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SVM156-A
October, 2001
TM
POWER WAVE 455/R
For use with machines having Code Numbers: 10675
10676
Safety Depends on You
Lincoln arc welding and cutting
equipment is designed and built
with safety in mind. However,
your overall safety can be in-
creased by proper installation . . .
and thoughtful operation on
your part. DO NOT INSTALL,
OPERATE OR REPAIR THIS
EQUIPMENT WITHOUT
VE 455/R
A
POWER
W
W
A
VE 455/R
POWER
I O
O
N
O
FF
READING THIS MANUAL AND
THE SAFETY PRECAUTIONS
CONTAINED THROUGHOUT.
And, most importantly, think
before you act and be careful.
IEC 60974-1
SERVICE MANUAL
Copyright © 2001 Lincoln Global Inc.
• World's Leader in Welding and Cutting Products •
• Sales and Service through Subsidiaries and Distributors Worldwide •
Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com
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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
products.
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
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iv
iv
SAFETY
5. Toujours porter des lunettes de sécurité dans la zone de
PRÉCAUTIONS DE SÛRETÉ
soudage. Utiliser des lunettes avec écrans lateraux dans les
zones où l’on pique le laitier.
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:
6. Eloigner les matériaux inflammables ou les recouvrir afin de
prévenir tout risque d’incendie dû aux étincelles.
Sûreté Pour Soudage A L’Arc
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.
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.
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 lev-
age, 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.
b. Faire trés attention de bien s’isoler de la masse quand on
soude dans des endroits humides, ou sur un plancher
metallique ou des grilles metalliques, principalement dans
les positions assis ou couché pour lesquelles une
grande partie du corps peut être en contact avec la
masse.
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.
c. Maintenir le porte-électrode, la pince de masse, le câble
de soudage et la machine à souder en bon et sûr état
defonctionnement.
d. Ne jamais plonger le porte-électrode dans l’eau pour le
refroidir.
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 forte-
ment toxique) ou autres produits irritants.
e. Ne jamais toucher simultanément les parties sous tension
des porte-électrodes connectés à deux machines à soud-
er parce que la tension entre les deux pinces peut être le
total de la tension à vide des deux machines.
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.
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.
2. Dans le cas de travail au dessus du niveau du sol, se pro-
téger 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.
PRÉCAUTIONS DE SÛRETÉ POUR
LES MACHINES À SOUDER À
TRANSFORMATEUR ET À
REDRESSEUR
1. Relier à la terre le chassis du poste conformement au code
de l’électricité et aux recommendations du fabricant. Le dis-
positif de montage ou la piece à souder doit être branché à
une bonne mise à la terre.
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
rayonnement de l’arc et des projections quand on soude
ou quand on regarde l’arc.
b. Porter des vêtements convenables afin de protéger la
peau de soudeur et des aides contre le rayonnement de
l‘arc.
2. Autant que possible, I’installation et l’entretien du poste
seront effectués par un électricien qualifié.
c. Protéger l’autre personnel travaillant à proximité au
soudage à l’aide d’écrans appropriés et non-inflamma-
bles.
3. Avant de faires des travaux à l’interieur de poste, la
debrancher 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,
pantalons sans revers, et chaussures montantes.
4. Garder tous les couvercles et dispositifs de sûreté à leur
place.
Mar. ‘93
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v
v
- MASTER TABLE OF CONTENTS FOR ALL SECTIONS -
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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
Electrical Diagrams..............................................................................................................Section G
Parts Manual ................................................................................................................................P-377
POWER WAVE 455/R
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Section A
Section A
TABLE OF CONTENTS
- INSTALLATION SECTION -
Installation.............................................................................................................................Section A
Technical Specifications..............................................................................................................A-2
Safety Precautions......................................................................................................................A-4
Select Suitable Location..............................................................................................................A-4
Lifting ....................................................................................................................................A-4
Stacking................................................................................................................................A-4
Machine Grounding.....................................................................................................................A-4
High Frequency Protection..........................................................................................................A-4
Input Connection.........................................................................................................................A-5
Input Fuse and Supply Wire Considerations........................................................................A-5
Input Voltage Change Over (For Multiple Input Voltage Machines Only).............................A-6
Welding with Multiple Power Waves ...........................................................................................A-6
Electrode and Work Cable Connections.....................................................................................A-7
Negative Electrode Polarity.........................................................................................................A-7
Voltage Sensing ..........................................................................................................................A-8
Work Voltage Sensing ..........................................................................................................A-9
Electrode Voltage Sensing ...................................................................................................A-9
Power Wave / Power Feed Wire Feeder Interconnections.........................................................A-9
Control Cable Specifications ................................................................................................A-9
External I/O Connector.........................................................................................................A-9
Dip Switch Settings and Locations.....................................................................................A-10
Control Board Dip Switch ...................................................................................................A-10
Feed Head Board Dip Switch.............................................................................................A-10
Devicenet/Gateway Board Dip Switch, Bank (S2)..............................................................A-11
POWER WAVE 455/R
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A-2
A-2
INSTALLATION
TECHNICAL SPECIFICATIONS - POWER WAVE 455/R (K1761-1), (K1761-2)
INPUT AT RATED OUTPUT - THREE PHASE ONLY
INPUT
VOLTS
OUTPUT
INPUT
CURRENT
AMPS
IDLE
POWER FACTOR
EFFICIENCY
@ RATED OUTPUT
CONDITIONS
POWER
@ RATED OUTPUT
(K1761-1)
208/230/460V - 60HZ
70/65/35
87/82/48
450A@38V 100%
570A@43V 60%
0.89 MIN
0.95 MIN
400A@36V 100%
500A@40V 60%
64/58/32
79/74/41
200/220/440V - 50HZ
400 Watts
MAX
88%
(K1761-2)
208/230/460/575V-60HZ
450@38V 100%
570@43V 60%
58/53/25/22
82/78/37/31
400@36V 100%
500A@40V 60%
49/45/23
67/61/31
200/220/440V - 50HZ
OUTPUT
OPEN
CIRCUIT
VOLTAGE
CURRENT
RANGE
PULSE
PULSE
PULSE AND
STT
AUXILIARY POWER
FREQUENCY VOLTAGE BACKGROUND
PARAMETERS (CIRCUIT BREAKER
PROTECTED)
RANGE
TIME RANGE
75 VDC
5 - 570
0.15 - 1000 Hz 5 - 55 VDC 100 MICRO SEC.
-3.3 SEC.
40-325 AMPS
40 VDC @10 AMPS
115VAC @10 AMPS
PROCESS CURRENT RANGES (DC)
CURRENT
MIG/MAG
FCAW
SMAW
Pulse
50-570 Average Amps
40-570 Average Amps
30-570 Average Amps
5-750 Peak Amps
STT
40-325 Average Amps
RECOMMENDED INPUT WIRE AND FUSE SIZES
INPUT
VOLTAGE /
FREQUENCY
AMPS/
DUTY
CYCLE
INPUT AMPERE
RATING ON
NAMEPLATE
TYPE 75°C
COPPER WIRE GROUND WIRE (SUPER LAG)
IN CONDUIT IN CONDUIT OR BREAKER
AWG[IEC] SIZES AWG[IEC] SIZES SIZE (AMPS)
TYPE 75°C
TYPE 75°C
(mm2)
(mm2)
(K1761-1)
208/230V - 60HZ
460V - 60HZ
200/220V - 50HZ
440V - 50HZ
208/230V - 60HZ
460V - 60HZ
200/220V - 50HZ
440V - 50HZ
450/100%
450/100%
400/100%
400/100%
570/60%
570/60%
500/60%
500/60%
70/65
35
64/58
32
87/82
48
79/74
41
4 (25)
8 (10)
4 (25)
8 (10)
4 (25)
8 (10)
4 (25)
8 (10)
8 (10)
10 (6)
8 (10)
10 (6)
6 (10)
10 (6)
8 (10)
10 (6)
90/90
45
90/80
45
110/110
70
100/100
60
(K1761-2)
208/230V - 60HZ
460V - 60HZ
575V - 60HZ
200/220V - 50HZ
440V - 50HZ
208/230V - 60HZ
460V - 60HZ
575V - 60HZ
200/220V - 50HZ
440V - 50HZ
450/100%
450/100%
450/100%
400/100%
400/100%
570/60%
570/60%
570/60%
500/60%
500/60%
58/53
25
22
49/45
23
82/78
37
31
67/61
31
4 (25)
10 (6)
10 (6)
6 (10)
10 (6)
4 (25)
8 (10)
10 (6)
8 (10)
10 (6)
8 (10)
10 (6)
10 (6)
8 (10)
10 (6)
6 (10)
10 (6)
10 (6)
8 (10)
10 (6)
70/60
35
30
70/60
30
110/100
50
40
90/80
40
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A-3
A-3
INSTALLATION
TECHNICAL SPECIFICATIONS - POWER WAVE 455/R (K1761-1), (K1761-2)
(continued)
PHYSICAL DIMENSIONS
HEIGHT
WIDTH
DEPTH
WEIGHT
(K1761-1) 247 lbs.
112 kg.
(K1761-2) 254 lbs.
115 kg.
26.10 in
663 mm
19.86 in
505 mm
32.88 in
835 mm
TEMPERATURE RANGES
OPERATING TEMPERATURE RANGE
STORAGE TEMPERATURE RANGE
-40°C to +40°C
-20°C to +40°C
POWER WAVE 455/R
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A-4
A-4
INSTALLATION
SAFETY PRECAUTIONS
CAUTION
Read this entire installation section before you
start installation.
DO NOT MOUNT OVER COMBUSTIBLE SURFACES.
Where there is a combustible surface directly under
stationary or fixed electrical equipment, that surface
shall be covered with a steel plate at least .06”(1.6mm)
thick, which shall extend not less than 5.90”(150mm)
beyond the equipment on all sides.
WARNING
ELECTRIC SHOCK can kill.
• Only qualified personnel should per-
form this installation.
• Turn the input power OFF at the dis-
connect switch or fuse box before working on this
equipment. Turn off the input power to any other equip-
ment connected to the welding system at the discon-
nect switch or fuse box before working on the equip-
ment.
LIFTING
Lift the machine by the lift bail only. The lift bail is
designed to lift the power source only. Do not attempt
to lift the Power Wave with accessories attached to it.
STACKING
• Do not touch electrically hot parts.
• Always connect the Power Wave grounding lug
(located inside the reconnect input access door) to a
proper safety (Earth) ground.
Power Wave machines can be stacked a maximum of
three high.
CAUTION
SELECT SUITABLE LOCATION
The bottom machine must always be placed on a firm,
secure, level surface. There is a danger of machines
toppling over if this precaution is not taken.
Do not use Power Waves in outdoor environments. The
Power Wave power source should not be subjected to
falling water, nor should any parts of it be submerged
in water. Doing so may cause improper operation as
well as pose a safety hazard. The best practice is to
keep the machine in a dry, sheltered area.
MACHINE GROUNDING
The frame of the welder must be grounded. A ground
Place the welder where clean cooling air can freely cir-
culate in through the rear louvers and out through the
case sides and bottom. Dirt, dust, or any foreign mate-
rial that can be drawn into the welder should be kept at
a minimum. Do not use air filters on the air intake,
because the air flow will be restricted. Failure to
observe these precautions can result in excessive
operating temperatures and nuisance shutdowns.
terminal marked with the symbol
is located inside
the reconnect/input access door for this purpose. See
your local and national electrical codes for proper
grounding methods.
HIGH FREQUENCY PROTECTION
Locate the Power Wave away from radio controlled
machinery.
Machines above code 10500 are equipped with F.A.N.
(fan as needed) circuitry. The fan runs whenever the
output is enabled, whether under loaded or open circuit
conditions. The fan also runs for a period of time
(approximately 5 minutes) after the output is disabled,
to ensure all components are properly cooled.
CAUTION
The normal operation of the Power Wave may adverse-
ly affect the operation of RF controlled equipment,
which may result in bodily injury or damage to the
equipment.
If desired, the F.A.N. feature can be disabled (causing
the fan to run whenever the power source is on). To dis-
able F.A.N., connect leads 444 and X3A together at the
output of the solid state fan control relay, located on the
back of the Control PC board enclosure. (See the
Wiring Diagram.)
POWER WAVE 455/R
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A-5
A-5
INSTALLATION
FIGURE A.1
(K1761-1) CONNECTION DIAGRAM ON CONNECTION/INPUT ACCESS DOOR
INPUT SUPPLY CONNECTION DIAGRAM
VOLTAGE=200-208V
W / L3
V / L2
U / L1
WARNING
Disconnect input power before
inspecting or servicing machine.
Do not operate with covers
removed.
Do not touch electrically live parts.
200-208V
220-230V
380-415V
440-460V
CR1
.
.
.
'A'
'A'
ELECTRIC
SHOCK
CAN KILL
.
Only qualified persons should install,
use or service this equipment.
VOLTAGE=220-230V
VOLTAGE=380-415V
VOLTAGE=440-460V
200-208V
220-230V
380-415V
440-460V
200-208V
220-230V
380-415V
440-460V
200-208V
220-230V
380-415V
440-460V
'A'
'A'
(K1761-2) CONNECTION DIAGRAM ON CONNECTION/INPUT ACCESS DOOR
INPUT SUPPLY CONNECTION DIAGRAM
VOLTAGE = 200-208V
W / L3
V / L2
U / L1
WARNING
WARNING
200-208V
220-230V
440-460V
550-575V
CR1
'A'
ELECTRIC
SHOCK
CAN KILL
VOLTAGE = 220-230V
VOLTAGE = 440-460V
VOLTAGE = 550-575V
200-208V
220-230V
440-460V
550-575V
200-208V
220-230V
440-460V
550-575V
200-208V
220-230V
440-460V
550-575V
'A'
'A'
'A'
NOTE:Turn main input power to the machine OFF before performing connection procedure. Failure to do
so will result in damage to the machine.
INPUT FUSE AND SUPPLY WIRE
CONSIDERATIONS
INPUT CONNECTION
WARNING
Refer to the Technical Specifications at the beginning
of this Installation section for recommended fuse and
wire sizes. Fuse the input circuit with the recommend-
ed super lag fuse or delay type breakers (also called
“inverse time” or “thermal/magnetic” circuit breakers).
Choose an input and grounding wire size according to
local or national electrical codes. Using fuses or circuit
breakers smaller than recommended may result in
“nuisance” shut-offs from welder inrush currents, even
if the machine is not being used at high currents.
Only a qualified electrician should connect the input
leads to the Power Wave. Connections should be made
in accordance with all local and national electrical codes
and the connection diagram located on the inside of the
reconnect/input access door of the machine. Failure to
do so may result in bodily injury or death.
Use a three-phase supply line. A 1.75 inch (45 mm)
diameter access hole for the input supply is located on
the upper left case back next to the input access door.
Connect L1, L2, L3 and ground according to the Input
Supply Connection Diagram decal located on the
inside of the input access door, or refer to Figure A.1.
POWER WAVE 455/R
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A-6
A-6
INSTALLATION
INPUT VOLTAGE CHANGE OVER
(FOR MULTIPLE INPUT VOLTAGE
MACHINES ONLY)
WELDING WITH MULTIPLE POWER
WAVES
CAUTION
Special care must be taken when more than one Power
Wave is welding simultaneously on a single part. Arc
blow and arc interference may occur or be magnified.
Welders are shipped connected for the highest input
voltage listed on the rating plate. To move this con-
nection to a different input voltage, see the diagram
located on the inside of the input access door. (Figure
A.1.) If the main reconnect switch or link position is
placed in the wrong position, the welder will not pro-
duce output power.
Each power source requires a work lead from the work
terminal to the welding fixture. Do not combine all of the
work leads into one lead. The welding travel directions
should be in the direction moving away from the work
lead as shown in Figure A.2. Connect all of the work
sense leads from each power source to the work piece
at the end of the weld.
If the Auxiliary (A) lead is placed in the wrong position,
there are two possible results. If the lead is placed in
a position higher than the applied line voltage, the
welder may not come on at all. If the auxiliary (A) lead
is placed in a position lower than the applied line volt-
age, the welder will not come on, and the two circuit
breakers in the reconnect area will open. If this occurs,
turn off the input voltage, properly connect the (A) lead,
reset the breakers, and try again.
For the best results when pulse welding, set the wire
size and wire feed speed the same for all the Power
Waves.
FIGURE A.2 – MULTIPLE POWER WAVE CONNECTIONS
TWO POWER WAVES
I ON
I ON
POWERWAVE 455/R
POWERWAVE 455/R
O OFF
O OFF
ELECTRODE
ELECTRODE
SENSE LEAD
CONNECT ALL WORK
SENSE LEADS AT THE
END OF THE JOINT
WORK LEAD
WORK LEAD
CONNECT ALL WELDING
WORK LEADS AT THE
BEGINNING OF THE JOINT
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A-7
A-7
INSTALLATION
When these parameters are identical, the pulsing fre-
quency will be the same, helping to stabilize the arcs.
Most welding applications run with the electrode being
positive (+). For those applications, connect one end of
the electrode cable to the positive (+) output terminal
on the power source (located beneath the spring
loaded output cover near the bottom of the case front).
Connect the other end of the electrode cable to the
wire drive feed plate using the stud, lockwasher, and
nut provided on the wire drive feed plate. The electrode
cable lug must be against the feed plate. Be sure the
connection to the feed plate makes tight metal-to-metal
electrical contact. The electrode cable should be sized
according to the specifications given in Table A.1.
Connect a work lead from the negative (-) power
source output terminal to the work piece. The work
piece connection must be firm and secure, especially if
pulse welding is planned.
Every welding gun requires a separate shielding gas
regulator for proper flow rate and shielding gas cover-
age.
Do not attempt to supply shielding gas for two or more
guns from only one regulator.
If an anti-spatter system is in use, each gun must have
its own anti-spatter system. See Figure A.2.
ELECTRODE AND WORK CABLE
CONNECTIONS
Connect a work lead of sufficient size and length (per
Table A.1) between the proper output terminal on the
power source and the work. Be sure the connection to
the work makes tight metal-to-metal electrical contact.
To avoid interference problems with other equipment
and to achieve the best possible operation, route all
cables directly to the work or wire feeder. Avoid exces-
sive lengths and do not coil excess cable. Do not tight-
ly bundle the electrode and work cables together.
CAUTION
Excessive voltage drops caused by poor work piece
connections often result in unsatisfactory welding per-
formance.
When welding with the STT process, use the positive
output connection labeled (STT) for STT welding. (If
desired, other welding modes can be used on this ter-
minal; however, their average output current will be lim-
ited to 325 amps.) For non-STT processes, use the
positive output connection labeled (Power Wave), so
that the full output range of the machine is available.
Use K1796 coaxial welding cables wherever possible.
Minimum work and electrode cables sizes are as
follows:
TABLE A.1
(Current (60% Duty Cycle)
MINIMUM COPPER
WORK CABLE SIZE AWG
Up To 100 Ft. Length (30 m)
CAUTION
400 Amps
500 Amps
600 Amps
2/0 (67 mm2)
3/0 (85 mm2)
3/0 (85 mm2)
Do not connect the STT and Power Wave terminals
together. Paralleling the terminals will bypass STT cir-
cuitry and severely deteriorate STT welding perfor-
mance.
When using an inverter type power source like the
Power Wave, use the largest welding (electrode and
ground) cables that are practical. At least 2/0 copper
wire - even if the average output current would not nor-
mally require it.
NEGATIVE ELECTRODE POLARITY
When negative electrode polarity is required, such as
in some Innershield applications, reverse the output
connections at the power source (electrode cable to
the negative (-) terminal, and work cable to the positive
(+) terminal).
CAUTION
When pulsing, the pulse current can reach very high
levels. Voltage drops can become excessive, leading
to poor welding characteristics, if undersized welding
cables are used.
When operating with electrode polarity negative, the
Dip switch 7 must be set to ON on the Wire Feed Head
PC Board. The default setting of the switch is OFF to
represent positive electrode polarity.
To set the Negative Polarity switch on Wire Feed Head
PC board, refer to the section DIP SWITCH
SETTINGS AND LOCATIONS.
POWER WAVE 455/R
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A-8
A-8
INSTALLATION
The sense leads connect to the Power Wave at the
four-pin connector located underneath the output ter-
minal cover. Lead 67 senses electrode voltage. Lead
21 senses work voltage.
VOLTAGE SENSING
The best arc performance occurs when the Power
Wave has accurate data about the arc conditions.
Depending upon the process, inductance within the
electrode and work lead cables can influence the volt-
age apparent at the terminals of the welder. Voltage
sense leads improve the accuracy of the arc conditions
and can have a dramatic effect on performance.
Enable the voltage sense leads as follows:
TABLE A.2
Process
Electrode Voltage
Sensing 67 lead *
Work Voltage
Sensing 21 lead
GMAW
67 lead required
21 lead optional
21 lead optional
21 lead optional
21 lead required
CAUTION
GMAW-P 67 lead required
If the voltage sensing is enabled but the sense leads
are missing or improperly connected, extremely high
welding outputs may occur.
FCAW
STT
67 lead required
67 lead required
GTAW
Voltage sense at
terminals
Voltage sense at
terminals
Do not tightly bundle the work sense lead to the work
lead.
SAW
67 lead required
21 lead optional
* The electrode voltage 67 sense lead is integral to the con-
trol cable to the wire feeder.
FIGURE A.3 – DIP SWITCH LOCATION
VE 455/R
A
W
POWER
I
O
N
O
REMOVE
FRONT
COVER
O
F
F
POWER
W
A
VE 455/R
WIRE FEED
HEAD BOARD
ON RIGHT
CONTROL
BOARD
ON LEFT
POWER WAVE 455/R
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A-9
A-9
INSTALLATION
WORK VOLTAGE SENSING
CONTROL CABLE SPECIFICATIONS
The Power Wave is shipped from the factory with the
work sense lead enabled.
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.
For processes requiring work voltage sensing, connect
the (21) work voltage sense lead from the Power Wave
to the work. Attach the sense lead to the work as close
to the weld as practical. To enable the work voltage
sensing in the Power Wave, refer to the section DIP
SWITCH SETTINGS AND LOCATIONS.
CAUTION
The use of non-standard cables, especially in lengths
greater than 25 feet, can lead to communication prob-
lems (system shutdowns), poor motor acceleration
(poor arc starting) and low wire driving force (wire feed-
ing problems).
ELECTRODE VOLTAGE SENSING
Enabling or disabling electrode voltage sensing is auto-
matically configured through software. Electrode sense
lead 67 must be connected at the wire feeder.
Lincoln control cables are copper 22 conductor cable in
a SO-type rubber jacket.
POWER WAVE / POWER FEED WIRE
FEEDER INTERCONNECTIONS
EXTERNAL I/O CONNECTOR
The Power Wave is equipped with a port for making sim-
ple input signal connections. The port is divided into
three groups: Trigger group, Cold Inch Group and
Shutdown Group. Because the Power Wave is a “slave”
on the DeviceNet network, the Trigger and Cold Inch
Groups are disabled when the DeviceNet/Gateway is
active.
Connect the control cable between the power source
and wire feeder. The wire feeder connection on the
robotic Power Wave is located under the spring loaded
output cover, near the bottom of the case front. The
control cable is keyed and polarized to prevent improp-
er connection.
For convenience sake, the electrode and control
cables can be routed behind the left or right strain
reliefs (under the spring loaded output cover), and
along the channels formed into the base of the Power
Wave, out the back of the channels, and then to the
wire feeder.
The Shutdown Group is always enabled. Shutdown 2 is
used for signaling low flow in the water cooler. Unused
shutdowns must be jumpered. Machines from the fac-
tory come with the shutdowns already jumpered. (See
Figure A.4)
FIGURE A.4 – INPUT PORT CONNECTIONS
Output connections on some Power Waves are made
via 1/2-13 threaded output terminals located beneath
the spring-loaded output cover at the bottom of the
case front. On machines which carry the CE mark, out-
put connections are made via Twist-Mate receptacles,
also located beneath the spring-loaded output cover at
the bottom of the case front.
A work lead must be run from the negative (-) power
source output connection to the work piece. The work
piece connection must be firm and secure, especially if
pulse welding is planned.
4
9
10
11
7
8
1
3
6
2
5
12
CAUTION
Excessive voltage drops at the work piece connection
often result in unsatisfactory pulse welding perfor-
mance.
A
D
G
B
E
H
C
F
I
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A-10
A-10
INSTALLATION
DIP SWITCH SETTINGS AND LOCATIONS
CONTROL BOARD DIP SWITCH:
DIP switches on the PC boards allow for custom con-
figuration of the Power Wave. Access the DIP switch-
es as follows:
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
WARNING
ELECTRIC SHOCK CAN KILL.
• Do not touch electrically live parts or
electrodes with your skin or wet cloth-
ing.
• Insulate yourself from the work and
switch 8
work sense lead
ground.
off
on
work sense lead not connected
work sense lead connected
• Always wear dry insulating gloves.
FEED HEAD BOARD DIP SWITCH:
• Turn off power at the disconnect 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 = negative polarity switch
switch 8 = high speed gear
• Remove the top four screws securing the front access
panel.
• Loosen, but do not completely remove, the bottom
two screws holding the access panel.
• Open the access panel, allowing the weight of the
panel to be carried by the bottom two screws. Make
sure to prevent the weight of the access panel from
hanging on the harness.
• Adjust the DIP switches as necessary. Using a pen-
cil or other small object, slide the switch left for the
ON position or to the right for the OFF position, as
appropriate.
switch 7
electrode polarity
positive
off
on
negative
• Replace the panel and screws and restore power.
switch 8
wire drive gear
low speed gear
high speed gear
FEED HEAD
BOARD
(LOCATED IN
CONTROL
BOX BEHIND
CASE FRONT)
CONTROL BOARD
(LOCATED IN
CONTROL BOX
BEHIND CASE
FRONT)
off
on
DEVICENET/
GATEWAY
CASE FRONT
BANK S1
BANK S2
BOARD
(LOCATED
BEHIND
FRONT
OPENING IN
CASE FRONT
TO ACCESS
CONTROL
BOX
COVER)
FRONT
COVER
LEFT
RIGHT
POWER WAVE 455/R
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A-11
A-11
INSTALLATION
DEVICENET/GATEWAY BOARD
DIP SWITCH, BANK (S2):
switch 1,2 = configure the baud rate
for DeviceNET
Prior to S24958-6 software
switch 1
switch 2
baud rate
off
on
off
on
off
off
on
on
-------
125K
250K
500
S24958-6 and later software
switch 1
switch 2
baud rate
125K
off
off
on
on
off
on
off
on
250K
500K
500K
Programmable value. Consult local Lincoln Technical
representative.
switch 5 = reserved for future use
switch 6 = reserved for future use
switch 7 = reserved for future use
switch 8 = reserved for future use
POWER WAVE 455/R
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A-12
A-12
NOTES
POWER WAVE 455/R
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Section B-1
Section B-1
TABLE OF CONTENTS
- OPERATION SECTION -
Operation...............................................................................................................................Section B
Safety Precautions......................................................................................................................B-2
Graphic Symbols.........................................................................................................................B-3
General Description ....................................................................................................................B-4
Design Features and Advantages ........................................................................................B-4
Recommended Processes and Equipment.................................................................................B-5
Recommended Processes....................................................................................................B-5
Recommended Equipment ...................................................................................................B-5
Required Equipment.............................................................................................................B-5
Limitations.............................................................................................................................B-5
Duty Cycle and Time Period.................................................................................................B-5
Case Front Controls....................................................................................................................B-6
Welding Mode Descriptions ........................................................................................................B-7
Constant Voltage Welding ....................................................................................................B-7
Pulse Welding.......................................................................................................................B-8
STT Welding.........................................................................................................................B-9
POWER WAVE 455/R
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B-2
B-2
OPERATION
SAFETY PRECAUTIONS
Read this entire section of operating instructions
before operating the machine.
WARNING
ELECTRIC SHOCK can kill.
• Unless using cold feed feature, when
feeding with gun trigger, the electrode and
drive mechanism are always electrically
energized and could remain energized
several seconds after the welding ceases.
• Do not touch electrically live parts or electrodes with
your skin or wet clothing.
• Insulate yourself from the work and ground.
• Always wear dry insulating gloves.
FUMES AND GASES can be
dangerous.
• Keep your head out of fumes.
• Use ventilation or exhaust to remove
fumes from breathing zone.
WELDING SPARKS can cause
fire or explosion.
• Keep flammable material away.
• Do not weld on containers that have held
combustibles.
ARC RAYS can burn.
• Wear eye, ear, and body protection.
Observe additional guidelines detailed in the beginning
of this manual.
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B-3
B-3
OPERATION
GRAPHIC SYMBOLS THAT APPEAR ON
THIS MACHINE OR IN THIS MANUAL
SMAW
INPUT POWER
ON
GMAW
FCAW
GTAW
OFF
HIGH TEMPERATURE
MACHINE STATUS
CIRCUIT BREAKER
WIRE FEEDER
POSITIVE OUTPUT
NEGATIVE OUTPUT
3 PHASE INVERTER
INPUT POWER
THREE PHASE
DIRECT CURRENT
OPEN CIRCUIT VOLT-
AGE
U
U
U
I
0
1
2
INPUT VOLTAGE
OUTPUT VOLTAGE
INPUT CURRENT
OUTPUT CURRENT
1
I
2
PROTECTIVE
GROUND
WARNING OR
CAUTION
POWER WAVE 455/R
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B-4
B-4
OPERATION
DESIGN FEATURES AND ADVANTAGES
GENERAL DESCRIPTION
• Designed to the IEC 974-1 Standard.
The Power Wave power source is designed to be a part
of
a
modular, multi-process welding system.
• Power Wave 455 multiple process output ranges:
5 - 570 amps
Depending on configuration, it can support constant
current, constant voltage, Surface Tension Transfer
and pulse welding modes.
• Easy access for input connections. Connections are
simple strip and clamp (no lugs required).
The Power Wave power source is designed to be used
with the family of Power Feed wire feeders, operating
as a system. Each component in the system has spe-
cial circuitry to “talk with” the other system compo-
nents, so each component (power source, wire feeder,
electrical accessories) knows what the other is doing at
all times. The components communicate using ArcLink
protocol.
• F.A.N. (Fan As Needed). Cooling fan runs only when
necessary (above Code 10500 only, and all STT
machines).
• Modular construction for easy servicing.
• Thermostatically protected.
• Electronic over-current protection.
• Input over-voltage protection.
Robotic systems can communicate with other industri-
al machines via DeviceNET protocol. The result is a
highly intrigated and flexible welding cell.
• Utilizes digital signal processing and microprocessor
control.
The Power Wave 455/R is a high performance, digital-
ly controlled inverter welding power source capable of
complex, high-speed waveform control. Properly
equipped, it can support the GMAW, GMAW-P, FCAW,
GTAW and STT processes. It carries an output rating of
either 450 amps, 38 volts; or 400 amps, 36 volts (both
at 100% duty cycle), depending on input voltage and
frequency. The Surface Tension transfer process (STT)
is supported at currents up to 325 amps, at 100% duty
cycle.
• Simple, reliable input voltage change over.
• All system components communicate and transfer
information.
• Auto device recognition simplifies accessory cable
connections.
If the duty cycle is exceeded, a thermostat will shut off
the output until the machine cools to a reasonable
operating temperature.
