
600 / 9.5  
700 / 11  
3/16  
1/4  
600 / 11.25  
400 / 7.0  
400 / 7.5  
POWER WAVE 355/405  
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B-7  
B-7  
INSTALLATION  
PULSE WELDING (GMAW-P)  
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, lower wire  
feed speeds and leads to less distortion and improved  
overall quality and appearance. This is especially  
important with stainless, nickel and other alloys that  
are sensitive to heat input.  
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).  
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  
FREQUENCY  
SPRAY TRANSITION  
CURRENT  
POWER WAVE 355  
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B-8  
B-8  
INSTALLATION  
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 transfer and weld  
deposition rate. Since Arc Control varies weld droplet  
transfer rate, the Arc Control can be used to vary the  
ripple spacing in the weld bead.  
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 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.  
BENEFITS OF PULSE ON PULSE FROM  
LINCOLN ELECTRIC  
• Excellent appearance of the weld bead  
• Improved cleaning action  
• Reduced porosity  
Table B.2 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.).  
"N" PULSES  
"N" PULSES  
HIGH HEAT  
PULSES  
LOW HEAT  
PULSES  
PEAK  
AMPS  
BACKGROUND  
AMPS  
TIME  
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)  
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.  
WELDING PROCEDURES FOR PULSE-ON-PULSE  
MATERIAL  
GAS  
Aluminum 4043  
100% Ar.  
E4043  
Aluminum 4043  
100% Ar.  
E4043  
Aluminum 5356  
100% Ar.  
E5356  
Aluminum 5356  
100% Ar.  
E5356  
WIRE  
WIRE SIZE  
0.035  
3/64  
0.035  
3/64  
14 ga.  
250 / 0  
400 / 0  
550 / 0  
600 / 0  
200 / 0  
280 / 0  
340 / 0  
400 / 0  
230 / 0  
425 / 0  
670 / 0  
700 / 0  
225 / 0  
400 / 0  
500 / 0  
550 / 0  
10 ga.  
3/16  
1/4  
Not Recommended  
below 200 WFS  
Not Recommended  
below 100 WFS  
Not Recommended  
below 200 WFS  
Not Recommended  
below 200 WFS  
COMMENTS  
POWER WAVE 355  
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C-1  
C-1  
TABLE OF CONTENTS  
- ACCESSORIES SECTION -  
Accessories...........................................................................................................................Section C  
Optional Equipment....................................................................................................................C-2  
Field Installed .......................................................................................................................C-2  
Compatible Lincoln Equipment............................................................................................C-2  
POWER WAVE 355/405  
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C-2  
C-2  
ACCESSORIES  
OPTIONAL EQUIPMENT  
FACTORY INSTALLED  
None Available.  
FIELD INSTALLED  
K940-Work Voltage Sense Lead Kit  
K1764-1-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  
Welding Cable Connectors:  
K852-70 1/0-2/0 CABLE  
K852-95 2/0-3/0 CABLE  
COMPATIBLE LINCOLN EQUIPMENT  
Any Linc-Net compatible semi-automatic wire feeding  
equipment. Specifically, the semi-automatic Power Feed  
family (PF-10, PF-10X2, PF-11).  
POWER WAVE 355/405  
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Section D-1  
Section D-1  
TABLE OF CONTENTS  
-MAINTENANCE-  
Maintenance .........................................................................................................................Section D  
Capacitor Discharge Procedure .................................................................................................D-2  
Visual Inspection.........................................................................................................................D-2  
Routine Maintenance..................................................................................................................D-2  
Periodic Maintenance.................................................................................................................D-2  
Major Component Locations .....................................................................................................D-3  
POWER WAVE 355/405  
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D-2  
D-2  
MAINTENANCE  
VISUAL INSPECTION  
WARNING  
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.  
Have qualified personnel do the maintenance  
work. Always use the greatest care when  
working near moving parts.  
Do not put your hands near the cooling blower  
fan. If a problem cannot be corrected by  
following the instructions, take the machine to  
the nearest Lincoln Field Service Shop.  
ROUTINE MAINTENANCE  
1. Every 6 months or so the machine should be  
cleaned with a low pressure airstream. Keeping  
the machine clean will result in cooler operation  
and higher reliability. Be sure to clean these  
areas:  
-----------------------------------------------------------------------  
ELECTRIC SHOCK can kill.  
• Do not touch electrically live parts or  
electrode with skin or wet clothing.  
• Insulate yourself from work and  
ground  
• All printed circuit boards  
• Power switch  
• Main transformer  
• Always wear dry insulating gloves.  
------------------------------------------------------------------------  
EXPLODING PARTS can cause  
• Input rectifier  
• Auxiliary Transformer  
• Reconnect Switch Area  
• Fan (Blow air through the rear louvers)  
injury.  
•
Failed parts can explode or cause other  
parts to explode when power is applied.  
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.  
•
Always wear a face shield and long  
sleeves when servicing.  
------------------------------------------------------------------------  
See additional warning information  
throughout this Manual.  
------------------------------------------------------------------------  
PERIODIC MAINTENANCE  
Calibration of the POWER WAVE 355/405 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.  
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.  
RESISTOR  
CAPACITOR  
TERMINALS  
3. Use a DC voltmeter to check that voltage is not  
present across the terminals on all four capaci-  
tors.  
POWER WAVE 355/405  
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D-3  
D-3  
MAINTENANCE  
FIGURE D.1 – MAJOR COMPONENT LOCATIONS  
1. Center Panel  
2. Case Back  
3. Case Front  
4. Base Assembly  
5. Case Wraparound  
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POWER WAVE 355/405  
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D-4  
D-4  
NOTES  
POWER WAVE 355/405  
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Section E-1  
Section E-1  
TABLE OF CONTENTS  
-THEORY OF OPERATION SECTION-  
Theory of Operation .............................................................................................................Section E  
General Description ....................................................................................................................E-2  
Input Line Voltage, Auxiliary Transformer and Precharge...........................................................E-2  
Switch Board and Main Transformer ..........................................................................................E-3  
DC Bus Board, Power board and Control Board .......................................................................E-4  
Output Rectifier and Choke........................................................................................................E-5  
Thermal Protection .....................................................................................................................E-6  
Protective Circuits.......................................................................................................................E-6  
Over current Protection ........................................................................................................E-6  
Under/Over Voltage Protection ............................................................................................E-6  
Insulated Gate Bipolar Transistor (IGBT) Operation ...................................................................E-7  
Pulse Width Modulation..............................................................................................................E-8  
Minimum/Maximum Output..................................................................................................E-8  
FIGURE E.1 – PW-355 BLOCK LOGIC DIAGRAM  
To Control  
Main Switch Board  
Board  
Positive  
Output  
Terminal  
Input  
Rectifier  
Primary  
Current  
Sensor  
Input switch  
Choke  
Negative  
Output  
Terminal  
Reconnect  
Switch  
Primary  
Current  
Sensor  
Fan  
Primary Current Feedback(2)  
115VAC Fan Supply  
Input Relay Control  
Soft Start Control  
V/F Capacitor Feedback (2)  
Auxiliary  
Transformer  
P
o
w
e
r
220 VAC  
Machine Control Supply  
+15VDC, -15VDC, +5VDC  
Yellow  
Thermal  
LED  
W
a
40VDC  
Power  
Board  
v
e
Control Board  
Status  
Red/Green  
LED  
RS232 Supply +5VDC  
Can Supply +5VDC  
42VAC  
4
0
5
220  
Receptacle  
{
o
n
l
Arc  
Link  
DC  
Bus  
Board  
Electrode  
Sense  
21 Lead  
y
Wire  
Feeder  
Recp.  
Voltage  
Sense  
Recp.  
40VDC  
R232  
Connector  
Thermostats  
2
To  
Feeder  
POWER WAVE 355/405  
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E-2  
E-2  
THEORY OF OPERATION  
FIGURE E.2 – INPUT VOLTAGE AND PRECHARGE  
Main Switch Board  
Board  
Positive  
Output  
Terminal  
Input  
Rectifier  
Primary  
Current  
Sensor  
Input switch  
Choke  
Negative  
Output  
Terminal  
Reconnect  
Switch  
Primary  
Current  
Sensor  
Fan  
Primary Current Feedback(2)  
Input Relay Control  
115VAC Fan Supply  
Soft Start Control  
V/F Capacitor Feedback (2)  
Auxiliary  
Transformer  
P
o
w
e
r
220 VAC  
Machine Control Supply  
+15VDC, -15VDC, +5VDC  
Yellow  
Thermal  
LED  
W
a
40VDC  
Power  
Board  
v
e
Control Board  
Status  
Red/Green  
LED  
RS232 Supply +5VDC  
Can Supply +5VDC  
42VAC  
4
0
5
220  
Receptacle  
{
o
n
l
Arc  
Link  
DC  
Bus  
Board  
Electrode  
Sense  
21 Lead  
y
Wire  
Feeder  
Recp.  
Voltage  
Sense  
Recp.  
40VDC  
R232  
Connector  
Thermostats  
2
phases of the input voltage are applied to the auxiliary  
transformer. The auxiliary transformer 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  
have an additional 220VAC winding that is connected  
to a 220 AC receptacle.  
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 Linc-Net (a digital communications sys-  
tem).  
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 connect the  
two pairs of input capacitors either in a parallel (lower  
voltage) or series (higher voltage) configuration to  
accommodate the applied input voltage.  
The POWER WAVE 355/405 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.  
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. A 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  
become under or over voltage the control board will  
de-energize the input relays and the 355/405 output  
will be disabled. Other possible faults may also cause  
the input relays to drop out.  
INPUT LINE VOLTAGE, AUXILIARY  
TRANSFORMER, & PRECHARGE  
The POWER WAVE 355/405 can be connected for a  
variety of three-phase or single-phase input voltages.  
The initial power is applied to the 355/405 through a  
line switch located on the front of the machine. Two  
POWER WAVE 355/405  
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E-3  
E-3  
THEORY OF OPERATION  
FIGURE E.3 – SWITCH BOARD & MAIN TRANSFORMER  
To Control  
Main Switch Board  
Board  
Positive  
Output  
Terminal  
Input  
Rectifier  
Primary  
Current  
Sensor  
Input switch  
Choke  
Negative  
Output  
Terminal  
Reconnect  
Switch  
Primary  
Current  
Sensor  
Fan  
Primary Current Feedback(2)  
115VAC Fan Supply  
Input Relay Control  
Soft Start Control  
V/F Capacitor Feedback (2)  
Auxiliary  
Transformer  
P
o
w
e
r
220 VAC  
Machine Control Supply  
+15VDC, -15VDC, +5VDC  
Yellow  
Thermal  
LED  
W
a
40VDC  
Power  
Board  
v
e
Control Board  
Status  
Red/Green  
LED  
RS232 Supply +5VDC  
Can Supply +5VDC  
42VAC  
4
0
5
220  
Receptacle  
{
o
n
l
Arc  
Link  
DC  
Bus  
Board  
Electrode  
Sense  
21 Lead  
y
Wire  
Feeder  
Recp.  
Voltage  
Sense  
Recp.  
40VDC  
R232  
Connector  
Thermostats  
2
To  
main transformer. The two current 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.  
SWITCH BOARD &  
MAIN TRANSFORMER  
There is one switch board in the POWER WAVE  
355/405. This board incorporates two pairs of input  
capacitors, two insulated gate bipolar transistor (IGBT)  
switching circuits, a fan motor drive circuit, and a volt-  
age/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 . Thus  
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. Thus  
four capacitors in series. This is required to accom-  
modate the higher input voltages.  
The POWER WAVE 355/405 has a F.A.N. fan as need-  
ed circuit. The fan operates when the welding output  
terminals are energized or when a thermal over tem-  
perature condition exists. Once the fan is activated it  
will remain on for a minimum of five minutes. The fan  
driver circuit is housed on the switch board but it is  
activated from a control board signal.  
When the input capacitors are fully charged they act  
as power supplies for the IGBT 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. See  
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  
AC square wave output signal at the secondary of the  
POWER WAVE 355/405  
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E-4  
E-4  
THEORY OF OPERATION  
FIGURE E.4 – POWER BOARD, CONTROL BOARD  
AND SERIAL PERIPHERAL INTERFACE (SPI) COMMUNICATIONS  
To Control  
Main Switch Board  
Board  
Positive  
Output  
Terminal  
Input  
Rectifier  
Primary  
Current  
Sensor  
Input switch  
Choke  
Negative  
Output  
Terminal  
Reconnect  
Switch  
Primary  
Current  
Sensor  
Fan  
Primary Current Feedback(2)  
115VAC Fan Supply  
Input Relay Control  
Soft Start Control  
V/F Capacitor Feedback (2)  
Auxiliary  
Transformer  
P
o
w
e
r
220 VAC  
Machine Control Supply  
+15VDC, -15VDC, +5VDC  
Yellow  
Thermal  
LED  
W
a
40VDC  
Power  
Board  
v
e
Control Board  
Status  
Red/Green  
LED  
RS232 Supply +5VDC  
Can Supply +5VDC  
42VAC  
4
0
5
220  
Receptacle  
{
o
n
l
Arc  
Link  
DC  
Bus  
Board  
Electrode  
Sense  
21 Lead  
y
Wire  
Feeder  
Recp.  
Voltage  
Sense  
Recp.  
40VDC  
R232  
Connector  
Thermostats  
2
To  
Feeder  
DC BUS BOARD, POWER BOARD CONTROL BOARD  
AND CONTROL BOARD  
The Control Board performs the primary interfacing  
functions to establish and maintain output control of  
the POWER WAVE 355/405. The function generator  
and weld files exist within the Control Board hardware  
and software. Digital command signals received from  
the user interface/feed head and feedback information  
received from the current sensor and output voltage  
sensing leads, are processed at the control board.  
Software within the control board processes the com-  
mand and feedback information and sends the appro-  
priate pulse width modulation (PWM) signals (See  
PULSE WIDTH MODULATION in this section) to the  
switch board IGBT’s. In this manner, the digitally con-  
trolled high speed welding waveform is created.  
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 +5VDC 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.  
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.  
POWER WAVE 355/405  
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E-5  
E-5  
THEORY OF OPERATION  
FIGURE E.5 – OUTPUT RECTIFIER AND CHOKE  
To Control  
Board  
Main Switch Board  
Positive  
Output  
Terminal  
Input  
Rectifier  
Primary  
Current  
Sensor  
Input switch  
Choke  
Negative  
Output  
Terminal  
Reconnect  
Switch  
Primary  
Current  
Sensor  
Fan  
Primary Current Feedback(2)  
Input Relay Control  
115VAC Fan Supply  
Soft Start Control  
V/F Capacitor Feedback (2)  
Auxiliary  
Transformer  
P
o
w
e
r
220 VAC  
Machine Control Supply  
+15VDC, -15VDC, +5VDC  
Yellow  
Thermal  
LED  
W
a
40VDC  
Power  
Board  
v
e
Control Board  
Status  
Red/Green  
LED  
RS232 Supply +5VDC  
Can Supply +5VDC  
42VAC  
4
0
5
220  
Receptacle  
{
o
n
l
Arc  
Link  
DC  
Bus  
Board  
Electrode  
Sense  
21 Lead  
y
Wire  
Feeder  
Recp.  
Voltage  
Sense  
Recp.  
40VDC  
R232  
Connector  
Thermostats  
2
To  
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.  
NOTE: Unshaded areas of Block Logic Diagram are the subject of discussion.  
POWER WAVE 355/405  
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E-6  
E-6  
THEORY OF OPERATION  
OVER CURRENT  
PROTECTION  
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.  
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.)  
PROTECTIVE CIRCUITS  
Protective circuits are designed into the POWER  
WAVE 355/405 to sense trouble and shut down the  
machine before damage occurs to the machine's  
internal components.  
3. Any major internal component damage.  
POWER WAVE 355/405  
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E-7  
E-7  
THEORY OF OPERATION  
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.  
INSULATED GATE BIPOLAR  
TRANSISTOR (IGBT)  
OPERATION  
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, 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  
FIGURE E.6 – IGBT  
POSITIVE  
VOLTAGE  
APPLIED  
GATE  
GATE  
SOURCE  
SOURCE  
n +  
n +  
n +  
n +  
p
BODY REGION  
p
BODY REGION  
DRAIN DRIFT REGION  
DRAIN DRIFT REGION  
n -  
n -  
n +  
p +  
BUFFER LAYER  
n +  
p +  
BUFFER LAYER  
INJECTING LAYER  
INJECTING LAYER  
DRAIN  
DRAIN  
B. ACTIVE  
A. PASSIVE  
POWER WAVE 355/405  
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E-8  
E-8  
THEORY OF OPERATION  
FIGURE E.7 — TYPICAL IGBT OUTPUTS.  
sec  
48  
sec  
sec  
sec  
50  
MINIMUM OUTPUT  
sec  
24  
sec  
sec  
24  
2
sec  
50  
MAXIMUM OUTPUT  
MAXIMUM OUTPUT  
PULSE WIDTH  
MODULATION  
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 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.  