POWER WAVE 455/R
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B-5
B-5
OPERATION
REQUIRED EQUIPMENT
RECOMMENDED PROCESSES
AND EQUIPMENT
• PF-10/R Wire Feeder, K1780-1
• Control Cables (22 pin to 22 pin), K1795-10,-25,-50,-
RECOMMENDED PROCESSES
100
• Control Cables (for use on FANUC robot arm, 22 pin
to 14 pin, 10 ft), K1804-1
The Power Wave 455/R can be set up in a number of
configurations, some requiring optional equipment or
welding programs. Each machine is factory prepro-
grammed with multiple welding procedures, typically
including GMAW, GMAW-P, FCAW, GTAW and STT
for a variety of materials, including mild steel, stainless
steel, cored wires, and aluminum. The STT process
supports mild steel and stainless steel welding.
• Control Cables (for use on FANUC robot arm, 22 pin
to 14 pin, 18 in), K1805-1
• Control Cables (for use on FANUC robot arm, 22 pin
to 14 pin, 18 in), K1804-2
LIMITATIONS
The Power Wave 455/R is recommended only for
automatic or mechanized applications such as robotic
welding.
• The Power Wave 455/R is not suitable for SMAW,
CAC-A or other processes not listed.
• Power Waves are not to be used in outdoor environ-
ments.
RECOMMENDED EQUIPMENT
Automatic Operation
• Only ArcLink Power Feed wire feeders and user
interfaces may be used. Other Lincoln wire feeders
or non-Lincoln wire feeders cannot be used.
All welding programs and procedures are set through
software for the robotic Power Wave. FANUC robots
equipped with RJ-3 controllers may communicate
directly with the Power Wave. Other pieces of equip-
ment such as PLCs or computers can communicate
with the Power Wave using DeviceNET. All wire weld-
ing processes require a robotic Power Feed wire feeder.
DUTY CYCLE AND TIME PERIOD
The Power Feed wire feeders are capable of welding at
a 100% duty cycle (continuous welding). The power
source will be the limiting factor in determining system
duty cycle capability. Note that the duty cycle is based
upon a ten minute period. A 60% duty cycle represents
6 minutes of welding and 4 minutes of idling in a ten
minute period.
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B-6
B-6
OPERATION
CASE FRONT CONTROLS
3. HIGH TEMPERATURE LIGHT (thermal overload):
A yellow light that comes on when an over tem-
perature situation occurs. Output is disabled until
the machine cools down. When cool, the light
goes out and output is enabled.
All operator controls and adjustments are located on
the case front of the Power Wave. (See Figure B.1)
1. POWER SWITCH: Controls input power to the
Power Wave.
2. STATUS LIGHT: A two color light that indicates sys-
tem errors. Normal operation is a steady green
light. Error conditions are indicated, per Table B.1.
4. 10 AMP WIRE FEEDER CIRCUIT BREAKER:
Protects 40 volt DC wire feeder power supply.
5. 10 AMP AUXILIARY POWER CIRCUIT BREAKER:
Protects 115 volt AC case front receptacle auxil-
iary supply.
NOTE: The robotic Power Waves’ status light will flash
green, and sometimes red and green, for up to
one minute when the machine is first turned on.
This is a normal situation as the machine goes
through a self test at power up.
6. LEAD CONNECTOR S2 (SENSE LEAD)
7. 5-PIN ARC LINK S1
TABLE B.1
8. 5-PIN DEVICENET CONNECTOR S5
9. I / O CONNECTOR
Light
Meaning
Condition
10. NEGATIVE OUTPUT TERMINAL
11. INTERFACE CONNECTOR S6
12. STT TERMINAL
Steady
Green
System OK. Power source
communicating normally with
wire feeder and its components.
Blinking
Green
Normal for first 1-10 seconds
after power is turned on.
13. POSITIVE OUTPUT TERMINAL
14. AUXILIARY OUTPUT
Alternating
Green
and Red
Non-recoverable system fault.
Must turn power source off, find
source of error, and turn power
back on to reset. See
Troubleshooting Guide.
Steady
Red
See Troubleshooting Guide.
FIGURE B.1 – POWER WAVE CASE FRONT CONTROLS
2
3
I ON
O OFF
1
6
7
POWERWAVE 455/R
8
9
11
12
13
10
5
14
4
POWER WAVE 455/R
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B-7
B-7
OPERATION
WELDING MODE DESCRIPTIONS
CONSTANT VOLTAGE WELDING
For each wire feed speed, a corresponding voltage is
preprogrammed into the machine through special soft-
ware at the factory. The preprogrammed voltage is the
best average voltage for a given wire feed speed. With
synergic programs, when the wire feed speed changes,
the Power Wave will automatically adjust the corre-
sponding voltage.
Wave control adjusts the inductance of the waveshape.
(This adjustment is often referred to as "pinch". In-
ductance is inversely proportional to pinch.) Increasing
wave control greater than 0 results in a harsher, colder
arc, while decreasing the wave control to less than 0
provides a softer, hotter arc. (See Figure B.2.)
FIGURE B.2 – CV WAVE CONTROL CHARACTERISTICS
Wave Control +10.0
Wave Control 0.00
Wave Control -10.0
Current
Time
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B-8
B-8
OPERATION
PULSE WELDING
The Power Wave utilizes “adaptive control” to compen-
sate for changes in electrical stick-out while welding.
(Electrical stick-out is the distance from the contact tip
to the work piece.) The Power Wave waveforms are
optimized for a 0.75" (19mm) stick-out. The adaptive
behavior supports a range of stickouts from 0.50"
(13mm) to 1.25" (32mm). At very low or high wire feed
speeds, the adaptive range may be less due to reach-
ing the physical limitations of the welding process.
Pulse welding procedures are set by controlling an
overall “arc length” variable. When pulse welding, the
arc voltage is highly dependent upon the waveform.
The peak current, background current, rise time, fall
time and pulse frequency all affect the voltage. The
exact voltage for a given wire feed speed can only be
predicted when all the pulsing waveform parameters
are known. Using a preset voltage becomes impracti-
cal, and instead the arc length is set by adjusting “trim.”
Wave control in pulse programs usually adjusts the
focus or shape of the arc. Wave control values greater
than 0 increase the pulse frequency while decreasing
the background current, resulting in a tight, stiff arc
best for high speed sheet metal welding. Wave control
values less than 0 decrease the pulse frequency while
increasing the background current for a soft arc good
for out-of-position welding. (See Figure B.3.)
Trim adjusts the arc length and ranges from 0.50 to
1.50, with a nominal value of 1.00. Trim values greater
than 1.00 increase the arc length, while values less
than 1.00 decrease the arc length.
Most pulse welding programs are synergic. As the wire
feed speed is adjusted, the Power Wave will automati-
cally recalculate the waveform parameters to maintain
similar arc properties.
FIGURE B.3 – PULSE WAVE CONTROL CHARACTERISTICS
Wave Control -10.0
Wave Control 0.00
Wave Control +10.0
Current
Time
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B-9
B-9
OPERATION
STT WELDING
Trim in the STT mode adjusts the tailout and back-
ground portion of the waveform. Trim values greater
than 1.0 add more energy to the weld and make the
weld puddle hotter; trim values less than 1.0 reduce
energy to weld. A nominal value of 1.0 will work for
most applications. (See Figure B.4.)
The pictures illustrate the waveshape of current for the
process. They are not drawn to scale, and are intend-
ed only for the purpose of showing how the variables
affect the waveform.
FIGURE B.4 – STT TRIM CONTROL CHARACTERISTICS
Trim 1.50
Trim 1.00
Trim 0.50
Current
Time
For most programs, peak current is adjusted by wave
control values. A value of +10.0 maximizes the peak
current, while a wave control of -10.0 minimizes peak
current. In general, the peak current is proportional to
torch arc length. (See Figure B.5.)
NOTE: The ranges on Wave Control and Trim are
dependent on the weld programs. The values
shown are typical ranges.
FIGURE B.5 – STT WAVE CONTROL CHARACTERISTICS
Wave Control +10.0
Wave Control 0.00
Wave Control -10.0
Current
Time
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B-10
B-10
NOTES
POWER WAVE 455/R
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Section C-1
Section C-1
TABLE OF CONTENTS
- ACCESSORIES SECTION -
Accessories ..........................................................................................................................Section C
Optional Equipment ....................................................................................................................C-2
Factory Installed ...................................................................................................................C-2
Field Installed .......................................................................................................................C-2
POWER WAVE 455/R
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C-2
C-2
ACCESSORIES
OPTIONAL EQUIPMENT
FACTORY INSTALLED
The water cooler is designed to cool only one welding
gun and should be not used to cool multiple guns or
other devices.
There are no factory installed options available for the
Power Wave 455R.
FIELD INSTALLED
Water cooler manufacturers often specify additives
to the coolant such as fungicides or alkalies. Follow
the manufacturers’ recommendations to achieve
proper operation and long lifetime without clogging.
•
Gas Guard Regulator (K659-1)
The Gas Guard regulator is available as an option-
al accessory for the Power Feed Robotic wire drive
unit. Install the 5/8-18 male outlet on the regulator
to the proper 5/8-18 female gas inlet on the back
panel of the wire drive. Secure the fitting with the
flow adjuster key at the top.
•
Water Flow Sensor (K1536-1)
Water cooled guns can be damaged very quickly if
they are used even momentarily without water flow-
ing. Recommend practice is to install a water flow
sensor such as on the water return line of the torch.
When fully integrated into the welding system, the
sensor will prevent welding if no water flow is pre-
sent.
•
•
Voltage Sense Leads (K940-10, -25 or -50)
The voltage sense leads connect at the front of the
machine. (See Figure A.2.)
Power Wave Water Cooler (K1767-1)*
•
•
Dual Cylinder Undercarriage, K1570-1*
Coaxial Welding Cable, K1796
The K1767-1 is the recommended water cooler for
the Power Wave. Incorporated into the cooler is an
automatic flow sensor to detect low coolant flow. In
the event of a low flow condition, a fault signal is
sent to the Power Wave, and welding output auto-
matically stops to protect the torch.
*The Dual Cylinder Undercarriage, K1570-1, is not
compatible in combination with the Power Wave
Water Cooler K1767-1.
POWER WAVE 455/R
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Section D-1
Section D-1
TABLE OF CONTENTS
- MAINTENANCE SECTION -
Maintenance..........................................................................................................................Section D
Safety Precautions......................................................................................................................D-2
Routine and Periodic Maintenance.............................................................................................D-2
Main Assembly (Exploded View) ...............................................................................................D-3
POWER WAVE 455/R
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D-2
D-2
MAINTENANCE
PERFORM THE FOLLOWING DAILY:
SAFETY PRECAUTIONS
WARNING
1. Check that no combustible materials are in the
welding or cutting area or around the machine.
2. Remove any debris, dust, dirt, or materials that
could block the air flow to the machine for cooling.
ELECTRIC SHOCK can kill.
• Only Qualified personnel should
perform this maintenance.
3. Inspect the electrode cables for any slits or punc-
tures in the cable jacket, or any condition that
would affect the proper operation of the machine.
• Turn the input power OFF at the
disconnect switch or fuse box
before working on this equipment.
PERFORM PERIODICALLY:
•
Do not touch electrically hot parts.
Clean the inside of the machine with a low pressure air
stream. Clean the following parts. Refer to Figure
D.1.
• Transformer and output rectifier assembly.
• Electrode and work cable connections.
• PC board connections..
ROUTINE AND PERIODIC
MAINTENANCE
1. Disconnect input AC power supply lines to the
machine before performing periodic maintenance,
tightening, cleaning, or replacing parts. See
Figure D.1.
• Intake and outlet louvers on the machine case.
• Any obvious accumulations of dirt within the
machine.
• Fan Assembly.
NOTE: The fan motor has sealed bearings which
require no maintenance.
POWER WAVE 455/R
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D-3
D-3
MAINTENANCE
FIGURE D.1 – MAIN ASSEMBLY (EXPLODED VIEW)
7
7
1
7
3
4
2
2
6
5
1. CASE FRONT ASSEMBLY
2. TRANSFORMER AND OUTPUT
RECTIFIER ASSEMBLY
3. INPUT ASSEMBLY
2
4. CONTROL BOX AND VERTICAL
DIVIDER ASSEMBLY
5. BASE, LIFT BAIL AND FAN
ASSEMBLY
6. SWITCH BOARD HEATSINK
ASSEMBLY
7. CASE PARTS
POWER WAVE 455/R
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D-4
D-4
NOTES
POWER WAVE 455/R
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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 Voltage and Precharge ......................................................................................................E-3
Switch Boards and Main Transformer.........................................................................................E-4
DC Bus Board, Power Board, Feed Head Board, Gateway Board
and Voltage Sense Board ...........................................................................................................E-5
Control Board..............................................................................................................................E-7
Output Rectifier, Output Choke and STT Chopper Board ..........................................................E-8
Thermal Protection, Protective Circuits, Over Current Protection
and Under/Over Voltage Protection ............................................................................................E-9
General Description of STT (Surface Tension Transfer) Process.............................................E-10
Insulated Gate Bipolar Transistor (IGBT) Operation.................................................................E-11
Pulse Width Modulation ............................................................................................................E-12
FIGURE E.1 – BLOCK LOGIC DIAGRAM
IGBT DRIVE
FROM
CONTROL
BOARD
CT CURRENT
TO CONTROL
BOARD
MAIN
TRANSFORMER
POWER WAVE 455/R
OUTPUT DIODES
D1 -D4
ELECTRODE
TERMINAL
CAP. V/F
FEEDBACK
+
LEFT
SWITCH
BOARD
INPUT
CR1
+20 VDC FROM
POWER BOARD
RECTIFIER
STT
ELECTRODE
TERMINAL
CURRENT
TRANSDUCER
IGBT DRIVE
FROM
CONTROL
BOARD
RECONNECT
SWITCH
STT CHOPPER
BOARD
CT CURRENT
TO CONTROL
BOARD
+
SW1
RIGHT
SWITCH
BOARD
STT
DRIVE
CAP. V/F
FEEDBACK
CURRENT
TRANSDUCER
WORK
TERMINAL
OUTPUT
CHOKE
67A
S1
INPUT
BOARD
C
U
R
R
VOLT
SENSE
BOARD
67B
S6
VOLTAGE SENSE
OUTPUT
S
T
T
CONTACTOR AND PRECHARGE
CONTROL SIGNALS FROM
CONTROL BOARD
DEVICE NET
S5
TO
E
TO
LEFT
S.B.
RIGHT
N
VOLTAGE SENSE SELECT
ARC LINK
S.B.
T
F
B
CONNECTION
TO
ROBOT
GATEWAY
BOARD
F
B
2
4
V
A
C
FROM CONTROL
BOARD
40 VDC
FEED
HEAD
BOARD
40 VDC
AUX
RECONNECT
TO FAN RELAY
IGBT
DRIVES
115 VAC
CONTACTOR AND
PRECHARGE
RELAY
FAN
ARC LINK
CONTROL SIGNALS
115 VAC
+5V RS232
THERMOSTATS
CONTROL
BOARD
+5 V ARC LINK
65 VDC
52 VAC
CONNECTION
TO WIRE
DRIVE
S6
S2 WORK
SENSE
POWER
BOARD
+5V SPI
DC
BUS
BOARD
BUS BOARD
RECTIFIER
T1
+15V SPI
+5 V
S3
RS232
40 VDC
40 VDC
+15 V
-15 V
230 VAC
WATER
COOLER
LEFT S.B.
CAP. V/F
RIGHT S.B.
CAP. V/F
40 VDC
+20 VDC
TO
CHOPPER
BOARD
ARC LINK
WIRE
FEEDER
RECP.
115 VAC
RECP.
S1
115 VAC
RIGHT CT
CURRENT
FB
LEFT CT
CURRENT
FB
T2
STATUS THERMAL
LIGHT LIGHT
POWER WAVE 455/R
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E-2
E-2
THEORY OF OPERATION
FIGURE E.2 – INPUT VOLTAGE AND PRECHARGE
IGBT DRIVE
FROM
CONTROL
BOARD
CT CURRENT
TO CONTROL
BOARD
MAIN
TRANSFORMER
POWER WAVE 455/R
OUTPUT DIODES
D1 -D4
ELECTRODE
TERMINAL
CAP. V/F
FEEDBACK
+
LEFT
SWITCH
BOARD
INPUT
CR1
+20 VDC FROM
POWER BOARD
RECTIFIER
STT
ELECTRODE
TERMINAL
CURRENT
TRANSDUCER
IGBT DRIVE
FROM
CONTROL
BOARD
RECONNECT
SWITCH
STT CHOPPER
BOARD
CT CURRENT
TO CONTROL
BOARD
+
SW1
RIGHT
SWITCH
BOARD
STT
DRIVE
CAP. V/F
FEEDBACK
CURRENT
TRANSDUCER
WORK
TERMINAL
OUTPUT
CHOKE
67A
S1
INPUT
BOARD
C
U
R
R
VOLT
SENSE
BOARD
67B
S6
VOLTAGE SENSE
OUTPUT
S
T
T
CONTACTOR AND PRECHARGE
CONTROL SIGNALS FROM
CONTROL BOARD
DEVICE NET
S5
TO
E
TO
LEFT
S.B.
RIGHT
N
VOLTAGE SENSE SELECT
ARC LINK
S.B.
T
F
B
CONNECTION
TO
ROBOT
GATEWAY
BOARD
F
B
2
4
V
A
C
FROM CONTROL
BOARD
40 VDC
FEED
HEAD
BOARD
40 VDC
AUX
RECONNECT
TO FAN RELAY
IGBT
DRIVES
115 VAC
CONTACTOR AND
PRECHARGE
RELAY
FAN
ARC LINK
CONTROL SIGNALS
115 VAC
+5V RS232
THERMOSTATS
CONTROL
BOARD
+5 V ARC LINK
65 VDC
52 VAC
CONNECTION
TO WIRE
DRIVE
S6
S2 WORK
SENSE
POWER
BOARD
+5V SPI
DC
BUS
BOARD
BUS BOARD
RECTIFIER
T1
+15V SPI
+5 V
S3
RS232
40 VDC
40 VDC
+15 V
-15 V
230 VAC
WATER
COOLER
LEFT S.B.
CAP. V/F
RIGHT S.B.
CAP. V/F
40 VDC
+20 VDC
TO
CHOPPER
BOARD
ARC LINK
WIRE
FEEDER
RECP.
115 VAC
RECP.
S1
115 VAC
RIGHT CT
CURRENT
FB
LEFT CT
CURRENT
FB
T2
STATUS THERMAL
LIGHT LIGHT
GENERAL DESCRIPTION
The Power Wave 455/R power source is designed to
be a part of a modular, multi-process welding system.
It is a high performance, digitally controlled inverter
welding power source capable of complex, high-speed
waveform control. Depending upon configuration, it
can support constant current, constant voltage, surface
tension transfer and pulse welding modes. Each
machine is factory preprogrammed with multiple weld-
ing procedures. Typically these procedures include
GMAW, GMAW-P, FCAW, GTAW and STT (Surface
Tension Transfer) for a variety of materials such as
mild steel, stainless steel, cored wires and aluminum.
The STT process supports mild steel and stainless
steel welding.
The Power Wave 455/R has an output rating of either
450 amps at 38 volts or 400 amps at 36 volts. The two
output ratings are dependent upon input voltage and
frequency. Both have a duty cycle of 100%. The STT
process is rated at currents up to 325 amps at a 100%
duty cycle.
NOTE: Unshaded areas of Block Logic Diagram are the subject of discussion.
POWER WAVE 455/R
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E-3
E-3
THEORY OF OPERATION
INPUT VOLTAGE AND PRECHARGE
the precharge or "soft start" sequence, these two phas-
es are current limited by the Input Board. The AC input
voltage is rectified, and the resultant DC voltage is
applied through the reconnect switches to the input
capacitors located on the right and left switch boards.
The Control Board monitors the voltage across the
capacitors. When the capacitors have charged to an
acceptable level, the Control Board signals the Input
Board to energize the main input contactor, making all
three phases of input power, without current limiting,
available to the input capacitors. At this point the
Power Wave 455/R is in the "Run Mode" of operation.
If the capacitors become undervoltaged, overvoltaged,
or unbalanced, the Control Board will signal the Input
Board to de-energize the main input contactor, and the
Power Wave 455/R will be disabled. See Figure E.2.
The Power Wave 455/R can be connected for a variety
of three-phase input voltages. Refer to Figure E.2.
The initial input power is applied to the Power Wave
455/R through a line switch located on the front of the
machine. Two phases of the three-phase input power
are applied to the Input Board and both auxiliary trans-
formers. The various secondary voltages developed
by transformer T1 are applied to the Input Board, the
fan motor (via a control relay) and the Bus Board recti-
fier. The 65VDC produced from the Bus Board rectifi-
er is used by the Bus Board to provide various DC volt-
ages for the Power Board, the Feed Head Board and
the wire feeder receptacle. The 115/230VAC devel-
oped on the secondary of auxiliary transformer T2 is
applied to the 115VAC receptacle and to the water
cooler receptacle.
The two phases that are connected to the Input Board,
through the input line switch SW1, are connected to the
input rectifier through the CR1 precharge relay. During
POWER WAVE 455/R
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E-4
E-4
THEORY OF OPERATION
FIGURE E.3 - SWITCH BOARDS AND MAIN TRANSFORMER
IGBT DRIVE
FROM
CONTROL
BOARD
CT CURRENT
TO CONTROL
BOARD
MAIN
TRANSFORMER
POWER WAVE 455/R
OUTPUT DIODES
D1 -D4
ELECTRODE
TERMINAL
CAP. V/F
FEEDBACK
+
LEFT
SWITCH
BOARD
INPUT
CR1
+20 VDC FROM
POWER BOARD
RECTIFIER
STT
ELECTRODE
TERMINAL
CURRENT
TRANSDUCER
IGBT DRIVE
FROM
CONTROL
BOARD
RECONNECT
SWITCH
STT CHOPPER
BOARD
CT CURRENT
TO CONTROL
BOARD
+
SW1
RIGHT
SWITCH
BOARD
STT
DRIVE
CAP. V/F
FEEDBACK
CURRENT
TRANSDUCER
WORK
TERMINAL
OUTPUT
CHOKE
67A
S1
INPUT
BOARD
C
U
R
R
VOLT
SENSE
BOARD
67B
S6
VOLTAGE SENSE
OUTPUT
S
T
T
CONTACTOR AND PRECHARGE
CONTROL SIGNALS FROM
CONTROL BOARD
DEVICE NET
S5
TO
E
TO
LEFT
S.B.
RIGHT
N
VOLTAGE SENSE SELECT
ARC LINK
S.B.
T
F
B
CONNECTION
TO
ROBOT
GATEWAY
BOARD
F
B
2
4
V
A
C
FROM CONTROL
BOARD
40 VDC
FEED
HEAD
BOARD
40 VDC
AUX
RECONNECT
TO FAN RELAY
IGBT
DRIVES
115 VAC
CONTACTOR AND
PRECHARGE
RELAY
FAN
ARC LINK
CONTROL SIGNALS
115 VAC
+5V RS232
THERMOSTATS
CONTROL
BOARD
+5 V ARC LINK
65 VDC
52 VAC
CONNECTION
TO WIRE
DRIVE
S6
S2 WORK
SENSE
POWER
BOARD
+5V SPI
DC
BUS
BOARD
BUS BOARD
RECTIFIER
T1
+15V SPI
+5 V
S3
RS232
40 VDC
40 VDC
+15 V
-15 V
230 VAC
WATER
COOLER
LEFT S.B.
CAP. V/F
RIGHT S.B.
CAP. V/F
40 VDC
+20 VDC
TO
CHOPPER
BOARD
ARC LINK
WIRE
FEEDER
RECP.
115 VAC
RECP.
S1
115 VAC
RIGHT CT
CURRENT
FB
LEFT CT
CURRENT
FB
T2
STATUS THERMAL
LIGHT LIGHT
SWITCH BOARDS AND MAIN
TRANSFORMER
There are two switch boards in the Power Wave 455/R
machine. Each contains an input capacitor and insu-
lated gate bipolar transistor (IGBT) switching circuitry.
Refer to Figure E.3. When the machine reconnect
switches are configured for a lower input voltage
(below 300VAC), the input capacitors are connected in
parallel. When the machine is configured for higher
input voltages (300VAC and above), the input capaci-
tors are connected in series.
Each switch board feeds current to a separate, oppo-
sitely 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
switch boards induce an AC square wave output signal
at the secondary of the main transformer. Current
transformers located on the switch boards monitor the
primary currents. If the primary currents become
abnormally high, the Control Board will shut off the
IGBTs, thus disabling the machine’s output. The DC
current flow through each primary winding is clamped
back to each respective input capacitor when the
IGBTs are turned off. This is needed due to the induc-
tance of the transformer primary windings. The firing of
the two switch boards occurs during halves of a 50-
microsecond interval, creating a constant 20 KHZ out-
put.
When the input capacitors are fully charged, they act
as power supplies for the IGBT switching circuits. The
insulated gate bipolar transistors switch the DC power
from the input capacitors "on and off," thus supplying
pulsed DC current to the main transformer primary
windings. See IGBT OPERATION DISCUSSION AND
DIAGRAMS in this section.
NOTE: Unshaded areas of Block Logic Diagram are the subject of discussion.
POWER WAVE 455/R
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E-5
E-5
THEORY OF OPERATION
FIGURE E-4 – DC BUS BOARD, POWER BOARD, FEED HEAD BOARD,
GATEWAY BOARD AND VOLTAGE SENSE BOARD
IGBT DRIVE
FROM
CONTROL
BOARD
CT CURRENT
TO CONTROL
BOARD
MAIN
TRANSFORMER
POWER WAVE 455/R
OUTPUT DIODES
D1 -D4
ELECTRODE
TERMINAL
CAP. V/F
FEEDBACK
+
LEFT
SWITCH
BOARD
INPUT
CR1
+20 VDC FROM
POWER BOARD
RECTIFIER
STT
ELECTRODE
TERMINAL
CURRENT
TRANSDUCER
IGBT DRIVE
FROM
CONTROL
BOARD
RECONNECT
SWITCH
STT CHOPPER
BOARD
CT CURRENT
TO CONTROL
BOARD
+
SW1
RIGHT
SWITCH
BOARD
STT
DRIVE
CAP. V/F
FEEDBACK
CURRENT
TRANSDUCER
WORK
TERMINAL
OUTPUT
CHOKE
67A
S1
INPUT
BOARD
C
U
R
R
VOLT
SENSE
BOARD
67B
S6
VOLTAGE SENSE
OUTPUT
S
T
T
CONTACTOR AND PRECHARGE
CONTROL SIGNALS FROM
CONTROL BOARD
DEVICE NET
S5
TO
E
TO
LEFT
S.B.
RIGHT
N
VOLTAGE SENSE SELECT
ARC LINK
S.B.
T
F
B
CONNECTION
TO
ROBOT
GATEWAY
BOARD
F
B
2
4
V
A
C
FROM CONTROL
BOARD
40 VDC
FEED
HEAD
BOARD
40 VDC
AUX
RECONNECT
TO FAN RELAY
IGBT
DRIVES
115 VAC
CONTACTOR AND
PRECHARGE
RELAY
FAN
ARC LINK
CONTROL SIGNALS
115 VAC
+5V RS232
THERMOSTATS
CONTROL
BOARD
+5 V ARC LINK
65 VDC
52 VAC
CONNECTION
TO WIRE
DRIVE
S6
S2 WORK
SENSE
POWER
BOARD
+5V SPI
DC
BUS
BOARD
BUS BOARD
RECTIFIER
T1
+15V SPI
+5 V
S3
RS232
40 VDC
40 VDC
+15 V
-15 V
230 VAC
WATER
COOLER
LEFT S.B.
CAP. V/F
RIGHT S.B.
CAP. V/F
40 VDC
+20 VDC
TO
CHOPPER
BOARD
ARC LINK
WIRE
FEEDER
RECP.
115 VAC
RECP.
S1
115 VAC
RIGHT CT
CURRENT
FB
LEFT CT
CURRENT
FB
T2
STATUS THERMAL
LIGHT LIGHT
When the Feed Head Board activates the Voltage
Sense Board, the actual arc voltage is sensed (lead
67), and this information is delivered through the volt-
age sense board to the Control Board.
DC BUS BOARD, POWER BOARD,
FEED HEAD BOARD, GATEWAY
BOARD AND VOLTAGE SENSE
BOARD
The Power Wave 455R uses two digital communication
platforms. Internally the PC boards communicate via
ArcLink. Externally the Power Wave 455R communi-
cates using the industry standard Device Net protocol.
The Gateway Board makes the translation between the
two platforms possible. The Power Wave 455R does
not have a dedicated interface device or board. The
robot (or other input device – PLC, etc.) acts as the
user interface, issuing commands through the Device
Net protocol that are translated by the Gateway Board
to ArcLink compatible messages. The following block
diagram (Figure E.5) depicts the flow of communica-
tion information.
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 Feed Head Board, the Power
Board, and the wire feeder receptacle.
The switching power supplies on the Power Board sup-
ply a variety of regulated DC voltages to the Control
Board and a +20VDC to the STT Chopper Board. The
Control Board uses these regulated voltages to power
the many circuits and communication functions incor-
porated within the Control Board.
NOTE: Unshaded areas of Block Logic Diagram are the subject of discussion.
POWER WAVE 455/R
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E-6
E-6
THEORY OF OPERATION
FIGURE E.5 – POWER WAVE 455/R COMMUNICATIONS
Arc Link
Gateway
Board
Feed
Head
Board
Control
Board
Translator
Weld Controller /
Sequencer
PF-10R
PW-455R
Device Net
Robot
Controller
POWER WAVE 455/R
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E-7
E-7
THEORY OF OPERATION
FIGURE E.6 – CONTROL BOARD
IGBT DRIVE
FROM
CONTROL
BOARD
CT CURRENT
TO CONTROL
BOARD
MAIN
TRANSFORMER
POWER WAVE 455/R
OUTPUT DIODES
D1 -D4
ELECTRODE
TERMINAL
CAP. V/F
FEEDBACK
+
LEFT
SWITCH
BOARD
INPUT
CR1
+20 VDC FROM
POWER BOARD
RECTIFIER
STT
ELECTRODE
TERMINAL
CURRENT
TRANSDUCER
IGBT DRIVE
FROM
CONTROL
BOARD
RECONNECT
SWITCH
STT CHOPPER
BOARD
CT CURRENT
TO CONTROL
BOARD
+
SW1
RIGHT
SWITCH
BOARD
STT
DRIVE
CAP. V/F
FEEDBACK
CURRENT
TRANSDUCER
WORK
TERMINAL
OUTPUT
CHOKE
67A
S1
INPUT
BOARD
C
U
R
R
VOLT
SENSE
BOARD
67B
S6
VOLTAGE SENSE
OUTPUT
S
T
T
CONTACTOR AND PRECHARGE
CONTROL SIGNALS FROM
CONTROL BOARD
DEVICE NET
S5
TO
E
TO
LEFT
S.B.
RIGHT
N
VOLTAGE SENSE SELECT
ARC LINK
S.B.