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.  
1
An IGBT group consists of two IGBT  
modules feeding one transformer primary  
winding.  
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  
1
group conducting for one microsecond. The negative  
1
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.  
POWER WAVE 355/405  
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Section F-1  
Section F-1  
TABLE OF CONTENTS  
TROUBLESHOOTING & REPAIR SECTION  
Troubleshooting & Repair Section.................................................................................Section F  
How to Use Troubleshooting Guide ....................................................................................F-2  
PC Board Troubleshooting Procedures and Replacement .................................................F-3  
Troubleshooting Guide ........................................................................................................F-4  
Test Procedures  
Input Filter Capacitor Discharge Procedure .................................................................F-13  
Main Switch Board Test ................................................................................................F-15  
Input Rectifier Test ........................................................................................................F-19  
Power Board Test..........................................................................................................F-23  
DC Bus Board Test........................................................................................................F-27  
Output Diode Modules Test ..........................................................................................F-31  
Auxiliary Transformer Test .............................................................................................F-35  
Current Transducer Test................................................................................................F-39  
Fan Control and Motor Test ..........................................................................................F-43  
Replacement Procedures  
Control Board Removal and Replacement ...................................................................F-47  
Main Switch Board Removal and Replacement ...........................................................F-51  
Snubber Board Removal and Replacement .................................................................F-55  
Power Board Removal and Replacement.....................................................................F-57  
DC Bus Board Removal and Replacement...................................................................F-61  
Input Rectifier Removal and Replacement ...................................................................F-65  
Output Rectifier Modules Removal and Replacement .................................................F-69  
Current Transducer Removal and Replacement...........................................................F-73  
Retest after Repair ........................................................................................................F-78  
POWER WAVE 355/405  
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F-2  
F-2  
TROUBLESHOOTING & REPAIR  
HOW TO USE TROUBLESHOOTING GUIDE  
CAUTION  
Service and repair should be performed by only Lincoln Electric Factory Trained Personnel.  
Unauthorized repairs performed on this equipment may result in danger to the technician and machine  
operator and will invalidate your factory warranty. For your safety and to avoid Electrical Shock, please  
observe all safety notes and precautions detailed throughout this manual.  
This Troubleshooting Guide is provided to help  
you locate and repair possible machine  
malfunctions. Simply follow the three-step  
procedure listed below.  
Step 3. PERFORM COMPONENT TESTS. The  
last column, labeled “Recommended Course of  
Action” lists the most likely components that may  
have failed in your machine. It also specifies the  
appropriate test procedure to verify that the  
subject component is either good or bad. If there  
are a number of possible components, check the  
components in the order listed to eliminate one  
possibility at a time until you locate the cause of  
your problem.  
Step 1. LOCATE PROBLEM (SYMPTOM). Look  
under the column labeled “PROBLEM  
(SYMPTOMS)”. This column describes possible  
symptoms that the machine may exhibit. Find  
the listing that best describes the symptom that  
the machine is exhibiting. Symptoms are  
grouped into three main categories: Output  
Problems, Function Problems, and LED Function  
Problems.  
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  
referred to 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.  
Step 2. PERFORM EXTERNAL TESTS. The  
second column, labeled “POSSIBLE AREAS OF  
MISADJUSTMENT(S)”, lists the obvious external  
possibilities that may contribute to the machine  
symptom. Perform these tests/checks in the  
order listed. In general, these tests can be  
conducted without removing the case  
wrap-around cover.  
CAUTION  
If for any reason you do not understand the test procedures or are unable to perform the test/repairs  
safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before  
you proceed. Call 1-800-833-9353.(WELD)  
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F-3  
F-3  
TROUBLESHOOTING & REPAIR  
PC BOARD TROUBLESHOOTING PROCEDURES  
- Remove the PC board from the static-shielding bag  
and place it directly into the equipment. Don’t set the  
PC board on or near paper, plastic or cloth which  
could have a static charge. If the PC board can’t be  
installed immediately, put it back in the static-shield-  
ing bag.  
WARNING  
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.  
- 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.  
CAUTION  
Sometimes machine failures appear to be due to PC  
board failures. These problems can sometimes be  
traced to poor electrical connections. To avoid prob-  
lems when troubleshooting and replacing PC boards,  
please use the following procedure:  
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.  
1. Determine to the best of your technical ability  
that the PC board is the most likely component  
causing the failure symptom.  
NOTE: Allow the machine to heat up so that all  
electrical components can reach their operating  
temperature.  
2. Check for loose connections at the PC board to  
assure that the PC board is properly connected.  
5. Remove the replacement PC board and  
substitute it with the original PC board to  
recreate the original problem.  
3. If the 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:  
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.  
PC board can be damaged by static electricity.  
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.  
- 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  
6. Always indicate that this procedure was  
followed when warranty reports are to be  
submitted.  
to  
a
grounded part of the  
equipment frame.  
ATTENTION  
Static-Sensitive  
Devices  
Handle only at  
Static-Safe  
- 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.  
NOTE: Following this procedure and writing on the  
warranty report, “INSTALLED AND SWITCHED PC  
BOARDS TO VERIFY PROBLEM,” will help avoid  
denial of legitimate PC board warranty claims.  
Workstations  
- Tools which come in contact with the PC board must  
be either conductive, anti-static or static-dissipative.  
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F-4  
F-4  
TROUBLESHOOTING & REPAIR  
Observe Safety Guidelines  
detailed in the beginning of this manual.  
TROUBLESHOOTING GUIDE  
PROBLEMS  
POSSIBLE AREAS OF  
RECOMMENDED  
(SYMPTOMS)  
MISADJUSTMENT(S)  
COURSE OF ACTION  
OUTPUT PROBLEMS  
Major physical or electrical damage 1. Contact your local authorized 1. Contact the Lincoln Electric  
is evident when the sheet metal  
cover is removed.  
Lincoln Electric Field Service  
Facility for technical assistance.  
Service Department,  
1-800-833-9353(WELD).  
The machine is dead—no output— 1. Make sure the input line switch is 1. Perform  
the  
Auxiliary  
no LED’s.  
in the ON position.  
Transformer Test.  
2. Check the main input line fuses.  
If open , replace.  
2. Perform the DC Bus Board Test.  
2. Perform the Power Board Test.  
3. Check the 15 amp circuit break-  
er (CB1). Reset if tripped. Also  
check CB3.  
3. The Bus Board rectifier and or  
associated filter capacitor (C5)  
may be faulty.  
replace as necessary.  
Check and  
4. Make sure the reconnect switch  
and jumper lead is configured  
correctly for the applied input  
voltage.  
4. The Control Board may be faulty.  
5. If the machine is being operated  
with single phase input voltage  
make sure the correct lead is not  
connected. See the Installation  
Section.  
The main input fuses (or breaker) 1. Make certain the fuses or break- 1. Check the reconnect switches  
repeatedly fail.  
ers are sized properly.  
and associated wiring. See the  
Wiring Diagram.  
2. Make sure the reconnect switch  
and jumper lead is configured  
correctly for the applied input  
voltage.  
2. Perform the Input Rectifier  
Test.  
3. Perform the Main Switch Board  
Test.  
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.  
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 test/repairs safely, con-  
tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call  
1-800-833-9353(WELD).  
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F-5  
F-5  
TROUBLESHOOTING & REPAIR  
TROUBLESHOOTING GUIDE  
Observe Safety Guidelines  
detailed in the beginning of this manual.  
PROBLEMS  
(SYMPTOMS)  
POSSIBLE AREAS OF  
MISADJUSTMENT(S)  
RECOMMENDED  
COURSE OF ACTION  
OUTPUT PROBLEMS  
The machine does not have weld-  
ing output.  
1. Make sure the reconnect switch 1. Check the reconnect switch and  
is configured correctly for the  
input voltage applied.  
associated leads for loose or  
faulty connections. See the  
wiring diagram.  
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.  
2. Perform the DC Bus Board  
Test.  
3. Perform the Main Switch  
Board Test.  
4. Perform the Power Board  
Test.  
5. Perform the Output Diode  
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.  
Module Test.  
6. The control board may be faulty.  
7. The input filter capacitors may  
be faulty. Check and replace if  
necessary.  
4. If an error code is displayed  
see Fault Code Explanations.  
If thermal light is on, wait for  
machine to cool.  
The POWER WAVE 355/405 will  
not produce full output.  
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.  
1. Perform the Output Rectifier  
Test.  
2. Perform the Main Switch  
Board Test.  
3. Perform the Power Board  
Test.  
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.  
4. Perform the Current  
Transducer Test.  
5. The control board may be  
faulty.  
3. The welding current may be too  
high . The machine will fold  
back to 100 amps if the weld-  
ing current exceeds 450 amps.  
CAUTION  
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, con-  
tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed.  
Call 1-800-833-9353(WELD).  
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F-6  
F-6  
TROUBLESHOOTING & REPAIR  
Observe Safety Guidelines  
detailed in the beginning of this manual.  
TROUBLESHOOTING GUIDE  
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-  
trolled by the control board via  
the main switch board. Perform  
the Fan Motor And Control  
Test.  
and the yellow thermal light is ON  
indicating a thermal overload.  
be exceeding the recommended  
duty cycle of the POWER WAVE  
355/405.  
2. Dirt and dust may have clogged  
the cooling channels inside the 1. A thermostat or associated cir-  
machine.  
cuitry may be faulty. See the  
wiring diagram. One normally  
closed thermostat is located on  
the output choke, one on the DC  
Bus Board and the other is  
located on the main switch  
board heat sink. See the wiring  
diagram.  
3. Air intake and exhaust louvers  
may be blocked due to inade-  
quate clearance around the  
machine.  
4. Make certain the fan as needed  
(F.A.N.) is operating properly.  
The fan should operate when  
welding voltage is present  
and/or when there is an over  
temperature condition.  
Note: The Main Switch Board  
Removal Procedure will be  
required to gain access to  
the heat sink thermostat.  
An attached wire feeder will not 1. Make certain the wire feeder 1. Check for 40 VDC on pin “D” (+)  
function correctly. Apparently the  
wire feeder is not being powered-  
up.  
control cable is connected to  
the wire feeder receptacle. See  
the Wiring Diagram.  
and pin “E” (-) at the Power Wave  
wire feeder receptacle. See  
Wiring Diagram.  
If 40 volts DC is Not present at  
the Power Wave wire feeder  
receptacle, perform the DC Bus  
Board Test.  
2. Check the two circuit breakers  
located at the front of the  
machine. Reset if tripped.  
3. The wire feeder or control cable  
may be faulty.  
2. Check the DC Bus Board rectifi-  
er. See Wiring Diagram.  
3. Perform the T1 Auxiliary trans-  
former Test.  
4. 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.  
CAUTION  
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, con-  
tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call  
1-800-833-9353(WELD).  
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F-7  
F-7  
TROUBLESHOOTING & REPAIR  
Observe Safety Guidelines  
detailed in the beginning of this manual.  
TROUBLESHOOTING GUIDE  
PROBLEMS  
POSSIBLE AREAS OF  
RECOMMENDED  
(SYMPTOMS)  
MISADJUSTMENT(S)  
COURSE OF ACTION  
FUNCTION PROBLEMS  
The machine often “noodle welds” 1. The machine may be trying to 1. Perform  
the  
Current  
with a particular procedure. The  
output is limited to approximately  
100 amps.  
deliver too much power. When  
the average output current  
exceeds a maximum limit, the 2. The control board may be faulty.  
machine will “phase back” to  
Transducer Test.  
protect itself. Adjust the proce-  
dure or reduce the load to lower  
the current draw from the Power  
Wave machine.  
Excessively long and erratic arc.  
1. Check for proper configuration 1. Check the connections between  
and implementation of voltage  
sensing circuits.  
the voltage sense receptacle  
and the control board. See the  
Wiring Diagram.  
2. The control board may be faulty.  
CAUTION  
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, con-  
tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed.  
Call 1-800-833-9353(WELD).  
POWER WAVE 355/405  
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F-8  
F-8  
TROUBLESHOOTING & REPAIR  
Observe Safety Guidelines  
detailed in the beginning of this manual.  
TROUBLESHOOTING GUIDE  
PROBLEMS  
POSSIBLE AREAS OF  
RECOMMENDED  
(SYMPTOMS)  
MISADJUSTMENT(S)  
COURSE OF ACTION  
FUNCTION PROBLEMS  
Auxiliary receptacle is “dead” no 1. Circuit breaker CB1 (on case 1. Perform the Auxiliary  
auxiliary voltage.  
front) may have opened. Reset.  
Transformer Test.  
2. Circuit breaker CB3 (in recon-  
nect area) may have opened.  
Reset.  
3. On PW 405 models, the circuit  
breaker CB4 protects the  
220VAC receptacle. Reset if  
tripped.  
A fault or error code is displayed.  
1. See Fault Code Explanations.  
1. See Fault Code Explanations.  
General degradation of the weld 1. Check for feeding problems, 1. Perform the Voltage and  
performance.  
bad connections, excessive  
loops in cabling, etc.  
Current Calibration  
Procedure.  
2. Verify weld mode is correct for 2. Perform the Current  
processes. Transducer Test.  
3. The power source may require 2. Perform the Output Diode  
calibration. Module Test.  
4. Check the actual current dis- 5. The control board may be  
played on the Power Feed 10  
vs. actual current measured via  
external meter.  
faulty.  
5. Check the actual voltage dis-  
played on the Power Feed 10  
vs. actual voltage measured via  
external meter.  
6. 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 test/repairs safely, con-  
tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed.  
Call 1-800-833-9353(WELD).  
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F-9  
F-9  
TROUBLESHOOTING & REPAIR  
Included in this section is information about the  
power source Status LED, and some basic trou-  
bleshooting charts for both machine and weld perfor-  
mance.  
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 source status light for error  
sequences as noted below. This is especially  
important if the user interface displays “Err 006”  
or “Err 100”.  
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 355/405 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.  
LIGHT CONDITION  
INDICATION  
Status LED is solid green (no blinking)  
1. System OK. Power source communicating nor-  
mally with wire feeder and its components.  
Status LED is blinking green  
2. Occurs during a reset, and indicates the  
POWER WAVE 355/405 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 opera-  
tion.  
Status LED is blinking red and green  
3. Non-recoverable system fault. If the PS Status  
light is flashing any combination of red and  
green, errors are present in the POWER WAVE  
355/405. Read the error code before the  
machine 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.  
Status LED is solid red (no blinking).  
Status LED is blinking red.  
Non-recoverable hardware fault. Generally indi-  
cates nothing is connected to the POWER  
WAVE 355/405 wire feeder receptacle. See  
Trouble Shooting Section.  
Not applicable  
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F-10  
F-10  
TROUBLESHOOTING & REPAIR  
STATUS LED ERROR CODE TABLE  
NOTE: The error code signal sequence is always preceded by a 2 second green light. If more than one error  
code is present, a 4 second off signal will separate the individual error code signals. Note that the  
[2 sec. green] is only displayed at the beginning of the entire code sequence, not between codes if  
more than one error code is present.  
Example: (Code. #11 “one long red” followed by “one short red”) followed by (Code. #21 “two long reds” fol-  
lowed by “one short red”).  
[2 sec. green] [1.2 sec. red] [1.6 sec. off] [0.4 sec. red] [4.0 sec. off] [1.2 sec. red] [0.4 sec. off]  
[1.2 sec. red] [1.6 sec. off] [0.4 sec. red]  
ERROR CODES FOR THE POWER WAVE  
The following is a list of possible error codes that the POWER WAVE 355/405 can output via the status light  
(see “Troubleshooting the Power Wave / Power Feed System using the Status LED.” 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.  
11  
12  
CAN communication bus off.  
User interface time out error.  
Probably due to excessive number of communication errors.  
UI is no longer responding to the Power Source. The most  
likely cause is a fault/bad connection in the communication  
leads or control cable.  
Contact the service department for instructions on reloading  
the Welding Software.  
Unprogrammed weld mode.  
Empty weld table.  
21  
22  
Contact the service department for instructions on reloading  
the Welding Software.  
Contact the service department for instructions on reloading  
the Welding Software.  
Weld table checksum error.  
Primary overcurrent error.  
Capacitor “A” under voltage.  
Capacitor “B” under voltage.  
23  
31  
32  
33  
Excessive Primary current present. May be related to a  
short in the main transformer or output rectifier.  