T
F
B
CONNECTION
TO
ROBOT
GATEWAY
BOARD
F
B
2
4
V
A
C
FROM CONTROL
BOARD
40 VDC
FEED
HEAD
BOARD
40 VDC
AUX
RECONNECT
TO FAN RELAY
IGBT
DRIVES
115 VAC
CONTACTOR AND
PRECHARGE
RELAY
FAN
ARC LINK
CONTROL SIGNALS
115 VAC
+5V RS232
THERMOSTATS
CONTROL
BOARD
+5 V ARC LINK
65 VDC
52 VAC
CONNECTION
TO WIRE
DRIVE
S6
S2 WORK
SENSE
POWER
BOARD
+5V SPI
DC
BUS
BOARD
BUS BOARD
RECTIFIER
T1
+15V SPI
+5 V
S3
RS232
40 VDC
40 VDC
+15 V
-15 V
230 VAC
WATER
COOLER
LEFT S.B.
CAP. V/F
RIGHT S.B.
CAP. V/F
40 VDC
+20 VDC
TO
CHOPPER
BOARD
ARC LINK
WIRE
FEEDER
RECP.
115 VAC
RECP.
S1
115 VAC
RIGHT CT
CURRENT
FB
LEFT CT
CURRENT
FB
T2
STATUS THERMAL
LIGHT LIGHT
CONTROL BOARD
The Control Board performs the primary interfacing
functions to establish and maintain output control of the
Power Wave 455R machine. The function generator
and weld files exist within the Control Board hardware
and software. Digital command signals and feedback
information is received and processed at the Control
Board. Software within the Control Board processes
the command and feedback information and sends the
appropriate pulse width modulation (PWM) signals
(see PULSE WIDTH MODULATION in this section) to
the switch board IGBTs. In this manner, the digitally
controlled high-speed welding waveform is created.
The Control Board also monitors and controls the STT
(Surface Tension Transfer) circuitry incorporated in the
Power Wave 455R. STT output currents and arc volt-
ages are monitored, and the appropriated gate firing
signals are applied (or removed) from the STT
Chopper Board and switch boards to create a low spat-
ter, low fume MIG welding process. See GENERAL
DESCRIPTION OF STT (SURFACE TENSION
TRANSFER PROCESS) in this section.
In addition, the Control Board monitors the ther-
mostats, the main transformer primary currents and
input filter capacitor voltages. Depending on the fault
condition, the Control Board will activate the thermal
and/or the status light and will disable or reduce the
machine output. In some conditions the input contac-
tor will be de-energized.
POWER WAVE 455/R
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E-8
E-8
THEORY OF OPERATION
FIGURE E.7 – OUTPUT RECTIFIER, OUTPUT CHOKE AND STT CHOPPER BOARD
IGBT DRIVE
FROM
CONTROL
BOARD
CT CURRENT
TO CONTROL
BOARD
MAIN
TRANSFORMER
POWER WAVE 455/R
OUTPUT DIODES
D1 -D4
ELECTRODE
TERMINAL
CAP. V/F
FEEDBACK
+
LEFT
SWITCH
BOARD
INPUT
CR1
+20 VDC FROM
POWER BOARD
RECTIFIER
STT
ELECTRODE
TERMINAL
CURRENT
TRANSDUCER
IGBT DRIVE
FROM
CONTROL
BOARD
RECONNECT
SWITCH
STT CHOPPER
BOARD
CT CURRENT
TO CONTROL
BOARD
+
SW1
RIGHT
SWITCH
BOARD
STT
DRIVE
CAP. V/F
FEEDBACK
CURRENT
TRANSDUCER
WORK
TERMINAL
OUTPUT
CHOKE
67A
S1
INPUT
BOARD
C
U
R
R
VOLT
SENSE
BOARD
67B
S6
VOLTAGE SENSE
OUTPUT
S
T
T
CONTACTOR AND PRECHARGE
CONTROL SIGNALS FROM
CONTROL BOARD
DEVICE NET
S5
TO
E
TO
LEFT
S.B.
RIGHT
N
VOLTAGE SENSE SELECT
ARC LINK
S.B.
T
F
B
CONNECTION
TO
ROBOT
GATEWAY
BOARD
F
B
2
4
V
A
C
FROM CONTROL
BOARD
40 VDC
FEED
HEAD
BOARD
40 VDC
AUX
RECONNECT
TO FAN RELAY
IGBT
DRIVES
115 VAC
CONTACTOR AND
PRECHARGE
RELAY
FAN
ARC LINK
CONTROL SIGNALS
115 VAC
+5V RS232
THERMOSTATS
CONTROL
BOARD
+5 V ARC LINK
65 VDC
52 VAC
CONNECTION
TO WIRE
DRIVE
S6
S2 WORK
SENSE
POWER
BOARD
+5V SPI
DC
BUS
BOARD
BUS BOARD
RECTIFIER
T1
+15V SPI
+5 V
S3
RS232
40 VDC
40 VDC
+15 V
-15 V
230 VAC
WATER
COOLER
LEFT S.B.
CAP. V/F
RIGHT S.B.
CAP. V/F
40 VDC
+20 VDC
TO
CHOPPER
BOARD
ARC LINK
WIRE
FEEDER
RECP.
115 VAC
RECP.
S1
115 VAC
RIGHT CT
CURRENT
FB
LEFT CT
CURRENT
FB
T2
STATUS THERMAL
LIGHT LIGHT
OUTPUT RECTIFIER, OUTPUT
CHOKE AND STT CHOPPER
BOARD
The STT Chopper Board is in series with the STT out-
put terminal and is used to interrupt the welding cur-
rent for very short periods of time during the short-arc
MIG welding process. The IGBT modules incorporat-
ed on this board receive their gate firing commands
from the Control Board.
The output rectifier receives the AC output from the
main transformer secondary and rectifies it to a DC
voltage level. The output choke is in series with the
negative leg of the output rectifier and also in series
with the welding load. Due to the current "smoothing"
capability of the output choke, a filtered DC output cur-
rent is applied through machine output terminals to the
welding arc.
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E-9
E-9
THEORY OF OPERATION
THERMAL PROTECTION
OVER CURRENT PROTECTION
Three normally closed (NC) thermostats protect the
machine from excessive operating temperatures.
These thermostats are wired in series and are con-
nected to the control board. One of the thermostats is
located on the heat sink of the output rectifier, one on
the DC bus, and one on the output choke. Excessive
temperatures may be caused by a lack of cooling air or
by operating the machine beyond its duty cycle or out-
put rating. If excessive operating temperatures should
occur, the thermostats will prevent output from the
machine. The yellow thermal light, located on the front
of the machine, will be illuminated. The thermostats
are self-resetting once the machine cools sufficiently. If
the thermostat shutdown was caused by excessive
output or duty cycle and the fan is operating normally,
the power switch may be left on and the reset should
occur within a 15-minute period. If the fan is not turn-
ing or the intake air louvers are obstructed, the power
must be removed from the machine and the fan condi-
tion or air obstruction corrected. On later production
machines (above code 10500) the cooling fan runs
only when necessary. The F.A.N. (fan as needed) sys-
tem is controlled by the Control Board via a solid state
relay.
If the average current exceeds 570 amps, the peak cur-
rent will be limited to 100 amps until the average cur-
rent decreases to under 50 amps or the system is re-
triggered.
UNDER/OVER VOLTAGE
PROTECTION
A protective circuit is included on the Control Board to
monitor the voltage across the input capacitors. In the
event that a capacitor voltage is too high, too low, or
becomes unbalanced side-to-side, the protection cir-
cuit will de-energize the input contactor. Machine out-
put will be disabled, and the "soft start" mode will be
repeated. The protection circuit will prevent output if
any of the following circumstances occur.
1. Capacitor conditioning is required. (This may be
required if the machine has been off for a long peri-
od of time and is connected for high input voltage
operation.)
2. Voltage across a capacitor exceeds 390 volts. (This
could result from high line surges or improper input
voltage connections.)
3. Voltage across a capacitor is under 70 volts. (This
would be due to improper input voltage connec-
tions.)
PROTECTIVE CIRCUITS
Protective circuits are designed into the Power Wave
455/R to sense trouble and shut down the machine
before damage occurs to the machine’s internal com-
ponents.
4. Internal component damage.
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E-10
E-10
THEORY OF OPERATION
FIGURE E.8 – STT WAVEFORMS
Wave Control +10.0
Wave Control 0.00
Wave Control -10.0
Current
Time
STT Wave control characteristics
Trim 1.50
Current
Trim 1.00
Trim 0.50
Time
STT Trim control characteristics
GENERAL DESCRIPTION OF
THE STT (SURFACE TENSION
TRANSFER) PROCESS
The STT process cannot be classified as either a con-
stant current (CC) or a constant voltage (CV) applica-
tion. The STT function produces current of a desired
waveform to reduce spatter and fumes. The STT
process is optimized for short-circuit GMAW welding
only.
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E-11
E-11
THEORY OF OPERATION
FIGURE E.9 – IGBT OPERATION
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
INSULATED GATE BIPOLAR
TRANSISTOR (IGBT) OPERATION
Drawing B shows the IGBT in an active mode. When
the gate signal, a positive DC voltage relative to the
source, is applied to the gate terminal of the IGBT, it
is capable of conducting current. A voltage supply
connected to the drain terminal will allow the IGBT to
conduct and supply current to circuit components cou-
pled to the source. Current will flow through the con-
ducting IGBT to downstream components as long as
the positive gate signal is present. This is similar to
turning ON a light switch.
An IGBT is a type of transistor. IGBTs are semicon-
ductors well suited for high frequency switching and
high current applications.
Drawing A shows an IGBT in a passive mode. There is
no gate signal, zero volts relative to the source, and
therefore, no current flow. The drain terminal of the
IGBT may be connected to a voltage supply; but since
there is no conduction, the circuit will not supply current
to components connected to the source. The circuit is
turned off like a light switch in the OFF position.
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E-12
E-12
THEORY OF OPERATION
FIGURE E.10 – TYPICAL IGBT OUTPUTS
25 sec
sec
sec
sec
50 sec
MINIMUM OUTPUT
24 sec
sec
1 sec
24
1 sec
50 sec
MAXIMUM OUTPUT
PULSE WIDTH MODULATION
The shaded portion of the signal represents one IGBT
group1, conducting for 1 microsecond. The negative por-
tion is the other IGBT group. The dwell time (off time) is
48 microseconds (both IGBT groups off). Since only 2
microseconds of the 50-microsecond time period are
devoted to conducting, the output power is minimized.
The term PULSE WIDTH MODULATION (PWM) is
used to describe how much time is devoted to conduc-
tion in the positive and negative portions of the cycle.
Changing the pulse width is known as MODULATION.
Pulse Width Modulation is the varying of the pulse
width over the allowed range of a cycle to affect the
output of the machine.
MAXIMUM OUTPUT
MINIMUM OUTPUT
By holding the gate signals on for 24 microseconds each
and allowing only 2 microseconds of dwell or off time
(one microsecond during each half cycle) during the 50
microsecond cycle, the output is maximized. The dark-
ened area under the minimum output curve can be com-
pared to the area under the maximum output curve. The
more darkened area, the more power is present.
By controlling the duration of the gate signal, the IGBT
is turned on and off for different durations during a
cycle. The top drawing below shows the minimum out-
put signal possible over a 50-microsecond time period.
1 An IGBT group consists of the sets of IGBT modules grouped onto
one switch board.
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Section F-1
Section F-1
TABLE OF CONTENTS
- TROUBLESHOOTING & REPAIR SECTION -
Troubleshooting & Repair ...................................................................................................Section F
How to Use Troubleshooting Guide ...........................................................................................F-2
PC Board Troubleshooting Procedures.......................................................................................F-3
Troubleshooting Guide ................................................................................................................F-4
Test Procedures ..........................................................................................................................F-9
Input Filter Capacitor Discharge Procedure .........................................................................F-9
Switch Board Test ...............................................................................................................F-11
Input Rectifier Test .............................................................................................................F-14
Input Contactor Test............................................................................................................F-17
DC Bus Power Supply PC Board Test................................................................................F-20
Power Board Test ..............................................................................................................F-23
Input Board Test .................................................................................................................F-26
STT Chopper Board Test....................................................................................................F-30
Power Wave Current Transducer Test ...............................................................................F-33
STT Current Transducer Test ............................................................................................F-37
Output Rectifier Test ..........................................................................................................F-41
Auxiliary Transformer No. 1 Test .......................................................................................F-43
Auxiliary Transformer No. 2 Test .......................................................................................F-46
Component Removal and Replacement Procedure..................................................................F-48
Input Rectifier Removal and Replacement ........................................................................F-48
Input Contactor Removal and Replacement ......................................................................F-50
Auxiliary Transformer No. 1 Removal and Replacement Procedure..................................F-52
Auxiliary Transformer No. 2 Removal and Replacement Procedure..................................F-55
Control, Feed Head, or Voltage Sense PC Board Removal and Replacement .................F-58
Gateway PC Board Removal and Replacement ...............................................................F-62
STT Current Transducer Removal and Replacement ...................................................... F-64
Power Wave Current Transducer Removal and Replacement.......................................... F-67
Output Rectifier, STT Chopper Board and Rectifier Module Removal
and Replacement ........................................................................................................F-70
Switch Board and Filter Capacitor Removal and Replacement .........................................F-74
Retest after Repair ...................................................................................................................F-77
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F-2
F-2
TROUBLESHOOTING & REPAIR
HOW TO USE TROUBLESHOOTING GUIDE
WARNING
Service and repair should be performed by only Lincoln Electric Factory Trained Personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician and machine
operator and will invalidate your factory warranty. For your safety and to avoid Electrical Shock, please
observe all safety notes and precautions detailed throughout this manual.
This Troubleshooting Guide is provided to help
you locate and repair possible machine malfunc-
tions. Simply follow the three-step procedure
listed below.
Step 3. PERFORM COMPONENT TESTS. The
last column, labeled “Recommended Course of
Action” lists the most likely components that may
have failed in your machine. It also specifies the
appropriate test procedure to verify that the sub-
ject component is either good or bad. If there are
a number of possible components, check the
components in the order listed to eliminate one
possibility at a time until you locate the cause of
your problem.
Step 1. LOCATE PROBLEM (SYMPTOM). Look
under the column labeled “PROBLEM” (SYMP-
TOMS). This column describes possible symp-
toms that the machine may exhibit. Find the list-
ing that best describes the symptom that the
machine is exhibiting. Symptoms are grouped
into two main categories: Output Problems and
Function Problems.
All of the referenced test procedures referred to in
the Troubleshooting Guide are described in detail
at the end of this section.
Refer to the
Troubleshooting and Repair Table of Contents to
locate each specific Test Procedure. All of the
referred to test points, components, terminal
strips, etc., can be found on the referenced elec-
trical wiring diagrams and schematics. Refer to
the Electrical Diagrams Section Table of Contents
to locate the appropriate diagram.
Step 2. PERFORM EXTERNAL TESTS. The
second column, labeled “POSSIBLE AREAS OF
MISADJUSTMENT(S)”, lists the obvious external
possibilities that may contribute to the machine
symptom. Perform these tests/checks in the
order listed. In general, these tests can be con-
ducted without removing the case cover.
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.
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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-
shielding bag.
WARNING
ELECTRIC SHOCK can kill.
Have an electrician install and service
this equipment. Turn the machine OFF
before working on equipment. Do not
touch electrically hot parts.
• 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.
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 symp-
tom has been corrected by the replacement PC
board.
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 electri-
cal components can reach their operating tem-
perature.
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 elec-
trical damage and electrical shock. Read the warn-
ing 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 termi-
nal 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 to a
grounded part of the equipment
frame.
ATTENTION
Static-Sensitive
Devices
Handle only at
Static-Safe
Workstations
6. Always indicate that this procedure was followed
when warranty reports are to be submitted.
NOTE: Following this procedure and writing on the
• If you don’t have a wrist strap,
touch an unpainted, grounded,
part of the equipment frame. Keep
touching the frame to prevent sta-
tic build-up. Be sure not to touch
any electrically live parts at the
same time.
warranty
report,
“INSTALLED
AND
SWITCHED PC BOARDS TO VERIFY PROB-
LEM,” will help avoid denial of legitimate PC
board warranty claims.
• 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 Contact your local authorized Contact the Lincoln Electric Service
is evident when the sheet metal Lincoln Electric Field Service Department at 1-800-833-9353
covers are removed.
Facility for technical assistance.
(WELD).
The input fuses repeatedly fail or 1. Make certain the fuses or break- 1. Check the reconnect switches
the input circuit breakers keep trip-
ping.
ers are properly sized.
and associated wiring. See the
Wiring Diagram.
2. Make certain the reconnect
panel is configured properly for 2. Perform the Input Rectifier
the applied voltage.
Test.
3. The welding procedure may be 3. Perform the Switch BoardTest.
drawing too much input current
4. Perform the Input Contactor
or the duty cycle may be too
Test.
high. Reduce the welding cur-
rent and /or reduce the duty
cycle.
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.
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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 is dead—no lights— 1. Make certain the input power 1. Check the input power switch
no output—the machine appears to
be off.
switch SW1 is in the ON posi-
tion.
SW1 for proper operation. Also
check the associated leads for
loose or faulty connections.
See the Wiring Diagram.
2. Check the main input fuses (or
breakers). If open, replace or
reset.
2. Check circuit breaker CB4 for
proper operation.
3. Check the 6 amp CB4 breaker
located in the reconnect area. 3. Perform the T1 Auxiliary
Reset if tripped.
Transformer Test.
4. Make certain the reconnect 4. The power board rectifier may
panel is configured correctly for
the applied input voltage.
be faulty. Check rectifier and
associated wiring. See the
Wiring Diagram.
5. Perform the DC Bus Board
Test.
6. Perform the Power Board Test.
7. The Control Board may be
faulty.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely,
contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call
1-800-833-9353.
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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
OUTPUT PROBLEMS
The Power Wave 455R does not 1. Turn the input power off and 1. Perform the Input Contactor
have welding output. The main
input contactor CR1 is not activat-
ing.
make certain the reconnect
panel is configured correctly for
the applied input voltage.
Test.
2. Perform the Input Board Test.
3. Perform the T1 Auxiliary
2. If the Thermal light is lit, the unit
may be overheated. Let the
Transformer Test.
machine cool and adjust weld- 4. Perform the Input Rectifier
ing load and /or duty cycle to
coincide with the output limits of
the machine.
Test.
5. Perform the Switch BoardTest.
6. Perform the Power Board Test.
7. The Control Board may be faulty.
The thermal light is lit.
The 1. The welding application may be 1. One of the thermostats may be
machine regularly "overheats."
exceeding the recommended
duty cycle and/or current limits
of the machine.
faulty. Also check associated
wiring for loose or faulty con-
nections.
Diagram.
See the Wiring
2. Dirt and dust may have clogged
the cooling channels inside the
machine. Refer to the Maint-
enance Section of this manual.
3. Air intake and exhaust louvers
may be blocked due to inade-
quate clearance around the
machine.
4. Make sure the fan is functioning
correctly. Machines above code
10500 are equipped with F.A.N.
(fan as needed) circuitry. The
fan runs whenever the output is
enabled, whether under load or
open circuit conditions. The fan
also runs for a period of time
(approximately 5 minutes) after
the output is disabled.
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.
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F-7
F-7
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
FUNCTION PROBLEMS
The machine often "noodle welds" 1. The machine may be trying to 1. Perform
the
Current
when running a particular process.
The output is limited to approxi-
mately 100 amps.
deliver too much power. When
the average output current
exceeds 570 amps, the
machine will "phase back" to
protect itself. Adjust the proce-
dure or reduce the load to lower
the current draw from the Power
Wave 455R machine.
Transducer Test.
2. The Control Board may be
faulty.
The Power Wave 455R will not pro- 1. The input voltage may be too 1. Perform the Output Rectifier
duce full output.
low, limiting the output capability
of the machine. Make certain
the input voltage is correct for
the machine and the reconnect
panel configuration.
Test.
2. Perform the Current Trans-
ducer Test.
3. Perform the Power Board Test.
2. Make sure all three phases of 4. The Control Board may be
input power are being applied to
the machine.
faulty.
5. If using the STT output terminal,
the STT Chopper Board may be
faulty. See the Wiring Diagram.
3. If using the STT output terminal,
be aware that the STT output is
limited to 325 amps.
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.
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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
The Auxiliary Receptacle is "dead." 1. Check the 10 amp circuit break- 1. Check the receptacle and asso-
The 120VAC is not present at the
receptacle.
er (CB2) located on the case
front. Reset if necessary.
ciated wiring for loose or faulty
connections. See the Wiring
Diagram.
2. Check the 6 amp circuit breaker
(CB4) located in the reconnect 2. Perform the T2 Auxiliary
area. Reset if necessary.
Transformer Test.
3. Make sure all three phases of
input power are being applied to
the machine.
The Power Wave 455R is "trig- 1. Make sure that the triggering Use troubleshooting software to
gered" for output but there is no
welding output.
method and device is correct find the problem. Contact Lincoln
and operating properly.
Electric Service Department to
obtain software.
2. Check circuit breaker CB4.
Reset if tripped.
When in the STT mode, 1. Make certain the work sense 1. Perform the STT Chopper
the spatter is higher than normal
and the arc is inconsistent.
lead (21) is connected properly.
Board Test.
2. Make certain the electrode 2. Perform
the
Current
cable is connected only to the
STT output terminal and NOT
the Power Wave positive output
terminal.
Transducer (STT) Test.
3. The Control Board may be
faulty.
3. Make sure the welding parame-
ters are correct for the process.
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.
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F-9
F-9
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 trou-
bleshooting assistance before you proceed. Call 1-800-833-9353 (WELD).
DESCRIPTION
This “safety” procedure should be performed before any internal maintenance or repair
procedures are attempted on the Power Wave 455/R. Capacitance normally discharges
within 2 minutes of removing input power. This procedure is used to check that the capac-
itors have properly discharged.
MATERIALS NEEDED
3/8” Nut driver
Volt-ohmmeter
25-1000 ohms @ 25 watts (minimum) resistor
Electrically insulated gloves and pliers
This procedure should take approximately 15 minutes to perform.
POWER WAVE 455/R
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F-10
F-10
TROUBLESHOOTING & REPAIR
INPUT FILTER CAPACITOR DISCHARGE PROCEDURE (CONTINUED)
FIGURE F.1 – CAPACITOR DISCHARGE PROCEDURE
SWITCH
BOARD
CAPACITOR
TERMINALS
TEST PROCEDURE
6. Using the high wattage resistor (25-1000
ohms @ 25 watts (minimum), electrically
insulated gloves and pliers, connect the
resistor across the two capacitor terminals.
Hold the resistor in place for 10 seconds.
DO NOT TOUCH THE CAPACITOR TERMI-
NALS WITH YOUR BARE HANDS. NEVER
USE A SHORTING STRAP FOR THIS
PROCEDURE.
1. Remove input power to the Power Wave
455/R.
2. Using the 3/8” nut driver, remove the left and
right case sides.
3. Be careful not to make contact with the
capacitor terminals that are located in the
bottom center of the left and right side switch
boards. See Figure F.1.
7. Repeat procedure for the other capacitor.
4. Carefully check for a DC voltage at the
capacitor terminals on both boards. Note
the polarity is marked on the PC board and
also lead #19 is positive.
8. Recheck the voltage across the capacitor
terminals. The voltage should be zero. If
any voltage remains, repeat the discharge
procedure.
5. If any voltage is present, proceed to Step #6.
If no voltage is present, the capacitors are
discharged.
NOTE: If the capacitor voltage is present after
the discharge has been performed, this
may indicate a faulty switch board.
NOTE: Normally the capacitors discharge in
about two minutes after input power is
removed.
POWER WAVE 455/R
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F-11
F-11
TROUBLESHOOTING & REPAIR
SWITCH BOARD TEST
WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician
or machine operator and will invalidate your factory warranty. For your safety and to avoid
electrical shock, please observe all safety notes and precautions detailed throughout this
manual.
If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou-
bleshooting assistance before you proceed. Call 1-800-833-9353 (WELD).
DESCRIPTION
This test will help determine if the “power section” of the switch boards are functioning cor-
rectly. This test will NOT indicate if the entire PC board is functional. This resistance test
is preferable to a voltage test with the machine energized because these boards can be
damaged easily. In addition, it is dangerous to work on these boards with the machine
energized.
MATERIALS NEEDED
3/8” Nut driver
3/8” Wrench
Analog volt-ohmmeter
Wiring Diagram
This procedure should take approximately 20 minutes to perform.
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F-12
F-12
TROUBLESHOOTING & REPAIR
SWITCH BOARD TEST (CONTINUED)
FIGURE F.2 – RECONNECT SWITCHES
19C
19D
RECONNECT
SWITCHES
TEST PROCEDURE
5. Using the Analog ohmmeter, perform the
resistance tests detailed in Table F.1. Refer
to Figure F.3 for the test points.
1. Remove input power to the Power Wave
455/R.
2. Using the 3/8” nut driver, remove the case
6. If any test fails replace both switch boards.
See Switch Board Removal and
Replacement.
top and sides.
3. Perform
Procedure.
the
Capacitor
Discharge
7. If the switch board resistance tests are OK,
check the molex pin connections and asso-
ciated wiring from the switch boards to the
control board. See the Wiring Diagram.
4. Locate label and remove leads 19C and 19D
from the reconnect switches with the 3/8”
wrench. Note lead placement for reassem-
bly. Clear leads. Refer to Figure F.2.
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F-13
F-13
TROUBLESHOOTING & REPAIR
SWITCH BOARD TEST (CONTINUED)
FIGURE F.3 – SWITCH BOARD TEST POINTS
13/14
OR
17/18
SWITCH
BOARD
-20 +19
11/12
OR
15/16
8. Reconnect leads 19C and 19D to the recon-
nect switches. Ensure that the leads are
installed in the same location they were
removed from.
9. Install the right and left case sides and top
using the 3/8” nut driver.
TABLE F.1 – SWITCH BOARD RESISTANCE TEST
APPLY POSITIVE TEST
PROBE TO TERMINAL
APPLY NEGATIVE TEST
NORMAL
PROBE TO TERMINAL
RESISTANCE READING
+19
+19
11/12 OR 15/16
13/14 OR 17/18
- 20
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
11/12 OR 15/16
13/14 OR 17/18
- 20
- 20
11/12 OR 15/16
13/14 OR 17/18
+19
- 20
11/12 OR 15/16
13/14 OR 17/18
+19
POWER WAVE 455/R
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F-14
F-14
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 trou-
bleshooting assistance before you proceed. Call 1-800-833-9353 (WELD).
TEST DESCRIPTION
This test will help determine if the input rectifier has “shorted” or “open” diodes.
MATERIALS NEEDED
Analog volt-ohmmeter
Phillips head screw driver
Wiring Diagram
3/8” Nut driver
This procedure should take approximately 15 minutes to perform.
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F-15
F-15
TROUBLESHOOTING & REPAIR
INPUT RECTIFIER TEST (CONTINUED)
FIGURE F.4 – INPUT RECTIFIER TEST
C
INPUT
RECTIFIER
B
A
NEG (-)
POS (+)
TEST PROCEDURE
NOTE: Some RTV sealant may have to be
removed from the input rectifier termi-
nals. The RTV should be replaced
when test is complete.
1. Remove input power to the Power Wave
455/R.
2. Using the 3/8” nut driver, remove the case
top.
5. With the phillips head screw driver remove
the positive and negative leads from the rec-
tifier.
3. Perform
Procedure.
the
Capacitor
Discharge
4. Locate the Input Rectifier and lead locations.
Refer to Figure F.4.
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F-16
F-16
TROUBLESHOOTING & REPAIR
INPUT RECTIFIER TEST (CONTINUED)
6. Use the analog ohmmeter to perform the
tests detailed in Table F.2.
9. If the input rectifier is good, be sure to
reconnect the positive and negative leads
to the correct terminals and torque to 31
in.-lbs. See the Wiring Diagram.
7. If the input rectifier does not meet the
acceptable readings outlined in the table,
the component may be faulty. Replace.
10. Replace any RTV sealant previously
removed.
NOTE: Before replacing the input rectifier, per-
form the Switch Board Test and the
Input Contactor Test.
11. Install the case top.
8. When installing a new input rectifier, see
Input
Rectifier
Removal
and
Replacement procedure.
TABLE F.2 – INPUT RECTIFIER TEST POINTS AND ACCEPTABLE READINGS
ANALOG METER X100
RANGE
TEST POINT TERMINALS
+ Probe
- Probe
Acceptable Meter Readings
A
B
C
NEG
NEG
NEG
Greater than 1000 ohms
Greater than 1000 ohms
Greater than 1000 ohms
A
B
C
POS
POS
POS
Approx. 500 ohms
Approx. 500 ohms
Approx. 500 ohms
NEG
NEG
NEG
A
B
C
Approx. 500 ohms
Approx. 500 ohms
Approx. 500 ohms
POS
POS
POS
A
B
C
Greater than 1000 ohms
Greater than 1000 ohms
Greater than 1000 ohms
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F-17
F-17
TROUBLESHOOTING & REPAIR
INPUT CONTACTOR TEST
WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician
or machine operator and will invalidate your factory warranty. For your safety and to avoid
electrical shock, please observe all safety notes and precautions detailed throughout this
manual.
If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou-
bleshooting assistance before you proceed. Call 1-800-833-9353 (WELD).
TEST DESCRIPTION
This test will help determine if the input contactor is functional and if the contacts are
functioning correctly.
MATERIALS NEEDED
3/8” Nut driver
Volt-ohmmeter
External 24 VAC supply
This procedure should take approximately 17 minutes to perform.
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F-18
F-18
TROUBLESHOOTING & REPAIR
INPUT CONTACTOR TEST (CONTINUED)
FIGURE F.5 – INPUT CONTACTOR COIL
INPUT
CONTACTOR
601
X4
TEST PROCEDURE
4. Using the external 24 VAC supply, apply 24
VAC to the terminals of the input contactor
coil. If the contactor does NOT activate, the
input contactor is faulty. Replace.
1. Remove input power to the Power Wave
455/R.
2. Using the 3/8” nut driver, remove the input
access panel and case top.
3. Locate, mark, and remove the two leads
(601, X4) that are connected to the input
contactor coil. Refer to Figure F.5.
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F-19
F-19
TROUBLESHOOTING & REPAIR
INPUT CONTACTOR TEST (CONTINUED)
FIGURE F.6 – INPUT CONTACTOR TEST POINTS
L3
T3
L2
L1
T2
T1
5. With the input contactor activated, check the
continuity across the three sets of contacts.
(Zero ohms or very low resistance is nor-
mal.) Refer to Figure F.6. If the resistance
is high, the input contactor is faulty. Replace
the input contactor.
7. Reconnect the two leads (601, X4) to the
input contactor coil.
8. Install the input access door and case top
using the 3/8” nut driver.
6. When the contactor is NOT activated, the
resistance should be infinite or very high
across the contacts. If the resistance is low,
the input contactor is faulty.
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F-20
F-20
TROUBLESHOOTING & REPAIR
DC BUS POWER SUPPLY PC BOARD TEST
WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician
or machine operator and will 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.