Low voltage on the main capacitors. May be caused by  
improper input configuration.  
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.  
Capacitor “B” overvoltage.  
34  
35  
Excessive voltage on the main capacitors. May be caused  
by improper input configuration.  
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 of the machine.  
Indicates over temperature. Usually accompanied by ther-  
mal LED. Check fan operation. Be sure process does not  
exceed duty cycle limit of the machine.  
36  
Thermal error.  
Capacitor precharge failed. Usually accompanied by codes  
32-35.  
37  
41  
Softstart 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”  
Secondary overcurrent error  
NOTE: The secondary limit is 570 for the standard stud, and  
325 amps for all single phase operation.  
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F-11  
F-11  
TROUBLESHOOTING & REPAIR  
43  
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.  
Other  
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F-12  
F-12  
NOTES  
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F-13  
F-13  
TROUBLESHOOTING & REPAIR  
INPUT FILTER CAPACITOR DISCHARGE PROCEDURE  
WARNING  
Service and repair should be performed by only Lincoln Electric factory trained  
personnel. Unauthorized repairs performed on this equipment may result in danger to  
the technician or machine operator and will invalidate your factory warranty. For your  
safety and to avoid electrical shock, please observe all safety notes and precautions  
detailed throughout this manual.  
If for any reason you do not understand the test procedures or are unable to perform the  
test/repairs safely, contact the Lincoln Electric Service Department for electrical  
troubleshooting assistance before you proceed. Call 1-800-833-9353 (WELD).  
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  
This procedure takes approximately 20 minutes to perform.  
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F-14  
F-14  
TROUBLESHOOTING & REPAIR  
INPUT FILTER CAPACITOR DISCHARGE PROCEDURE (continued)  
WARNING  
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.  
ELECTRIC SHOCK can kill.  
• Have an electrician install and service  
this equipment.  
5. Locate the eight capacitor terminals shown in fig-  
ure F.1.  
• Turn the input power off at the fuse box  
before working on equipment.  
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.  
• Do not touch electrically hot parts.  
• Prior to performing preventative maintenance,  
perform the following capacitor discharge procedure  
to avoid electric shock.  
7. Repeat the discharge procedure for the other  
three capacitors.  
DISCHARGE PROCEDURE  
1. Remove the input power to the POWER WAVE  
355/405.  
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-  
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.  
charge procedure.  
FIGURE F.1 – LOCATION OF INPUT FILTER CAPACITOR TERMINALS  
EIGHT  
CAPACITOR  
TERMINALS  
- +  
- +  
INSULATED  
PLIERS  
- +  
- +  
INSULATED  
GLOVES  
POWER  
RESISTOR  
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F-15  
F-15  
TROUBLESHOOTING & REPAIR  
MAIN SWITCH BOARD TEST  
WARNING  
Service and repair should be performed by only Lincoln Electric factory trained personnel.  
Unauthorized repairs performed on this equipment may result in danger to the technician or  
machine operator and will invalidate your factory warranty. For your safety and to avoid  
electrical shock, please observe all safety notes and precautions detailed throughout this  
manual.  
If for any reason you do not understand the test procedures or are unable to perform the  
test/repairs safely, contact the Lincoln Electric Service Department for electrical  
troubleshooting assistance before you proceed. Call 1-800-833-9353 (WELD).  
DESCRIPTION  
This test will help determine if the “power section” of the switch boards are functioning cor-  
rectly. This test will NOT indicate if the entire PC board is functional. This resistance test is  
preferable to a voltage test with the machine energized because this board can be damaged  
easily. In addition, it is dangerous to work on this board with the machine energized.  
MATERIALS NEEDED  
Analog Volt/Ohmmeter  
5/16 in. Wrench  
7/16 in. Wrench  
This procedure takes approximately 30 minutes to perform.  
POWER WAVE 355/405  
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F-16  
F-16  
TROUBLESHOOTING & REPAIR  
MAIN SWITCH BOARD TEST (continued)  
FIGURE F.2 MAIN SWITCH BOARD LEAD LOCATIONS  
207  
202  
J22  
- +  
- +  
209  
201  
204  
208  
205  
J21  
J20  
- +  
- +  
206  
203  
TEST PROCEDURE  
4. Using a 7/16” wrench locate, label and remove  
leads 201, 202, 203, 204, 205, 206, 207 and  
208 from the switch board. Note lead and  
washer placement for reassembly. Clear  
leads.  
1. Remove input power to the POWER WAVE  
355/405.  
2. Using a 5/16” nut driver, remove the case  
wraparound.  
3. Perform the Input Filter Capacitor Discharge  
5. Using the Analog ohmmeter, perform the resis-  
tance tests detailed in Table F.1. Refer to 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.  
Procedure detailed earlier in this section.  
POWER WAVE 355/405  
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F-17  
F-17  
TROUBLESHOOTING & REPAIR  
MAIN SWITCH BOARD TEST (continued)  
6. If any test fails replace the switch board. See  
8. 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 lbs. before tight-  
ening them to 44 inch lbs.  
Main Switch Board Removal and Replacement.  
7. If the switch board resistance tests are OK, check  
connections on plugs J20, J21, J22 and all asso-  
ciated wiring. See wiring diagram.  
9. Replace the case wraparound cover using a 5/16”  
nut driver.  
TABLE F.1. SWITCH BOARD RESISTANCE TEST  
APPLY NEGATIVE TEST  
PROBE TO TERMINAL  
NORMAL  
RESISTANCE READING  
APPLY POSITIVE TEST  
PROBE TO TERMINAL  
+206  
+208  
+202  
+201  
+205  
+203  
+204  
+207  
-205  
-203  
-204  
-207  
-206  
-208  
-202  
-201  
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 355/405  
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F-18  
F-18  
NOTES  
POWER WAVE 355/405  
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F-19  
F-19  
TROUBLESHOOTING & REPAIR  
INPUT RECTIFIER TEST  
WARNING  
Service and repair should be performed by only Lincoln Electric factory trained personnel.  
Unauthorized repairs performed on this equipment may result in danger to the technician or  
machine operator and will invalidate your factory warranty. For your safety and to avoid  
electrical shock, please observe all safety notes and precautions detailed throughout this  
manual.  
If for any reason you do not understand the test procedures or are unable to perform the  
test/repairs safely, contact the Lincoln Electric Service Department for electrical  
troubleshooting assistance before you proceed. Call 1-800-833-9353 (WELD).  
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  
This procedure takes approximately 25 minutes to perform.  
POWER WAVE 355/405  
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F-20  
F-20  
TROUBLESHOOTING & REPAIR  
INPUT RECTIFIER TEST (CONTINUED)  
TEST PROCEDURE  
6. Using  
a
phillips head screwdriver,  
1. Remove input power to the POWER  
WAVE 355/405 machine.  
remove leads 207, 207A, and 209 from  
the input rectifier.  
2. Using a 5/16” nut driver, remove the case  
wraparound cover.  
7. Use the analog ohmmeter to perform the  
tests detailed in Table F.2. See the  
Wiring Diagram.  
3. Perform the Capacitor Discharge  
Procedure detailed earlier in this section.  
8. Visually inspect the three MOV’S for  
damage (TP1,TP2,TP3). Replace if nec-  
essary.  
4. Locate the input rectifier and associated  
leads. See Figure F.3.  
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  
C
B
#207  
#207A  
A
#209  
Small Lead "A"  
To Circuit Breaker  
FRONT  
REAR  
POWER WAVE 355/405  
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F-21  
F-21  
TROUBLESHOOTING & REPAIR  
INPUT RECTIFIER TEST (CONTINUED)  
Table F.2 Input Rectifier Test Points  
ANALOG METER  
X10 RANGE  
TEST POINT TERMINALS  
Acceptable Meter Readings  
+ PROBE  
- PROBE  
207  
207  
207  
Greater than 1000 ohms  
Greater than 1000 ohms  
Greater than 1000 ohms  
A
B
C
207A  
207A  
207A  
Greater than 1000 ohms  
Greater than 1000 ohms  
Greater than 1000 ohms  
A
B
C
209  
209  
209  
Less than 100 ohms  
Less than 100 ohms  
Less than 100 ohms  
A
B
C
A
B
C
Less than 100 ohms  
Less than 100 ohms  
Less than 100 ohms  
207  
207  
207  
A
B
C
Less than 100 ohms  
Less than 100 ohms  
Less than 100 ohms  
207A  
207A  
207A  
A
B
C
Greater than 1000 ohms  
Greater than 1000 ohms  
Greater than 1000 ohms  
209  
209  
209  
9. If the input rectifier does not meet the  
acceptable readings outlined in Table F.2  
the component may be faulty. Replace  
11. If the input rectifier is faulty, see the  
Input Rectifier Bridge Removal &  
Replacement procedure.  
Note: Before replacing the input rectifier,  
check the input power switch and per-  
form the Main Switch Board Test. Also  
check for leaky or faulty filter capacitors.  
12. Replace the case wraparound cover.  
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 lbs. Apply silicone sealant.  
POWER WAVE 355/405  
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F-22  
F-22  
NOTES  
POWER WAVE 355/405  
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F-23  
F-23  
TROUBLESHOOTING & REPAIR  
POWER BOARD TEST  
WARNING  
Service and repair should be performed by only Lincoln Electric factory trained personnel.  
Unauthorized repairs performed on this equipment may result in danger to the technician or  
machine operator and will invalidate your factory warranty. For 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  
troubleshooting assistance before you proceed. Call 1-800-833-9353 (WELD).  
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  
This procedure takes approximately 30 minutes to perform.  
POWER WAVE 355/405  
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F-24  
F-24  
TROUBLESHOOTING & REPAIR  
POWER BOARD TEST (CONTINUED)  
FIGURE F.4 – POWER BOARD TEST  
J42  
J41  
J43  
4 3  
6 5 4  
12 11 10 9 8 7  
3 2 1  
6 5 4 3 2 1  
2 1  
J43  
J42  
J41  
TEST PROCEDURE  
6. Turn on the Power Wave 355/405. Carefully  
test for the correct voltages at the Power  
Board according to Table F.4.  
1. Remove input power to the Power Wave  
355/405.  
2. Using the 3/8” nut driver, remove the case  
top.  
7. If either of the 40 VDC voltages is low or not  
present at plug J41, perform the DC Bus PC  
Board Test. See the Wiring Diagram. Also  
perform the T1 Auxiliary Transformer  
Test.  
3. Perform  
the  
Capacitor  
Discharge  
Procedure.  
4. Locate the Power Board and plugs J42 and  
J43. Do not remove plugs or leads from  
the Power Board. Refer to Figure F.8.  
8. If any of the DC voltages are low or not pre-  
sent at plugs J42 and/or 43, the Power  
Board may be faulty.  
5. Carefully apply input power to the Power  
Wave 355/405.  
9. Install the case top using the 3/8” nut driver.  
WARNING  
ELECTRIC SHOCK can kill.  
High voltage is present when  
input power is applied to the  
machine.  
POWER WAVE 355/405  
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F-25  
F-25  
TROUBLESHOOTING & REPAIR  
POWER BOARD TEST (CONTINUED)  
TABLE F.3 – POWER BOARD VOLTAGE CHECKS  
CHECK POINT  
LOCATION  
TEST  
DESCRIPTION  
CONNECTOR  
PLUG PIN NO.  
LEAD NO. OR  
IDENTITY  
NORMAL  
ACCEPTABLE  
VOLTAGE  
READING  
POWER BOARD  
CONNECTOR  
PLUG J41  
CHECK 40 VDC  
INPUT FROM  
DC BUS BOARD  
2 (+)  
1 (-)  
477 (+)  
475 (-)  
38 – 42 VDC  
475  
412  
477  
POWER BOARD  
CONNECTOR  
PLUG J42  
CHECK +15  
VDC SUPPLY FROM  
POWER BOARD  
1 (+)  
5 (-)  
+15 VDC  
412 (+)  
410 (-)  
410  
3 (+)  
5 (-)  
POWER BOARD  
CONNECTOR  
PLUG J42  
CHECK +5 VDC  
SUPPLY FROM  
POWER BOARD  
408 (+)  
410 (-)  
+5 VDC  
-15 VDC  
+5 VDC  
+5 VDC  
408  
410  
2 (+)  
5 (-)  
411 (+)  
410 (-)  
POWER BOARD  
CONNECTOR  
PLUG J42  
CHECK -15 VDC  
SUPPLY FROM  
POWER BOARD  
411  
410  
1104 (+)  
1103 (-)  
5 (+)  
10 (-)  
CHECK +5 VDC  
ARCLINK SUPPLY  
FROM POWER BOARD  
POWER BOARD  
CONNECTOR  
PLUG J43  
1104  
1103  
406  
4 (+)  
9 (-)  
406 (+)  
405 (-)  
POWER BOARD  
CONNECTOR  
PLUG J43  
CHECK +5 VDC  
“RS-232” SUPPLY  
FROM POWER BOARD  
405  
3 (+)  
12 (-)  
403 (+)  
401 (-)  
POWER BOARD  
CONNECTOR  
PLUG J43  
403  
CHECK +5 VDC  
SPI SUPPLY FROM  
POWER BOARD  
+5 VDC  
401  
POWER WAVE 355/405  
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F-26  
F-26  
NOTES  
POWER WAVE 355/405  
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F-27  
F-27  
TROUBLESHOOTING & REPAIR  
DC BUS BOARD TEST  
WARNING  
Service and repair should be performed by only Lincoln Electric factory trained personnel.  
Unauthorized repairs performed on this equipment may result in danger to the technician  
or machine operator and will invalidate your factory warranty. For your safety and to avoid  
electrical shock, please observe all safety notes and precautions detailed throughout this  
manual.  
If for any reason you do not understand the test procedures or are unable to perform the  
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou-  
bleshooting assistance before you proceed. Call 1-800-833-9353 (WELD).  
TEST DESCRIPTION  
This test will determine if the DC Bus Power Supply PC Board is receiving and process-  
ing the proper voltages.  
MATERIALS NEEDED  
3/8” Nut driver  
Volt/ohmmeter  
Wiring Diagram  
This procedure should take approximately 30 minutes to perform.  
POWER WAVE 355/405  
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F-28  
F-28  
TROUBLESHOOTING & REPAIR  
DC BUS BOARD TEST (CONTINUED)  
FIGURE F.5 – DC BUS POWER SUPPLY POWER SUPPLY PC BOARD  
DC BUS BOARD  
STATUS  
THERMAL  
LINCOLN  
ELECTRIC  
W
A
R
N
I
N
G
R
E
M
O
T
E
P
O
W
E
R
O
N
TEST PROCEDURE  
WARNING  
1. Remove input power to the machine.  
ELECTRIC SHOCK can kill.  
2. Using the 3/8” nut driver, remove the wrap-  
around cover.  
High voltage is present when  
input power is applied to the  
machine.  
3. Locate the DC Bus Board. See Figure F.5.  
4. Carefully apply input power to the Power  
Wave 355/405.  
5. Turn on the Power Wave 355/405. The LED  
on the DC Bus Power Supply PC Board  
should light.  
FIGURE F.6 – DC BUS POWER SUPPLY POWER SUPPLY PC BOARD  
J47  
J47  
Bus  
Rectifier  
51  
475  
52  
477  
Thermostat  
J46  
66  
65  
J46  
POWER WAVE 355/405  
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F-29  
F-29  
TROUBLESHOOTING & REPAIR  
DC BUS BOARD TEST(CONTINUED)  
6. Check the DC Bus Board input and output  
7. If all the voltages are correct, the DC Bus  
Board is operating properly.  
voltages according to Table F.4. See Figure  
F.6 and the Wiring Diagram.  
8. If any of the output voltages are not correct  
and the input voltage is correct, the DC Bus  
Board may be faulty.  
WARNING  
9. If the input voltage is not correct, check the  
leads between the DC Bus Board and the  
Bus Rectifier. See the Wiring Diagram.  
ELECTRIC SHOCK can kill.  
High voltage is present at the  
terminals of Capacitor C3 near  
where testing is to be done.  
10. When finished testing, replace the case  
wraparound cover.  
TABLE F.4 – DC BUS POWER SUPPLY PC BOARD VOLTAGE TABLE  
Positive Meter Probe  
Negative Meter Probe  
Test Point  
Approximate Voltage  
Reading  
Conditions/Comments  
Test Point  
Plug P46 – Pin 1  
Lead 65  
Plug P46 – Pin 3  
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  
38.0 – 42.0 VDC  
Supply to the Wire  
Feeder Receptacle  
Plug P47 – Pin 3(+)  
Lead 477  
Plug P47 – Pin 6(-)  
Lead 475  
Supply to Power Board  
POWER WAVE 355/405  
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F-30  
F-30  
NOTES  
POWER WAVE 355/405  
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F-31  
F-31  
TROUBLESHOOTING & REPAIR  
OUTPUT DIODE MODULES TEST  
WARNING  
Service and repair should be performed by only Lincoln Electric factory trained personnel.  