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F-21
F-21
TROUBLESHOOTING & REPAIR
DC BUS POWER SUPPLY PC BOARD TEST (CONTINUED)
FIGURE F.7 – DC BUS POWER SUPPLY POWER SUPPLY PC BOARD
LED
DC BUS
POWER
SUPPLY
PC BOARD
J47
J46
CAPACITOR
C3
CAUTION!
J46
J47
1 2 3 4
1 2
3 4
5 6 7 8
TEST PROCEDURE
WARNING
1. Remove input power to the machine.
ELECTRIC SHOCK can kill.
2. Using the 3/8” nut driver, remove the case
top.
High voltage is present when
input power is applied to the
machine.
3. Locate the DC Bus Power Supply PC Board
and plugs P46 and P47. See Figure F.7.
4. Carefully apply input power to the Power
Wave 455/R.
5. Turn on the Power Wave 455/R. The LED
on the DC Bus Power Supply PC Board
should light.
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F-22
F-22
TROUBLESHOOTING & REPAIR
DC BUS POWER SUPPLY PC BOARD TEST(CONTINUED)
6. Check the DC Bus Power Supply PC Board
input and output voltages according to Table
7. If all the voltages are correct, the DC Bus
Power Supply PC Board is operating prop-
erly.
F.3.
See Figure F.7 and the Wiring
Diagram.
8. If any of the output voltages are not cor-
rect and the input voltage is correct, the
DC Bus Power Supply PC Board may be
faulty.
WARNING
ELECTRIC SHOCK can kill.
9. If the input voltage is not correct, check
the leads between the DC Bus Power
Supply PC Board and the Power PC
Board Rectifier. See the Wiring Diagram.
High voltage is present at the
terminals of Capacitor C3 near
where testing is to be done.
10. When finished testing, replace the case
top.
TABLE F.3 – 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
Plug P46 – Pin 3
65 – 75 VDC
Should be same as the
Power PC Board
Rectifier
Supply to Power PC
Board
Plug P47 – Pin 7
Plug P47 – Pin 8
Plug P47 – Pin 4
Plug P47 – Pin 3
Plug P47 – Pin 6
Plug P47 – Pin 6
Plug P47 – Pin 2
Plug P47 – Pin 1
38.0 – 42.0 VDC
38.0 – 42.0 VDC
38.0 – 42.0 VDC
38.0 – 42.0 VDC
Supply to Power PC
Board
Supply to Feed Head PC
Board
Supply to S1 Wire
Feeder Receptacle
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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 trou-
bleshooting assistance before you proceed. Call 1-800-833-9353 (WELD).
TEST DESCRIPTION
This test will help determine if the Power Board is receiving the correct voltages and also
if the Power Board is regulating and producing the correct DC voltages.
MATERIALS NEEDED
3/8” Nut driver
Volt-ohmmeter
Wiring Diagram
This procedure should take approximately 30 minutes to perform.
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F-24
F-24
TROUBLESHOOTING & REPAIR
POWER BOARD TEST (CONTINUED)
FIGURE F.8 – POWER BOARD TEST
J42
J41
J43
1
2
4
1
4
2
3
6
1
7
2
8
3
4
5
6
3
5
J42
9 10 11 12
J43
J41
TEST PROCEDURE
6. Turn on the Power Wave 455/R. Carefully
test for the correct voltages at the Power
Board according to Table F.4.
1. Remove input power to the Power Wave
455/R.
2. Using the 3/8” nut driver, remove the case
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.
top.
3. Perform
Procedure.
the
Capacitor
Discharge
4. Locate the Power Board and plugs J42 and
J43. Do not remove plugs or leads from
the Power Board. Refer to Figure 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 455/R.
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.
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F-25
F-25
TROUBLESHOOTING & REPAIR
POWER BOARD TEST (CONTINUED)
TABLE F.4 – 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
225
477
POWER BOARD
CONNECTOR
PLUG J42
CHECK +15
VDC SUPPLY FROM
POWER BOARD
1 (+)
5 (-)
+15 VDC
225 (+)
222 (-)
222
3 (+)
5 (-)
POWER BOARD
CONNECTOR
PLUG J42
CHECK +5 VDC
SUPPLY FROM
POWER BOARD
221 (+)
222 (-)
+5 VDC
-15 VDC
+5 VDC
+5 VDC
221
222
2 (+)
5 (-)
222 (+)
223 (-)
POWER BOARD
CONNECTOR
PLUG J42
CHECK -15 VDC
SUPPLY FROM
POWER BOARD
223
222
274 (+)
273 (-)
5 (+)
10 (-)
CHECK +5 VDC
ARCLINK SUPPLY
FROM POWER BOARD
POWER BOARD
CONNECTOR
PLUG J43
274
273
226
4 (+)
9 (-)
226 (+)
228 (-)
POWER BOARD
CONNECTOR
PLUG J43
CHECK +5 VDC
“RS-232” SUPPLY
FROM POWER BOARD
228
6 (+)
11 (-)
266 (+)
267 (-)
CHECK +15 VDC
SPI SUPPLY FROM
POWER BOARD
+15 VDC
38 – 42 VDC
+5 VDC
POWER BOARD
CONNECTOR
PLUG J43
266
267
CHECK +40 VDC
INPUT FROM
DC BUS BOARD
4 (+)
3 (-)
478 (+)
476 (-)
POWER BOARD
CONNECTOR
PLUG J41
476
478
POWER BOARD
CONNECTOR
PLUG J43
CHECK +5 VDC
SPI SUPPLY FROM
POWER BOARD
3 (+)
12 (-)
268A (+)
262 (-)
268A
262
7 (+)
1 (-)
345 (+)
346 (-)
POWER BOARD
CONNECTOR
PLUG J43
+20 VDC
CHECK +20 VDC STT
SUPPLY FROM
346
345
POWER BOARD
POWER WAVE 455/R
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F-26
F-26
TROUBLESHOOTING & REPAIR
INPUT 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 help determine if the Input Board is sending the correct voltages and also if
the Input Board is regulating and producing the correct DC voltages.
MATERIALS NEEDED
3/8” Nut driver
Volt-ohmmeter
Wiring Diagram
This procedure should take approximately 30 minutes to perform.
POWER WAVE 455/R
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F-27
F-27
TROUBLESHOOTING & REPAIR
INPUT BOARD TEST (CONTINUED)
FIGURE F.9 – INPUT CONTACTOR CR1
J60
J61
601
1
2
3 4
1
6
2
3 4
5
X4
INPUT
CONTACTOR
5
6
7
8
7
8
9 10
J60
J61
TEST PROCEDURE
WARNING
1. Remove input power to the Power Wave
455/R.
ELECTRIC SHOCK can kill.
2. Using the 3/8” nut driver, remove the case
High voltage is present when
input power is applied to the
machine.
top.
3. Remove lead X4 from the coil terminal of
main input contactor CR1. Insulate lead X4.
Refer to Figure F.9.
5. Turn on the Power Wave 455/R. Carefully
test for the correct voltages according to
Table F.5.
4. Carefully apply input power to the Power
Wave 455/R.
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F-28
F-28
TROUBLESHOOTING & REPAIR
INPUT BOARD TEST(CONTINUED)
6. Remove input power to the Power Wave
455/R. If any of the voltages are low or not
present, perform the Input Contactor Test.
If that checks out, the Input Board may by
faulty.
9. Turn on the Power Wave 455/R. Check for
the presence of 24 VAC from lead X4 to
lead 601. See Figure F.9. If the voltage
is not present, perform the Auxiliary
Transformer #1 Test.
7. Reconnect lead X4 to the main input contac-
tor CR1 coil terminal.
9. This 24 VAC is the coil voltage for main
input contactor CR1. It will normally be
present approximately 12 seconds after
input line switch (SW1) is activated.
8. Carefully apply the correct input voltage to
the Power Wave 455/R.
10. When the test is completed, remove input
power from the Power Wave 455/R.
WARNING
11. Install the case top using the 3/8” nut driver.
ELECTRIC SHOCK can kill.
High voltage is present when
input power is applied to the
machine.
POWER WAVE 455/R
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F-29
F-29
TROUBLESHOOTING & REPAIR
INPUT BOARD TEST(CONTINUED)
TABLE F.5 – INPUT BOARD VOLTAGE CHECKS
LEAD
NUMBERS
EXPECTED
VOLTAGE
TEST POINTS
COMMENTS
READINGS
PLUG J61 PIN 8 (H1D)
TO
J61
SAME AS
INPUT
Present when Input
Switch SW1 is closed.
PLUG J61 PIN 2 (612)
VOLTAGE
#612
H1D
PLUG J61 PIN 10 (T3)
TO
PLUG J61 PIN 2 (T1)
J61
A LITTLE LESS
THAN INPUT
VOLTAGE
This is Pre-Charge Voltage and
will normally be present 6 sec-
onds after activating Input Switch
SW1. The Pre-Charge Voltage
should remain for approximately 6
seconds and then be removed.
T1
T3
PLUG J60 PIN 3 (238)
TO
PLUG J60 PIN 4 (604)
J60
13 – 15 VDC
This is the Coil Voltage for the
Pre-Charge Relay. Normally this
DC Voltage will be present 6 sec-
onds after Input Switch SW1 is
activated. This 13 - 15 VDC will
remain for approximately 6 sec-
onds and then be removed. The
Relay is controlled by the Control
Board. See the Wiring Diagram.
#604
#238
PLUG J60 PIN 3 (238)
TO
PLUG J60 PIN 5 (232)
J60
13 – 15 VDC
This is the DC Coil Voltage for the
Control Relay. Normally this DC
Voltage will be present approxi-
mately 12 seconds after Input
Switch SW1 is activated. The
Relay is controlled by the Control
PC Board. See the Wiring
Diagram.
#238
#232
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F-30
F-30
TROUBLESHOOTING & REPAIR
STT CHOPPER BOARD TEST
WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician
or machine operator and will invalidate your factory warranty. For your safety and to avoid
electrical shock, please observe all safety notes and precautions detailed throughout this
manual.
If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou-
bleshooting assistance before you proceed. Call 1-800-833-9353 (WELD).
TEST DESCRIPTION
This test will help determine if the STT Chopper Board is receiving the necessary voltages
to function and if the related circuitry is correct.
MATERIALS NEEDED
3/8” Nut driver
Volt-ohmmeter
Wiring Diagram
This procedure should take approximately 30 minutes to perform.
POWER WAVE 455/R
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F-31
F-31
TROUBLESHOOTING & REPAIR
STT CHOPPER BOARD TEST (CONTINUED)
FIGURE F.10 – STT CHOPPER BOARD TEST DETAILS
CONTROL PC BOARD
POWER PC BOARD
J7
J43
J43
J7
1
2
3
4
5
6
7
8
1
7
2
8
3
4
5
6
346
9 10 11 12
9
10 11 12 13 14 15 16
4W 4R
345
STT OUTPUT
TERMINAL
POWER WAVE
+ OUTPUT
TERMINAL
TEST PROCEDURE
+ probe on the Power Wave + output ter-
minal
1. Remove input power to the Power Wave
455/R.
- probe on the STT output terminal
2. Using the 3/8” nut driver, remove the case
top and the control box cover. See Figure
F.10.
The reading should be less than 500 ohms
If both the polarity resistance tests are low,
either the STT Chopper Module is faulty or
diode D6 is shorted. See the Wiring
Diagram.
3. Perform the following resistance tests:
+ probe on the STT output terminal
- probe on the Power Wave + output ter-
minal
The reading should be approximately
300,000 ohms
POWER WAVE 455/R
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F-32
F-32
TROUBLESHOOTING & REPAIR
STT CHOPPER BOARD TEST (CONTINUED)
4. Carefully apply input power to the Power
Wave 455/R.
6. Measure the voltage from Control Board
plug J7 lead 4W pin 13 (-) to lead 4R pin 14
(+). The voltage should be 4 – 5 VDC. This
is the pulse width modulation signal to the
STT Chopper Board. If not correct, the
Control Board may be faulty.
WARNING
ELECTRIC SHOCK can kill.
High voltage is present when
input power is applied to the
machine.
7. When the test is completed, remove input
power from the Power Wave 455/R.
For steps 5 and 6, see Figure F.10.
8. Install the case top using the 3/8” nut driver.
5. Turn on the Power Wave 455/R. Measure
the voltage from Power Board plug J43 lead
345 pin 7 (+) to lead 346 pin 1 (-). The volt-
age should be approximately 20 VDC. If not
correct, the Power Board may be faulty.
POWER WAVE 455/R
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F-33
F-33
TROUBLESHOOTING & REPAIR
POWER WAVE CURRENT TRANSDUCER TEST
WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician
or machine operator and will invalidate your factory warranty. For your safety and to avoid
electrical shock, please observe all safety notes and precautions detailed throughout this
manual.
If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou-
bleshooting assistance before you proceed. Call 1-800-833-9353 (WELD).
TEST DESCRIPTION
This test will help determine if the Power Wave current transducer and associated wiring
is functioning correctly.
MATERIALS NEEDED
3/8” nut driver
Volt-Ohmmeter
This procedure should take approximately 25 minutes to perform.
POWER WAVE 455/R
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F-34
F-34
TROUBLESHOOTING & REPAIR
POWER WAVE CURRENT TRANSDUCER TEST (CONTINUED)
FIGURE F.11 – POWER WAVE CURRENT TRANSDUCER TEST
CONTROL BOARD
J8
J8
211 212 213
1
2
3 4
5
6
7 8
216
CURRENT
TRANSDUCER
1234
P91
TEST PROCEDURE
WARNING
1. Remove input power to the Power Wave
455/R.
ELECTRIC SHOCK can kill.
2. Using the 3/8” nut driver, remove the case
High voltage is present when
input power is applied to the
machine.
top and the control box cover.
3. Locate the Power Wave current transducer
leads at Control Board plug J8. See Figure
F.11.
4. Carefully apply input power to the Power
Wave 455/R.
POWER WAVE 455/R
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F-35
F-35
TROUBLESHOOTING & REPAIR
POWER WAVE CURRENT TRANSDUCER TEST (CONTINUED)
FIGURE F.12 – RECEPTACLE S7 TRIGGERED
RECEPTACLE
S7
STT
PO
WER
E
WA
V
5. Turn on the Power Wave 455/R. Check for
the correct DC supply voltage to the current
transducer at plug J8. See Figure F.11.
NOTE: The machine can be triggered by
jumpering pin 1 to pin 2 at receptacle
S7. See Figure F.12.
A. Pin 2 (lead 212+) to pin 6 (lead 216-)
should read +15 VDC.
7. With the Power Wave 455/R triggered,
check the feedback voltage from the current
transducer. The current feedback voltage
can be read at plug J8 on the Control Board.
B. Pin 3 (lead 213-) to pin 6 (lead 216+)
should read -15 VDC.
A. Pin 1 (lead 211) to pin 6 (lead 216)
should read 2.0 VDC (machine loaded
to 250 amps).
If the DC supply voltages are not present,
the control board may be faulty.
6. If both of the supply voltages are low or
missing, check the associated leads
between plug J8 and current transducer plug
P91 and the Control Board.
POWER WAVE 455/R
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F-36
F-36
TROUBLESHOOTING & REPAIR
POWER WAVE CURRENT TRANSDUCER TEST (CONTINUED)
8. If for any reason the machine cannot be
loaded to 250 amps, Table F.6 shows what
feedback voltage is produced at various cur-
rent loads.
not correct, the current transducer may be
faulty. Also make certain that lead 211
(plug J8 pin 1) has continuity (zero ohms)
between the current transducer and the
control board. See the Wiring Diagram.
9. If the correct supply voltages are applied to
the current transducer, and with the machine
loaded, the feedback voltage is missing or
10. Install the right side case cover using the
3/8” nut driver.
TABLE F.6 - CURRENT FEEDBACK AT VARIOUS OUTPUT LOADS
OUTPUT LOAD CURRENT
EXPECTED TRANSDUCER FEEDBACK
VOLTAGE
500
450
400
350
300
250
200
150
100
50
4.0
3.6
3.2
2.8
2.4
2.0
1.6
1.2
0.8
0.4
POWER WAVE 455/R
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F-37
F-37
TROUBLESHOOTING & REPAIR
STT CURRENT TRANSDUCER TEST
WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician
or machine operator and will invalidate your factory warranty. For your safety and to avoid
electrical shock, please observe all safety notes and precautions detailed throughout this
manual.
If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou-
bleshooting assistance before you proceed. Call 1-800-833-9353 (WELD).
TEST DESCRIPTION
This test will help determine if the STT current transducer and associated wiring is func-
tioning correctly.
MATERIALS NEEDED
3/8” nut driver
Volt-Ohmmeter
This procedure should take approximately 25 minutes to perform.
POWER WAVE 455/R
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F-38
F-38
TROUBLESHOOTING & REPAIR
STT CURRENT TRANSDUCER TEST (CONTINUED)
FIGURE F.13 – STT CURRENT TRANSDUCER TEST
CONTROL BOARD
J8
813
1
5
2
6
3 4
7 8
816 812
811
J8
1234
P90
CURRENT
TRANSDUCER
TEST PROCEDURE
WARNING
1. Remove input power to the Power Wave
455/R.
ELECTRIC SHOCK can kill.
2. Using the 3/8” nut driver, remove the case
High voltage is present when
input power is applied to the
machine.
top and the control box cover.
3. Locate the STT current transducer leads at
Control Board plug J8. See Figure F.13.
4. Carefully apply input power to the Power
Wave 455/R.
POWER WAVE 455/R
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F-39
F-39
TROUBLESHOOTING & REPAIR
STT CURRENT TRANSDUCER TEST (CONTINUED)
FIGURE F.14 – RECEPTACLE S7 TRIGGERED
RECEPTACLE
S7
S
T
P
O
T
W
E
R
WA
V
E
5. Turn on the Power Wave 455/R. Check for
the correct DC supply voltage to the current
transducer at plug J8.
NOTE: The machine can be triggered by
jumpering pin 1 to pin 2 at receptacle
S7. See Figure F. 14.
A. Pin 8 (lead 812+) to pin 7 (lead 816-)
should read +15 VDC.
7. With the Power Wave 455/R triggered,
check the feedback voltage from the current
transducer. The current feedback voltage
can be read at plug J8 on the Control Board.
B. Pin 4 (lead 813-) to pin 7 (lead 816+)
should read -15 VDC.
A. Pin 5 (lead 811) to pin 7 (lead 816)
should read 2.0 VDC (machine loaded
to 50 amps).
If the DC supply voltages are not present,
the control board may be faulty.
6. If both of the supply voltages are low or
missing, check the associated leads
between plug J8 and current transducer plug
P90 and the Control Board.
POWER WAVE 455/R
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F-40
F-40
TROUBLESHOOTING & REPAIR
STT CURRENT TRANSDUCER TEST (CONTINUED)
8. If for any reason the machine cannot be
loaded to 50 amps, Table F.6 shows what
feedback voltage is produced at various cur-
rent loads.
faulty. Also make certain that lead 811 (plug
J8 pin 5) has continuity (zero ohms)
between the current transducer and the
control board. See the Wiring Diagram.
9. 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
10. Install the right side case cover using the
3/8” nut driver.
POWER WAVE 455/R
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F-41
F-41
TROUBLESHOOTING & REPAIR
OUTPUT RECTIFIER TEST
WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician
or machine operator and will invalidate your factory warranty. For your safety and to avoid
electrical shock, please observe all safety notes and precautions detailed throughout this
manual.
If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou-
bleshooting assistance before you proceed. Call 1-800-833-9353 (WELD).
TEST DESCRIPTION
The test will help determine if any of the output rectifiers are shorted.
MATERIALS NEEDED
Analog Volt-Ohmmeter
3/8” Nut driver
5/16” Wrench
This procedure should take approximately 20 minutes to perform.
POWER WAVE 455/R
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F-42
F-42
TROUBLESHOOTING & REPAIR
OUTPUT RECTIFIER TEST (CONTINUED)
FIGURE F.15 – OUTPUT RECTIFIER TEST
I ON
POWERWAVE 455/R
O OFF
NEGATIVE (-)
OUTPUT
TERMINAL
STT OUTPUT
TERMINAL
POSITIVE (+)
OUTPUT
TERMINAL
TEST PROCEDURE
IMPORTANT: The positive (+) meter probe
must be attached to the positive (+) output ter-
minal and the negative (-) meter probe must be
attached to the negative (-) output terminal.
1. Remove main input supply power to the
Power Wave 455/R.
2. Remove the case top and sides and perform
the Input Filter Capacitor Discharge pro-
cedure.
6. If the reading is more than 200 ohms, the
output rectifier modules are not shorted. If
the reading is less than 200 ohms, one or
more of the rectifier modules are shorted.
Refer to the Output Rectifier Module
Replacement procedure.
3. Using the 5/16” wrench, remove and insu-
late lead 202A from the negative output ter-
minal.
4. Remove any output load that may be con-
nected to the Power Wave 455/R.
7. Reconnect lead 202A to the negative output
terminal.
5. With the analog ohmmeter, measure the
resistance between the positive and nega-
tive output terminals (NOT the STT termi-
nal). Refer to Figure F.15.
8. Replace the case top and sides.
POWER WAVE 455/R
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F-43
F-43
TROUBLESHOOTING & REPAIR
AUXILIARY TRANSFORMER NO. 1 TEST
WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician
or machine operator and will invalidate your factory warranty. For your safety and to avoid
electrical shock, please observe all safety notes and precautions detailed throughout this
manual.
If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou-
bleshooting assistance before you proceed. Call 1-800-833-9353 (WELD).
TEST DESCRIPTION
This test will determine if the correct voltage is being applied to the primary of Auxiliary
Transformer No. 1 and also if the correct voltages are being induced on the secondary
windings of the transformer.
MATERIALS NEEDED
Volt-ohmmeter (Multimeter)
3/8” Nut driver
Wiring Diagram
This procedure should take approximately 30 minutes to perform.
POWER WAVE 455/R
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F-44
F-44
TROUBLESHOOTING & REPAIR
AUXILIARY TRANSFORMER NO. 1 TEST (CONTINUED)
FIGURE F.16 – AUXILIARY TRANSFORMER NO. 1 TEST
X3
X5
INPUT
CONTACTOR
601
X4
FAN MOTOR
LEADS
+
X1
-
X2
POWER BOARD
RECTIFIER BRIDGE
TEST PROCEDURE
5. Locate secondary leads X3 and X5 (fan
motor leads).
1. Remove the main input power to the Power
Wave 455/R machine.
6. Locate secondary lead X4 (at main contac-
tor).
2. Using the 3/8” nut driver, remove the case
top and sides.
3. Perform the Capacitor Discharge proce-
dure.
4. Locate secondary leads X1 and X2 (at
power board rectifier bridge). Refer to
Figure F.16.
POWER WAVE 455/R
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F-45
F-45
TROUBLESHOOTING & REPAIR
AUXILIARY TRANSFORMER NO. 1 TEST (CONTINUED)
TABLE F.7 – SECONDARY VOLTAGES
LEAD IDENTIFICATION
NORMAL EXPECTED VOLTAGE
X1 to X2
X3 to X5
X3 to X4
52 VAC
115 VAC
24 VAC
7. Carefully apply the correct input voltage to
the Power Wave 455/R.
9. If the correct secondary voltages are pre-
sent, the T1 auxiliary transformer is func-
tioning properly. If any of the secondary
voltages are missing or low, check to make
certain the primary is configured correctly
for the input voltage applied. See the
Wiring Diagram.
WARNING
ELECTRIC SHOCK can kill.
High voltage is present at prima-
ry of the Auxiliary Transformer.
10. If the correct input voltage is applied to the
primary, and the secondary voltage(s) are
not correct, the T1 transformer may be
faulty.
11. Replace any cables ties and insulation
removed earlier.
8. Check for the correct secondary voltages
according to Table F.7.
12. Install the case sides and top using the 3/8”
NOTE: The secondary voltages will vary if the
nut driver.
input line voltage varies.
POWER WAVE 455/R
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F-46
F-46
TROUBLESHOOTING & REPAIR
AUXILIARY TRANSFORMER NO. 2 TEST
WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician
or machine operator and will invalidate your factory warranty. For your safety and to avoid
electrical shock, please observe all safety notes and precautions detailed throughout this
manual.
If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou-
bleshooting assistance before you proceed. Call 1-800-833-9353 (WELD).
TEST DESCRIPTION
This test will determine if the correct voltage is being applied to the primary of Auxiliary
Transformer No. 2 and also if the correct voltages are being induced on the secondary
windings of the transformer.
MATERIALS NEEDED
Volt-ohmmeter (Multimeter)
3/8” Nut driver
Wiring Diagram
This procedure should take approximately 25 minutes to perform.
POWER WAVE 455/R
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F-47
F-47
TROUBLESHOOTING & REPAIR
AUXILIARY TRANSFORMER NO. 2 TEST (CONTINUED)
FIGURE F.17 – AUXILIARY TRANSFORMER NO. 2 TEST
H4 H3 H1
1
2
3
6
VIEWED FROM
TRANSFORMER
LEAD SIDE
4
5
H5 H6 H2
P50
350 352
1
2
VIEWED FROM
TRANSFORMER
LEAD END
3
4
33A
P52
TEST PROCEDURE
6. Check for 115 VAC at plug P52 pins 1 and
4 (leads 350 to 33A). Check for 230 VAC
at plug P52 pins 1 and 2 (leads 350 to
352).
1. Remove the main input power to the Power
Wave 455/R machine.
2. Remove any load that may be connected to
the 115 VAC receptacle.
7. If 115 VAC and 230 VAC are present,
Auxiliary Transformer No. 2 is good.
3. Using the 3/8” nut driver, remove the case
top.
8. If 115 is not present between pins 1 and 4,
and 230 VAC is not present between pins 1
and 2, check the associated leads and
plugs for loose or faulty connections.
4. Locate plugs P52 and P50 at the Auxiliary
Transformer No. 2. Refer to Figure F.17.
5. Carefully apply the correct input power.
9. Carefully test for the correct AC input volt-
age applied to the primary windings at plug
P50. See the Wiring Diagram.
WARNING
10. If the correct AC input voltage is applied to
the primary of the Auxiliary Transformer
No. 2 and the secondary voltage is NOT
correct, the transformer may be faulty.
Replace.
ELECTRIC SHOCK can kill.
High voltage is present at both
plugs.
11. Replace any cables ties and insulation
removed earlier.
12. Install the case top using the 3/8” nut dri-
POWER WAVE 455/R
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F-48
F-48
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 trou-
bleshooting assistance before you proceed. Call 1-800-833-9353 (WELD).
DESCRIPTION
This procedure will aid the technician in the removal and replacement of the input rectifi-
er module.
MATERIALS NEEDED
3/8” nut driver
3/16” Allen wrench
Phillips head screwdriver
This procedure should take approximately 15 minutes to perform.
POWER WAVE 455/R
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F-49
F-49
TROUBLESHOOTING & REPAIR
INPUT RECTIFIER REMOVAL AND REPLACEMENT (CONTINUED)
FIGURE F.18 – INPUT RECTIFIER REMOVAL AND REPLACEMENT
C
INPUT
RECTIFIER
B
A
NEG (-)
POS (+)
REMOVAL PROCEDURE
REPLACEMENT PROCEDURE
1. Remove input power to the Power Wave
455/R.
1. Clean heat sink surfaces.
2. Apply an even coating of joint compound
(Penetrox A-13) to both the heat sink and
module mounting surfaces. The joint com-
pound should be 0.002 - 0.005 in. thick per
surface.
2. Using the 3/8” nut driver, remove the case
top, sides, and input access panel.
3. Perform the Capacitor Discharge proce-
dure.
3. Mount the module to the heat sink and even-
ly torque the mounting screws (with wash-
ers) to 44 in/lbs.
4. Locate and remove the RTV sealant from
the input rectifier connection terminals. See
Figure F. 18.
4. Assemble the leads to the correct module
terminals and torque to 26 in/lbs. See
Figure F.18.
5. Label and, using the phillips head screwdriv-
er, carefully remove the five leads from the
input rectifier terminals. Note placement for
reassembly. See Figure F.18.
5. Apply RTV sealant to the rectifier connection
terminals.
6. Using the 3/16” allen wrench, remove the
two mounting screws and washers from the
rectifier module.
6. Install the case top, sides, and input access
panel using the 3/8” nut driver.
7. Carefully remove the input rectifier module.
POWER WAVE 455/R
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F-50
F-50
TROUBLESHOOTING & REPAIR
INPUT CONTACTOR REMOVAL AND REPLACEMENT
WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician
or machine operator and will invalidate your factory warranty. For your safety and to avoid
electrical shock, please observe all safety notes and precautions detailed throughout this
manual.
If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou-
bleshooting assistance before you proceed. Call 1-800-833-9353 (WELD).
TEST DESCRIPTION
This procedure will aid the technician in the removal and replacement of the input con-
tactor.
MATERIALS NEEDED
3/8” nut driver
5/16” nut driver
Phillips head screwdriver
This procedure should take approximately 15 minutes to perform.
POWER WAVE 455/R
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F-51
F-51
TROUBLESHOOTING & REPAIR
INPUT CONTACTOR REMOVAL AND REPLACEMENT (CONTINUED)
FIGURE F.19 – INPUT CONTACTOR REMOVAL AND REPLACEMENT
INPUT
CONTACTOR
601
X4
REMOVAL PROCEDURE
REPLACEMENT PROCEDURE
1. Remove input power to the Power Wave
455/R.
1. Mount the contactor and tighten the mount-
ing screws.
2. Using the 3/8” nut driver, remove the case
2. Assemble the leads to the correct terminals.
top, sides, and input access panel.
See Figure F.18.
3. Perform the Capacitor Discharge proce-
3. Install the case top, sides, and input access
dure
panel using the 3/8” nut driver.
4. Locate the input contactor. Label and,
using the phillips head screwdriver, careful-
ly remove the leads from the input contac-
tor terminals. Note placement for reassem-
bly. See Figure F.19.
5. With the 5/16” nut driver, remove the three
mounting screws. See Figure F.19.
6. Carefully remove the input contactor.
POWER WAVE 455/R
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F-52
F-52
TROUBLESHOOTING & REPAIR
AUXILIARY TRANSFORMER NO. 1 REMOVAL AND
REPLACEMENT PROCEDURE
WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician
or machine operator and will invalidate your factory warranty. For your safety and to avoid
electrical shock, please observe all safety notes and precautions detailed throughout this
manual.
If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou-
bleshooting assistance before you proceed. Call 1-800-833-9353 (WELD).
DESCRIPTION
This procedure will aid the technician in the removal and replacement of auxiliary trans-
former No. 1.
MATERIALS NEEDED
3/8” Nut driver
Wire cutters
Wire splicer or soldering equipment
This procedure should take approximately 25 minutes to perform.
POWER WAVE 455/R
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F-53
F-53
TROUBLESHOOTING & REPAIR
AUXILIARY TRANSFORMER NO. 1 REMOVAL AND
REPLACEMENT PROCEDURE (CONTINUED)
FIGURE F.20 – AUXILIARY TRANSFORMER NO. 1 REMOVAL AND REPLACEMENT
X3
X5
RECONNECT
TERMINALS
H1
INPUT
CONTACTOR
H2
H3
H4
H5
CB4
601
X4
FAN MOTOR
LEADS
+
X1
-
X2
POWER BOARD
RECTIFIER BRIDGE
REMOVAL PROCEDURE
4. Using the 3/8” nut driver, remove the case
1. Remove input power to the Power Wave
455/R.
back.
5. Remove lead X4 from the input contactor
coil terminal.
2. Using the 3/8” nut driver, remove the case
top, sides and input access panel.
3. Perform the Capacitor Discharge proce-
dure.
POWER WAVE 455/R
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F-54
F-54
TROUBLESHOOTING & REPAIR
AUXILIARY TRANSFORMER NO. 1 REMOVAL AND
REPLACEMENT PROCEDURE (CONTINUED)
6. Remove leads X1 and X2 from the power
board rectifier bridge. Refer to Figure
F.20.
6. Splice the new transformer fan leads to
the fan motor leads X3 and X5.
7. Connect lead X4 to the main contactor
coil terminal.
7. Cut X3 and X5 from the fan motor leads.
Leave enough lead length to splice in the
new transformer leads.
8. Connect leads X1 and X2 to the power
board rectifier bridge.
8. Cut the X3 lead that is connected to the
input board. Leave enough lead length to
splice in the new transformer lead.
9. Reposition any wire leads and install
cable ties as necessary.
10. Install the case back using the 3/8” nut
9. Locate, label, and remove primary lead H1
from circuit breaker CB4.
driver.
11. Install the case top, sides, and input
10. Label and remove primary leads H2, H3,
H4, and H5 from the reconnect terminals
on the reconnect panel. Note lead place-
ment for reassembly.
access panel using the 3/8” nut driver.
11. Cut any necessary cable ties and clear the
leads.
12. Using the 3/8” nut driver, remove the two
mounting screws that hold the transformer
to the fan baffle and the machine base.
13. Carefully remove the transformer from the
Power Wave 455/R.
REPLACEMENT PROCEDURE
1. Carefully place the transformer into the
Power Wave 455/R.
2. Install the two mounting screws that hold
the transformer to the fan baffle and the
machine base using the 3/8” nut driver.
3. Install the primary leads H2, H3, H4, and
H5 to the reconnect terminals on the
reconnect panel.
4. Connect primary lead H1 to circuit breaker
CB4.
5. Splice the new transformer lead with the
X3 lead connected to the input board.
POWER WAVE 455/R
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F-55
F-55
TROUBLESHOOTING & REPAIR
AUXILIARY TRANSFORMER NO. 2 REMOVAL AND
REPLACEMENT PROCEDURE
WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician
or machine operator and will invalidate your factory warranty. For your safety and to avoid
electrical shock, please observe all safety notes and precautions detailed throughout this
manual.
If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou-
bleshooting assistance before you proceed. Call 1-800-833-9353 (WELD).
TEST DESCRIPTION
This procedure will aid the technician in the removal and replacement of auxiliary trans-
former No. 2.
MATERIALS NEEDED
3/8” Nut driver
Wire cutters
This procedure should take approximately 25 minutes to perform.
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F-56
F-56
TROUBLESHOOTING & REPAIR
AUXILIARY TRANSFORMER NO. 2 REMOVAL AND
REPLACEMENT PROCEDURE (CONTINUED)
FIGURE F.21 – AUXILIARY TRANSFORMER NO. 2 REMOVAL AND REPLACEMENT
INPUT
CONTACTOR
601
X4
P52
P50
CB4 CIRCUIT
BREAKER &
115V RECEPTACLE
LEADS 33/32
REMOVAL PROCEDURE
5. Disconnect plugs P50 and P52.
1. Remove input power to the Power Wave
455/R.
6. Disconnect leads 33 and 32 to circuit breaker
CB2 and the 115 V receptacle.
2. Using the 3/8” nut driver, remove the case
top, sides and input access panel.
7. Using the 3/8” nut driver, remove the two
transformer mounting screws.
3. Perform the Capacitor Discharge proce-
dure.
4. Using the 3/8” nut driver, remove the case
back.
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F-57
F-57
TROUBLESHOOTING & REPAIR
AUXILIARY TRANSFORMER NO. 2 REMOVAL AND
REPLACEMENT PROCEDURE (CONTINUED)
REPLACEMENT PROCEDURE
1. Carefully place the transformer into the
Power Wave 455/R.
2. Install the two mounting screws that hold the
transformer to the machine base using the
3/8” nut driver.
3. Connect leads 33 and 32 to circuit breaker
CB4 and the 115 V receptacle.
4. Connect plugs P50 and P52.
5. Reposition any wire leads and install cable
ties as necessary.
6. Install the case back using the 3/8” nut driver.
7. Install the case top, sides, and input access
panel using the 3/8” nut driver.
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F-58
F-58
TROUBLESHOOTING & REPAIR
CONTROL, FEED HEAD, OR VOLTAGE SENSE PC BOARD
REMOVAL AND REPLACEMENT
WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician
or machine operator and will invalidate your factory warranty. For your safety and to avoid
electrical shock, please observe all safety notes and precautions detailed throughout this
manual.
If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou-
bleshooting assistance before you proceed. Call 1-800-833-9353 (WELD).
DESCRIPTION
This procedure will aid the technician in the removal and replacement of either the
Control Board the Feed Head Board, or the Voltage Sense Board.
MATERIALS NEEDED
3/8” Nut driver
Anti-static wrist strap
This procedure should take approximately 15 minutes to perform.
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F-59
F-59
TROUBLESHOOTING & REPAIR
CONTROL, FEED HEAD, OR VOLTAGE SENSE PC BOARD
REMOVAL AND REPLACEMENT (CONTINUED)
FIGURE F.22 – CONTROL OR FEED HEAD BOARD REMOVAL AND REPLACEMENT
COMPARTMENT
COVER
CONTROL
BOARD
POWER
BOARD
REMOVAL PROCEDURE
6. Using the 3/8” nut driver, remove the two
screws holding the rear of the Control Box in
place.
1. Remove input power to the Power Wave
455/R.
2. Using the 3/8” nut driver, remove the case
7. Clear the leads in the sleeving and the grom-
mets on the sides of the control box.
top and sides.
3. Perform the Capacitor Discharge proce-
8. Label and remove the molex plugs from the
Control Board and the Feed Head Board.
dure.
4. Observe all static electricity precautions.
5. Using the 3/8” nut driver, remove the PC
board compartment cover. Refer to Figure
F.22.
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F-60
F-60
TROUBLESHOOTING & REPAIR
CONTROL, FEED HEAD, OR VOLTAGE SENSE PC BOARD
REMOVAL AND REPLACEMENT (CONTINUED)
FIGURE F.23 – VOLTAGE SENSE BOARD REMOVAL AND REPLACEMENT
COMPARTMENT
COVER
CONTROL
BOARD
VOLTAGE
SENSE
BOARD
POWER
BOARD
9. Tilt back the rear of the control box to
REPLACEMENT PROCEDURE
access the PC board mounting nuts. Using
the 3/8” nut driver, remove the self-locking
mounting nuts from the Control and Feed
1. Install either the Control or the Feed Head
Board to the back of the control box with the
self-locking nuts. Use the 3/8” nut driver.
Head Boards.
boards.
Carefully remove the
2. Connect the molex plugs to the Control
Board and the Feed Head Board. Be sure
the lead harnesses are securely and proper-
ly positioned.
10. Remove plugs J1 and J2 from the Voltage
Sense Board. See Figure F.23.
11. Using the needle-nose pliers, carefully
pinch the three plastic standoffs. Remove
the Voltage Sense Board.
3. Secure the rear of the control box in place
using two screws and the 3/8” nut driver.
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F-61
F-61
TROUBLESHOOTING & REPAIR
CONTROL, FEED HEAD, OR VOLTAGE SENSE PC BOARD
REMOVAL AND REPLACEMENT (CONTINUED)
3. Secure the rear of the control box in place
using two screws and the 3/8” nut driver.
4. Press the Voltage Sense Board onto its
standoffs. Make sure the board snaps into
place on all three standoffs.
5. Connect the two molex plugs to the Voltage
Sense Board.
6. Install the PC board compartment cover
using the 3/8” nut driver.
7. Install the case top and sides using the 3/8”
nut driver.
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F-62
F-62
TROUBLESHOOTING & REPAIR
GATEWAY PC BOARD REMOVAL AND REPLACEMENT
WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician
or machine operator and will invalidate your factory warranty. For your safety and to avoid
electrical shock, please observe all safety notes and precautions detailed throughout this
manual.
If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou-
bleshooting assistance before you proceed. Call 1-800-833-9353 (WELD).
DESCRIPTION
This procedure will aid the technician in the removal and replacement of the Gateway PC
Board.
MATERIALS NEEDED
Phillips head screw driver
3/8” Nut driver
Anti-static wrist strap
This procedure should take approximately 15 minutes to perform.
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F-63
F-63
TROUBLESHOOTING & REPAIR
GATEWAY PC BOARD REMOVAL AND REPLACEMENT (CONTINUED)
FIGURE F.24 – GATEWAY BOARD REMOVAL AND REPLACEMENT
DEVICENET/
GATEWAY BOARD
(LOCATED BEHIND
FRONT COVER)
PHILLIPS
SCREW
REMOVAL PROCEDURE
REPLACEMENT PROCEDURE
1. Remove input power to the Power Wave
455/R.
1. Install the Gateway Board to the case front
cover with the self-locking nuts. Use the 3/8”
nut driver.
2. Using the phillips head screw driver, remove
the six screws from the case front cover. Tilt
open the cover and support it. See Figure
F.24.
2. Connect the four molex plugs to the
Gateway Board.
3. Using the phillips head screw driver, attach
the cover to the case front.
3. Observe all static electricity precautions.
4. Label and remove the four molex plugs from
the Gateway Board.
5. Using the 3/8” nut driver, remove the self-
locking mounting nuts from the Gateway
Board. Carefully remove the board. Refer
to Figure F.24.
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F-64
F-64
TROUBLESHOOTING & REPAIR
STT CURRENT TRANSDUCER
REMOVAL AND REPLACEMENT
WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician
or machine operator and will invalidate your factory warranty. For your safety and to avoid
electrical shock, please observe all safety notes and precautions detailed throughout this
manual.
If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou-
bleshooting assistance before you proceed. Call 1-800-833-9353 (WELD).
DESCRIPTION
This procedure will aid the technician in the removal and replacement of the STT Current
Transducer.
MATERIALS NEEDED
3/8” Nut driver
5/16” Open end wrench
5/16” Socket wrench with extension
Universal adapter
3/4” Wrench
Phillips head screw driver
Wire cutters
Wiring Diagram
This procedure should take approximately 25 minutes to perform.
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F-65
F-65
TROUBLESHOOTING & REPAIR
STT CURRENT TRANSDUCER
REMOVAL AND PLACEMENT (CONTINUED)
FIGURE F.25 – STT CURRENT TRANSDUCER REMOVAL AND REPLACEMENT PROCEDURE
RESISTOR
ASSEMBLY
1234
P90
STT OUTPUT
TERMINAL
CURRENT
(TOP RIGHT)
TRANSDUCER
REMOVAL PROCEDURE
5. Label and remove the leads to the resistor
assembly. See Figure F.25. Using the
5/16” socket wrench, extension and univer-
sal adapter, remove the resistor assembly.
It may be necessary to remove the glastic
high voltage protection shield. (Use the
3/8” nut driver.) It may also be necessary to
use a 5/16” open end wrench to remove the
inside screws. Carefully swing the resistor
assembly aside.
1. Remove input power to the Power Wave
455/R.
2. Using the 3/8” nut driver, remove the case
top and right side.
3. Perform the Capacitor Discharge proce-
dure.
4. Using the wire cutters, cut all cable ties to
the transducer lead harness. Unplug the
harness and swing it aside.
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F-66
F-66
TROUBLESHOOTING & REPAIR
STT CURRENT TRANSDUCER
REMOVAL AND REPLACEMENT (CONTINUED)
6. With the 5/16” open end wrench, remove
the small screw from the STT output termi-
nal. Label and remove the small leads.
See the Wiring Diagram.
3. Attach the double heavy leads to the STT
output terminal with the 3/4” bolt, lock wash-
er and flat washer.
4. Attach the small leads to the STT output ter-
7. Using the 3/4” wrench, remove the bolt,
lock washer and flat washer from the STT
output terminal. Remove the double heavy
output leads. Cut any necessary cable
ties.
minal with the 5/16” screw.
5. Install the resistor assembly using the 5/16”
socket wrench, extension and universal
adapter. Install the glastic high voltage pro-
tection shield with the 3/8” nut driver.
8. Using the phillips head screw driver,
remove the screws and lock washers that
hold the transducer to the front panel.
6. Replace all cable ties cut during removal.
7. Install the case top and right side using the
3/8” nut driver.
9. Remove the STT current transducer, care-
fully feeding the output leads through it.
10. Remove the standoffs from the transducer
and save them for reassembly with the new
transducer.
REPLACEMENT PROCEDURE
1. Attach the standoffs to the transducer.
2. Position the transducer on the back of the
front panel and attach it with the two
phillips screws and lock washers. Feed the
output leads through the transducer.
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F-67
F-67
TROUBLESHOOTING & REPAIR
POWER WAVE CURRENT TRANSDUCER
REMOVAL AND REPLACEMENT
WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician
or machine operator and will invalidate your factory warranty. For your safety and to avoid
electrical shock, please observe all safety notes and precautions detailed throughout this
manual.
If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou-
bleshooting assistance before you proceed. Call 1-800-833-9353 (WELD).
TEST DESCRIPTION
This procedure will aid the technician in the removal and replacement of the Power Wave
Current Transducer.
MATERIALS NEEDED
3/8” Nut driver
5/16” Open end wrench
9/16” Wrench
3/4” Wrench
Phillips head screw driver
Wire cutters
Wiring Diagram
This procedure should take approximately 25 minutes to perform.
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F-68
F-68
TROUBLESHOOTING & REPAIR
POWER WAVE CURRENT TRANSDUCER
REMOVAL AND REPLACEMENT (CONTINUED)
FIGURE F.26 – POWER WAVE CURRENT TRANSDUCER REMOVAL AND REPLACEMENT PROCEDURE
CURRENT
TRANSDUCER
HEAVY LEAD
BOLTED CONNECTION
(BEHIND CASE FRONT)
REMOVAL PROCEDURE
6. Label all leads to all output terminals. Using
the 5/16” wrench and the 3/4” wrench,
remove all leads from the three output termi-
nals. See the Wiring Diagram.
1. Remove input power to the Power Wave
455/R.
2. Using the 3/8” nut driver, remove the case
top and sides and the control box cover.
7. Cut any necessary cable ties. Then careful-
ly swing the front panel aside.
3. Perform the Capacitor Discharge proce-
dure.
8. Remove the insulating tape from the heavy
lead bolted connection. See Figure F.26.
Using the 9/16” wrenches, remove the bolt,
lock washer and nut.
4. Using the 3/8” socket wrench or nut driver,
remove the three screws along the bottom
case front. See Figure F.26.
5. Using the 3/8” socket wrench, remove the
four screws that hold the case front to the
machine.
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F-69
F-69
TROUBLESHOOTING & REPAIR
POWER WAVE CURRENT TRANSDUCER
REMOVAL AND REPLACEMENT (CONTINUED)
9. Using the phillips head screw driver,
remove the screws and lock washers that
hold the transducer to the front panel.
4. Using the 5/16” wrench and the 3/4” wrench,
attach all leads to the three output terminals.
See the Wiring Diagram.
10. Remove the Power Wave current trans-
ducer.
5. Replace all cable ties cut during removal.
6. Install the case top and sides using the 3/8”
11. Remove the standoffs from the transducer
and save them for reassembly with the
new transducer.
nut driver.
REPLACEMENT PROCEDURE
1. Attach the standoffs to the transducer.
2. Position the transducer on the back of the
front panel and attach it with the two
phillips screws and lock washers. Feed the
output leads through the transducer.
3. Run the heavy lead through transducer
and secure the bolted connection with the
9/16” bolt, lock washer and nut. Replace
the insulating tape around the connection.
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F-70
F-70
TROUBLESHOOTING & REPAIR
OUTPUT RECTIFIER, STT CHOPPER BOARD AND RECTIFIER MODULE
REMOVAL AND REPLACEMENT
WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician
or machine operator and will invalidate your factory warranty. For your safety and to avoid
electrical shock, please observe all safety notes and precautions detailed throughout 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 procedure will aid the technician in the removal and replacement of the output recti-
fier assembly and individual rectifier module replacement.
This procedure takes approximately 35 minutes to remove and replace the output rectifi-
er, 5 minutes to remove the STT Chopper Board and 5 minutes to remove and replace the
rectifier module.
MATERIALS NEEDED
3/8” Nut driver
7/16” Wrench
9/16” Wrench
9/64” Allen wrench
3/16” Allen wrench
Needle-nose pliers
Slot head screwdriver
Penetrox A13 Thermal Joint Compound
Wiring Diagram
This procedure should take approximately 45 minutes to perform.
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F-71
F-71
TROUBLESHOOTING & REPAIR
OUTPUT RECTIFIER, STT CHOPPER BOARD AND RECTIFIER MODULE
REMOVAL AND REPLACEMENT (CONTINUED)
FIGURE F.27 – OUTPUT RECTIFIER, STT CHOPPER BOARD AND RECTIFIER MODULE
REMOVAL AND REPLACEMENT
RECTIFIER
THERMOSTAT
(LEADS 291 & 292)
LEAD 287
(SNUBBER
DIODE)
LEAD 289B
(STT SNUBBER
CAPACITOR)
PLUG J10
TRANSFORMER
LEADS
STT LEAD
RECTIFIER
MODULE
HEATSINK
MOUNT
BOLTS (4X)
POSITIVE
OUTPUT
LEAD
HEATSINK
RECTIFIER ASSEMBLY
REMOVAL PROCEDURE
1. Remove input power to the Power Wave
455/R.
5. Using the 7/16” wrench, remove the STT
output lead from the rectifier heat sink. Note
fastener hardware for reassembly. Refer to
Figure F.27.
2. Using the 3/8” nut driver, remove the case
top and sides.
6. Using the 7/16” wrench, remove the eight
transformer leads from the rectifier modules.
Label the leads and take note of lead place-
ment for reassembly. Note that each screw
has two flat washers and one lock washer.
3. Perform the Capacitor Discharge proce-
dure.
4. Using the 9/16” wrench, remove the Power
Wave positive output lead from the rectifier
heat sink. Note fastener hardware for
reassembly. Refer to Figure F.27.
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F-72
F-72
TROUBLESHOOTING & REPAIR
OUTPUT RECTIFIER, STT CHOPPER BOARD AND RECTIFIER MODULE
REMOVAL AND REPLACEMENT (CONTINUED)
7. Using the needle-nose pliers, remove
leads #292 and #291 from the rectifier ther-
mostat.
4. Using the 3/16” allen wrench, remove the
four screws and lock washers holding the
board to the heat sink.
8. Disconnect plug J10 from the STT
Chopper Board.
5. Carefully remove the STT Chopper Board.
9. With the 7/16” wrench, remove lead #287
REPLACEMENT PROCEDURE
from the STT Snubber Diode D5.
1. Position the new board on the heat sink,
using the standoffs for the slot head nylon
screws and the allen head screws.
10. With the 7/16” wrench, remove lead #289B
from the STT Snubber Capacitor C10.
11. Using the 7/16” wrench, remove the four
nuts and associated washers from the heat
sink mounting bolts. The heat-sink assem-
bly can be removed by carefully sliding the
assembly forward and removing the mount-
ing bolts.
2. Install the four 3/16” allen head screws and
lock washers.
3. Install the two nylon slot head screws.
4. Install the two 7/16” bolts, lock washers and
flat washers.
STT CHOPPER BOARD REMOVAL
AND REPLACEMENT PROCEDURE
1. Place the output rectifier assembly on a
clean bench surface.
2. Using a slot head screw driver, remove the
two nylon screws holding the board to the
heat sink. Save the standoffs for reassem-
bly.
3. Using the 7/16” wrench, remove the two
bolts, lock washers and flat washers. Save
the standoffs for reassembly.
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F-73
F-73
TROUBLESHOOTING & REPAIR
OUTPUT RECTIFIER, STT CHOPPER BOARD AND RECTIFIER MODULE
REMOVAL AND REPLACEMENT (CONTINUED)
RECTIFIER MODULE REMOVAL AND RECTIFIER ASSEMBLY REPLACE-
REPLACEMENT PROCEDURE
MENT PROCEDURE
1. Using the 9/64” allen wrench, remove the
cap screw from the center of the rectifier
module that is to be replaced.
1. Position the assembly in place with the
mounting bolts.
2. Assemble the nuts and associated wash-
ers to the mounting bolts.
2. Using the 7/16” wrench, remove the two
mounting bolts and associated washers
from the rectifier module to be replaced.
3. Using the 7/16” wrench, tighten the four
nuts on the mounting bolts.
3. Remove the faulty module.
4. Replace leads #292 and #291 to the ther-
mostat.
4. This module requires special mounting con-
siderations to prevent warping of the base
plate. The heat sink surfaces must be clean
and flat. Apply a thin, even coating of ther-
mal compound, (Penetrox A13) 0.004 to
0.010 inches thick. Keep the compound
away from the area of the mounting holes.
5. Connect plug J10 to the STT Chopper
Board.
6. With the 7/16” wrench, attach lead #287
from the STT Snubber Diode D5.
7. With the 7/16” wrench, attach lead #289B
5. Press the new module firmly against the
heat sink while aligning the mounting holes.
Start all three screws two to three turns by
hand.
from the STT Snubber Capacitor C10.
8. Connect the eight transformer leads to the
correct rectifier modules. Tighten the
screws (with two flat washers and one lock
washer) to between 30 and 40 in/lbs. Do
not stress the terminals when making
these connections.
6. Tighten each of the outer screws to between
5 and 10 in-lbs.
7. Tighten the center screw to between 12 and
18 in-lbs.
9. Apply a thin coat of Penetrox A13 to the
heat sink where the Power Wave positive
output lead and the STT output lead attach.
8. Tighten each of the outer screws again, this
time to between 30 and 40 in/lbs.
10. Attach the Power Wave positive output
lead to the heat sink using the 9/16”
wrench.
11. Attach the STT output lead to the heat sink
using the 7/16” wrench.
12. Install the case top and sides using the 3/8”
nut driver.
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F-74
F-74
TROUBLESHOOTING & REPAIR
SWITCH BOARD AND FILTER CAPACITOR
REMOVAL AND REPLACEMENT
WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician
or machine operator and will invalidate your factory warranty. For your safety and to avoid
electrical shock, please observe all safety 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 procedure will aid the technician in the removal and replacement of the switch
board(s) and/or filter capacitor(s).
MATERIALS NEEDED
3/8” Nut driver
7/16” Wrench
3/16” Allen wrench
Slot head screwdriver
Penetrox A13 thermal joint compound
This procedure should take approximately 25 minutes to perform.
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F-75
F-75
TROUBLESHOOTING & REPAIR
SWITCH BOARD AND FILTER CAPACITOR
REMOVAL AND REPLACEMENT (CONTINUED)
FIGURE F.28 – SWITCH BOARD AND FILTER CAPACITOR REMOVAL AND REPLACEMENT
MOLEX PLUG
MOUNTING
SCREW (4X)
13/14
OR
17/18
SWITCH
BOARD
19+
20-
NYLON
SCREW
(2X)
11/12
OR
15/16
REMOVAL PROCEDURE
4. Using the 5/16” nut driver, remove the three
screws mounting the glastic high voltage
protective shield. Remove the shield.
NOTE: Observe all static electricity precautions.
Lead and plug references below use a slash (/)
to indicate machine right side/left side wire
number differences.
5. Remove molex plug J40/J50 from the top of
the switch board. Refer to Figure F.28.
1. Remove input power to the Power Wave
455/R.
6. Remove the mylar insulating shield covering
leads 13/14 or 17/18. Cut the cable tie.
2. Using the 3/8” nut driver, remove the case
top and sides.
3. Perform the Capacitor Discharge proce-
dure.
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F-76
F-76
TROUBLESHOOTING & REPAIR
SWITCH BOARD AND FILTER CAPACITOR
REMOVAL AND REPLACEMENT (CONTINUED)
7. Using the 7/16” wrench, remove leads
5. Mount the new switch board and tighten
the four cap head screws in the following
manner.
13/14 or 17/18 from the switch board.
8. Using the 7/16” wrench, remove leads
11/12 or 15/16 from the switch board.
Tighten all until snug.
9. Using the 7/16” wrench, remove leads
19C/D+ and 20C/D- from the switch board
capacitor connection bolts.
Tighten all from 24 to 28 in-lbs.
Tighten all from 40 to 48 in-lbs.
6. Make sure the capacitor is positioned cor-
rectly. Connect leads 19C/D+ and 20C/D-
to the correct terminals. Tighten to 55
in/lbs.
10. With the slot head screwdriver, remove the
two nylon mounting screws at the bottom of
the switch board. Note placement of the
shake-proof washers and fiber spacers.
7. Position and mount the two nylon screws,
fiber spacers, and washers. Torque from 4
to 8 in-lbs.
11. Using the 3/16” allen wrench, carefully
remove the four cap screws that mount the
switch board to the heat sink.
8. Connect leads 11/12 or 15/16 to the correct
terminal.
12. Carefully remove the switch board from the
heat sink.
9. Connect leads 13/14 or 17/18 to the correct
terminal.
13. If the filter capacitor is to be removed, care-
fully slide it out of the mounting bracket.
10. Install the mylar insulating shield covering
leads 11/12 or 15/16. Replace the cable
tie.
REPLACEMENT PROCEDURE
11. Connect molex plug J40/J50 to the top of
the switch board.
1. If the filter capacitor is to be replaced, care-
fully slide the new capacitor into the mount-
ing bracket. Position the capacitor so the
correct polarity terminal is lined up with the
correct hole on the switch board.
12. Using the 5/16” nut driver, install the glastic
high voltage protective shield.
13. Install the case top and sides using the 3/8”
2. All heat sink and IGBT mounting surfaces
must be clean.
nut driver.
3. Apply a thin coat of thermal compound
(Penetrox A13) 0.005 to 0.010 inches thick
to the mating surfaces. Do not apply
around mounting holes.
4. Apply a thin coat of Penetrox A13 to the
capacitor terminals. Be careful not to apply
compound to screw threads or threaded
area of terminals.
POWER WAVE 455/R
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F-77
F-77
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 455/R
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F-78
F-78
NOTES
POWER WAVE 455/R
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Section G-1
Section G-1
TABLE OF CONTENTS
- ELECTRICAL DIAGRAMS SECTION -
Electrical Diagrams..............................................................................................................Section G
Wiring Diagram (Code 10675)....................................................................................................G-2
Wiring Diagram (Code 10676)....................................................................................................G-3
Schematic - Complete Machine (Code 10675) ..........................................................................G-4
Schematic - Complete Machine (Code 10676) ..........................................................................G-5
Schematic - Chopper PC Board .................................................................................................G-6
PC Board Assembly - Chopper PC Board..................................................................................G-7
Schematic - DeviceNet/Gateway PC Board ...............................................................................G-8
PC Board Assembly - DeviceNet/Gateway PC Board................................................................G-9
Schematic - Control PC Board .................................................................................................G-10
PC Board Assembly - Control PC Board ..................................................................................G-11
Schematic - Digital Power Supply PC Board............................................................................G-12
PC Board Assembly - Digital Power Supply PC Board ............................................................G-13
Schematic - FeedHead PC Board #1 .......................................................................................G-14
Schematic - FeedHead PC Board #2 .......................................................................................G-15
Schematic - FeedHead PC Board #3 .......................................................................................G-16
PC Board Assembly - FeedHead PC Board.............................................................................G-17
Schematic - Input PC Board.....................................................................................................G-18
PC Board Assembly - Input PC Board......................................................................................G-19
Schematic - Switch PC Board ..................................................................................................G-20
PC Board Assembly - Switch PC Board ...................................................................................G-21
Schematic - Voltage Sense PC Board......................................................................................G-22
PC Board Assembly - Voltage Sense PC Board ......................................................................G-23
Schematic - 40 VDC Bus PC Board.........................................................................................G-24
PC Board Assembly - 40 VDC Bus PC Board..........................................................................G-25
POWER WAVE 455/R
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G-2
G-2
ELECTRICAL DIAGRAMS
WIRING DIAGRAM - POWER WAVE 455/R CODE 10675
POWER WAVETM 455 / R WIRING DIAGRAM
LEFT SIDE OF MACHINE
TO TP6
TO J9
CONTROL BOARD
202
TO
DEVICE NET
3R
3W
TO TP3
202A
1
TO
CB1
J47
J7
FEED HEAD
BOARD
DIGITAL POWER
SUPPLY BOARD
GATEWAY
2
3
4
BOARD
TO SW1
612B
4
-
+
3
743
CB3
10A
1
2
3
1
2
3
4
TO R1
1
TO
J72
AUXILIARY TRANSFORMER #1
5
6
7
8
225
TO
J4
-
741
800
840
J81
W
2
3
4
5
6
223
221
227
222
SOLID
TO CB4
612A
H6
X1
X2
CIRCUIT
BREAKER
H6A
WORK
(550-575)
4
J42
J41
STATE
RELAY
H6
H5
(51V)
U
H5
5
6
7
8
9
10
J1
H1A
TO AUX #2
H5A
H4A
C1
.05/600V
(440-460)
H4
(380-415)
9
153
154
500
540
1
L2
TO
J11
J47
1
L5
2
10
11
12
13
14
15
16
1
2
3
4
TP1
J82
TO
AUX #2
CB4
1
TO J61
CB3
612A
475
477
476
478
TO POWER BD.
RECTIFIER
X3
H4
CB4
J70
TO
J47
2
3
4
6A
S5
444
X3A
TP4
W
N
H3
(220-230)
H2
(200-208)
DEVICENET
CONNECTOR
H3A
H2A
X3
1
539
541
521
522
886
880
RECONNECT PANEL
CIRCUIT
BREAKER
11
12
13
14
15
16
612
H3
(24V)
TO FAN
TO AUX#1
224A
291
2
3
4
5
6
A
B
1
2
3
4
5
6
53
54
TO
S6
D6
346
X4
H1
TO
1
CHOKE
THERM
TO
H2
H1
TO AUX #1
J83
J84
S1
P73
J2VS
CB1
J47
(115V)
X5
R
H1
TO RECT
THERM
+24V
2
3
4
5
894
893
892
J75
251
MAIN CHOKE
L1
268A
226
274
266
2
+24V GND
CAN_H
CAN_L
WIRE
TO
TO SOLID STATE RELAY
444
C
D
E
67A
52
TO FAN
J2
J3
TO
S3
J4
3
4
1
2
3
4
5
6
253
254
FEEDER
TO
CR1
J60
J11
R5
891
1
2
3
4
RECEPTACLE
1
841
842
843
844
845
846
847
J43
FAN
345
7
8
P91
4
3
2
1
TO J8
2
3
4
5
6
7
8
51
216
211
213
212
TO
S6
S6
X3A
X5
TO AUX#1
228
273
267
262
9
CURRENT
TO SOLID STATE RELAY
5
6
7
8
9
10
10
11
12
ROBOTIC/
WIREDRIVE
INTERFACE
RECEPTACLE
+
J71
J72
TRANSDUCER
THIS AREA VIEWED FROM
REAR OF MACHINE
TO J5
7
8
9
10
TO
S1
224
MAIN
DC BUS
BOARD
TO J6,J10B
N.B.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
851
852
853
854
855
856
857
858
859
860
861
862
512
511
220
220A
TRANSFORMER
1
2
3
743
741
800
840
53
224A
OUTPUT
RECT
TO C3
POS
POS
NEG
NEG
LEFT SIDE
S2
TO
J81
1
2
3
4
5
6
7
8
9
1
267
266
268
RECONNECT SWITCH
A
B
C
D
E
F
G
H
I
J
K
L
M
N
841
844
842
843
845
846
847
1
2
L4
2
3
4
VOLTAGE
TO
J9
TO
J46
21A
4
1
SENSE
SWITCH BD #2
19D
292
RECT
THERM
16
TO
TO
S1
3
4
RECONNECT
PANEL
13
14
SWITCH BD #1
RECEPTACLE
54
2
228
226
227
221
TO
J73
J74
19C
TO
S7
CHOKE
TO SW1
51
500
50
540
475
476
477
478
1
2
3
4
5
6
7
8
3
4
1
2
1
3 CONDUCTOR
THERM
J4
J85
SEC
(TOP
LEFT)
PRI
(TOP
LEFT)
TWISTED/SHIELDED
SHIELD GROUND TO CASE
TO
291
TO
J42
J43
R5
1
2
3
4
5
6
SWITCH
BD #2
TO
N.C.