Unauthorized repairs performed on this equipment may result in danger to the technician or  
machine operator and will invalidate your factory warranty. For your safety and to avoid  
electrical shock, please observe all safety notes and precautions detailed throughout this  
manual.  
If for any reason you do not understand the test procedures or are unable to perform the  
test/repairs safely, contact the Lincoln Electric Service Department for electrical  
troubleshooting assistance before you proceed. Call 1-800-833-9353 (WELD).  
DESCRIPTION  
This test will help determine if any of the output diodes are “shorted”.  
MATERIALS NEEDED  
Analog Voltmeter/Ohmmeter  
Wiring Diagram  
This procedure takes approximately 20 minutes to perform.  
POWER WAVE 355/405  
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F-32  
F-32  
TROUBLESHOOTING & REPAIR  
OUTPUT DIODE MODULES TEST (continued)  
FIGURE F.7 Machine Output Terminals  
STATUS  
THERMAL  
_
+
NEGATIVE  
OUTPUT  
POSITIVE  
OUTPUT  
TERMINAL  
TERMINAL  
TEST PROCEDURE  
4. Using the analog ohmmeter test for more  
than 200 ohms resistance between positive  
and negative output terminals. Positive test  
lead to the positive terminal; Negative test  
lead to the negative terminal. See Figure  
F.8.  
1. Remove input power to the POWER WAVE  
355/405.  
2. Locate the output terminals on the front  
panel of the machine. See Figure F.7.  
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 erroneous results.  
POWER WAVE 355/405  
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F-33  
F-33  
TROUBLESHOOTING & REPAIR  
OUTPUT DIODE MODULES TEST (continued)  
Figure F.8 Terminal Probes  
_
+
5. If 200 ohms is measured then the output  
diodes are not “shorted”.  
9. Test all output diode modules individually.  
NOTE: This may require the disassembly of  
the leads and the snubber board from the  
diode modules. Refer to the Output Diode  
Modules Removal and Replacement  
Procedure for detailed instructions.  
NOTE: There is a 250 ohm resistor across  
the welding output terminals. See Wiring  
Diagram  
6. If less than 200 ohms is measured, one or  
more diodes or the snubber board may be  
faulty.  
7. Perform the Filter Capacitor Discharge  
Procedure detailed in the maintenance sec-  
tion.  
8. Locate the output diode modules and snub-  
ber board. See Figure F.9.  
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F-34  
F-34  
TROUBLESHOOTING & REPAIR  
OUTPUT DIODE MODULES TEST (continued)  
Figure F.9 Snubber and Output Diode Locations  
Output Diode  
Modules  
Snubber  
Board  
LEFT SIDE  
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F-35  
F-35  
TROUBLESHOOTING & REPAIR  
AUXILIARY TRANSFORMER TEST  
WARNING  
Service and repair should be performed by only Lincoln Electric factory trained personnel.  
Unauthorized repairs performed on this equipment may result in danger to the technician or  
machine operator and will invalidate your factory warranty. For your safety and to avoid  
electrical shock, please observe all safety notes and precautions detailed throughout this  
manual.  
If for any reason you do not understand the test procedures or are unable to perform the  
test/repairs safely, contact the Lincoln Electric Service Department for electrical  
troubleshooting assistance before you proceed. Call 1-800-833-9353 (WELD).  
DESCRIPTION  
This procedure will determine if the correct voltage is being applied to the primary of auxil-  
iary transformer and also if the correct voltage is being induced on the secondary windings  
of the transformer.  
MATERIALS NEEDED  
Volt-ohmmeter (Multimeter)  
5/16” Nut Driver  
Wiring Diagram  
This procedure takes approximately 25 minutes to perform.  
POWER WAVE 355/405  
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F-36  
F-36  
TROUBLESHOOTING & REPAIR  
AUXILIARY TRANSFORMER TEST (continued)  
FIGURE F.10 Auxiliary Transformer  
Auxiliary  
Transformer  
Secondary Lead  
Plugs P52  
STATUS  
THERMAL  
LINCOLN  
ELECTRIC  
W
A
R
N
I
N
G
R
E
M
O
T
E
P
O
W
E
R
O
N
TEST PROCEDURE  
4. Locate the auxiliary transformer. See Figure  
F.10.  
1. Remove input power to the POWER WAVE  
355/405.  
5. Locate the secondary leads and plug P52.  
See Figure F.10 and F.11.  
2. Using a 5/16” nut driver, remove the case  
wraparound cover.  
3. Perform the Input Capacitor Discharge  
Procedure detailed earlier in this section.  
FIGURE F.11 Plug Lead Connections Viewed From Transformer Lead Side of Plug  
PW405  
Only  
(220V)  
532  
(115V)  
Plug P52  
Com 2  
(31)  
POWER WAVE 355/405  
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F-37  
F-37  
TROUBLESHOOTING & REPAIR  
AUXILIARY TRANSFORMER NO.1 TEST (continued)  
TABLE F.5  
NORMAL EXPECTED VOLTAGE  
LEAD IDENTIFICATION  
COM 2 (31) TO 115V (532)  
115 VAC  
42 VAC  
42 TO COM 1A (quick connects)  
7. Carefully apply the correct input voltage to the  
POWER WAVE 355/405 and check for the cor-  
rect secondary voltages per table F.5. Make  
sure the reconnect jumper lead and switch are  
configured correctly for the input voltage  
being applied. Make sure circuit breaker  
(CB3) is functioning properly.  
WARNING  
High voltage is present at primary of  
Auxiliary Transformer.  
9. If the correct input voltage is applied to the  
primary, and the secondary voltage(s) are not  
correct, the auxiliary transformer may be  
faulty.  
NOTE: The secondary voltages will vary if the  
input line voltage varies.  
8. 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.  
10. Remove the input power to the POWER WAVE  
355/405.  
11. Install the case wraparound cover using a  
5/16” nut driver.  
POWER WAVE 355/405  
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F-38  
F-38  
NOTES  
POWER WAVE 355/405  
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F-39  
F-39  
TROUBLESHOOTING AND REPAIR  
CURRENT TRANSDUCER TEST  
WARNING  
Service and repair should be performed by only Lincoln Electric factory trained personnel.  
Unauthorized repairs performed on this equipment may result in danger to the technician or  
machine operator and will invalidate your factory warranty. For your safety and to avoid  
electrical shock, please observe all safety notes and precautions detailed throughout this  
manual.  
If for any reason you do not understand the test procedures or are unable to perform the  
test/repairs safely, contact the Lincoln Electric Service Department for electrical  
troubleshooting assistance before you proceed. Call 1-800-833-9353 (WELD).  
DESCRIPTION  
This test will help determine if the current transducer and associated wiring are functioning  
correctly.  
MATERIALS NEEDED  
Volt-ohmmeter  
5/16” Nut Driver  
Grid Bank  
External DC Ammeter  
This procedure takes approximately 45 minutes to perform.  
POWER WAVE 355/405  
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F-40  
F-40  
TROUBLESHOOTING AND REPAIR  
CURRENT TRANSDUCER TEST (continued)  
FIGURE F.12 Metal Plate Removal & Plug J8 Location  
STATUS  
THERMAL  
LINCOLN  
ELECTRIC  
W
A
R
N
I
N
G
R
E
M
O
T
E
P
O
W
E
R
O
N
F
Plug J8  
6. Check for the correct DC supply voltages to  
the current transducer at plug J8. See Figure  
F.12.  
TEST PROCEDURE  
1. Remove input power to the POWER WAVE  
355/405.  
A. Pin 2 (lead 802+) to pin 6 (lead 806-)  
should read +15 VDC.  
2. Using the 5/16” nut driver, remove the case  
wraparound cover.  
B. Pin 4 (lead 804+) to pin 6 (lead 806-)  
should read -15 VDC.  
3. Perform the Input Capacitor Discharge  
Procedure.  
7. If either of the supply voltages are low or miss-  
ing, the control board may be faulty.  
4. Locate plug J8 on the control board. Do not  
remove the plug from the P.C. Board.  
5. Apply the correct input power to the POWER  
WAVE 355/405.  
FIGURE F.13. Plug J8 Viewed From Lead Side of Plug  
802  
804  
801  
Plug J8  
806  
POWER WAVE 355/405  
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F-41  
F-41  
TROUBLESHOOTING AND REPAIR  
CURRENT TRANSDUCER TEST (continued)  
TABLE F.6  
EXPECTED TRANSDUCER FEEDBACK  
OUTPUT LOAD CURRENT  
VOLTAGE  
300  
250  
2.4  
2.0  
200  
150  
100  
1.6  
1.2  
0.8  
8. Check the feedback voltage from the current  
transducer using a resistive load bank and  
with the POWER WAVE 355/405 in mode 200.  
Mode 200 is a constant current test mode.  
This mode can be accessed using a wire feed-  
er placed in mode 200 or a laptop computer  
and the appropriate software. Apply the grid  
load across the output of the POWER WAVE  
355/405. Set machine output to 300 amps  
and enable WELD TERMINALS. Adjust the  
grid load to obtain 300 amps on the external  
ammeter and check feedback voltages per  
Table F.6.  
Before replacing the current transducer, check  
the leads and plugs between the control board  
(J8) and the current transducer (J90). See The  
Wiring Diagram. For access to plug J90 and  
the current transducer refer to: Current  
Transducer Removal and Replacement  
Procedure.  
11. Remove input power to the POWER WAVE  
355/405.  
12. Replace the control box top and any cable ties  
previously removed.  
13. Install the case wraparound cover using the  
5/16” nut driver.  
A. Pin 1 (lead 801) to Pin 6 (lead 806) should  
read 2.4 VDC (machine loaded to 300  
amps).  
9. If for any reason the machine cannot be  
loaded to 300 amps, Table F.6. shows what  
feedback voltage is produced at various cur-  
rent loads.  
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.  
POWER WAVE 355/405  
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F-42  
F-42  
NOTES  
POWER WAVE 355/405  
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F-43  
F-43  
TROUBLESHOOTING AND REPAIR  
FAN CONTROL AND MOTOR TEST  
WARNING  
Service and repair should be performed by only Lincoln Electric factory trained personnel.  
Unauthorized repairs performed on this equipment may result in danger to the technician or  
machine operator and will invalidate your factory warranty. For your safety and to avoid  
electrical shock, please observe all safety notes and precautions detailed throughout this  
manual.  
If for any reason you do not understand the test procedures or are unable to perform the  
test/repairs safely, contact the Lincoln Electric Service Department for electrical  
troubleshooting assistance before you proceed. Call 1-800-833-9353 (WELD).  
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  
This procedure takes approximately 40 minutes to perform.  
POWER WAVE 355/405  
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F-44  
F-44  
TROUBLESHOOTING AND REPAIR  
FAN CONTROL AND MOTOR TEST (continued)  
TEST PROCEDURE  
3. Perform the Input Filter Capacitor Discharge  
1. Remove the input power to the POWER WAVE  
355/405 machine.  
Procedure.  
4. Locate plug J22 on the main switch board. Do  
not remove the plug from the board. See  
Figure F.14.  
2. Using the 5/16” nut driver, remove the case  
wraparound cover.  
FIGURE F.14 PLUG J22 LOCATION  
J22  
J21  
J20  
5. Carefully apply the correct input power to the  
machine.  
6. Carefully check for 115VAC at plug J22 pin-2  
to J22 pin-3. (leads 32A to 31B(C) See Figure  
F.15. WARNING: HIGH VOLTAGE IS PRE-  
SENT AT THE MAIN SWITCH BOARD.  
FIGURE F.15 PLUG J22  
Fan Lead  
2
1
3
Lead 32A  
4
Fan Lead  
Lead 31B(C)  
Plug J22  
POWER WAVE 355/405  
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F-45  
F-45  
TROUBLESHOOTING AND REPAIR  
FAN CONTROL AND MOTOR TEST (continued)  
7. If the 115VAC is low or not present check cir-  
FAN CONTROL TEST PROCEDURE  
cuit breaker CB2 located on the front panel. If  
the circuit breaker is OK, perform The  
Auxiliary Transformer Test. Check plug J22,  
circuit breaker CB2 and associated leads for  
loose or faulty connections. See the Wiring  
Diagram.  
1. Locate plug J20 on the switch board. Do not  
remove the plug from the switch board. See  
Figure F.14 and F.16.  
2. 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.  
8. Energize the weld output terminals with the  
PW 355/405 in mode 200. This mode can be  
accessed using a wire feeder placed in mode  
200 or a laptop computer and the appropriate  
software. Carefully check for 115VAC at plug  
J22 pin-1 to J22 pin-4 (fan leads). See 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 con-  
nections. See the Wiring Diagram. WARN-  
ING: HIGH VOLTAGE IS PRESENT AT THE  
SWITCH BOARD.  
WARNING: HIGH VOLTAGE IS PRESENT AT  
THE SWITCH BOARD.  
3. Remove the input power to the POWER WAVE  
355/405.  
9. If the 115VAC is NOT present in the previous  
step then proceed to the fan control test.  
Note: The fan motor may be accessed by the  
removal of the rear panel detailed in The  
Current  
Transducer  
Removal  
and  
Replacement Procedure.  
4. Replace the case wrap-around cover.  
FIGURE F.16 PLUG J20  
Lead 716-  
1
3
2
4
8
5 6 7  
Plug J20  
Lead 715+  
POWER WAVE 355/405  
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F-46  
F-46  
NOTES  
POWER WAVE 355/405  
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F-47  
F-47  
TROUBLESHOOTING & REPAIR  
CONTROL BOARD REMOVAL AND REPLACEMENT  
WARNING  
Service and repair should be performed by only Lincoln Electric factory trained personnel.  
Unauthorized repairs performed on this equipment may result in danger to the technician or  
machine operator and will invalidate your factory warranty. For your safety and to avoid  
electrical shock, please observe all safety notes and precautions detailed throughout this  
manual.  
If for any reason you do not understand the test procedures or are unable to perform the  
test/repairs safely, contact the Lincoln Electric Service Department for electrical  
troubleshooting assistance before you proceed. Call 1-800-833-9353) (WELD).  
DESCRIPTION  
The following procedure will aid the technician in removing the control board for maintenance  
or replacement.  
MATERIALS NEEDED  
5/16” Nut Driver  
3/8” Nut Driver  
Flathead Screwdriver  
Phillips Head Screwdriver  
This procedure takes approximately 30 minutes to perform.  
POWER WAVE 355/405  
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F-48  
F-48  
TROUBLESHOOTING & REPAIR  
CONTROL BOARD REMOVAL AND REPLACEMENT (continued)  
FIGURE F.17 - CONTROL BOARD LOCATION  
STATUS  
THERMAL  
LINCOLN  
ELECTRIC  
W
A
R
N
I
N
G
R
E
M
O
T
E
P
O
W
E
R
O
N
Control Board  
PROCEDURE  
4. Locate the control board behind the front panel of  
the machine. See Figure F.17.  
1. Remove input power to the POWER WAVE  
355/405.  
5. Using a 5/16” nut driver remove the two screws  
from the bottom of the front of the machine. See  
Figure F.18.  
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.  
FIGURE F.18 CASE FRONT SCREW REMOVAL  
STATUS  
THERMAL  
Phillips Head  
Screws  
Phillips Head  
Screws  
_
+
5/16"  
Mounting Screws  
POWER WAVE 355/405  
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F-49  
F-49  
TROUBLESHOOTING & REPAIR  
CONTROL BOARD REMOVAL AND REPLACEMENT (continued)  
FIGURE F.19 - CONTROL BOARD ALL PLUG LOCATIONS  
J6  
J7  
J5  
J8  
J9  
J4  
J2  
STATU  
S
TH  
ERMAL  
LINCOLN  
J10B  
ELECTRIC  
W
A
R
N
I
N
G
R
E
M
O
T
E
J10A  
P
O
W
E
R
O
N
8. 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.  
CAUTION  
Observe static precautions detailed in PC  
Board Troubleshooting Procedures at the  
beginning of this section.  
9. 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.  
10. 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.  
6. Using a phillips head screwdriver remove the two  
screws and their washers from above and below  
the input power switch. See Figure F.18.  
11. Working your way down the left side of the board,  
label and remove plugs #J4 and #J2. See Figure  
F.19.  
7. Using a phillips head screwdriver remove the four  
screws from around the two welder output termi-  
nals on the front of the machine. See Figure F.18.  
POWER WAVE 355/405  
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F-50  
F-50  
TROUBLESHOOTING & REPAIR  
CONTROL BOARD REMOVAL AND REPLACEMENT (continued)  
12. Using a 3/8” nut driver remove the two mounting  
nuts from the top two corners of the control  
board. See Figure F.20.  
14. Replace the control board.  
13. Cut any necessary cable ties.  
FIGURE F.20 CONTROL BOARD MOUNTING SCREW LOCATION  
Mounting  
Nuts (3/8")  
15. Replace the two 3/8” mounting nuts at the top  
two corners of the control board.  
19. Replace the four screws from around the two  
welder output terminals on the front of the  
machine.  
16. Replace any previously removed cable ties.  
20. Replace the two case front mounting screws at  
the bottom of the front of the machine.  
17. Replace plugs #J2, #J4, #J5, #J6, #J7, #J8, #J9,  
#J10B, and #J10A previously removed.  
21. Replace the case wraparound cover.  
18. Replace the two screws and their washers from  
above and below the input power switch.  
POWER WAVE 355/405  
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F-51  
F-51  
TROUBLESHOOTING & REPAIR  
MAIN SWITCH BOARD REMOVAL AND REPLACEMENT  
WARNING  
Service and repair should be performed by only Lincoln Electric factory trained personnel.  
Unauthorized repairs performed on this equipment may result in danger to the technician or  
machine operator and will invalidate your factory warranty. For your safety and to avoid  
electrical shock, please observe all safety notes and precautions detailed throughout this  
manual.  
If for any reason you do not understand the test procedures or are unable to perform the  
test/repairs safely, contact the Lincoln Electric Service Department for electrical  
troubleshooting assistance before you proceed. Call 1-800-833-9353 (WELD).  
DESCRIPTION  
The following procedure will aid the technician in removing the main switch board for main-  
tenance or replacement.  
MATERIALS NEEDED  
5/16” Nut Driver  
Flathead Screwdriver  
7/16” mm Socket  
3/16” Allen Wrench  
3/8” Nut Driver  
This procedure takes approximately 35 minutes to perform.  
POWER WAVE 355/405  
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F-52  
F-52  
TROUBLESHOOTING & REPAIR  
MAIN SWITCH BOARD REMOVAL & REPLACEMENT (continued)  
FIGURE F.21 – MAIN SWITCH BOARD LEAD LOCATIONS  
207  
202  
J22  
- +  
- +  
209  
201  
204  
208  
205  
J21  
J20  
- +  
- +  
206  
203  
PROCEDURE  
5. Using a 3/8” nut driver, remove the input lead  
shield from the area at the bottom of the main  
switch board.  
1. Remove the input power to the POWER WAVE  
355/405.  
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  
switch board. Note lead terminal locations and  
washer positions upon removal.  
3. Perform the Input Filter Capacitor Discharge  
Procedure detailed earlier in this section.  
7. Locate and disconnect the three harness plugs  
associated with the main switch board. Plugs  
#J20, #J21, #J22. See Figure F.21.  
CAUTION  
8. Locate the eight capacitor terminals and  
remove the nuts using a 7/16” socket or nut  
driver. Note the position of the washers behind  
each nut for replacement.  
Observe static precautions detailed in PC Board  
Troubleshooting Procedures at the beginning of  
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 355/405  
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F-53  
F-53  
TROUBLESHOOTING & REPAIR  
MAIN SWITCH BOARD REMOVAL & REPLACEMENT (continued)  
FIGURE F.22 – 3/16” ALLEN BOLT LOCATION  
- +  
- +  
3/16" ALLEN BOLTS  
- +  
- +  
9. Using a 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.  
15. Reconnect the nine leads (#201-#209) that  
were previously removed.  
16. Replace any necessary cable ties previously  
removed.  
10. Carefully maneuver the board out of the  
machine.  
17. Pre-torque all screws to 25 inch lbs. before  
tightening to 44 inch lbs.  
11. 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.  
18. Replace the input lead shield previously  
removed.  
12. Replace the four allen bolts and washers  
previously removed.  
19. Replace the case wraparound cover.  
13. Replace the eight capacitor terminal nuts,  
washers, and necessary leads previously  
removed.  
14. Reconnect the three harness plugs previous-  
ly removed.  
POWER WAVE 355/405  
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F-54  
F-54  
NOTES  
POWER WAVE 355/405  
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F-55  
F-55  
TROUBLESHOOTING & REPAIR  
SNUBBER BOARD REMOVAL AND REPLACEMENT  
WARNING  
Service and repair should be performed by only Lincoln Electric factory trained personnel.  
Unauthorized repairs performed on this equipment may result in danger to the technician or  
machine operator and will invalidate your factory warranty. For your safety and to avoid  
electrical shock, please observe all safety notes and precautions detailed throughout this  
manual.  
If for any reason you do not understand the test procedures or are unable to perform the  
test/repairs safely, contact the Lincoln Electric Service Department for electrical  
troubleshooting assistance before you proceed. Call 1-800-833-9353 (WELD).  
DESCRIPTION  
The following procedure will aid the technician in removing the snubber board for mainte-  
nance or replacement.  
MATERIALS NEEDED  
5/16” Nut Driver  
7/16 Socket or Nut Driver  
This procedure takes approximately 15 minutes to perform.  
POWER WAVE 355/405  
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F-56  
F-56  
TROUBLESHOOTING & REPAIR  
SNUBBER BOARD REMOVAL AND REPLACEMENT (continued)  
PROCEDURE  
3. Perform the Input Filter Capacitor Discharge  
1. Remove input power to the POWER WAVE  
355/405.  
Procedure detailed earlier in this section.  
4. Locate the snubber board.. See Figure F.23.  
2. Using a 5/16” nut driver remove the case wrap-  
around cover.  
FIGURE F.23 – SNUBBER BOARD LOCATION  
Snubber  
Board  
LEFT SIDE  
5. Remove small lead #B1 from the board. See  
Figure F.24.  
8. Replace the snubber board.  
9. Replace the bolts, leads, and washers previously  
removed. Torque bolt to 30-40 Inch Lbs.  
6. Remove the four bolts using a 7/16” socket. Two  
of these bolts have leads #30 and #10 connected  
to them. Note the position of all leads and associ-  
ated washers upon removal.  
10. Reconnect small lead B1 previously removed.  
11. Replace the case wraparound cover.  
7. Carefully remove the snubber board.  
FIGURE F.24 – SNUBBER BOARD LEADS (CLOSE UP)  
Lead 30  
Lead B1  
Lead 10  
POWER WAVE 355/405  
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F-57  
F-57  
TROUBLESHOOTING & REPAIR  
POWER BOARD REMOVAL AND REPLACEMENT  
WARNING  
Service and repair should be performed by only Lincoln Electric factory trained personnel.  
Unauthorized repairs performed on this equipment may result in danger to the technician or  
machine operator and will invalidate your factory warranty. For your safety and to avoid  
electrical shock, please observe all safety notes and precautions detailed throughout this  
manual.  
If for any reason you do not understand the test procedures or are unable to perform the  
test/repairs safely, contact the Lincoln Electric Service Department for electrical  
troubleshooting assistance before you proceed. Call 1-800-833-9353 (WELD).  
DESCRIPTION  
The following procedure will aid the technician in removing the power board for maintenance  
or replacement.  
MATERIALS NEEDED  
5/16” Nut Driver  
3/8” Nut Driver  
This procedure takes approximately 25 minutes to perform.  
POWER WAVE 355/405  
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F-58  
F-58  
TROUBLESHOOTING & REPAIR  
POWER BOARD REMOVAL AND REPLACEMENT (continued)  
FIGURE F.25 POWER BOARD LOCATION  
Power Board  
LEFT SIDE  
PROCEDURE  
3. Perform the Input Filter Capacitor Discharge  
1. Remove input power to the POWER WAVE  
355/405.  
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.  
POWER WAVE 355/405  
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F-59  
F-59  
TROUBLESHOOTING & REPAIR  
POWER BOARD REMOVAL AND REPLACEMENT (continued)  
7. Remove the three nuts at the corners of the board  
using a 3/8” nut driver. Board is ready for removal.  
CAUTION  
8. Replace the power board.  
Observe static precautions detailed in PC  
Board Troubleshooting Procedures at the  
beginning of this section.  
9. Secure the new power board into its proper posi-  
tion with the three 3/8” nuts previously removed.  
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  
J43  
J42  
J41  
POWER WAVE 355/405  
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F-60  
F-60  
NOTES  
POWER WAVE 355  
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F-61  
F-61  
TROUBLESHOOTING & REPAIR  
DC BUS BOARD REMOVAL AND REPLACEMENT  
WARNING  
Service and repair should be performed by only Lincoln Electric factory trained personnel.  
Unauthorized repairs performed on this equipment may result in danger to the technician or  
machine operator and will invalidate your factory warranty. For your safety and to avoid  
electrical shock, please observe all safety notes and precautions detailed throughout this  
manual.  
If for any reason you do not understand the test procedures or are unable to perform the  
test/repairs safely, contact the Lincoln Electric Service Department for electrical  
troubleshooting assistance before you proceed. Call 1-800-833-9353 (WELD).  
DESCRIPTION  
The following procedure will aid the technician in removing the DC Bus Board for mainte-  
nance or replacement.  
MATERIALS NEEDED  
5/16” Nut Driver  
3/8” Open End Wrench  
Flat Head Screwdriver  
Phillips Head Screwdriver  
This procedure takes approximately 40 minutes to perform.  
POWER WAVE 355  
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F-62  
F-62  
TROUBLESHOOTING & REPAIR  
DC BUS BOARD REMOVAL AND REPLACEMENT (Continued)  
PROCEDURE  
6. Using a phillips head screwdriver remove the two  
screws and their washers from above and below  
the input power switch. See Figure F.28.  
1. Remove input power to the POWER WAVE  
355/405.  
2. Using a 5/16” nut driver remove the case wrap-  
around cover.  
7. Using a phillips head screwdriver remove the four  
screws mounting the two welder output terminals  
on the front of the machine. See Figure F.28.  
3. Perform the Input Filter Capacitor Discharge  
Procedure detailed earlier in this section.  
8. 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.  
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.  
FIGURE F.27 DC BUS BOARD LOCATION  
DC BUS BOARD  
STATUS  
THERMAL  
L
IN  
ELECTR  
COLN  
IC  
W
A
R
N
I
N
G
R
E
M
O
T
E
P
O
W
E
R
O
N
POWER WAVE 355  
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F-63  
F-63  
TROUBLESHOOTING & REPAIR  
DC BUS BOARD REMOVAL AND REPLACEMENT (Continued)  
FIGURE F.28 CASE FRONT SCREW REMOVAL  
STATUS  
THERMAL  
Phillips Head  
Screws  
Phillips Head  
Screws  
_
+
5/16"  
Mounting Screws  
9. Label and remove two thermostat leads and four  
leads from the bus rectifier.  
13. Reconnect previously removed leads to their prop-  
er locations.  
10. Using a 3/8” open end wrench, remove the three  
DC Bus Board mounting nuts. See Figure F.29.  
14. Replace the four phillips head screws mounting  
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  
and below the input power switch.  
12. Secure the new DC Bus Board in its proper loca-  
tion using the 3/8” mounting nuts.  
FIGURE F.29 CASE FRONT SCREW REMOVAL  
J47  
Bus  
Rectifier  
3/8" Mounting  
Nuts  
Thermostat  
J46  
POWER WAVE 355  
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F-64  
F-64  
TROUBLESHOOTING & REPAIR  
DC BUS BOARD REMOVAL AND REPLACEMENT (Continued)  
16. Replace the two 5/16” mounting screws to the  
bottom of the case front.  
17. Replace the case wraparound cover.  
POWER WAVE 355  
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F-65  
F-65  
TROUBLESHOOTING & REPAIR  
INPUT RECTIFIER REMOVAL AND REPLACEMENT  
WARNING  
Service and repair should be performed by only Lincoln Electric factory trained personnel.  
Unauthorized repairs performed on this equipment may result in danger to the technician or  
machine operator and will invalidate your factory warranty. For your safety and to avoid  
electrical shock, please observe all safety notes and precautions detailed throughout this  
manual.  
If for any reason you do not understand the test procedures or are unable to perform the  
test/repairs safely, contact the Lincoln Electric Service Department for electrical  
troubleshooting assistance before you proceed. Call 1-800-833-9353 (WELD).  
DESCRIPTION  
The following procedure will aid the technician in removing the input rectifier for maintenance  
or replacement.  
MATERIALS NEEDED  
3/16” Allen wrench  
5/16” Nut Driver  
Flathead Screwdriver  
Penetrox A-13 Heatsink Compound  
Silicon Sealant  
This procedure takes approximately 30 minutes to perform.  
POWER WAVE 355/405  
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F-66  
F-66  
TROUBLESHOOTING & REPAIR  
INPUT RECTIFIER REMOVAL AND REPLACEMENT (continued)  
PROCEDURE  
6. Remove the six screws from the terminals using a  
flathead screwdriver. Carefully note the position of  
all leads and their positions upon removal. See  
Figure F.31.  
1. Remove input power to the POWER WAVE  
355/405.  
2. Using a 5/16” nut driver remove the case  
wraparound cover.  
7. Using a 3/16”in. allen wrench remove the two  
mounting screws and washers from the input  
bridge. See Figure F.31.  
3. Perform the Input Filter Capacitor Discharge  
Procedure detailed earlier in this section.  
8. Remove the input bridge.  
4. Locate the input rectifier. See figure F.30.  
5. Carefully remove the silicon sealant insulating the  
six input rectifier terminals.  
FIGURE F.30 – INPUT RECTIFIER LOCATION  
INPUT  
RECTIFIER  
STATUS  
THERMAL  
LINCOLN  
ELECTRIC  
W
A
R
N
IN  
G
R
E
M
O
T
E
P
O
W
E
R
O
N
POWER WAVE 355/405  
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F-67  
F-67  
TROUBLESHOOTING & REPAIR  
INPUT RECTIFIER REMOVAL AND REPLACEMENT (continued)  
9. Apply a thin coat of Penetrox A-13 heatsink com-  
pound to the point of contact between the input  
rectifier and the mounting surface.  
11. Reconnect the previously removed leads to their  
proper locations. Torque to 31 inch pounds.  
12. Cover the input rectifier and its six terminals with  
silicon sealant.  
10. Secure the new input bridge into its proper posi-  
tion with the two 3/16”in. allen mounting screws  
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  
C
B
#207  
#207A  
A
#209  
Small Lead "A"  
To Circuit Breaker  
FRONT  
REAR  
POWER WAVE 355/405  
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F-68  
F-68  
NOTES  
POWER WAVE 355/405  
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F-69  
F-69  
TROUBLESHOOTING & REPAIR  
OUTPUT RECTIFIER MODULES REMOVAL AND  
REPLACEMENT  
WARNING  
Service and repair should be performed by only Lincoln Electric factory trained personnel.  
Unauthorized repairs performed on this equipment may result in danger to the technician or  
machine operator and will invalidate your factory warranty. For your safety and to avoid  
electrical shock, please observe all safety notes and precautions detailed throughout this  
manual.  
If for any reason you do not understand the test procedures or are unable to perform the  
test/repairs safely, contact the Lincoln Electric Service Department for electrical  
troubleshooting assistance before you proceed. Call 1-800-833-9353 (WELD).  
DESCRIPTION  
The following procedure will aid the technician in removing the output rectifier modules for  
maintenance or replacement.  
MATERIALS NEEDED  
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  
This procedure takes approximately 30 minutes to perform.  
POWER WAVE 355/405  
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F-70  
F-70  
TROUBLESHOOTING & REPAIR  
OUTPUT RECTIFIER MODULES  
REMOVAL AND REPLACEMENT (continued)  
PROCEDURE  
1. Remove input power to the POWER WAVE  
355/405.  
5. Before the output rectifier modules can be  
reached, the Snubber Board Removal  
Procedure must be performed.  
2. Using a 5/16” nut driver remove the case wrap-  
around cover.  
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. See Figure  
F.33.  
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 figure F.32.  
7. Remove the copper plates from the tops of the  
modules.  
FIGURE F.32 – OUTPUT RECTIFIER MODULE LEAD LOCATIONS  
Output Diode  
Modules  
Snubber  
Board  
LEFT SIDE  
POWER WAVE 355/405  
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F-71  
F-71  
TROUBLESHOOTING & REPAIR  
OUTPUT RECTIFIER MODULES  
REMOVAL AND REPLACEMENT (continued)  
8. Under the copper plate previously removed, there  
is an allen bolt. Remove it using a 9/64” allen  
wrench. See Figure F.33.  
13. 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).  
9. Using a 7/16” socket remove the mounting bolts at  
the top and bottom of the modules. See Figure  
F.33.  