TO AUX #1
H2
POS
253
254
CB1
J41
J82
TO
TO
67B
539
541
200-208V
220-230V
380-415V
440-460V
J47
J83
S3
J84
INPUT RECT
10
11
12
TO
J1VS
222
223
225
892
893
D4
TO
S5
2
3
4
5
6
1
2
3
4
J2VS
TO
J2
H3
H4
H5
S1
TO
RS232
'A
F4
F4
18
SWITCH BD #1
J75
J76
J40
'
891
894
1
2
3
CONNECTOR
251
7
TO
20C
521
522
20D
224
220
RECT
THERM
J5
220A
SWITCH BOARD
#1
20
TO RECT
THERM
TO
DC BUS
THERM
P
1
2
3
SWITCH BD #2
4
12
830
NEG
292
1
231
232
R
S
T
U
V
W
X
52
50
+
TO
L2
BUSS BD
CB1
TO
2
3
4
3500µF
BD
CHOPPER
2.7 10W
INPUT RECT
4
10A CIRCUIT
BREAKER
500V
GND-A
PRI
TO
5
6
C4
.022
800V
J86
SEC
(BOTTOM
LEFT)
(BOTTOM SWITCH
COLLECTOR
1
S8
1
2
350
352
504
503
406
405
238
505
5
6
7
8
9
10
LEFT)
BD #1
TO
11
7
8
9
10
12
TO D5
WATER
COOLER
345
J20
J40
J50
287
TO
MAIN TRANSFORMER
TO
AUX #2
20C 19C
D3
2
3
4
5
6
3
4
4R
346
TO
WORK
ELECTRODE
TO C8
289A
J10
J6
F3
F3
33A
14
RECEPTACLE
TP3
1
2
3
4
5
16
11 12
15
TO RECONNECT SWITCH
11
12
13
14
15
16
4W
289B
TO C10
S7
604
506
403
404
12 PIN
EMITTER
CONNECTOR
S4
115V
851
1
262
R5
15
6
7
TO
J4
TO
WORK
STT
2.7 10W
852
853
854
855
856
857
858
859
860
861
862
2
3
4
5
6
7
8
9
RECEPTACLE
INPUT BOARD
TP6
J43
.022
800V
1
8
9
268
J87
1
PRI
TO
601
2
3
4
268A
TO
ROBOT
IFACE
SWITCH
BD #2
(BOTTOM
RIGHT)
1W
1B
X3
2
3
4
5
6
7
8
10
11
12
13
14
15
16
SEC
(BOTTOM
RIGHT)
TO
J85
31
TO
CR1
J6
POWER BD
RECTIFIER
238
604
232
TO
5
6
7
8
9
10
J60
32
D2
SSR
J10CH
2W
2B
AUX #1
F2
F2
POS
TO
AUX 2
CB2
17
11
10
11
12
TO
VOLTAGE SENSE
SELECT
TO J6, J10B
J7
TO
C3
AUX. #1
RECONNECT
SWITCH
231
TO
D6
AC
X2
AC
BOARD
11
12
13
14
15
16
J47
S1
512
1
NEG
X1
GND-B
GND-A
4W
4R
3R
NEG
J11
POS
TO
INPUT
2
3
4
5
6
TP7
D1
SSR, J10 CHOPPER BD.
17
67
511
TO
J9
J85
202A
206A
RECTIFIER
18
J1
J2
2.7 10W
PRI
1
SEC
(TOP
TO
3W
(TOP
SWITCH
BD #1
TO
J73
TO
WORK
ELECTRODE
2
3
4
5
6
7
8
9
T1
T2
1
RIGHT)
211
212
213
813
811
216
816
812
RIGHT)
50Ω
POS
R
NEG
NEG
NEG
NEG
2
3
4
5
6
1
.022
800V
F1
TO
1
2
TO
TO
S1
S6
67A
67B
P90
P91
C3
POS
CR1
SW1
CB4
AC
AC
AC
1
J61
J8
612
H1D
T3
POS
POS
3
2
13
J50
CB2
7
8
F1
31
33
287
TO
S4
AUX 2
TO J46
POWER BD RECT
2400µF
100V
SWITCH BOARD
#2
10A CIRCUIT
BREAKER
10
D6
1
206
RIGHT SIDE
-
TO J1 VOLTAGE SENSE
2
3
4
+40VDC
WORK
202
67
+
ELECTRODE
S2
+
TO J61
DIODE
J9
STT SNUBBER
DIODE D5
3500µF
500V
STT CURRENT
TRANSDUCER
5
6
1
2
1
2
1
2
3
1W
1B
C5
880
N.A.
288B
288A
TO
J83
T3
T2
T1
TO J60
601
21A
414
418
514
518
154
153
273
274
STATUS LED (R/G)
TO J7
TO
J40,J50
J10A
J10B
TO C10
15 16
AC
AC
886
TO C8
P90
1
2
3
4
TO J8
20D 19D
2W
2B
CR1
812
N.A.
THERMAL LED (Y)
TO J7
813
811
816
X4
+
TO
J11
TO
TO AUX #1
L2
L1
L3
TO
J43
J88
RECONNECT
SWITCH
MAIN
TRANSFORMER
4
NOTES:
TO J9
206
TO SW1
L3A
TO SW1
L1A
P50
5
N.A. PIN NEAREST THE FLAT EDGE OF LED LENS (CATHODE)
ALIGNS WITH BLACK LEAD OF LED SOCKET.
H6
(550-575)
H5
(440-460)
H4
(380-415)
H3
(220-230)
H2
(200-208)
H1
H6A
H5A
H4A
H3A
TO TP6
W
V
U
P52
1
6
N.B. PLACE SWITCH IN APPROPRIATE POSITION FOR INPUT
VOLTAGE. CONNECTION SHOWN IS FOR 380-460V
C2
.05/600V
C6
.05/600V
W
R
TO SUPPLY LINES
350
33A
352
3
2
4
1
TO D5
TP2
TP5
1
4
(115V)
(230V)
OPERATION.
32
33
288D
288E
288F
289D
4
2
288A
288C
TO
CB3
AUX #1
R2
N.C. PLACE "A" LEAD ON APPROPRIATE CONNECTION FOR
INPUT VOLTAGE. CONNECTION SHOWN IS FOR 440-460V
OPERATION.
TO R1
206A
C8
20uF
400V
H2A
H1A
G
2
+
+
STT SNUBBER
TO TP3
2Ω
289E
289F
289A
289C
TO
S4
CB2
TO RECONNECT PANEL (TOP)
TO A SYSTEM GROUND PER
NATIONAL ELECTRICAL CODE.
R3
CAPACITOR BANK
ELECTRODE
STT
A
AUXILIARY TRANSFORMER #2
288B
288C
288D
288E
289B
289C
289D
289E
2Ω
LOAD LINE
J2,J5,J11,
J1VS,J9,J10CH,
J14,J40J42,
J50,J75,J83
TO J61
H1D
TO CONTACTOR
L3A
J8,
J47,J60
J84
J10,J2VS
J74
R4
J41,J46,J72
J73,J76,J81
J82
J3,
J61,J86
J4,J13,
J43,J71
J1,J6,J7
J10,J70,J85
J87
ELECTRICAL SYMBOLS PER E1537
LEAD COLOR CODING
RIGHT SIDE OF MACHINE
C10
2Ω
20uF
SW1
400V
STT SNUBBER
RESISTOR BANK
B=BLACK
G=GREEN
N=BROWN
R=RED
COMPONENT VALUES:
6
1
1
2
1
3
1
5
1
1
7
1
8
1
5
7
4
8
8
POWER
CAPACITORS=MFD/VOLTS
RESISTORS=OHMS/WATTS
TO CONTACTOR
L1A
TO CB3
612B
2
16
3
4
4
6
6
10
9
12
14
U=BLUE
W=WHITE
11-3-2000A
(VIEWED FROM COMPONENT SIDE OF BOARD)
CONNECTOR CAVITY NUMBERING SEQUENCE
G3792
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The wiring diagram specific to your code is pasted inside one of the enclosure panels of your machine.
POWER WAVE 455/R
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G-3
G-3
ELECTRICAL DIAGRAMS
WIRING DIAGRAM- POWER WAVE 455/R CODE 10676
POWER WAVETM 455 / R WIRING DIAGRAM
LEFT SIDE OF MACHINE
TO TP6
TO J9
CONTROL BOARD
202
TO
DEVICE NET
3R
3W
TO TP3
202A
1
TO
CB1
J47
J7
FEED HEAD
BOARD
DIGITAL POWER
SUPPLY BOARD
GATEWAY
2
3
4
BOARD
TO SW1
612B
4
-
+
3
743
CB3
10A
1
2
3
1
2
3
4
TO R1
1
TO
J72
AUXILIARY TRANSFORMER #1
5
6
7
8
225
TO
J4
-
741
800
840
J81
W
2
3
4
5
6
223
221
227
222
SOLID
TO CB4
612A
H6
X1
X2
CIRCUIT
BREAKER
H6A
WORK
(550-575)
4
J42
J41
STATE
RELAY
H6
H5
(51V)
U
H5
5
6
7
8
9
10
J1
H1A
TO AUX #2
H5A
H4A
C1
.05/600V
(440-460)
H4
(380-415)
9
153
154
500
540
1
L2
TO
J11
J47
1
L5
2
10
11
12
13
14
15
16
1
2
3
4
TP1
J82
TO
AUX #2
CB4
1
TO J61
CB3
612A
475
477
476
478
TO POWER BD.
RECTIFIER
X3
H4
CB4
J70
TO
J47
2
3
4
6A
S5
444
X3A
TP4
W
N
H3
(220-230)
H2
(200-208)
DEVICENET
CONNECTOR
H3A
H2A
X3
1
539
541
521
522
886
880
RECONNECT PANEL
CIRCUIT
BREAKER
11
12
13
14
15
16
612
H3
(24V)
TO FAN
TO AUX#1
224A
291
2
3
4
5
6
A
B
1
2
3
4
5
6
53
54
TO
S6
D6
346
X4
H1
TO
1
CHOKE
THERM
TO
H2
H1
TO AUX #1
J83
J84
S1
P73
J2VS
CB1
J47
(115V)
X5
R
H1
TO RECT
THERM
+24V
2
3
4
5
894
893
892
J75
251
MAIN CHOKE
L1
268A
226
274
266
2
+24V GND
CAN_H
CAN_L
WIRE
TO
TO SOLID STATE RELAY
444
C
D
E
67A
52
TO FAN
J2
J3
TO
S3
J4
3
4
1
2
3
4
5
6
253
254
FEEDER
TO
CR1
J60
J11
R5
891
1
2
3
4
RECEPTACLE
1
841
842
843
844
845
846
847
J43
FAN
345
7
8
P91
4
3
2
1
TO J8
2
3
4
5
6
7
8
51
216
211
213
212
TO
S6
S6
X3A
X5
TO AUX#1
228
273
267
262
9
CURRENT
TO SOLID STATE RELAY
5
6
7
8
9
10
10
11
12
ROBOTIC/
WIREDRIVE
INTERFACE
RECEPTACLE
+
J71
J72
TRANSDUCER
THIS AREA VIEWED FROM
REAR OF MACHINE
TO J5
7
8
9
10
TO
S1
224
MAIN
DC BUS
BOARD
TO J6,J10B
N.B.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
851
852
853
854
855
856
857
858
859
860
861
862
512
511
220
220A
TRANSFORMER
1
2
3
743
741
800
840
53
224A
OUTPUT
RECT
TO C3
POS
POS
NEG
NEG
LEFT SIDE
S2
TO
J81
1
2
3
4
5
6
7
8
9
1
267
266
268
RECONNECT SWITCH
A
B
C
D
E
F
G
H
I
J
K
L
M
N
841
844
842
843
845
846
847
1
2
L4
2
3
4
VOLTAGE
TO
J9
TO
J46
21A
4
1
SENSE
SWITCH BD #2
POS
292
RECT
THERM
16
TO
TO
S1
3
4
RECONNECT
PANEL
13
14
SWITCH BD #1
RECEPTACLE
54
2
228
226
227
221
TO
J73
J74
19C
TO
S7
CHOKE
TO SW1
3 CONDUCTOR
51
500
50
540
475
476
477
478
1
2
3
4
5
6
7
8
3
4
1
2
1
THERM
J4
J85
TWISTED/SHIELDED
SHIELD GROUND TO CASE
SEC
(TOP
LEFT)
PRI
(TOP
LEFT)
TO
291
TO
J42
J43
R5
1
2
3
4
5
6
SWITCH
BD #2
TO
N.C.
TO AUX #1
H2
19
253
254
CB1
J41
J82
TO
TO
67B
539
541
200-208V
220-230V
440-460V
550-575V
J47
J83
S3
J84
HARMONIC
FILTER
10
11
12
TO
J1VS
222
223
225
892
893
D4
TO
S5
2
3
4
5
6
1
2
3
4
J2VS
TO
J2
H3
H5
H6
S1
TO
RS232
'A
F4
F4
18
SWITCH BD #1
J75
J76
J40
'
891
894
1
2
3
CONNECTOR
251
7
TO
NEG
521
522
20D
224
220
RECT
THERM
J5
220A
SWITCH BOARD
#1
20
TO RECT
THERM
TO
DC BUS
THERM
P
1
2
3
SWITCH BD #2
4
12
830
20
292
TO
1
231
232
R
S
T
U
V
W
X
52
50
+
TO
L2
BUSS BD
CB1
HARMONIC
FILTER
2
3
4
3500µF
BD
CHOPPER
2.7 10W
4
10A CIRCUIT
BREAKER
500V
GND-A
PRI
TO
5
6
C4
.022
800V
J86
SEC
(BOTTOM
LEFT)
(BOTTOM SWITCH
COLLECTOR
1
S8
1
2
350
352
504
503
406
405
238
505
5
6
7
8
9
10
LEFT)
BD #1
TO
11
7
8
9
10
12
TO D5
WATER
COOLER
345
J20
J40
J50
287
TO
AUX #2
20C 19C
D3
2
3
4
5
6
TO
3
4
4R
346
TO
WORK
ELECTRODE
MAIN TRANSFORMER
TO C8
289A
J10
J6
F3
F3
33A
14
RECEPTACLE
TP3
1
2
3
4
5
16
11 12
15
11
12
13
14
15
16
TO RECONNECT SWITCH
4W
TO
289B
TO C10
S7
RECONNECT
SWITCH
604
506
403
404
12 PIN
EMITTER
HARMONIC
FILTER
CONNECTOR
S4
19
20
115V
851
1
262
R5
15
6
7
TO
J4
TO
WORK
STT
2.7 10W
852
853
854
855
856
857
858
859
860
861
862
2
3
4
5
6
7
8
9
RECEPTACLE
TP6
J43
.022
800V
1
8
9
268
J87
PRI
TO
2
3
4
268A
TO
ROBOT
IFACE
SWITCH
BD #2
(BOTTOM
RIGHT)
1W
1B
10
11
12
13
14
15
16
SEC
(BOTTOM
RIGHT)
TO
J85
31
POWER BD
RECTIFIER
POS
NEG
TO
5
6
7
8
9
10
32
D2
SSR
J10CH
19D
20C
2W
2B
F2
F2
POS
TO
AUX 2
CB2
17
11
10
11
12
VOLTAGE SENSE
SELECT
TO J6, J10B
J7
TO
C3
AUX. #1
TO
D6
AC
X2
AC
BOARD
11
12
13
14
15
16
J47
S1
INPUT BOARD
512
1
NEG
X1
GND-B
GND-A
4W
4R
3R
J11
TO
INPUT
2
3
4
5
6
1
TP7
D1
601
X3
238
604
232
SSR, J10 CHOPPER BD.
17
18
67
511
TO
J9
J85
202A
206A
RECTIFIER
2
3
4
J1
J2
2.7 10W
PRI
SEC
(TOP
TO
TO
CR1
J6
3W
(TOP
SWITCH
BD #1
TO
J73
TO
WORK
ELECTRODE
1
RIGHT)
211
212
213
813
811
216
816
812
RIGHT)
50Ω
J60
POS
R
NEG
NEG
NEG
NEG
5
2
3
4
5
6
1
.022
800V
F1
TO
AUX #1
6
7
8
1
2
TO
S1
S6
67A
67B
P90
P91
C3
POS
AC
AC
AC
J8
POS
POS
3
2
1
231
13
J50
CB2
7
8
F1
1
2
3
4
5
31
33
287
TO
S4
AUX 2
TO J46
POWER BD RECT
2400µF
100V
SWITCH BOARD
10A CIRCUIT
BREAKER
T1
T2
D6
#2
1
206
RIGHT SIDE
-
TO J1 VOLTAGE SENSE
2
3
4
+40VDC
TO
WORK
202
67
+
ELECTRODE
S2
+
TO J61
DIODE
CR1
SW1
CB4
J9
J61
STT SNUBBER
DIODE D5
3500µF
6
612
H1D
T3
STT CURRENT
TRANSDUCER
500V
5
6
1
2
1
2
1
2
3
7
8
9
1W
1B
C5
880
N.A.
288B
288A
TO
J83
T3
T2
T1
TO J60
601
21A
414
418
514
518
154
153
273
274
STATUS LED (R/G)
TO J7
TO
J40,J50
J10A
J10B
TO C10
15 16
AC
AC
886
TO C8
P90
1
2
3
4
10
TO J8
20D 19D
2W
2B
CR1
812
N.A.
THERMAL LED (Y)
TO J7
813
811
816
X4
+
J11
TO
TO AUX #1
L2
L1
TO
L3
TO
J43
J88
RECONNECT
SWITCH
MAIN
4
NOTES:
TRANSFORMER
TO J9
206
TO SW1
L3A
TO SW1
L1A
P50
H6
(550-575)
H5
N.A. PIN NEAREST THE FLAT EDGE OF LED LENS (CATHODE)
ALIGNS WITH BLACK LEAD OF LED SOCKET.
5
6
H6A
H5A
H4A
H3A
TO TP6
W
V
U
P52
1
N.B. PLACE SWITCH IN APPROPRIATE POSITION FOR INPUT
VOLTAGE. CONNECTION SHOWN IS FOR 440-575V
C2
.05/600V
C6
.05/600V
(440-460)
H4
(380-415)
H3
(220-230)
H2
(200-208)
H1
W
R
TO SUPPLY LINES
350
33A
352
3
2
4
1
TO D5
TP2
TP5
1
4
(115V)
(230V)
OPERATION.
32
33
288D
288E
288F
289D
4
2
288A
288C
TO
CB3
AUX #1
R2
N.C. PLACE "A" LEAD ON APPROPRIATE CONNECTION FOR
INPUT VOLTAGE. CONNECTION SHOWN IS FOR 550-575V
OPERATION.
TO R1
206A
C8
20uF
400V
H2A
H1A
G
2
+
+
STT SNUBBER
TO TP3
2Ω
289E
289F
289A
289C
TO
S4
CB2
TO RECONNECT PANEL (TOP)
TO A SYSTEM GROUND PER
NATIONAL ELECTRICAL CODE.
R3
CAPACITOR BANK
ELECTRODE
STT
A
AUXILIARY TRANSFORMER #2
288B
288C
288D
288E
289B
289C
289D
289E
2Ω
LOAD LINE
J2,J5,J11,
J1VS,J9,J10CH,
J14,J40J42,
J50,J75,J83
TO J61
H1D
TO CONTACTOR
L3A
J8,
J47,J60
J84
J10,J2VS
J74
R4
J41,J46,J72
J73,J76,J81
J82
J3,
J61,J86
J4,J13,
J43,J71
J1,J6,J7
J10,J70,J85
J87
ELECTRICAL SYMBOLS PER E1537
LEAD COLOR CODING
RIGHT SIDE OF MACHINE
C10
2Ω
20uF
SW1
400V
STT SNUBBER
RESISTOR BANK
B=BLACK
G=GREEN
N=BROWN
R=RED
COMPONENT VALUES:
6
1
1
2
1
3
1
5
1
6
1
7
1
8
1
5
7
4
8
8
POWER
CAPACITORS=MFD/VOLTS
RESISTORS=OHMS/WATTS
TO CONTACTOR
L1A
TO CB3
612B
2
16
3
4
4
6
10
9
12
14
U=BLUE
5-11-2001F
W=WHITE
(VIEWED FROM COMPONENT SIDE OF BOARD)
CONNECTOR CAVITY NUMBERING SEQUENCE
G4010
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The wiring diagram specific to your code is pasted inside one of the enclosure panels of your machine.
POWER WAVE 455/R
Download from Www.Somanuals.com. All Manuals Search And Download.
G-4
G-4
ELECTRICAL DIAGRAMS
SCHEMATIC - COMPLETE MACHINE 10675
.022u
800V
2.7
10W
N.A.
MAIN TRANSFORMER T1
SWITCH BOARD #1 (LEFT)
N.A.
RECONNECT
SWITCH
F
CONTROL BOARD
2.7
10W
.022u
800V
+
ELECTRODE
INPUT
RECTIFIER
S3 RS232
CONNECTOR
A
380-460V
208-230V
S
13
CR1
19C
19D
206
2.7
10W
AC3
POS
.022u
800V
206A
C2
.05uF
600V
TP2
320V
160J
L1
OUTPUT DIODES
D1-D4
RS232 RECEIVE
F
3J2
4J2
253
254
T1
2
14
POS
U
B
RS232 TRANSMIT
3
S
1J9
+ELECTRODE VOLTAGE SENSE
AC2
R1
50
NEG
TP3
150V
80J
2.7
10W
L2
L3
T2
T3
.022u
800V
4
11
V
CURRENT
TRANSDUCER
414
418
403
404
405
406
1J40
2J40
3J40
4J40
5J40
6J40
CT CURRENT (-)
CT CURRENT (+)
IGBT DRIVE (+)
V/F (+)
5
AC1
NEG
+
3J9
- ELECTRODE VOLTAGE SENSE
ARC LINK H
202
202A
12
+
20C
20D
W
G
NEG
6
1J11
154
153
ELECTRODE
-
1J2
251
RS232 COMMON
ARC LINK L
7
CR1
2J11
6J8
C4
MAIN
CHOKE
L1
(CAP "A")
3500uF
500V
D6
20
N.A.
216
211
213
212
CONTROL BOARD COMMON
886
880
TP1
320V
160J
C1
.05uF
600V
FEED HD BD
P91
1J8
3J8
2J8
CURRENT FEEDBACK
V/F (-)
TP6
150V
80J
3J83
X4
521
522
539
541
841
842
843
844
845
846
847
851
852
853
854
855
856
857
858
859
860
861
862
SOLENOID +40VDC
-15V
+15
S2 VOLTAGE SENSE
RECEPTACLE
IGBT DRIVE (-)
601
N.A.
4J83
SOLENOID INPUT
INPUT BOARD
1J83
2J83
1J84
2J84
3J84
4J84
5J84
6J84
7J84
1J85
2J85
3J85
4J85
5J85
6J85
7J85
8J85
9J85
MOTOR "+"
N.C.
1
C10
C8
816
811
813
812
7J8
CONTROL BOARD COMMON
STT FEEDBACK
N.A.
ON
1J60
+13V
2J60
X3
CURRENT
TRANSDUCER
SW1
POWER
MOTOR "-"
2
SWITCH BOARD #2 (RIGHT)
5J8
4J8
8J8
D5
L4
+
5J60
OFF
232
R2
6J9
21A
WORK VOLTAGE SENSE
-15V
3
4
N.C.
+15VDC TACH
R3
R4
STT
+
H1D
MAIN CONTACTOR CONTROL
+15V
TACH 1A DIFF. INPUT
TACH 1B DIFF. INPUT
TACH COMMON
A
612B
CHOPPER BOARD
S
8J7
4W
4R
13J7
14J7
STT CHOPPER DRIVE (-)
STT CHOPPER DRIVE (+)
2B
THERMAL LED
THERMAL LED
15
8J61
10J61
2J61
4J60
T3
T1
TP5
320V
160J
C6
.05uF
600V
C
YELLOW
THERMAL
LED
P90
F
17
6J61
612
6J6
5J6
503
504
IGBT DRIVE (+)
V/F (+)
7J7
3J7
+13V
2W
S
514
518
503
504
505
506
1J50
2J50
3J50
4J50
5J50
6J50
CT CURRENT (-)
CT CURRENT (+)
IGBT DRIVE (+)
V/F (+)
16
TACH 2A DIFF. INPUT
TACH 2B DIFF. INPUT
SINGLE TACH INPUT
AUX. RECONNECT
604
D
F
+
STATUS LED (HI FOR RED)
1W
H2
18
200-208V
A
PRECHARGE RELAY
+20V STT
1J10
345
346
10J6
14J6
V/F (-)
505
506
6J10
3J10
H3
H4
4W
4R
220-230V
380-415V
440-460V
COMMON
4J10
4J61
T2
15
16
RED/GREEN
STATUS
LED
IGBT DRIVE (-)
C5
(CAP "B")
3500uF
500V
H5
TRIGGER +15VDC
TRIGGER INPUT
3J60
8J60
1J10B
+13V
514
CT CURRENT (-)
238
231
STATUS LED (HI FOR GREEN)
4J7
V/F (-)
1B
2J10B
15J6
CT CURRENT (+)
IGBT DRIVE (+)
SINGLE PHASE DETECT
(LOW=1 PHASE)
518
403
IGBT DRIVE (-)
DUAL PROC. INPUT
S6 ROBOTIC
INTERFACE
RECEPTACLE
16J6
8J6
404
405
V/F (+)
V/F (-)
4 STEP INPUT
N.A.
6J83
+40VDC
+40VDC
880
GATEWAY BD
1J73
COLD INCH +15VDC
COLD IN. FORWARD
COLD IN. REVERSE
841
844
842
843
845
846
847
5J83
2J82
886
154
A
B
C
D
E
F
G
I
TACH +15VDC
TACH COMMON
ARCLINK -
53
54
7J6
1J10A
2J10A
406
414
IGBT DRIVE (-)
ARCLINK
ARCLINK L
ARCLINK H
ARCLINK L
COMMON
+40VDC
H
TACH 1A DIFF SIGNAL
TACH 1B DIFF SIGNAL
TACH 2A DIFF SIGNAL
TACH 2B DIFF SIGNAL
SINGLE TACH INPUT
VOLTAGE SENSE
MOTOR "+"
1J76
830
2J73
ARCLINK +
1J82
2J81
1J81
153
741
743
800
840
500
540
511
512
CT CURRENT (-)
3J76
2J72
1J72
3J72
4J72
ARCLINK H
ARCLINK L
COMMON
+40VDC
418
224
CT CURRENT (+)
GAS PURGE INPUT
SHUTDOWN +15VDC
67B
539
541
521
522
224A
CHOKE
THERMOSTAT
J
K
N
P
T
2J5
MOTOR "-"
THERMOSTAT
291
(NORMALLY CLOSED)
SOLENOID +40VDC
SOLENOID INPUT
3J81
4J81
}
3J5
THERMOSTAT
220A
220
3W
292
SHUTDOWN 1 INPUT
SHUTDOWN 2 INPUT
10J85
11J85
12J85
GND-A
16J7
FAN CONTROL (-)
FAN CONTROL (+)
OUTPUT RECTIFIER
THERMOSTAT
DCBUS
THERMOSTAT
COMMON
3J82
5J75
2J75
1J75
4J75
894
893
892
891
+24VDC
S7 I/O
RECEPTACLE
15J7
3J4
3R
R5
10
INPUT B
4J82
+40VDC
VOLTAGE SENSE SELECT (-)
VOLTAGE SENSE SELECT (+)
+24V GND
CAN_H
262
268
+5V SPI
+13V
851
852
853
854
855
856
857
858
859
860
861
862
TRIGGER +15VDC
TRIGGER INPUT
DUAL PROC. INPUT
4 STEP INPUT
1
2
14J85
13J85
268A
3
9J6
12J6
1J6
238
604
231
232
CAN_L
4
5
COLD INCH +15VDC
COLD IN. FORWARD
COLD IN. REVERSE
GAS PURGE INPUT
SHUTDOWN +15VDC
SHUTDOWN 1 INPUT
SHUTDOWN 2 INPUT
INPUT B
PRECHARGE CONTROL
6
SINGLE PHASE DETECT
(LOW=1 PHASE)
7
8
9
2J6
MAIN CONTACTOR CONTROL
VOLTAGE SENSE
10
11
12
SOLID STATE RELAY
VOLT SENSE BD
N.A.
N.A.
3R
+
4J9
POWER BOARD
67
X3A
444
S1 WIRE FEEDER
RECEPTACLE
2J2
ROBOTIC VOLTAGE SENSE
VOLTAGE SENSE SELECT (-)
67B
L5
AUXILIARY
TRANSFORMER T1
TP4
266
267
227
2J4
+15V SPI
6J43
+15V SPI
4J1
1J1
3J1
1J2
511
512
67
H6
(550-575)
H5
(440-460)
H4
3W
A
B
C
D
E
ARCLINK -
ARCLINK +
ELECTRODE SENSE
+40VDC
53
H6A
H5A
SPI COMMON
1J4
7J4
11J43
4J42
SPI COMMON
-
VOLTAGE SENSE SELECT (+)
VOLTAGE SENSE OUTPUT
X3
7J43
1J43
0V
345
346
STT +20V
54
67A
52
POWER BD. RECT.
X3
POWER DOWN INTERUPT
STT COMMON
POWER DOWN INTERUPT
FAN
(380-415)
24V
H4A
H3A
X4
POS
225
221
222
223
12J4
H3
1J42
3J42
5J42
2J42
WIRE FEEDER VOLTAGE SENSE
67A
+15V
+15V
(220-230)
65VDC
C3
12J43
3J43
262
SPI COMMON
+5V
115V
24000uF/100V
X5
X1
8J4
+5V
H2
0VDC
51
CB4
6A
NEG
(200-208)
268A
SPI +5V
CONTROL BOARD COMMON
H2A
H1
DC BUS BD
10J4
52V
CONTROL BOARD COMMON
-15V
N.A.