14. Using a 7/16” socket, tighten each mounting bolt  
to between 5 and 10 inch pounds.  
10. The output rectifier modules are ready for removal  
and/or replacement.  
15 Tighten the center allen screw to between 12 and  
18 inch pounds.  
11. Before replacing the diode module, apply a thin  
even coat of Penetrox A-13 heatsink compound  
to the bottom surface of the diode module. Note:  
Keep the compound away from the mounting  
holes.  
16. Tighten each mounting bolt again (30 to 40 inch  
pounds this time).  
15. Replace leads #X2, #X4, #20, #40 to their original  
terminals in their proper positions. Torque bolts to  
30-40 Inch Pounds.  
12. 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).  
16. Perform the Snubber Board Replacement  
Procedure detailed earlier in this section.  
17. Replace the case wraparound cover.  
FIGURE F.33 – OUTPUT RECTIFIER MODULE MOUNTING BOLT LOCATIONS  
Mounting  
Bolts  
40 20  
X4  
X2  
3/16" Allen  
Bolts  
9/64" Allen  
Bolts  
Mounting  
Bolts  
POWER WAVE 355/405  
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F-72  
F-72  
NOTES  
POWER WAVE 355/405  
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F-73  
F-73  
TROUBLESHOOTING & REPAIR  
CURRENT TRANSDUCER REMOVAL AND REPLACEMENT  
WARNING  
Service and repair should be performed by only Lincoln Electric factory trained personnel.  
Unauthorized repairs performed on this equipment may result in danger to the technician or  
machine operator and will invalidate your factory warranty. For your safety and to avoid  
electrical shock, please observe all safety notes and precautions detailed throughout this  
manual.  
If for any reason you do not understand the test procedures or are unable to perform the  
test/repairs safely, contact the Lincoln Electric Service Department for electrical  
troubleshooting assistance before you proceed. Call 1-800-833-9353 (WELD).  
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  
This procedure takes approximately 45 minutes to perform.  
POWER WAVE 355/405  
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F-74  
F-74  
TROUBLESHOOTING & REPAIR  
CURRENT TRANSDUCER REMOVAL AND REPLACEMENT (continued)  
PROCEDURE  
4. Using a 5/16” nut driver remove the four screws  
from the bottom and right side of the rear assem-  
bly. See Figure F.34.  
1. Remove input power to the POWER WAVE  
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.  
FIGURE F.34 – CASE BACK SCREW LOCATIONS  
REAR  
OFF  
OFF  
OFF  
Plastic  
Nut  
5/16" Mounting Screws  
POWER WAVE 355/405  
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F-75  
F-75  
TROUBLESHOOTING & REPAIR  
CURRENT TRANSDUCER REMOVAL AND REPLACEMENT (continued)  
5. Label and remove the four leads connected to the  
reconnect panel. Pliers may be necessary.  
9. Using a hammer and a flathead screwdriver, firmly  
tap the metal nut from the bottom of one of its ribs.  
This tapping will loosen the nut. Note: Be sure to  
tap from the bottom so the nut loosens in a counter  
clockwise fashion if viewed from the front of the  
machine.  
6. Label and remove the two leads connected to the  
CB2 circuit breaker.  
7. Using a crescent wrench, remove the large plastic  
nut from around the input power line located at bot-  
tom of the rear assembly. See Figure F.35.  
10. Using a 3/8” nut driver label and remove leads  
#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  
#206  
#202  
#207A  
#203  
STATUS  
THERMAL  
LINCOLN  
ELECTRIC  
W
ARNING  
REMOTE  
POWER  
ON  
POWER WAVE 355/405  
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F-76  
F-76  
TROUBLESHOOTING & REPAIR  
CURRENT TRANSDUCER REMOVAL AND REPLACEMENT (continued)  
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  
removed completely.  
16. Using 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.  
12. Carefully swing the rear of the machine open to  
the left while facing the rear of the machine.  
17. Cut any necessary cable ties and carefully remove  
the heavy lead from the diode heatsink using a  
1/2” nut driver.  
13. Perform the Snubber Board Removal  
Procedure.  
18. Remove the output diode heatsink assembly  
through the rear of the machine.  
14. Remove leads #X2 and #20 from the output diode  
module.  
19. Remove plug #J90 from the current transducer.  
15. Remove leads #X4 and #40 from the other output  
diode module.  
20. 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  
BOLTS  
POWER WAVE 355/405  
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F-77  
F-77  
TROUBLESHOOTING & REPAIR  
CURRENT TRANSDUCER REMOVAL AND REPLACEMENT (continued)  
21. Replace the current transducer.  
29. The rear of the machine may now be placed back  
into its original position.  
22. Replace the two 3/8” mounting nuts previously  
removed.  
30. Using a 3/8” wrench, replace leads #202, #203,  
#206, and #207A previously removed from the  
reconnect switches.  
23. Reconnect plug #J90 to the current transducer.  
24. Replace any necessary cable ties previously cut.  
31. Tighten the metal nut previously removed from the  
inside of the rear wall on the back of the machine.  
Channel locks may be necessary.  
25. 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.  
32. Replace the large plastic nut from around input  
power line located at the back of the machine.  
26. Replace the output diode heatsink assembly pre-  
viously removed using a 3/8” wrench.  
33. Replace the four leads to the reconnect panel in  
their proper locations.  
Note: Be sure to place insulation in its original  
34. Replace the two CB2 circuit breaker leads previ-  
ously removed.  
location.  
27. Replace leads X2, #20, X4, #40 previously  
removed from the two output diode modules.  
Torque to 30-40 inch lbs.  
35. Using a 5/16” nut driver, replace the four screws  
from the rear assembly.  
36. Replace the case wraparound cover.  
28. Perform the Snubber Board Replacement  
Procedure.  
POWER WAVE 355/405  
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F-78  
F-78  
TROUBLESHOOTING & REPAIR  
RETEST AFTER REPAIR  
Retest a machine:  
If it is rejected under test for any reason that requires you to remove any part which could affect the machine’s  
electrical characteristics.  
OR  
If you repair or replace any electrical components.  
INPUT IDLE AMPS AND WATTS  
Input Volts/Hertz  
Maximum Idle Amps  
Maximum Idle KW  
208/60  
230/60  
400/60  
460/60  
575/60  
4.0  
3.3  
2.1  
2.0  
1.8  
0.45  
0.45  
0.45  
0.45  
0.45  
MAXIMUM OUTPUT VOLTAGES  
Input Volts/Hertz  
Output Terminals  
X1 - X2  
115 Volt Receptacles  
- No load  
208/60  
230/60  
400/60  
460/60  
575/60  
OCV  
115 - 123 VAC  
10 Amp Load  
111 - 119 VAC  
50-70 VDC  
48.5 - 55 VDC  
POWER WAVE 355/405  
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G-1  
G-1  
ELECTRICAL DIAGRAMS  
TABLE OF CONTENTS  
-ELECTRICAL DIAGRAMS SECTION-  
ELECTRICAL DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION G  
WIRING DIAGRAM (G4131) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-2  
ENTIRE MACHINE SCHEMATIC (G4132) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-3  
CONTROL PC BOARD SCHEMATIC #1 (G3789-1D0/1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-4  
CONTROL PC BOARD SCHEMATIC #2 (G3789-1D0/2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-5  
CONTROL PC BOARD SCHEMATIC #3 (G3789-1D0/3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-6  
CONTROL PC BOARD SCHEMATIC #4 (G3789-1D0/4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-7  
CONTROL PC BOARD ASSEMBLY (S25385-[ ]for 355, S25425-[ ] for 405) . . . . . . . . . . . . . . . *  
DIGITAL POWER SUPPLY PC BOARD SCHEMATIC (G3631). . . . . . . . . . . . . . . . . . . . . . . . . G-8  
DIGITAL POWER SUPPLY PC BOARD ASSEMBLY (G3632-[ ]). . . . . . . . . . . . . . . . . . . . . . . . *  
SWITCH PC BOARD SCHEMATIC (L11487) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-9  
SWITCH PC BOARD ASSEMBLY (G3830-[ ]). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-10  
SNUBBER PC BOARD SCHEMATIC (S24761) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-11  
SNUBBER PC BOARD ASSEMBLY (M19532-[ ]) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-12  
40 VDC BUSS PC BOARD SCHEMATIC (M19330) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-13  
40 VDC BUSS PC BOARD ASSEMBLY (L11832-[ ]). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . *  
* NOTE: Many PC Board Assemblies are now totally encapsulated and are therefore considered to be unservice-  
able. The Assembly numbers are provided on this page but the actual drawings are no longer included.  
POWER WAVE 355/405  
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G-2  
G-2  
ELECTRICAL DIAGRAMS  
WIRING DIAGRAM - POWERWAVE 355/405 - G4131  
WIRING DIAGRAM - POWER WAVE 355/405  
RIGHT SIDE OF MACHINE  
}
INPUT  
PER  
N.A.  
+
C1,C3  
FLAT SIDE OF LED  
ALIGNED WITH  
BLACK LEAD  
3200/300  
206  
205  
203  
208  
SWITCH  
J20  
607  
2 B  
1010  
1
2
3
4
THERMAL  
YELLOW  
LED  
615  
716  
715  
611  
612  
609  
602  
5
6
7
8
4
3
2
1
8
7
6
5
1020  
610  
1002 1020  
53  
1001 1010  
209  
1103  
54  
1104  
605  
J21  
608  
616  
1
2
1
2
3
6
5
4
1
3
2
4
2 W  
1W  
1001  
1002  
903  
N.D.  
21  
67  
J9  
2
J22  
1
901  
804  
201  
3200/300 207  
1
2
204  
504  
505  
J11  
J10A J10B  
3
4
201  
4
3
8
7
6
5
STATUS  
202  
J8  
205  
RED/GREEN  
LED  
FAN  
FAN  
L6  
+
2
802  
806  
801  
32A  
31B  
C2,C4  
T
OU  
IN  
I-  
-
1
I
B
CONTROL  
BOARD  
R
PR  
P
8
7
16  
15  
2 B  
1B  
6
2
716  
715  
J7  
2 W  
PRIMARY  
C
X2  
E
RECONNECT  
S
T
FLAT SIDE OF LED  
ALIGNED WITH  
WHITE LEAD  
3
S
O
20  
204  
7
O
FAN  
B
FAN  
4
3
1 B  
L1  
UT  
13  
1
X3  
25  
14  
O
-
30 REACTOR  
1 W  
RI  
P
208  
X1  
203  
207A  
J1  
FAN  
N
I
30  
-
251  
RI  
P
CHOKE  
x x x x x x x  
254  
253  
608  
8
16  
15  
14  
13  
12  
11  
10  
9
J6  
505  
C
E
10  
616  
S
506  
503  
T
S
607  
615  
7
6
206  
O
A
O
B
202  
MAIN  
40  
5
4
3
2
1
605  
610  
612  
611  
( 380-575VAC POSITION )  
X4  
L2  
TRANSFORMER  
401  
REACTOR  
10  
A
CB3  
INPUT  
N.E.  
TP3  
A
A
BRIDGE  
602  
609  
209  
+
_
_
A
N.C.  
R2  
10  
A
B
C
253  
D
E
F
TP1  
504  
H4  
H2  
200-  
208V  
J2  
2
1
4
3
J5  
380-  
415V  
502  
503  
1
251  
254  
3
207A  
207  
B
403  
403A  
4
2
TP2  
J4  
J3  
502  
66C  
65C  
x x x x x x x  
550-  
575V  
440-  
460V  
220-  
9
8
7
12 11 10  
9
3
8
7
1
10  
5
C
230V  
DC BUS  
BOARD  
H6  
H5  
H3  
2
4
X2  
65  
66  
1
3
2
3
2
X4  
40  
6
5
4
4
1
OUTPUT  
RECTIFIER  
H1  
J46  
401A  
403A  
406  
WIRE FEEDER  
RECEPTACLE  
VOLTAGE SENSE  
RECEPTACLE  
5
6
1
2
3
4
51  
408  
402  
405  
410  
407  
475  
J47  
412  
411  
H2 H3  
H1  
H4 H5 H6  
477  
52  
7
8
L3  
E
A
1
20  
S
53  
AUXILIARY  
TRANSFORMER  
2
3
D
51  
220V  
COM2  
115V  
42V  
N
U
B
B
E
R
B
54  
4
COM1  
C
( )COLORS FOR PW405  
52  
SNB  
N.F.  
41  
67  
10  
G(G/Y)  
R(B)  
W(N)  
B(U)  
1103 1104  
401A  
L4  
L5  
W
V
U
~
1
5
8
-
65C  
66C  
C5  
J52  
405  
403  
401  
402  
65  
66  
407410  
477  
475  
R1  
406  
CB1  
A
31  
412 411  
B
42 COM1A  
408  
C
~
903B  
901B  
66B  
65B  
J52-1  
5201  
J52-11  
J52-3  
532  
532  
+
41  
3
6
1
3
2
4
2
8
3
9
1
4
2
5
1
7
4
5
6
31  
CB2  
_
10  
CONTROL  
RECTIFIER  
11 12  
42  
32A  
LEGEND  
ALL MACHINES  
J42  
J43  
903  
J41  
POWER  
CB2  
31B  
CB4  
32A  
31B  
OPTION  
COMPONENT OUTLINE  
31D  
J90  
2 3 4  
CURRENT  
TRANSDUCER  
COLOR CODE:  
FRONT VIEW OF MACHINE  
1
PW355  
PW405  
MODEL  
B = BLACK  
G = GREEN  
R = RED  
901  
LEFT SIDE OF MACHINE  
MODEL  
NOTES:  
W = WHITE  
U = BLUE  
N.A. 1. FOR MACHINES WITH RED, BLACK AND WHITE POWER CORDS-  
N = BROWN  
N.B. SINCE COMPONENTS OR CIRCUITRY OF A PRINTED CIRCUIT BOARD MAY CHANGE WITHOUT AFFECTING  
THE INTERCHANGEABILITY OF A COMPLETE BOARD, THIS DIAGRAM MAY NOT SHOW THE EXACT  
COMPONENTS OR CIRCUITRY HAVING A COMMON CODE NUMBER.  
N.C. PLACE "A" LEAD ON APPROPRIATE CONNECTION FOR INPUT VOLTAGE. CONNECTION SHOWN IS FOR  
550-575V OPERATION (PW405ONLY GO TO 415VAC)  
FOR SINGLE PHASE INPUT: CONNECT GREEN LEAD TO GROUND PER NATIONAL ELECTRICAL  
CODE. CONNECT BLACK AND WHITE LEADS TO SUPPLY CIRCUIT. WRAP RED LEAD WITH TAPE  
TO PROVIDE 600V. INSULATION.  
FOR THREE PHASE INPUT; CONNECT GREEN LEAD TO GROUND PER NATIONAL ELECTRICAL  
CODE. CONNECT BLACK, RED & WHITE LEADS TO SUPPLY CIRCUIT.  
Y = YELLOW  
J8,J20,  
J21, J47  
J2,J5,J11,  
J10A,  
J1,J6,J7  
J52  
N.D. INPUT POWER LINE FILTER IS PRESENT ONLY ON PW405.  
N.E. ON PW405, MOV'S ARE IN THE INPUT POWER LINE FILTER.  
N.F. 220VWINDING IS ONLY PRESENT ON PW405.  
TOP CENTER  
PANEL  
J9, J42  
1
J4, J43  
2. FOR MACHINES WITH BROWN, BLACK AND BLUE POWER CORDS-  
J22, J41, J46  
J10B  
1
9
8
2
1
4
5
6
1
3
1
1
7
1
FOR SINGLE PHASE INPUT: CONNECT GREEN/YELLOW LEAD TO GROUND PER NATIONAL  
ELECTRICAL CODE. CONNECT BLUE AND BROWN LEADS TO SUPPLY CIRCUIT. WRAP BLACK  
LEAD WITH TAPE TO PROVIDE 600V. INSULATION.  
CASE FRONT BASE  
FAN SHROUD  
PROTECTIVE BONDING CIRCUIT  
8
3
4
5
12  
6
10  
16  
4
6
2
FOR THREE PHASE INPUT: CONNECT GREEN/YELLOW GROUND PER NATIONAL ELECTRICAL  
CODE. CONNECT BLUE, BLACK & BROWN LEADS TO SUPPLY CIRCUIT.  
CONNECTOR CAVITY NUMBERING SEQUENCE  
(VIEWEDFROM COMPONENT SIDE OF BOARD)  
ELECTRICAL SYMBOLS PER E1537  
A
G4131  
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.  
POWERWAVE 355/405  
Download from Www.Somanuals.com. All Manuals Search And Download.  
G-3  
G-3  
ELECTRICAL DIAGRAMS  
SCHEMATIC - COMPLETE MACHINE  
2 1 3 G 4  
ENGINEERING CONTROLLED  
CHANGE DETAIL:  
Released from "X"  
MANUFACTURER:  
No  
+15  
SWITCH BOARD  
(Sch. L11487)  
609  
J20-4  
MAIN  
INPUT  
RELAY  
CR1  
CONTROL BOARD  
(Sch. G3789)  
602  
209  
J20-8  
+15V  
J6-9  
J6-2  
609  
602  
MAIN RELAY CONTROL  
RECONNECT SWITCH  
CR1  
VOLTAGE / FREQUENCY CONVERTER #1 (+)  
VOLTAGE / FREQUENCY CONVERTER #1 (-)  
616  
J6-16  
J6-8  
205  
206  
N.C.  
N.B.  
608  
1001  
1002  
SNUBBER  
BOARD  
T
U
J10A-1  
J10A-2  
PRIMARY CURRENT SENSE #1 (-)  
O
-
PRIMARY CURRENT SENSE #1 (+)  
B
(Sch. S24761)  
4200 uF  
S
616  
J21-6  
-
V/F CONVERTER # 1  
0
3
X
REACTOR  
608  
J21-2  
J21-1  
J21-5  
J8-1  
J8-2  
J8-4  
J8-6  
OUTPUT  
DIODES  
801  
802  
804  
806  
CURRENTFEEDBACK ( 4V=500A )  
I OUT  
+15V  
-15V  
801  
J90-3  
J90-1  
J90-2  
J90-4  
INPUT SWITCH  
1001  
1002  
S
+15V  
802  
804  
806  
0
2
-15V  
X
4200 uF  
H1  
N
FLAT SIDE OF LED  
GND  
CONTROL BOARD COMMON  
POS  
NEG  
AC3  
AC2  
AC1  
I
L1  
-
2
W
V
WHITE  
-
ALIGNED WITH BLACK LEAD  
X
C
B
A
A
POSITIVE  
J9-1  
J9-3  
203  
202  
(+) STUD VOLTAGE SENSE  
(-) STUD VOLTAGE SENSE  
(BROWN)  
L2  
208  
204  
+
901  
903  
TP3  
TP2  
901B  
INPUT  
LINES  
RED  
CURRENT  
TRANSDUCER  
C1/TP1  
.05uF  
600V  
320V  
160J  
3
R1  
(BLACK)  
X
TP1  
1
L3  
THERMAL  
X
U
THERMAL LED  
8J7  
BLACK  
(BLUE)  
2B  
T
U
TP3  
YELLOW  
LED  
O
-
150V  
4200 uF  
A
G
GREEN  
S
2W  
A
-
THERMAL LED  
7J7  
80J  
4
MAIN CHOKE  
x x x x x x x  
(GREEN/YELLOW)  
X
J21-7  
605  
610  
NEGATIVE  
903B  
-
0
V/F CONVERTER # 2  
3J7  
1W  
STATUS LED (HIFOR RED)  
4
X
( ) COLOR FOR PW405  
CB3  
STATUS  
GND  
6.0A  
J21-3  
S
THERMOSTAT  
C2/TP2  
.05uF  
600V  
RED/GREEN  
LED  
N
320V  
160J  
J21-4  
J21-8  
I
4200 uF  
REACTOR  
506  
Dashed lines represent  
copper busconnections.  
-
0
1
X
503  
-
B
N.D.  
207  
B1  
1B  
STATUS LED (HIFOR GREEN)  
4J7  
506  
505  
SNB  
201  
Shown connected for  
200 - 240Volt InputVoltage  
+15  
1010  
503  
502  
J5-3  
J5-2  
THERMOSTAT  
THERMOSTAT  
1020  
SOFT  
START  
FLAT SIDE OF LED  
ALIGNED WITH WHITE LEAD  
(+)  
(-)  
505  
504  
J6-5  
VOLTAGE / FREQUENCY CONVERTER #2 (+)  
VOLTAGE / FREQUENCY CONVERTER #2 (-)  
PRIMARY CURRENT SENSE #2 (-)  
PRIMARY CURRENT SENSE #2 (+)  
GND (a)  
SOFT START CONTROL  
PULSE TRANSFORMER GATE DRIVE  
PULSE TRANSFORMER GATE DRIVE  
+ 15 (a)  
605  
610  
1010  
1020  
611  
612  
615  
607  
715  
716  
J6-10  
J10B-1  
J10B-2  
J6-11  
J6-12  
AUXILIARY  
TRANSFORMER  
611  
FAN  
615  
607  
716  
612  
115 VAC  
715  
J6-15  
J6-7  
J7-15  
J7-16  
FAN  
FAN  
FAN CONTROL  
32A  
31B  
J4-7  
J4-12  
504  
407  
412  
J42-4  
J42-1  
407  
412  
408  
410  
411  
POWERDOWN SIGNAL (HIGH=RUN)  
+15V (a)  
POWER DOWN SIGNAL  
+15 (a)  
POWER  
MACHINE  
J4-8  
+5 (a) J42-3  
408  
410  
411  
+5V (a)  
GND (a)  
-15V (a)  
BOARD  
65  
J46-1  
J46-2  
(Sch. G3631)CONTROL  
65B  
42  
502  
POWER  
J4-10  
J4-11  
GND (a)  
J42-5  
-15 (a)  
J42-2  
65C  
SUPPLY  
C5  
31  
J46-3  
J46-4  
66  
+5 SPI (b)  
J43-3  
+15 SPI (b)  
J43-6  
J4-3  
J4-2  
403  
403A  
402  
+5V SPI (b)  
66C  
SPI  
402  
401  
406  
+15V SPI (b)  
CB1  
15A  
66B  
41  
POWER  
SUPPLY  
SPI GND (b)  
J43-12  
401A  
406  
R2  
10 Ohms  
J4-1  
J4-6  
477  
475  
GND SPI (b)  
+5V RS232 (e)  
+40VDC POWER  
J47-3  
J41-2  
+40 VDC  
J41-1  
+5 RS232 (e) J43-4  
RS232  
SUPPLY  
31B  
COMMON J47-6  
CB2  
2.5A  
405  
401A  
405  
J4-5  
GND (e)  
J43-9  
GND (e)  
532  
J43-11  
+20 (c) J43-8  
32A  
+40VDC J47-8  
FEEDER  
52  
51  
L3  
PW355  
CHOPPER  
GND (c)  
+20 (d)  
J43-2  
J43-7  
J43-1  
POWER  
SUPPLY  
J47-1  
COMMON  
MODEL  
SEE BELOW  
FOR PW405  
J2-1  
251  
253  
254  
21  
67  
54  
53  
1104  
J9-6  
J9-4  
J11-1  
J11-2  
J11-4  
GND (d)  
VOLTAGE SENSE  
LINCNET  
LINCNET  
J2-3  
J2-4  
DC BUS  
BOARD  
(Sch. M19330)  
+5  
J43-5  
13  
CAN  
25  
1103  
J11-3  
GND  
J43-10  
WIRE FEEDER  
RECEPTACLE  
L5  
251  
254  
J52-11  
31  
J52-1  
5201  
J52-3  
532  
CB2  
2.5A  
A LINCNET -  
53  
54  
67  
14  
253  
LINCNET +  
B
C
1
32A  
ELECTRODE SENSE  
52  
51  
D +40 VDC  
0VDC  
31B  
E
CB4  
2.5A  
L4  
VOLTAGE SENSE  
RECEPTACLE  
31D  
J2,J5,J11,  
J22,J41,J46  
1
2
3
J8,J20,  
J21,J47  
J10A,  
J10B  
1
NOTES :  
J1,J6,J7  
1
J4, J43  
J9,J42  
8
N.A. PCBOARD COMPONENTS SHOWN FOR REFERENCE  
ONLY. ALL COMPONENTS ARE NOT SHOWN.  
N.B. INPUT POWER LINE FILTER IS PRESENT ONLY ON PW405.  
2
1
J52  
1
4
1
21  
6
1
7
1
3
5
PW405  
ELECTRICAL SYMBOLS PER E1537  
4
MODEL  
9
16  
4
5
4
8
3
6
12  
LEGEND  
6
10  
N.C. ON PW405, MOV's ARE IN THE INPUT POWER LINE FILTER.  
2
ALL MACHINES  
N.D. PLACE "A" LEAD ONAPPROPRIATE CONNECTIONFOR  
INPUT VOLTAGE. CONNECTION SHOWN SI FOR 550-575V  
OPERATION (PW405 ONLY GO TO 415 VAC).  
OPTION  
COMPONENT OUTLINE  
CONNECTOR CAVITY NUMBERINGSEQUENCE  
(VIEWED FROM COMPONENT SIDE OF BOARD)  
THIS DOCUMENT CONTAINS PROPRIETARY INFORMATION OWNED BY LINCOLN GLOBAL, INC. AND MAY NOT BE DUPLICATED, COMMUNICATED  
TO OTHER PARTIES OR USED FOR ANY PURPOSE WITHOUT THE EXPRESS WRITTEN PERMISSION OF LINCOLN GLOBAL, INC.  
PROPRIETARY& CONFIDENTIAL:  
UNLESS OTHERWISE SPECIFIED TOLERANCE  
MANUFACTURING TOLERANCE PER E2056  
DESIGN INFORMATION  
REFERENCE:  
EQUIPMENT TYPE:  
SUBJECT:  
PAGE _1__ OF ___  
1
POWERWAVE 355/405  
ON  
2
PLACE DECIMALS IS .02  
DRAWN BY:  
F.Valencic  
L.Petrila  
G4093  
ON  
3
PLACE DECIMALS IS .002  
DOCUMENT  
NUMBER:  
DOCUMENT  
REVISION:  
ON ALL ANGLES IS .5 OF  
MATERIAL TOLERANCE ("  
WITH PUBLISHED STANDARDS.  
A
DEGREE  
MACHINE SCHEMATIC  
t
") TO AGREE  
ENGINEER:  
SCALE:  
MATERIAL  
APPROVAL  
DATE:  
PROJECT  
G4132  
CRM33683  
A
RW  
APPROVED:  
7/15/02  
J.O'Connor  
NONE  
DO NOT SCALE THIS DRAWING  
DISPOSITION:  
NUMBER:  
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.  
POWERWAVE 355/405  
Download from Www.Somanuals.com. All Manuals Search And Download.  
G-4  
G-4  
ELECTRICAL DIAGRAMS  
SCHEMATIC - DIGITAL CONTROL PC BOARD #1  
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.  
POWERWAVE 355/405  
Download from Www.Somanuals.com. All Manuals Search And Download.  
G-5  
G-5  
ELECTRICAL DIAGRAMS  
SCHEMATIC - DIGITAL CONTROL PC BOARD #2  
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.  
POWERWAVE 355/405  
Download from Www.Somanuals.com. All Manuals Search And Download.  
G-6  
G-6  
ELECTRICAL DIAGRAMS  
SCHEMATIC - DIGITAL CONTROL PC BOARD #3  
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.  
POWERWAVE 355/405  
Download from Www.Somanuals.com. All Manuals Search And Download.  
G-7  
G-7  
ELECTRICAL DIAGRAMS  
SCHEMATIC - DIGITAL CONTROL PC BOARD #4  
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.  
POWERWAVE 355/405  
Download from Www.Somanuals.com. All Manuals Search And Download.  
G-8  
G-8  
ELECTRICAL DIAGRAMS  
SCHEMATIC - POWER SUPPLY PRINTED CIRCUIT BOARD  
™¥’  
Ç‚ÁË̉ü¬ÓÌÛÓÒÎüœÓˆ‰Òü“ÙÔÔί  
—¥Ø  
…
µ¿  
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™
Û
µ¿  
ØØ’  
µØ’  
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Ø
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Ô
¬
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µ
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—
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µ
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»” «Œ‘ ”ü¿  
ƒ
¬” »Õ ü”«ƒü»Õ”ƒ —¬«¿Õ ƒ¿¡»À»”ÿüŒ ü¿ü¬ŒÃœÀƒ”ƒü¡  
Œ¿—´ü” «»“ü»¿ —¿Ãüÿÿ  
“‘œœ Àÿ ’ŒÀ”¿ ƒüÕƒ”  
ÕŒ”ü“«Œ÷ ü”«ƒüƒ¿ ¬”ü¬ŒÃœŒÕƒÕ”“üŒ—ü¬»—¬‘»”—ÿüŒü¬ŒÕ”—ŒÀ“ü«¿’»Õ ü¿ü¬ŒÃÃŒÕü¬Œƒ  
Ցთ  
œŒ÷ƒ—ü“‘ œœÀÿ ü“Œ‘— ¬ƒüœŒ»Õ”  
¬ŒÃÃŒÕü¬ŒÕÕƒ¬”»ŒÕ  
—¿Ã ƒü¬ŒÕÕƒ¬”»ŒÕ  
ƒ¿—”«ü—Œ‘Õ ü¬ŒÕÕƒ¬”»ŒÕ  
”
‘
«»“ü“ «ƒƒ ”ü¬ŒÕ” ¿»Õ“üœ  
—
Œ
œ
—»ƒ” ¿—ÿ ü»ÕŒ  
—
ÿ”»ŒÕüŒ  
÷
Õƒü¡ ÿ ü”«ƒüÀ»Õ¬ŒÀÕüƒÀƒ¬  
¬ÁÊü“Á‰‰ÛüÕÓ  
”
—
»¬ü¬  
Œ
à œ¿Õÿü¿Õü»“üÕŒ”ü”  
Œ
ü¡ƒü—ƒœ  
“»Õü»Õ Œ—ÿ”»ŒÕ  
¿÷Õü¡  
—Œ‘¬ ƒ  
´ ü ü»“¬À Œ“  
ƒ
üŒ  
—
ü‘  
“
ƒ
ü÷»” «Œ‘ ”ü” «ƒüƒ œ—ƒ“ “ü÷ —»” ƒÕüœƒ—û“ “»ŒÕüŒü”«ƒüÀ»Õ¬ŒÀÕüƒÀƒ¬”  
—
»¬ü¬ àœ¿Õÿ´üü¬Àƒ’ƒ À¿Õ´üüŒ«»Œ‘ü“¿  
Œ
ÕÀƒ““üŒ”«ƒ—÷ »“ƒ ü“œƒ¬» »ƒ ü”ŒÀƒ—¿Õ¬ƒ  
°
°ü»ÕŒ  
ƒ
ÿՑ¿¬ ”‘—»Õ ü”ŒÀƒ—¿Õ¬ƒüœƒ—üƒ µØ¥  
ŒÕü üœÀ¿ƒ¬üƒ¬»Ã¿ À“ ü»“  
ŒÕüü À¿ ¬ƒüƒ ¬»Ã¿À“ü»“ üØØ  
ŒÕü¿ÀÀü¿ÕÀƒ“ü»“ ü¥üŒü¿üƒ—ƒƒ  
ÿ ”ƒ—»¿Àü”ŒÀƒ—¿Õ¬ƒüß°üü°ü®”Œü¿—ƒƒ  
÷»”«üœ‘¡À»“«ƒü“ ”¿Õ¿—“  
ƒ–‘ »œÃƒÕ ” ü”ÿœƒ  
“‘¡ …ƒ¬”  
Ø
µ¨  
¨
ØØØ¿  
ØØ؃  
—
ÿ
œ
ب  
¨
ƒÕ»Õ ƒƒ—  
¿œœ—’Œƒ  
Û
“¬¿Àƒ  
¿
”ƒ  
—
¿÷» ÕüÕ  
Ó
«
Œü ÕŒ” ü“¬¿Àƒü” « »“ü —¿÷ »Õ  
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.  
POWERWAVE 355/405  
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G-9  
G-9  
ELECTRICAL DIAGRAMS  
SCHEMATIC - SWITCH PC BOARD  
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.  
POWERWAVE 355/405  
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G-10  
G-10  
ELECTRICAL DIAGRAMS  
PC BOARD ASSEMBLY - SWITCH PC BOARD  
ITEM  
REQ'D  
PART NO.  