H1
612
X2
-15V
11J4
4J11
3J11
TRANSFORMER T2
P80
2J47
4J47
COMMON
500
540
ARCLINK +5V
5J43
10J43
4J43
274
273
226
228
+5V ARCLINK +5V
ARCLINK COMMON
RS232 +5V
5J47
7J47
6J47
8J47
475
477
476
478
1J41
COMMON
+40VDC POWER
+40VDC POWER
+40V COMMON
S5 DEVICENET
CONNECTOR
H6
5
(550-575)
352
33A
2
4
S8 WATER COOLER
RECEPTACLE
H6A
H5A
230V
115V
0V
ARCLINK COMMON
+40V
352A
33
2
2J41
3J41
4J41
H5
6
(440-460)
612B
612A
6J4
5J4
CB2
RS232 +5V
2
894
893
892
891
+24VDC
+24V GND
CAN_H
+40V COMMON
COMMON
10A
H4
3
1
H4A
H3A
H2A
H1A
33
4
1
9J43
RS232 COMMON
+40V
RS232 COMMON
3
4
5
(380-415)
1J46
2J46
POS
POS
+40VDC POWER
350
3
H3
2
L2
32
(220-230)
COMMON
1J47
3J47
51
NOTES :
H2
4
CAN_L
32
31
CB3
10A
52
+40VDC FEEDER
50
(200-208)
N.A. PC BOARD COMPONENTS SHOWN FOR
REFERENCE ONLY. ALL COMPONENTS
ARE NOT SHOWN.
3J46
4J46
NEG
NEG
CB1
H1
1
S4
110V
RECEPTACLE
10A
N.C. R2, R3 AND R4 ARE 2 /300.
C8 AND C10 ARE 20 mfd/400V.
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
ELECTRICAL SYMBOLS PER E1537
"X" INFO.
Chg. Sheet No.
XB
DESIGN INFORMATION
REFERENCE:
MANUFACTURING TOLERANCE PER E2056
EQUIPMENT TYPE:
INVERTER WELDERS
ON
ON
2
3
PLACEDECIMALS IS .02
PLACE DECIMALS IS .002
DRAWN BY:
KJ
G3450
11-3-2000A
ON ALL ANGLES IS .5 OF ADEGREE
SUBJECT:
PW455/R MACHINE SCHEMATIC
7/11/00
MATERIAL TOLERANCE (" ") TO AGREE
WITH PUBLISHED STANDARDS.
ENGINEER: KJ
SUPERSEDING:
t
APPROVED:
SCALE:
NONE
DATE:
DRAWING No.:
3791
G
DO NOT SCALE THIS DRAWING
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
POWER WAVE 455/R
Download from Www.Somanuals.com. All Manuals Search And Download.
G-5
G-5
ELECTRICAL DIAGRAMS
SCHEMATIC-COMPLETE MACHINE CODE 10676
.022u
800V
27.
10W
N.A.
MAIN TRANSFORMER T1
SWITCH BOARD #1 (LEFT)
N.A.
F
CONTROL BOARD
27.
10W
.022u
800V
+
ELECTRODE
RECONNECT
SWITCH
S3 RS232
CONNECTOR
A
S
INPUT
RECTIFIER
13
380-460V
208-230V
206
27.
10W
.022u
800V
CR1
206A
C2
.05uF
600V
TP2
320V
160J
OUTPUT DIODES
D1-D4
RS232 RECEIVE
F
3J2
4J2
253
254
2
14
19C
19
AC3
AC2
AC1
POS
L1
T1
HARMONIC
FILTER
B
POS
RS232 TRANSMIT
3
S
U
V
1J9
+ELECTRODE VOLTAGE SENSE
R1
50
TP3
150V
80J
27.
10W
.022u
800V
19D
4
11
NEG
CURRENT
TRANSDUCER
L2
L3
T2
T3
414
418
403
404
405
406
1J40
2J40
3J40
4J40
5J40
6J40
CT CURRENT (-)
CT CURRENT (+)
IGBT DRIVE (+)
V/F (+)
20C
5
+
3J9
- ELECTRODE VOLTAGE SENSE
ARC LINK H
202
202A
12
+
6
NEG
1J11
154
153
ELECTRODE
20
-
W
G
1J2
251
RS232 COMMON
ARC LINK L
7
NEG
2J11
6J8
C4
MAIN
CHOKE
L1
(CAP "A")
3500uF
500V
20D
CR1
D6
20
216
211
213
212
CONTROL BOARD COMMON
886
880
TP1
320V
160J
C1
.05uF
600V
N.A.
FEED HD BD
P91
1J8
3J8
2J8
CURRENT FEEDBACK
V/F (-)
TP6
150V
80J
3J83
X4
521
522
539
541
841
842
843
844
845
846
847
851
852
853
854
855
856
857
858
859
860
861
862
SOLENOID +40VDC
-15V
+15
S2 VOLTAGE SENSE
RECEPTACLE
IGBT DRIVE (-)
601
N.A.
4J83
SOLENOID INPUT
INPUT BOARD
1J83
2J83
1J84
2J84
3J84
4J84
5J84
6J84
7J84
1J85
2J85
3J85
4J85
5J85
6J85
7J85
8J85
9J85
MOTOR "+"
N.C.
1
C10
C8
816
811
813
812
7J8
CONTROL BOARD COMMON
STT FEEDBACK
N.A.
ON
1J60
+13V
2J60
X3
CURRENT
TRANSDUCER
SW1
POWER
MOTOR "-"
2
SWITCH BOARD #2 (RIGHT)
5J8
4J8
8J8
D5
L4
+
5J60
OFF
232
R2
WORK VOLTAGE SENSE
-15V
6J9
21A
3
4
N.C.
+15VDC TACH
R3
R4
STT
+
H1D
MAIN CONTACTOR CONTROL
+15V
TACH 1A DIFF. INPUT
TACH 1B DIFF. INPUT
TACH COMMON
A
612B
CHOPPER BOARD
S
8J7
4W
4R
13J7
14J7
STT CHOPPER DRIVE (-)
STT CHOPPER DRIVE (+)
2B
THERMAL LED
THERMAL LED
15
8J61
10J61
2J61
4J60
T3
T1
TP5
320V
160J
C6
.05uF
600V
C
YELLOW
THERMAL
LED
P90
F
17
6J61
612
6J6
5J6
503
504
IGBT DRIVE (+)
V/F (+)
7J7
3J7
+13V
2W
S
514
518
503
504
505
506
1J50
2J50
3J50
4J50
5J50
6J50
CT CURRENT (-)
CT CURRENT (+)
IGBT DRIVE (+)
V/F (+)
16
TACH 2A DIFF. INPUT
TACH 2B DIFF. INPUT
SINGLE TACH INPUT
AUX. RECONNECT
604
D
F
+
STATUS LED (HI FOR RED)
1W
H2
18
200-208V
A
PRECHARGE RELAY
+20V STT
1J10
345
346
10J6
14J6
V/F (-)
505
506
6J10
3J10
H3
H5
4W
4R
220-230V
440-460V
550-575V
COMMON
4J10
4J61
T2
15
16
RED/GREEN
STATUS
LED
IGBT DRIVE (-)
C5
(CAP "B")
3500uF
500V
H6
TRIGGER +15VDC
TRIGGER INPUT
3J60
8J60
1J10B
+13V
514
CT CURRENT (-)
238
231
STATUS LED (HI FOR GREEN)
4J7
V/F (-)
1B
2J10B
15J6
CT CURRENT (+)
IGBT DRIVE (+)
SINGLE PHASE DETECT
(LOW=1 PHASE)
518
403
IGBT DRIVE (-)
DUAL PROC. INPUT
S6 ROBOTIC
INTERFACE
RECEPTACLE
16J6
8J6
404
405
V/F (+)
V/F (-)
4 STEP INPUT
N.A.
6J83
+40VDC
+40VDC
880
GATEWAY BD
1J73
COLD INCH +15VDC
COLD IN. FORWARD
COLD IN. REVERSE
841
844
842
843
845
846
847
5J83
2J82
886
154
A
B
C
D
E
F
G
I
TACH +15VDC
TACH COMMON
ARCLINK -
53
54
7J6
1J10A
2J10A
406
414
IGBT DRIVE (-)
ARCLINK
ARCLINK L
ARCLINK H
ARCLINK L
COMMON
+40VDC
H
TACH 1A DIFF SIGNAL
TACH 1B DIFF SIGNAL
TACH 2A DIFF SIGNAL
TACH 2B DIFF SIGNAL
SINGLE TACH INPUT
VOLTAGE SENSE
MOTOR "+"
1J76
830
2J73
ARCLINK +
1J82
2J81
1J81
153
741
743
800
840
500
540
511
512
CT CURRENT (-)
3J76
2J72
1J72
3J72
4J72
ARCLINK H
ARCLINK L
COMMON
+40VDC
418
224
CT CURRENT (+)
GAS PURGE INPUT
SHUTDOWN +15VDC
67B
539
541
521
522
224A
CHOKE
THERMOSTAT
J
K
N
P
T
2J5
MOTOR "-"
THERMOSTAT
291
(NORMALLY CLOSED)
SOLENOID +40VDC
SOLENOID INPUT
3J81
4J81
}
3J5
THERMOSTAT
220A
220
3W
292
SHUTDOWN 1 INPUT
SHUTDOWN 2 INPUT
10J85
11J85
12J85
GND-A
16J7
FAN CONTROL (-)
FAN CONTROL (+)
OUTPUT RECTIFIER
THERMOSTAT
DCBUS
THERMOSTAT
COMMON
3J82
5J75
2J75
1J75
4J75
894
893
892
891
+24VDC
S7 I/O
RECEPTACLE
15J7
3J4
3R
R5
10
INPUT B
4J82
+40VDC
VOLTAGE SENSE SELECT (-)
VOLTAGE SENSE SELECT (+)
+24V GND
CAN_H
262
268
+5V SPI
+13V
851
852
853
854
855
856
857
858
859
860
861
862
TRIGGER +15VDC
TRIGGER INPUT
1
2
3
4
5
6
7
8
9
14J85
13J85
268A
DUAL PROC. INPUT
4 STEP INPUT
9J6
12J6
1J6
238
604
231
232
CAN_L
COLD INCH +15VDC
COLD IN. FORWARD
COLD IN. REVERSE
GAS PURGE INPUT
SHUTDOWN +15VDC
PRECHARGE CONTROL
SINGLE PHASE DETECT
(LOW=1 PHASE)
2J6
MAIN CONTACTOR CONTROL
VOLTAGE SENSE
SHUTDOWN 1 INPUT 10
SHUTDOWN 2 INPUT 11
SOLID STATE RELAY
VOLT SENSE BD
N.A.
N.A.
3R
+
4J9
POWER BOARD
67
12
INPUT B
X3A
444
S1 WIRE FEEDER
RECEPTACLE
2J2
ROBOTIC VOLTAGE SENSE
VOLTAGE SENSE SELECT (-)
67B
L5
AUXILIARY
TRANSFORMER T1
TP4
266
267
227
2J4
+15V SPI
6J43
+15V SPI
4J1
1J1
3J1
1J2
511
512
67
H6
(550-575)
H5
(440-460)
H4
3W
A
B
C
D
E
ARCLINK -
ARCLINK +
ELECTRODE SENSE
+40VDC
53
H6A
H5A
SPI COMMON
1J4
7J4
11J43
4J42
SPI COMMON
-
VOLTAGE SENSE SELECT (+)
VOLTAGE SENSE OUTPUT
X3
7J43
1J43
0V
345
346
STT +20V
54
67A
52
POWER BD. RECT.
X3
POWER DOWN INTERUPT
STT COMMON
POWER DOWN INTERUPT
FAN
(380-415)
24V
H4A
H3A
X4
POS
225
221
222
223
12J4
H3
1J42
3J42
5J42
2J42
WIRE FEEDER VOLTAGE SENSE
67A
+15V
+15V
(220-230)
65VDC
C3
12J43
3J43
262
SPI COMMON
+5V
115V
24000uF/100V
X5
X1
8J4
+5V
H2
0VDC
51
CB4
6A
NEG
(200-208)
268A
SPI +5V
CONTROL BOARD COMMON
H2A
H1
DC BUS BD
10J4
52V
CONTROL BOARD COMMON
-15V
N.A.
H1
612
X2
-15V
11J4
4J11
3J11
TRANSFORMER T2
P80
2J47
4J47
COMMON
500
540
ARCLINK +5V
5J43
10J43
4J43
274
273
226
228
+5V ARCLINK +5V
ARCLINK COMMON
RS232 +5V
5J47
7J47
6J47
8J47
475
477
476
478
1J41
COMMON
+40VDC POWER
+40VDC POWER
+40V COMMON
S5 DEVICENET
CONNECTOR
H6
5
(550-575)
352
33A
2
4
S8 WATER COOLER
RECEPTACLE
H6A
H5A
230V
115V
0V
ARCLINK COMMON
+40V
352A
2
2J41
3J41
4J41
H5
6
(440-460)
612B
612A
6J4
5J4
CB2
RS232 +5V
2
894
893
892
891
+24VDC
+24V GND
CAN_H
+40V COMMON
COMMON
10A
H4
3
1
H4A
H3A
H2A
H1A
33
4
1
33
9J43
RS232 COMMON
+40V
RS232 COMMON
3
4
5
(380-415)
1J46
2J46
POS
POS
+40VDC POWER
350
3
H3
2
L2
32
(220-230)
COMMON
1J47
3J47
51
NOTES :
H2
4
CAN_L
32
31
CB3
10A
52
+40VDC FEEDER
50
(200-208)
N.A. PC BOARD COMPONENTS SHOWN FOR
REFERENCE ONLY. ALL COMPONENTS
ARE NOT SHOWN.
3J46
4J46
NEG
NEG
CB1
H1
1
S4
110V
RECEPTACLE
10A
N.C. R2, R3 AND R4 ARE 2 /300.
C8 AND C10 ARE 20 mfd/400V.
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
ELECTRICAL SYMBOLS PER E1537
"X" INFO.
XB-S
Chg. Sheet No.
5-11-2001F
DESIGN INFORMATION
REFERENCE:
MANUFACTURING TOLERANCE PER E2056
EQUIPMENT TYPE:
INVERTER WELDERS
ON
ON
2
3
PLACEDECIMALS IS .02
PLACE DECIMALS IS .002
DRAWN BY:
LW
G3719
ON ALL ANGLES IS .5 OF ADEGREE
SUBJECT:
PW455/R MACHINE SCHEMATIC
9/11/00
MATERIAL TOLERANCE (" ") TO AGREE
WITH PUBLISHED STANDARDS.
ENGINEER: TR
SUEPRSEDING:
t
APPROVED:
SCALE:
NONE
DATE:
DRAWING No.:
4009
G
DO NOT SCALE THIS DRAWING
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
POWER WAVE 455/R
Download from Www.Somanuals.com. All Manuals Search And Download.
G-6
G-6
ELECTRICAL DIAGRAMS
SCHEMATIC - CHOPPER PC BOARD
DZ1
L
-
C
D-
+15
+15
+15
+15
X4
IN
OUT
14
D1
D2
D4
R1
16
1
8
GND
1
C20
1.0
63V
C21
0.1
50V
X3
VS
VS
J10
+
t
C1
500
50V
C2
C3
0.1
50V
C6
1.0
63V
C7
C8
1.0
63V
C9
0.1
50V
C10
0.1
50V
X1
X2
.24
14 to 22 Vac
4093B
7
50
0.1
MIC4451BN
25V
50V
MC14538B
4
GND GND
J10
8
4
5
D3
KJ.
5
com
J10
J10
com
com
com
2
3-9
(
FINME:L340-1CA
LJ
+15
From Bridge
R9
301
R10
301
3
D5
1.0A
30V
20
17
14
11
8
5
2
1
8
7
RST
VS
VS
C1 C2 C3 C4 C5 C6 C7
R11
301
19
16
13
10
X2
G1
B
A
/Q
5
4
7
6
2
IN
OUT
OUT
GND
X1
G2
G3
G4
G5
G6
G7
Q
T2
3
4
6
NC
GND
R12
301
T1
A1
5
1
2
C18
.47
630Vdc
MIC4451BN
40N60B3
7
4
1
R13
301
DZ1
D6
R14
301
E1 E2 E3
21
E4 E5 E6 E7
12
15V
1W
1.0A
30V
C14
.0047
50V
18
15
9
6
3
R15
301
To STT Output
C'geShtNo.
com
com
+15
13
RST
+15
B
/Q
11
9
X1
A
Q
T2
12
10
T1
15
14
From Bridge
R16
301
C23
4.7
35V
R17
301
3.32K
20
17
14
11
8
5
2
C1 C2 C3 C4 C5 C6 C7
19
R18
301
3
G1
16
13
10
J10
com
G2
G3
G4
G5
G6
G7
R19
301
A2
D7
332
C19
.47
40N60B3
6
5
9
8
7
4
1
R20
301
630Vdc
1
13
12
4
10
R4
3.32K
X3
R27
X3
R6
PWM
INPUT
3
11
X3
X3
2
3.32K
475
1
5
R21
301
E1 E2 E3
E4 E5 E6 E7
C11
.0047
50V
21
18
15
12
9
6
3
C15
100p
100V
C16
100p
100V
C17
820p
50V
OCI1
CNY17-3
C12
C13
R22
301
820p
50V
100p
100V
To STT Output
2
6
4
C22
150p
50V
6
J10
com
R25
221K
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
POWER WAVE 455/R
Download from Www.Somanuals.com. All Manuals Search And Download.
G-7
G-7
ELECTRICAL DIAGRAMS
PC BOARD ASSEMBLY -CHOPPER
ITEM
REQ'D PART NO.
IDENTIFICATION
500/50
C1
C2
1
1
5
3
2
2
3
2
1
1
T11577-49
S13490-8
S16668-11
S13490-173
S16668-10
S16668-7
S16668-3
S20500-2
S16668-9
S13490-25
50/25
C3,C7,C9,10,C21
C6,C8,C20
C11,C14
C12,C17
C13,C15,C16
C18,C19
C22
.1/50
CAP.,MPF,1.0 uF,63VDC
4700pF/50
820pF/50
100pF/100
.47/630
150pF/100
4.7/35
C23
D1,D2,D3,D4,D7
D5,D6
5
2
T12199-1
1N4004
1N5818
T12705-23
DZ1
J10
1
1
1
T12702-29
S20351-6
S15000-10
1N4744A
.04
HEADER
5.50
OCI1
OPTO ISOLATOR
R1
1
1
3
1
1
2
S18380-5
THERM.,PTC,.5-1.17 OHM, .5A
332 1/4W
R2
S19400-3320
S19400-3321
S19400-4752
S19400-4750
S19400-4751
B48
B49
R3,R4,R27
3.32K 1/4W
R5
47.5K 1/4W
R6
475 1/4W
R8,R23
4.75K 1/4W
R15
R9,R10,R11,R12,R13,R14,
R23
R8
R15,R16,R17,R18,R19,R20,
14 S19400-3010
301 1/4W
R16
C10
D6
C6
R21,R22
R25
DZ1
D5
1
1
S19400-2213
S19400-3323
221K 1/4W
332K 1/4W
R26
C7
C21
X1
X2
X3
X4
1
1
1
1
S15018-9
S15018-21
S15018-15
S15128-6
CMOS MC14538B
X2
C8
IC,DRIVER,12A MOSFET(SS)
14 PIN IC
C9
X1
VOLTAGE REGULATOR
x
x
x
x
xx
xxx
x
x
x
x
xx
xxx
x
D7
C23
x
C17
C16
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
R6
x
x
x
x
x
x
x
x
x
x
CAPACITORS = MFD/VOLTS
RESISTORS = OHMS
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
C20
X3
C18
C19
C13
R27
C1
x
x
x
x
x
x
x
xx
xx
xxx
xxx
x
x
C2
X4
C11
OCI1
J10
B55
B53
.45
0
.04
7.50
0
4.00
1.30
1.30
:
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
"X" INFO.
Chg. Sheet No.
2-11-2000
8-4-2000J
9-22-2000A
DESIGN INFORMATION
REFERENCE:
MANUFACTURING TOLERANCE PER E2056
EQUIPMENT TYPE:
INVERTER WELDERS
ON
ON
2
3
PLACEDECIMALS IS .02
PLACE DECIMALS IS .002
DRAWN BY:
JLV/RAS
G3135-1
ON ALL ANGLES IS .5 OF ADEGREE
SUBJECT:
CHOPPER P.C. BOARD ASSEMBLY
2-23-98
MATERIAL TOLERANCE (" ") TO AGREE
ENGINEER: KJ
SUPERSEDING:
t
WITH PUBLISHED STANDARDS.
APPROVED:
SCALE:
1:1
DATE:
DRAWING No.:
DRS
3339-1
G
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 WAVE 455/R
Download from Www.Somanuals.com. All Manuals Search And Download.
G-8
G-8
ELECTRICAL DIAGRAMS
SCHEMATIC-DEVICENET/GATEWAY PC BOARD
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
POWER WAVE 455/R
Download from Www.Somanuals.com. All Manuals Search And Download.
G-9
G-9
ELECTRICAL DIAGRAMS
PC BOARD ASSEMBLY-DEVICENET/GATEWAY
ITEM
P A R T N O .
G3820-D
Q T Y
P C B O A R D R E F E R E N C E
D E S I G N A T O R S
D E S C R I P T I O N
G A T E W A Y P C B O A R D B L A N K
P L U G , K E Y I N G P L U G
P O T T I N G T R A Y
1
2
3
4
5
6
7
8
1
1
1
2
S24671
M19436-5
S8025-80
E2527
E 3 5 3 9
S24824-3
S24825-1
(5.84)
S E L F T A P P I N G S C R E W
195g.
A S R E Q .
(6. 87OZ) E P O X Y E N C A P S U L A T I N G R E S I N
E L E C T R I C A L I N S U L A T I N G C O M P O U N D
S O F T W A R E C P L D
1
1
X 1 1
X 1 3
S O F T W A R E , F L A S H
F O R I T E M S L I S T E D B E L O W R E F E R T O E L E C T R O N I C C O M P O N E N T D A T A B A S E F O R C O M P O N E N T S P E C I F I C A T I O N S
9
S 2 5 0 2 0 - 1 3 S M T
S 2 5 0 2 4 - 8 S M T
S13490-179
S 2 5 0 2 4 - 5 S M T
S 2 5 0 2 4 - 6 S M T
S 2 5 0 2 4 - 2 S M T
S 2 5 0 2 0 - 3 S M T
2
5
1
4
4
C 2 , C 7
C3, C4, C5, C6, C8
C 9
CAPACITOR, SMD, CERAMIC, 150pF, 100V, 5%, C
C A P A C I T O R , S M D , T A N T A L U M , 1 0 M F , 1 6 V , 1 0 % , S
CAPACITOR, ALEL, 1000, 35V, 20%
C A P A C I T O R , S M D , T A N T A L U M , 4 . 7 M F , 3 5 V , 1 0 % ,
C A P A C I T O R , S M D , T A N T A L U M , 2 2 M F , 1 6 V , 1 0 % , S
C A P A C I T O R , S M D , T A N T A L U M , 1 . 0 M F , 3 5 V , 1 0 % ,
CAPACITOR, SMD, CERAMIC, 0. 1MF, 50V, 10%, X
10
11
12
13
14
15
C10,C13,C27,C30
C11,C12,C43,C60
C14,C16,C20,C25
C15,C17,C18,C19,C21,C22
C23,C24,C26,C28,C31,C32
C33,C35,C36,C37,C38,C41
C42,C44,C45,C46,C47,C48
C49,C50,C51,C53,C54,C58
4
30
16
17
18
19
20
21
22
23
S 2 5 0 2 0 - 1 5 S M T
S13490-182
S13490-181
S 2 5 0 4 0 - 1 0 S M T
S 2 5 0 4 0 - 9 S M T
S 2 5 0 4 0 - 2 S M T
S 2 5 0 4 0 - 1 1 S M T
S 2 5 0 4 0 - 4 S M T
3
1
1
2
1
3
3
8
C29, C39, C40
C 5 6
C 5 9
D1, D5
D 2
D3, D6, D21
D4, D16, D20
D7, D8, D9, D10, D12, D13, D14
D 1 5
C A P A C I T O R , S M D , C E R A M I C , 2 2 P F , 5 0 V , 5 % , C O G
C A P ,ALEL,3300,63V,20%
C A P ,ALEL,22,63V,20%
DIODE, SMD, 3A, 400V, D0-214AB
DIODE, SMD, 3A, 200V, D0-214AB, ULTRA-FAST
DIODE, SMD, 1A, 400V, DO-214BA/AC
DIODE, S M D, 1A , 600V , S 403A , ULT RA - F A S T RE
DIODE, SMD, DUAL, 0. 200A, 70V, UFR
24
25
26
27
28
29
S 2 5 0 4 9 - 3 S M T
S 2 5 0 4 9 - 4 S M T
S 2 5 0 4 0 - 5 S M T
S 2 5 0 4 6 - 1 S M T
S 2 5 0 4 6 - 3 S M T
S 2 5 0 4 4 - 9 S M T
1
1
6
1
4
7
D 1 7
D 1 9
D I O DE, SMD, 3A, 40V, SCHOTTKY, CASE 403-3
D I O D E , S M D , D U A L , 2 0 0 M A , 3 0 V , S C H O T T K Y , S O T
DIODE, SMD, DUAL, 0. 200A, 70V, UFR
Z E N E R D I O D E , S M D , 0 . 5 W , 5. 1V, 5%, SOD123
Z E N E R D I O D E , S M D , 0 . 5 W , 18V, 5%, SOD123
D22,D23,D24,D25,D26,D27
D Z 1
DZ2, DZ3, DZ4, DZ5
DZ6, DZ7, DZ8, DZ10, DZ11, DZ12 Z E N E R D I O D E , S M D , 3 W , 6 . 2 V , 5 % , S M B
D Z 1 3
30
31
32
33
34
35
S18248-16
S18248-10
S24020-4
S24020-2
S24020-6
1
1
3
1
1
6
J70
J71
J72,J73,J76
J74
J75
C O N N E C T O R , M O L E X , M I N I,PCB,16-PIN
C O N N E C T O R , M O L E X , M I N I,PCB,10-PIN
C O N N E C T O R , M O L E X , M I N I,PCB,4-PIN,TIN
C O N N E C T O R , M O L E X , M I N I,PCB,2-PIN,TIN
C O N N E C T O R , M O L E X , M I N I,PCB,6-PIN,TIN
L E D , S M D , G R E E N , C L E A R , S 1 2 0 6
S 2 5 0 8 0 - 2 S M T
LED1, LED2, LED3, LED5, LED7
L E D 9
36
37
38
39
40
41
42
43
S 2 5 0 8 0 - 1 S M T
3
4
2
5
6
6
2
25
L E D 4 , L E D 6 , L E D 8
O C I1,O C I2,O C I3,O C I4
O C I5,O C I6
Q2, Q4, Q5, Q12, Q13
Q6, Q7, Q8, Q9, Q10, Q11
R1,R2,R39, R40, R66, R67
R3, R4
R5, R8, R9, R10, R11, R12, R13
R14,R15,R16,R17,R19,R20
R21,R22,R23,R24,R25,R29
R34,R35,R42,R60,R61,R69
L E D , S M D , R E D , C L E A R , S 1 2 0 6
S 1 5 0 0 0 - 2 8 S M T
S 1 5 0 0 0 - 3 2 S M T
S 2 5 0 5 0 - 2 S M T
O P T O C O U P L E R , S M D , T T L - O U T , H I - S P D , H I - C M R
O P T O C O U P L E R , S M D , C M O S , H I G H S P E E D , H I G H
TRANSISTOR, SMS, PNP, SOT23, 0. 5A, 40V, MM
TRANSISTOR, SMD, NM F, SOT-23, 0. 115A, 60V,
R E S IS T O R ,S M D ,METAL FILM, 1/10W , 4 7 5 O H M S
R E S IS T O R ,S M D ,1W , 200OHMS, 1%
(6.34)
S 2 5 0 5 1 - 4 S M T
S 25000- 4750S M T
S25003-2000SMT
S 25000- 1002S M T
R E S IS T O R ,S M D ,METAL FILM, 1/10W ,10.0K,1
44
45
46
47
48
49
50
51
S 25000- 4751S M T
S 25000- 1001S M T
S25001-1002SMT
S 25000- 1501S M T
S 25001- 3320S M T
S 25000- 7500S M T
S25001-1211SMT
S 25001- 2670S M T
5
6
2
1
6
3
2
7
R6, R38, R43, R45, R101
R18, R37, R41, R65, R68, R100
R27, R28
R E S IS T O R ,S M D ,METAL FILM, 1/10W ,4.75K,1
R E S IS T O R ,S M D ,METAL FILM, 1/10W ,1.00K,1
R E S IS T O R ,S M D ,10K,1/4W ,1206,1%,TR
R E S IS T O R ,S M D ,METAL FILM, 1/10W ,1.50K,1
R E S IS T O R ,S M D , 332OHMS,1/4W ,1206,1% ,TR
R E S IS T O R ,S M D ,METAL FILM, 1/10W , 7 5 0 O H M S
R E S IS T O R ,S M D ,1.21K,1/4W ,1206,1%,TR
R E S IS T O R ,S M D , 267OHMS, 1/4W ,1206,1% ,TR
R 3 0
R31,R32,R33,R46,R47,R72
R36, R44, R76
R48, R49
R50,R51,R52,R53,R57,R58
R 5 9
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
70
71
72
73
74
75
S 25000- 1000S M T
S 2 5 0 0 1 - 2 4 R 9 S M T
S 25001- 2000S M T
S18380-5
S19869-8
S20375-8
S 2 0 3 5 3 - 1 S M T
S 1 5 1 2 8 - 2 5 S M T
S 2 5 0 6 8 - 6 S M T
S 1 5 1 2 8 - 5 S M T
S24841-1
S 2 5 0 6 8 - 7 S M T
S 2 5 0 6 9 - 2 S M T
M 1 5 1 0 1 - 1 4 S M T
S 2 5 0 7 0 - 3 S M T
S 2 5 0 6 9 - 3 S M T
S 1 7 9 0 0 - 1 1 S M T
S 2 5 0 6 9 - 4 S M T
S 2 0 3 5 3 - 5 S M T
S 2 0 3 5 3 - 4 S M T
S 2 5 0 6 8 - 4 S M T
S 1 7 9 0 0 - 2 4 S M T
S 2 5 0 6 5 - 2 S M T
S 2 5 0 8 2 - 1 S M T
6
3
3
1
2
1
1
1
2
1
1
2
1
1
1
1
1
1
2
2
1
1
1
1
R54,R55,R56,R80,R81,R82
R E S IS T O R ,S M D ,METAL FILM, 1/10W , 1 0 0 O H M S
R E S IS T O R ,S M D ,24.9OHMS,1/4W ,1206,1%,TR
R E S IS T O R ,S M D , 200OHMS, 1/4W ,1206,1% ,TR
THERMISTOR, PTC, 0. 5-1. 17 OHMS, 0. 5A
S W ITCH, DIP, SPST, 8-CIRCUITS
R73, R74, R75
R77, R78, R79
R 8 3
S1, S2
T 1
X 2
X 3
X4, X24
X 5
X 6
X7, X9
X 8
X 1 0
X 1 1
X 1 3
X 1 4
X 1 5
X16, X18
X17, X22
X 2 0
T R A N S F O R M E R , P C B , P W M , F L Y B A C K
I C , S MD, CMOS, DRIVER, RECEIVER, EIA232, 14
I C , S M D , V O L T A G E R E G U L A T O R , F I X E D , P O S I T I
IC,SMD,VOLT REG,FIXED,3-T,(+),0.1A,5V
IC,VOLT REG,SMD,FIXED,3-T,(+),1A,5V
I C , M O D U L E , C O N V E R T E R , D C - D C , + 5 V / 3 A O U T
I C , S M D , C M O S , U N D E R V O L T - S E N S I N G , R E S E T , M
IC, SMD, CMOS, EEPROM, SERIAL, SPI, 64Kx8, S
IC, SMD, CMOS, MCU, 32-BIT, 2K-RAM, TPU, 25M
C P L D , P R O G R A M M A B L E , X C 9 5 3 6 ,44-PIN,VQFP(
I C , S MD, CMOS, EEPROM, FLASH, 16-BIT, 512K
I C , S M D , C M O S , T R A N C E I V E R , B U S , 3 - S T A T E , O C
RAM, STATIC, 16-BIT, 128K, 44-PIN, TSOP
I C , C M O S , C O N T R O L L E R , C O M M U N I C A T I O N , S E R I
IC, CMOS, SMD, XCVR, EIA485(SS)
.