IDENTIFICATION  
2
2
2
2
2
2
2
4
9
C1,C23  
C10,C11  
C2,C24  
C25,C26  
C3,C18  
C31,C32  
C4,C21  
C5,C6,C15,C16  
C7,C12,C13,C14,C20,C27,C28  
C29,C30  
S20500-4  
S13490-130  
S20500-7  
T11577-57  
S13490-93  
S16668-7  
S20500-1  
S16668-6  
S16668-5  
CAPACITOR,PPMF,.0047,1000V,BOX  
CAPACITOR,PCF,0.27,50V,5%  
CAPACITOR,PPMF,.047,1600V,BOX,10%  
CAPACITOR,PEF,0.1,400V,10%  
CAPACITOR,TAEL,27,35V,10%  
CAPACITOR,CEMO,820p,50V,5%  
CAPACITOR,PPMF,0.1,1000V,10%,BOX  
CAPACITOR,CEMO,4700p,50V,10%  
CAPACITOR,CEMO,.022, 50V,20%  
C8,C9,C22  
CR1,CR2  
D1,D4,D16,D17  
D7,D8,D9,D12,D14,D18,D19  
D20,D21  
3
2
4
9
S16668-9  
S14293-18  
T12705-59  
T12199-1  
CAPACITOR,CEMO,150p, 100V,5%  
RELAY,DPST,12VDC,AG-CDO  
DIODE,AXLDS,3A,600V,UFR  
DIODE,AXLDS,1A,400V  
DZ1,DZ2,DZ3,DZ5,DZ6,DZ15  
DZ16,DZ18,DZ19,DZ23  
DZ11,DZ22  
DZ4,DZ7,DZ17,DZ20  
DZ8  
DZ9,DZ10,DZ12,DZ13  
J20,J21  
J22  
10 T12702-29  
ZENER DIODE, 1W,15V,5% 1N4744A  
N.E., N.F.  
R2  
R1  
R127  
R126  
J21  
2
4
1
4
2
1
3
1
1
4
1
T12702-4  
T12702-40  
T12702-19  
T12702-45  
S24016-8  
S24016-4  
S15000-22  
S15000-29  
T12704-75  
T12704-73  
T12704-69  
ZENER DIODE, 1W,20V,5% 1N4747A  
ZENER DIODE, 1W,6.2V,5% 1N4735A  
ZENER DIODE, 1W,12V,5% 1N4742A  
ZENER DIODE, 1W,18V,5% 1N4746A  
CONNECTOR,MOLEX,MINI,PCB,RT-L,8-PIN  
CONNECTOR,MOLEX,MINI,PCB,RT-L,4-PIN  
OPTOCOUPLER,PHOTO-Q,70V,CNY17-3/VDE  
OPTOCOUPLER,TRIAC,DRV,RANDOM,600V  
TRANSISTOR,NMF,T247,4A,900V(SS)  
MOSFET,4-PIN DIP,1A,100V,RFD110(SS)  
TRANSISTOR,PNP,TO226,0.5A, 40V,2N4403  
RESISTOR,WW,5W,3.3K,5%,SQ  
6
7
2
1
2
1
R122  
DZ22  
R123  
C22  
R83  
DZ11  
R37  
.275  
.285  
X1  
R .045  
C9  
X4  
∅
OCI3  
OCI1,OCI2,OCI3  
OCI4  
Q1  
C3  
R65  
MAX.  
OCI2  
C18  
.105  
CRIMP  
N.A.  
R135  
R72  
D21  
C32  
R39  
R38  
N.A. Q2,Q3,Q4,Q5  
5
NON-COMPONENT  
SIDE  
Q6  
HEIGHT  
R1,R2,R3,R4,R7,R8,R9,R10  
16 T14648-5  
X2  
R124,R125,R126,R127,R130  
R131,R132,R133  
R11,R12,R30,R31  
R13,R39,R43,R60,R81,R92  
R137  
R138  
R139  
R14,R107  
R140  
R15,R20,R21,R22,R27,R28  
R97,R98,R99,R100,R101,R106  
R29,R83,R122,R141  
R32,R33,R34,R48,R49,R50  
R51,R62,R63,R74,R75,R85  
R86,R87,R134,R135  
R35,R52,R73,R84  
R36,R37,R123  
R38,R40,R42,R45,R53,R59  
R66,R69,R70,R72,R80,R82  
R142,R143  
R15  
4
B203  
B207  
EYELET DETAIL  
R19  
C5  
C12  
R41  
4
6
1
1
1
2
1
S19400-1503 RESISTOR,MF,1/4W,150K,1%  
S19400-3321 RESISTOR,MF,1/4W,3.32K,1%  
R99  
R43  
D9  
R20  
R93  
C15  
S19400-3570 RESISTOR,MF,1/4W,357,1%  
S19400-1500 RESISTOR,MF,1/4W,150,1%  
S19400-4750 RESISTOR,MF,1/4W,475,1%  
S19400-1652 RESISTOR,MF,1/4W,16.5K,1%  
S19400-39R2 RESISTOR,MF,1/4W,39.2,1%  
B218  
B211  
R78  
DZ9  
R97  
N.C.  
B213  
B217  
D1  
D16  
N.J.  
(8 PLACES)  
C31  
12 S19400-10R0 RESISTOR,MF,1/4W,10.0,1%  
R35  
R60  
C13  
C20  
C23  
C1  
4
S19400-1000 RESISTOR,MF,1/4W,100,1%  
R5  
R128  
DZ23  
R129  
16 S19400-1003 RESISTOR,MF,1/4W,100K,1%  
DZ1  
R6  
C2  
X3  
C24  
4
3
S19400-6191 RESISTOR,MF,1/4W,6.19K,1%  
S19400-2213 RESISTOR,MF,1/4W,221K,1%  
14 S19400-1002 RESISTOR,MF,1/4W,10.0K,1%  
R82  
R53  
B216  
B212  
R52  
B205  
B204  
R22  
R26  
R69  
R70  
R41,R67  
R44,R68  
R46,R76  
R47,R64  
R5,R6,R19,R26,R93,R105  
R109,R128,R129  
R55,R56,R57,R58  
R61,R77  
R65,R120  
R78,R79  
T1  
T2,T3  
TP1  
TRI1  
X1,X4  
X2,X3  
2
2
2
2
9
S19400-4752 RESISTOR,MF,1/4W,47.5K ,1%  
T12300-79 RESISTOR,WW, 1W,1.0,1%  
S19400-3322 RESISTOR,MF,1/4W,33.2K,1%  
S19400-2000 RESISTOR,MF,1/4W,200,1%  
S19400-1001 RESISTOR,MF,1/4W,1.00K,1%  
DZ13  
D4  
D17  
N.D.  
3
C6  
(16 PLACES)  
R106  
R105  
R27  
N.B., N.G., N.M.  
(5 PLACES)  
B206  
B202  
C16  
R101  
1
4
2
2
2
1
2
1
1
2
2
S24376-3  
RESISTOR,WW,10W,100,5%  
S19400-8251 RESISTOR,MF,1/4W,8.25K,1%  
S19400-2001 RESISTOR,MF,1/4W,2.00K,1%  
R133  
R130  
S16296-5  
S13000-46  
M19612  
T13640-24  
S15161-27  
S15128-10  
S15128-18  
TRIMMER,MT,1/2W,10K, 10%,LINEAR  
TRANSFORMER,PCB;  
CURRENT-TRANSDUCER,125-TURN  
MOV,175VRMS,120J,20MM  
TRIAC,T220,8A,800V  
VOLTAGE REF,ADJ, PRECISION,431I  
OP-AMP,QUAD, HIGH-PERF,33074  
R8  
R131  
R9  
MANUFACTURED AS:  
G3830-1B1  
R132  
N.K.  
(4 PLACES)  
R7  
R10  
N.K.  
TRI1  
(4 PLACES)  
R11  
J22  
IDENTIFICATION CODE  
B209  
T1  
R138  
R140  
R139  
R137  
PART NO.  
OCI1  
NOTES:  
N.L.  
CR2  
CR1  
C25  
N.A.  
THIS DEVICE IS SUBJECT TO DAMAGE BY  
STATIC ELECTRICITY. LINCOLN ELECTRIC TO SEE E2454  
BEFORE HANDLING.  
CAUTION:  
CAPACITORS = MFD/VOLTS  
INDUCTANCE = HENRIES  
RESISTOR = OHMS  
J20  
C26  
N.B. SNAP POWER TERMINALS INTO COMPONENT SIDE OF BOARD.  
N.C. THIS AREA TO BE COVERED ON BOTH SIDES OF BOARD (WHERE  
POSSIBLE) WITH SEALANT PRIOR TO ENCAPSULATION.  
N.D. INJECT SEALANT ITEM 8 THROUGH THE PC BOARD TO SEAL MODULE LEADS  
(16 PLACES), AND ALL COMPONENT LEADS ON THE NONO-COMPONENT  
SIDE OF THE BOARD, THAT ARE COVERED BY MODULE CASE.  
N.E. FEMALE EYELET TO BE AGAINST THE NON-COMPONENT SIDE AS SHOWN  
EYELET MUST NOT SPIN AFTER CLINCHING.  
N.F. SOLDER EYELET SO THAT SOLDER COVERS ENTIRE EYELET  
AND ALL AROUND EYELET ON COPPER SIDE ONLY.  
ITEM PART NO.  
DESCRIPTION  
QTY  
1
2
3
4
5
6
7
8
G3831-B  
M16100-44  
S23006  
M19612  
S24866  
P.C. BOARD BLANK  
1
ELECTRONIC MODULE (A1, A2)  
TERMINAL (B211,B218,B204,B205,B209)  
CURRENT TRANSDUCER (T2, T3)  
POWER TERMINAL (B201, B208)  
EYELET-FEMALE  
2
N.A.  
5
2
NO ICICLES OR SOLDER BLOBS PERMITTED.  
2
8
N.G. AFTER SOLDERING, INSPECT POWER TERMINAL CONNECTIONS  
TO ENSURE SOLDER HAS PROPERLY WET COMPONENT SIDE PAD  
ON A MINIMUM OF 3 OF THE 4 LEGS OF THE POWER TERMINAL.  
N.H. BAR MUST BE 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)  
T9147-11  
T9147-15  
E2861  
EYELET-MALE  
8
SEALANT  
5.0oz  
N.P.  
N.J. DO NOT COAT WITH ENCAPSULATION MATERIAL, TOP AND BOTTOM, .80 +/- .05” DIA.  
N.K. PC BOARD HOLES TO BE FREE OF ENCAPSULATION MATERIAL AND SEALANT  
FOR A DIAMETER OF .50” FOR THE LARGER HOLES, AND .25 FOR THE SMALLER  
HOLES, BOTH SIDES OF BOARD. (4 PLACES).  
N.L. THIS AREA TO BE COVERED ON COMPONENT SIDE OF BOARD WITH SEALANT  
PRIOR TO ENCAPSULATION. MATERIAL MUST BE APPLIED FROM TOP TO  
COMPLETELY FILL TO UNDERSIDE OF DEVICE. THEN APPLY SEALANT AROUND  
BASE OF DEVICE.  
2
MAKE PER E1911  
ENCAPSULATE WITH E1844, 3 COATS  
N.N.  
(2 PLACES)  
N.H.  
(2 PLACES)  
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” MAX.  
THIS SHEET CONTAINS PROPRIETARY INFORMATION OWNED BY THE LINCOLN ELECTRIC COMPANY AND IS NOT TO BE REPRODUCED, DISCLOSED OR USED WITHOUT THE EXPRESS WRITTEN PERMISSION OF THE LINCOLN ELECTRIC COMPANY, CLEVELAND, OHIO U.S.A.  
UNLESS OTHERWISE SPECIFIED TOLERANCE  
Chg. Sheet No.  
6-2-2000A  
"X" INFO.  
XM5626  
XA  
DESIGN INFORMATION  
REFERENCE:  
MANUFACTURING TOLERANCE PER E2056  
ON 2 PLACE DECIMALS IS .02  
EQUIPMENT TYPE:  
INVERTER WELDERS  
SWITCH P.C. BOARD ASSEMBLY  
DRAWN BY: F.V./JB  
ON 3 PLACE DECIMALS IS .002  
ON ALL ANGLES IS .5 OF A DEGREE  
SUBJECT:  
MATERIAL TOLERANCE (" ") TO AGREE  
t
SUPERSEDING:  
ENGINEER:  
WITH PUBLISHED STANDARDS.  
APPROVED:  
SCALE:  
FULL  
DATE:5-11-2000 DRAWING No.:  
G
3830-1B1  
DO NOT SCALE THIS DRAWING  
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 MIG 300  
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G-11  
G-11  
ELECTRICAL DIAGRAMS  
SCHEMATIC - SNUBBER PC BOARD  
6-2-2000  
S24761  
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.  
POWERWAVE 355/405  
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G-12  
G-12  
ELECTRICAL DIAGRAMS  
PC BOARD ASSEMBLY - SNUBBER PC BOARD  
ITEM  
C1,C2,C3,C4  
R1,R3  
REQ'D  
PART NO.  
DESCRIPTION  
4
2
2
S20500-4 CAPACITOR,PPMF,.0047,1000V,BOX  
T14648-20  
T14648-25  
1
RESISTOR,WW,5W,150,5%,SQ  
RESISTOR,WW,5W,10,5%,SQ  
R2,R4  
N.A., N.B.  
+.04  
2.90  
3
ITEM PART NO. DESCRIPTION  
QTY  
4
C3  
1
2
3
4
M19532-A  
1
1
4
4
P.C. BOARD BLANK  
B O X C P 4  
T13157-16 TAB TERMINAL  
C1  
EYELET-FEMALE  
T9147-11  
T9147-15 EYELET-MALE  
B O X C P 4  
R3  
R1  
B10  
1.92  
B1  
6
1
Q C  
.275  
.285  
NOTES:  
R .045  
∅
N.A. FEMALE EYELET TO BE AGAINST THE COPPER SIDE AS SHOWN  
BOXCP4  
C4  
EYELET MUST NOT SPIN AFTER CLINCHING.  
.105 MAX.  
CRIMP  
C2  
B O X C P 4  
N.B. SOLDER EYELET SO THAT SOLDER COVERS ENTIRE EYELET  
AND ALL AROUND EYELET ON COPPER SIDE ONLY.  
NO ICICLES OR SOLDER BLOBS PERMITTED.  
2
R2  
R4  
COPPER  
SIDE  
HEIGHT  
B20  
B30  
B40  
.55  
EYELET DETAIL  
MANUFACTURED AS:  
0
0
MAKE PER E1911  
ENCAPSULATE WITH E1844, 2 COATS  
TEST PER E3817-SN  
M19532-1A0  
+.04  
.60  
1.75  
2.90  
3.50  
IDENTIFICATION CODE  
THIS SHEET CONTAINS PROPRIETARY INFORMATION OWNED BY THE LINCOLN ELECTRIC COMPANY AND IS NOT TO BE REPRODUCED, DISCLOSED OR USED WITHOUT THE EXPRESS WRITTEN PERMISSION OF THE LINCOLN ELECTRIC COMPANY, CLEVELAND, OHIO U.S.A.  
UNLESS OTHERWISE SPECIFIED TOLERANCE  
Chg. Sheet No.  
"X" INFO.  
XM5626  
XC-UF  
DESIGN INFORMATION  
REFERENCE:  
MANUFACTURING TOLERANCE PER E2056  
ON 2 PLACE DECIMALS IS .02  
EQUIPMENT TYPE:  
INVERTER WELDERS  
SNUBBER P.C. BOARD ASSEMBLY  
6-2-2000  
DRAWN BY:  
ENGINEER:  
APPROVED:  
F.V.  
ON 3 PLACE DECIMALS IS .002  
ON ALL ANGLES IS .5 OF A DEGREE  
SUBJECT:  
SUPERSEDING:  
MATERIAL TOLERANCE (" ") TO AGREE  
t
WITH PUBLISHED STANDARDS.  
10-6-99  
SCALE:  
NONE  
DRAWING No.:  
DATE:  
19532-1  
M
DO NOT SCALE THIS DRAWING  
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.  
POWERWAVE 355/405  
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G-13  
G-13  
ELECTRICAL DIAGRAMS  
SCHEMATIC - 40 VDC BUSS PC BOARD  
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.  
POWERWAVE 355/405  
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SVM ERROR REPORTING FORM  
We need to know if there are errors in our manuals. We also value any suggestions as to  
additional tests or procedures that would make this SVM a better tool for you.  
If you discover new or different “Problems or Symptoms” that are not covered in the three col-  
umn troubleshooting chart, please share this information with us. Please include the  
machine’s code number and how the problem was resolved.  
Thank You,  
Technical Services Group  
Lincoln Electric Co.  
22801 ST. Clair Ave.  
Cleveland, Ohio 44117-1199  
FAX 216-481-2309  
SVM Number ___________________________  
Page Number if necessary__________________  
Your Company__________________________  
Your Name_____________________________  
Please give detailed description below:  
___________________________________________________________________________  
___________________________________________________________________________  
___________________________________________________________________________  
___________________________________________________________________________  
___________________________________________________________________________  
___________________________________________________________________________  
___________________________________________________________________________  
___________________________________________________________________________  
___________________________________________________________________________  
___________________________________________________________________________  
___________________________________________________________________________  
___________________________________________________________________________  
___________________________________________________________________________  
SD287 01/99  
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