IC, SMD, TRANSCEIVER, CAN, UC5350, S0IC-8
I C , S M D , C M O S , G A T E , N A N D , 2 - I N P U T , Q U A D , S C
I C , S M D, A CT , LA T CH, O CT A L, 3- S T A T E , T S S O P -
C R Y S T A L , S M D , Q U A R T Z , 16M HZ
X 2 3
X 3 1
Y 1
UNLESS OTHERWISE SPECIFIED:
RESISTANCE = OHMS
.
11-3-2000A
L11046-1
NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your factory warranty. Individual Printed Circuit Board Components are not available from Lincoln Electric. This information is pro-
vided for reference only. Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician. Improper PC board repairs could result in damage to the
machine.
POWER WAVE 455/R
Download from Www.Somanuals.com. All Manuals Search And Download.
G-10
G-10
ELECTRICAL DIAGRAMS
SCHEMATIC - CONTROL PC BOARD
475
+15V
+5V
3
BAV70LT1
D89
2
R16
J7
3
475
R9
6
+5V
J7
+5V
1
MISCR0 42
2
1
Q1
2
74AC573
X24
MMBT4401
11
1
DATA[0:15]
19 DATA0
18 DATA1
17 DATA2
16 DATA6
15 DATA7
14 DATA11
13 DATA3
12 DATA8
(4)
(4)
R18
C94 C107
475
LE
OE'
D 2 4
84
25
/RES
4.75K
7
VDDSYN
VDDE
C15
C105 C93 C109 C106
J7
J7
J7
J7
1 8 V
1R01.07K0
38
10.0K
R261
VSTDBY
2
3
4
5
6
7
8
9
W 1 . 5
1uF
35V
1uF
35V
D
D
D
D
D
D
D
D
X21
Q
Q
Q
Q
Q
Q
Q
Q
1
1
11
26
2
B 5 M 9 3 1 1 S
VSSE
X21
11
R10
R171
11
100pF
0.1uF 0.1uF 0.1uF 0.1uF
475
C95
1
X21
11
1
1
1
1
15
14
Q15
MC68332
X21
MMBT4403
C99
MMBT4401
1
3
1.00K
X21
11
11
0.1uF
3
NOISE_GND
R14
X21
R19
1
1
475
D
+5V
VPP
5
X21
11
J7
0.1uF
Q4
2
+15V
475
X21
R43
R172
MISC1
D 2 9
10.0K
R17
475
D
D
1 8 V
R8
R90
1
2
4.75K
C18
CAP1
7 4 A C 1 4
V 7 0 B L A T 1
D 8 4
W 1 . 5
22.1K
C119 C110 C120 C108
10.0K
R260
X10
(2,4)
B 5 M 9 3 1 1 S
9
8
+5V
D
1.00K
16
8
D 9
J6
J6
100pF
C44
0.1uF
0.1uF
3
22uF
20V
22uF
20V
+5V
5 . 1 V
W 1 / 2
S Z 5 M 2 3 M 1
X25
C111
14
13
37
4700pF
WP' VPP
RP' VCC
C143
330pF
R 2 5 5
3
+15V
MMBT4401
NOISE_GND
3
/RES 12
+5V
1 K
R 2 5 6
R20
BAV70LT1
D90
+15V
0.1uF
8
13
16
ADDR1 25
ADDR2 24
ADDR3 23
ADDR4 22
ADDR5 21
ADDR6 20
ADDR7 19
ADDR8 18
J7
D
1
A0
A1
A2
A3
Q6
NOISE_GND
D
C12
475
2
1
THERMAL_RLE4D7
MF-PRT05C0
D
1 K
R81
R88
+5V
(4)
(4)
2
D 3 1
C13
7
X10
X30
3
2
J4
4.75K
4.7uF
35V
11
10
3
4
A4
29 DATA0
31 DATA1
33 DATA2
35 DATA3
38 DATA4
40 DATA5
42 DATA6
44 DATA7
30 DATA8
32 DATA9
34 DATA10
36 DATA11
39 DATA12
41 DATA13
43 DATA14
45 DATA15
1 8 V
C25
475
X3
VS1
7 4 A C 1 4
7 4 A C 1 4
D0
475
10.0K
R259
A5
W 1 . 5
1
Q19
1
8
6
7
4
5
3
2
C43
D1
D 4 4
R179
120uF
50V
A6
B 5 M 9 3 1 1 S
R87
D2
100pF
5 . 1 V
1 / 2 W
VS2
OUTPUT1
OUTPUT2
GND1
3.32K
3
A7
NOISE_GND
10.0K
2
X23
ADDR9
ADDR10
ADDR11
ADDR12
ADDR13
ADDR14
ADDR15
ADDR16
8
7
6
5
4
3
2
1
D3
7
6
820pF
A8
C104
J6
J6
VDD
D4
S Z 5 M 2 3 M 1
1
1
A9
RES'
VSS
3
Q20
2
D5
C122
C135 C14
MMBT4401
3
2
A10
D6
NOISE_GND
MMBT4401
S80746AN
4.6V/2%
R15
GND2
1uF
35V
A11
D7
D
1
Q5
NC
A12
D8
J7
0.1uF
1uF
0.1uF
D
14
15
J6
J6
INPUT
PWRDN_INT
A13
D9
475
R46
A14
D10
A15
D11
A16
D12
A17
D13
A18
D14
STT_ON
MIC4451BM
R40 475
+5V
D
D
ADDR17 48
ADDR18 17
ADDR19 16
D 3 0
T 5 4 B S A
4.75K
1
C22
1
2
V 7 0 B L A T 1
D 8 5
1 8 V
D 8 0
10.0K
R258
W 1 . 5
B 5 M 9 3 1 1 S
/RES
X2
/CSB
R/W
26
11
28
47
100pF
CE' D15
NOISE_GND
1
3
/RES
R/W
+5V
3
+5V
VS1
WE'
46
27
(3)
(2)
8
GND1
OE'
VS2
6
GND2
MMBT4401
3
2
OUTPUT1
BYTE'
3
NOISE_GND
7
475
OUTPUT2
/RES
X30
BAV70LT1
D91
+5V
TE28F800B5-B90
4
11
10
7
6
5
10.0K
R254
D
J1
J1
J1
J1
J1
J1
1
GND1
J7
7 4 A C 1 4
Q7
5
C123 C136 C11
GND2
/BERR
FREEZE
/BKPT
/DS
R21
3
R51
2
1
X24
NC
2
D 3 2
FAN_CONTROL
2
INPUT
CRYSTAL 85
83
87
XFC
(4)
(4)
0.1uF
1uF
0.1uF
EXTAL
XTAL
1 8 V
90 CLK
CLKOUT
A B T 5 4 S
D 8 1
4.75K
W 1 . 5
1
MIC4451BM
C27
1
2
(1,4)
V 7 0 B L A T 1
D 8 6
10.0K
R257
13
140 /CSB
141 /CS0
142 /CS1
143 /CS2
B 5 M 9 3 1 1 S
/RES
92
CSBOOT'
BR' /CS0'
BG' /CS1'
BGACK' /CS2'
IPIPE' D/ SO
RESET'
HALT'
93
100pF
/RES
14
15
3
3
475
R36
TSC
80
TSC
/BERR 94
FREEZE 81
/BKPT 79
77
/IPIPE
/IFETCH
R/W
NOISE_GND
BERR'
2
+15V
78
FREEZE IFETCH' / DSI
103
D
D4
D3
BKPT/D' SCLK
R/W
9
2
R11
R41
J6
/RES
FPGA_RESET
FPGA_DONE
FPGA_RESET 114
FPGA_DONE 113
LEVEL_IN 112
RMC 111
NOISE_GND
+5V
X10
X30
LEVEL_IN
DSACK/0P' E0
DSACK/1P' E1
AVEC/P' E2
RMC/P' E3
115
39
40
41
42
43
44
45
46
49
50
51
52
56
57
58
60
63
64
6
(4)
(4)
5
6
13
12
9
S1G
S1G
A0
A1
(3)
J7
ADDR1
ADDR2
ADDR3
ADDR4
ADDR5
ADDR6
ADDR7
ADDR8
ADDR9
ADDR10
ADDR11
ADDR12
ADDR13
ADDR14
ADDR15
ADDR16
ADDR17
ADDR18
ADDR19
7 4 A C 1 4
7 4 A C 1 4
475
475
J6
RMC
/AS
/DS
A2
(4)
(4)
(4)
D 2 5
/AS 106
A3
12
2
3
J1
J1
AS'/PE4
IRLR120N
5 . 1 V
/DS 110
A4
R187
D 1 5
DS'/PE5
W 1 / 2
BAV99
D78
SOFTST 105
MN_CNT 104
A5
4
2
1
Q9
26.7K
SIZ0 /PE6
SIZ1 /PE7
1 6 V
W 1 . 5
B 5 M 9 3 1 0 S
S Z 5 M 2 3 M 1
A6
R84
A7
3
1
+15V
OUTPUT_ON
SYS_RESET
OUTPUT_ON 102
SYS_RESET 101
PWRDN_INT 100
A8
10A,100V
PF0/ MODCLK
PF1/ IRQ1'
PF2/ IRQ2'
PF3/ IRQ3'
PF4/ IRQ4'
PF5/ IRQ5'
PF6/ IRQ6'
PF7/ IRQ7'
(4)
475
1
10
A9
J7
D
(2,3,4)
0V = NORMAR
5V = FAULT
A10
A11
A12
A13
A14
A15
A16
A17
A18
NOISE_GND
1.00k R136
F u 0 . 1
3
FAULT_INT
FPGA_INT
INT_CAN
99
98
97
96
95
A T B 5 4 S
D 8 3
/RES
R38
R35
C 1 4 1
FPGA_INT
22.1K
22.1K
(4)
(2)
(4)
NOISE_GND
12
INT_CAN
FPGA_BAD
FPGA_BAD
CAPAOV
CAPA_OV
CAPA_UV
2
(4)INT_100
13
J6
+5V
+5V
13
34
33
32
31
30
29
28
27
24
23
22
21
17
16
15
14
J6
R 1 8 5
1 0 . 0
+5V
T2CLK
TPUCH0
TPUCH1
TPUCH2
TPUCH3
TPUCH4
TPUCH5
TPUCH6 PC0/CS3' /FC0
TPUCH7 PC1/CS4' /FC1
TPUCH8 PC2/CS5' /FC2
TPUCH9
TPUCH10
TPUCH11
TPUCH12
TPUCH13
TPUCH14
TPUCH15
2
R135
FAULT
SIGNAL
TPU0
TPU1
TPU2
TPU3
TPU4
TPU5
TPU6
CAPAUV
IRLR120N
K
D 1 8
3
PC3/CS6' /A19
PC4/CS7' /A20
PC5/CS8' /A21
PC6/CS9' /A22
CS10' /A23
J6
2
1
7
DSP_RESET
1 6 V
Q10
BAV99
D79
3
D 7
D 5 1.00K
(4)
C113
X27
RED
8 VPP_CTRL
1 . 5 W
C67 C73 C68
R85
44
43
42
27
26
25
24
21
20
19
18
5
11
33
ADDR1
ADDR2
ADDR3
ADDR4
ADDR5
ADDR6
ADDR7
ADDR8
ADDR9
ADDR10
ADDR11
ADDR12
ADDR13
ADDR14
ADDR15
ADDR16
ADDR17
9
IACK
A0 VCC1
A1 VCC2
A2
B 5 9 3 1 0 S M
C5
C3
LED7
1
5 . 1 V
5 . 1 V
C70
C71
(3)
(2)
D
10 CAN_CS
10A,100V
0.1uF
W 1 / 2
S Z 5 M 2 3 M 1
W 1 / 2
475
1
3
0.1uF
0.1uF
0.1uF
S Z 5 M 2 3 M 1
3
820pF
820pF
+5V
A3
D 8 2
A B T 5 4 S
820pF
820pF
4FPGA_CS
128KX16
7R51083
0 . 1 u F
C 1 4 2
A4
(3)
/RES
3
SRAM
5
FUNCEN
D
11
D
D
D
A5
(4)
J6
7
+5V
A6
DATA0
139
138
137
136
133
132
131
130
127
125
124
122
119
118
117
116
DATA0
DATA1
DATA2
DATA3
DATA4
DATA5
DATA6
DATA7
DATA8
DATA9
D0
8
+15V
D
+5V
K 0 1 0 .
D0
D1
A7
DATA1
DATA2
DATA3
DATA4
DATA5
DATA6
DATA7
DATA8
DATA9
DATA10
DATA11
DATA12
DATA13
DATA14
DATA15
NOISE_GND
D1
2
9
A8
+5V
D2
D3
CAP0
10
13
14
15
16
29
30
31
32
35
36
37
38
D2
A9
X30
(4)
0V = NORMAR
5V = FAULT
1
2
D3
A10
D4
7 4 A C 1 4
3
8
R39
R37
J1
D4
A11
D5
4
NOISE_GND
R174
(4)
22.1K
22.1K
D5
A12
D6
3
X17
J1
J1
J1
J1
D6
A13
D7
R168
2
R203
MISO
MOSI
SCK
SPI_CS0
SPI_CS1
SPI_CS2
SPI_CS3
65
66
67
68
69
70
71
75
76
CAPB_OV
43
44
1
CAPBOV
CLK_8
CLK
SCK7
CMP4
PQS0/MISO
PQS1/MOSI
PQS2/SCK
PQS3/PCS0/ SS'
PQS4/PCS1
PQS5/PCS2
PQS6/PCS3
PQS7/TXD
RXD
D7
A14
D8
1
5
GCK1
GCK2
GCK3
GTS1
GTS2
GSR
(2)
(1)
(4)
(4)
J6
9
D8
A15
D9
(3,4)
22
1.00k
22.1K
11
10
9
D9
A16
(3,4)
(4)
TCK
TMS
TDI
DATA10
DATA11
DATA12
DATA13
DATA14
DATA15
D10
11
10
36
34
33
D10
D11
D12
D13
D14
D15
R169
ADDR[1:19]
D11
D12
CAPBUV
CAPB_UV
(4)
4
CPLD
J6
24
/RES
(4)
6
D 6 1.00K
TDO
/CS2
R/W
/CS2
/CS0
/CS1
D13
D 8
5 . 1 V
W 1 / 2
S Z 5 M 2 3 M 1
CE'
(4)
D
40
41
42
39
38
37
32
31
30
29
28
27
23
22
21
20
19
17
41
39
40
THERMOSTAT
SSOUT
MISO7
RS232_TXD
(2)
RS232_RXD
D14
C69
IO1A
IO1B
IO2B
IO4B
IO7B
IO8B
IO9B
WE'
C6
C4
(4)
5 . 1 V
W 1 / 2
D15
C72
4700pF
IO2A
OE'
(2)
12
34
OVR_CUR
FET_B
CAPA_OV
CAPA_UV
FET_A
RESET_RAMP
STROBE_AD
CAPB_UV
CAPB_OV
CLR_CAP
CMP0
IO4A
LB' GND1
UB' GND2
(3)
(3)
S Z 5 M 2 3 M 1
MC68332PV
2
3
820pF
820pF
IO6A
(3)
820pF
+15V
IO8A
/CS0
/CS1
IS61C12816
5
D
(4)
(4)
IO9A
D
6
10
1
J6
J6
IO10A
IO11A
IO12A
IO13A
IO14A
IO15A
IO16A
IO17A
IO10B
IO11B
IO12B
IO13B
IO14B
IO15B
IO16B
IO17B
BANK1
(3)
(4)
(4)
7
R32
D
8
FILTER CAPACITOR VOLTAGE MONITORING NOISE_GND
MN_CNT
FAULT_INT
PRI_OC
PWRDN_INT
MN_OUT
CMP2
2.21K R34
12
13
14
16
18
CRYSTAL
OUTPUT_ON
SOFTST
R2
D
DATA[0:15]
2
(3)
J5
47.5
1.00K
(4)
DISABLE_4(455)
R33
R99
D 2
SPI_LATCH7
C2
C74
1
4
J5
J5
5 . 1 V
W 1 / 2
D 1 9
10.0K
10.0K
K 0
1 0 R . 2 4 2
D 1 7
V 9 9 B A
S Z 5 M 2 3 M 1
1uF
35V
820pF
C46
5 . 1 V
1 / 2 W
S Z 5 M 2 3 M 1
1uF
35V
R3
R100
D
475K
3
J5
D
47.5
NOISE_GND
THERMOSTAT
D
NOISE_GND
SINGLE/THREE PHASE DETECT
D
INT_1_3PH
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
(4)
"X" INFO.
XM5626
XA
Chg. Sheet No.
6-2-2000A
DESIGN INFORMATION
REFERENCE:
MANUFACTURING TOLERANCE PER E2056
ON 2 PLACE DECIMALS IS .02
ON 3 PLACE DECIMALS IS .002
EQUIPMENT TYPE:
INVERTER WELDERS
±
DRAWN BY: F.V.
ENGINEER: T. KOOKEN
APPROVED:
±
ON ALL ANGLES IS ± .5 OF A DEGREE
SUBJECT:
DIGITAL CONTROL SCHEMATIC
12-15-99
DRAWING No.:
MATERIAL TOLERANCE (" ") TO AGREE
t
SUPERSEDING:
WITH PUBLISHED STANDARDS.
SCALE:
NONE
DATE:
3789-1D0/1
G
DO NOT SCALE THIS DRAWING
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
POWER WAVE 455/R
Download from Www.Somanuals.com. All Manuals Search And Download.
G-11
G-11
ELECTRICAL DIAGRAMS
51
52
53
54
S25001-3321SMT
S25001-2212SMT
S25001-47R5SMT
S25001-4753SMT
4
6
2
1
SRES,3.32K,1206,1%,1/8W,NP(AM2
SRES,22.1K,1206,1%,1/8W,TR,NP
SRES,47.5,1206,1%,1/8W,TR,NP
SRES,475K,1206,1%,1/8W,TR,NP
R123 R128 R129 R179
R37 R38 R35 R203 R8 R39
R3 R2
R100
R55 R111 R49 R108 R115 R124 R142 R208
55
S25001-1003SMT
10
SRES,100K,1206,1%,1/8W,200PPM,
R207 R106
R70
R63 R65 R233
56
57
58
59
60
61
62
63
S25001-1213SMT
S25001-3322SMT
S25001-1000SMT
S25001-2210SMT
S25001-2671SMT
S25001-1502SMT
S25001-6811SMT
S25001-1500SMT
1
3
4
5
1
2
2
2
SRES,121K,1206,MF,1%,1/4W
SRES,33.2K,1206,1%,1/8W,TR,NP
SRES,100,1206,1%,1/8W,TR,NP
SRES,221,1206,1%,1/8W,NP
R62 R44 R52 R30
R59 R48 R102 R197 R45
SRES,2.67K,1206,1%,1/8W,TR,NP
SRES,150K,1206,1%,1/8W,NP
SRES,6.81K,1206,1%,1/8W,NP
SRES,150,1206,1%,1/8W,TR,NP
R109
R117 R125
R127 R130
R196 R198
R151 R154 R157 R160 R148 R161 R158 R155
FOR ITEMS LISTED BELOW REFER TO ELECTRICAL DATABASE FOR COMPONENT
SPECIFICATIONS
64
S25006-10R0
10
SRES,10,
C138 C134 C133 C125 C55 C96 C98 C100 C28
C82 C14 C11 C83 C103 C121 C101 C117 C115
C111 C113 C85 C90 C48 C93 C109 C120 C127
C106 C95 C105 C73 C68 C8 C114 C108 C99
C77 C76 C75 C84 C79 C67 C88 C80 C50 C78
C23 C21 C91 C51 C92 C58 C57 C52 C60 C59
C131 C123 C122 C124 C30 C129 C139 C140
C42 C137 C141 C142
R152 R149
Q17 Q16 Q15 Q13 Q14
65
66
S25050-2SMT
S25051-6SMT
S25050-1SMT
S25051-4SMT
S25051-7SMT
S24020-4
5
2
9
2
1
3
1
2
1
1
2
1
1
1
1
1
4
1
1
1
2
1
1
3
1
1
1
1
2
2
1
2
1
1
1
2
1
1
1
1
4
8
5
6
2
2
4
6
6
STRA,2N4403,SO23,TR,(500475),N
STRA,IRLR120N,10A,100V,MOSFET,
STRA,MMBT4401LT,NPN,SOT-23
STRA,2N7002,TR,NP
Q9 Q10
Q12 Q4 Q7 Q5 Q6 Q1 Q18 Q19 Q20
Q3 Q2
67
68
11
S25020-3SMT
68
SCAP,0.1uF,0805,50V,X7R,10%,TR
69
70
SICS,IRF7103,NP
CON,4P,TIN,MINI,NP
CON,6P,TIN,MINI,NP
Q11
J5 J11 J2
J9
71
S24020-6
72
S24020-2
CON,2P,TIN,MINI,NP
J10A J10B
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
S14390-173
S25020-2SMT
S25020-10SMT
S25020-5SMT
S25020-18SMT
S25020-13SMT
S25020-4SMT
S24833-1
2
2
2
4
1
7
11
2
2
9
8
4
4
1
1
CAP,1uF,RA,63V,10%,NP
SCAP,0.022uF,0805,50V,X7R,10%,
SCAP,4700pF,0805,50V,X7R,10%
SCAP,22pF,0805,50V,COG,5%,TR,N
SCAP,10pF,CER,0805,100V,5%
SCAP,150pF,0805,100V,COG,5%,TR,
SCAP,820pF,0805,50V,COG,5%,TR,
CAP,0.27uF,MF,50V,5mm,5%,TR,NP
SCAP,330pF,100V
C136 C135
73
S18248-10
CON,10P,MINI,NP
J3
C86 C7
74
S18248-16
CON,16P,MINI,NP
J1
C44 C69
75
76
S24020-16
S24020-12
CON,16P,TIN,MINI,NP
CON,12P,TIN,MINI,NP
J6 J7
J4
C118 C116 C128 C130
C32
77
S24020-8
CON,8P,TIN,MINI,NP (or TH600-265)
SICS,MAX485ESA,NP
J8
C64 C89 C26 C35 C36 C38 C37
C43 C4 C74 C3 C71 C19 C70 C5 C72 C6 C17
C56 C34
78
S20353-4SMT
S25065-2SMT
S25070-7SMT
S15000-28SMT
S20353-5
X29
79
SICS,74ACT573,OCTAL,TRANS.,LAT
SICS,TMS320F240PQA,NP
SICS,HCPL-0601,OPTOCOUPLER
SICS,AN82527
X21
80
X22
S25020-14SMT
S25025-5SMT
S25024-2SMT
S25024-8SMT
S25024-10SMT
S13490-179
C126 C143
81
OCI1 OCI2 OCI3 OCI4
SCAP,4.7uF,7343,35V,10%,TR,NP
SCAP,1uF,TAN,3528,35V,TR,NP
SCAP,10uF,TAN,6032,TR,NP
C12 C102 C1 C9 C10 C39 C40 C16 C61
C94 C97 C104 C107 C47 C81 C2 C46
C66 C62 C65 C63
82
X28
83
S25082-1SMT
S20353-1SMT
S25067-3SMT
S17900-1SMT
S15128-13SMT
S15128-18SMT
S25069-3SMT
S25069-4SMT
M15101-14SMT
S25068-8SM
S25065-3SMT
S25057-3SMT
M15105-9SMT
S15018-21SMT
S25067-2SMT
S25070-3SMT
S25069-2SMT
S15128-21SMT
S19869-8
SXTL,16MHZ,HC40,20PF,NP
SICS,MC145407,RECEIVER/DRVR,RS
SICS,ADG417,SPST,CMOS,SWT,SO8
74HC245, NEW PACKAGE
SICS,OP-27G,OPAMP,SO8,TR,NP
SICS,MC33074,QUAD,OPAMP,SO14,T
SICS,28F800B5-90,FLASH RO,90n
SICS,128Kx16,20nS,TSOP
SICS,MC68332
Y1
84
X16
SCAP,22uF,TAN,7343,25V,10%
CAP,1000uF,ALU,35V,20%,NP
SCAP,120MF,50V,20%,RADIAL,AE
C119 C110 C49 C54
85
X13 X31
C45
86
X33
S13490-183
C13
87
X1
D68 D67 D4 D3 D75 D63 D64 D65 D70 D72 D71
D73 D74
88
X8 X14 X20
27
28
S25040-2SMT
S25046-1SMT
13
19
SDIO,1A,400V,DO-214BA,GLS
SDIO,MMSZ5231BT1,5.1V,NP
(6.34)
89
X25
D25 D45 D44 D17 D9 D6 D2 D5 D7 D8 D35 D36
D38 D37 D42 D41 D40 D39 D69
D62 D61 D60 D13 D12 D1 D46
D53 D52 D58 D59
90
X27
91
X24
29
30
31
32
33
S25044-9SMT
S25046-3SMT
S25044-10SMT
S25044-5SMT
S25044-4SMT
7
4
3
9
2
SDIO,1SMB5920BT3,6.2V,NP
SDIO,MMSZ5248B,18V,ZENER,TR,NP
SDIO,B5930,16V,1.5W,ZENER,TR,N
SDIO,1SMB5931BT3,3W,18V,5%
SDIO,B5929,15V,1.5W,ZENER,TR,N
92
SICS,MC79L05ABD
X4
93
SICS,74VHC14,NP
X10 X30
D18 D15 D43
94
SICS,AD8403ARU10
X6 X32
D27 D32 D26 D30 D31 D29 D24 D14 D16
D10 D11
95
SICS,7945
X
12
96
ICS,MIC4451BM
SICS,ADG409BR
ICS,XC9536-15 VQ44
X2 X3
97
X15
D66 D50 D33 D49 D19 D78 D79 D102 D103
D104 D105 D106 D107
34
35
36
S25040-5SMT
S25049-4SMT
S25080-2SMT
13
8
SDIO,BAV99LT1,SOT23,DUAL SWITC
SDIO,BAT54S,DUAL,30V,200mA
SLED,GRN,1206,TR,NP
98
X17
99
SICS,25128,SERIAL EEPR,NP
SICS,LT1016,COMPARATOR
SWT,78B08S,DIP,SPST,8P,NP
SICS,AD7862,DUAL,12BIT,250kSPS
SICS,4.6V,2%,VOLT. DETECTOR,SO
SICS,XCS20,FPGA
X11
D34 D54 D28 D47 D80 D81 D82 D83
100
101
102
103
104
105
106
107
108
109
110
111
112
113
X5 X7
S1
X19
LED8 LED1 LED5 LED3 LED2 LED4 LED6
LED9
S25066-2SMT
S25068-7SMT
S25070-4SMT
S20620-1003
S25040-12SMT
S25020-SMT
S25000-1000SMT
T12702-60
8
X23
X18
37
38
39
40
S25080-1SMT
S25083-1SMT
2
1
8
8
SLED,RED,1206,TR,NP
SIND,FERRITEBEAD,TR,NP
SRES,47.5K,1206,1%,1/8W,TR,NP
SRES,2.21K,1206,1%,1/8W,NP
LED7 LED10
RES,100K,AX,5%,1/2W,HI VOLT,TR
SDIO,MURS320T3,3A,200V,ULTRAFA
SCAP,100pF,0805,COG,100V,5%
SRES,100,0805,1%,1/10W
DIO,1N5358B
R73 R79 R75 R77
D51 D55 D56 D57 D98 D99 D100 D101
C15, C18, C22, C25, C27
R223, R224, R240, R226, R227, R228
DZ3 DZ4
E1
S25001-4752SMT
S25001-2211SMT
R230 R27 R28 R26 R53 R29 R110 R57
R25 R13 R12 R32 R1 R31 R134 R66
R171 R178 R177 R193 R231 R167 R61 R34
R89 R82 R163 R135 R136 R169 R131 R112
R60 R56 R126 R71 R54 R69 R68 R143 R144
R58 R206 R213 R214 R90 R168 R255 R256
R173 R191 R181 R164 R170 R172 R189 R186
R180 R91 R92 R93 R94 R95 R96 R97 R98 R22
R174 R201 R185 R104 R87 R33 R99 R260
R261 R139 R140 R121 R200 R107 R199 R103
R221 R229 R204 R242 R241 R216 R217 R218
R243 R246 R244 R245 R247 R248 R249 R250
R251 R252 R253 R254 R257 R258 R259
R195 R194 R41 R11 R83 R86 R166 R165 R21
R15 R20 R88 R81 R14 R9 R17 R19 R10 R18
R16 R141 R138 R119 R116 R85 R84 R40 R36
41
S25001-1001SMT
S25001-1002SMT
33
SRES,1K,1206,1%,1/8W,TR(9X0056
T12702-59
DIO,1N5333B
DZ1 DZ2
S25049-2SMT
S25001-3320SMT
S25040-6SMT
SDIO,MBRA130LT3,1A,30V,SCHOTKY
SRES,332,1206,1%,1/4W
D76 D77 D114 D115
R262 R263 R264 R265 R266 R267
D84 D85 D86 D89 D90 D91
SDIO,BAV70
42
57
SRES,10K,MF,1206,1%,1/8W
43
44
S25001-4750SMT
S25001-4751SMT
28
15
SRES,475,1206,1%,1/8W,TR,NP
R190 R192 R182 R184 R137 R146 R209 R210
R222 R42 R43 R46 R47 R51 R67
SRES,4.75K,1206,1%,1/8W,SM100-
45
46
47
48
49
50
S25003-2000SMT
S25001-1501SMT
S25001-7500SMT
S25001-5110SMT
S25001-1004SMT
S25001-2672SMT
2
7
1
2
2
4
SRES,200,2512,1%,1W,TR,NP
SRES,1.5K,1206,1%,1/8W,NP
SRES,750,1206,1%,1/8W,NP
R132 R133
R113 R118 R122 R74 R76 R80 R78
R183
COMPONENT SIDE
SRES,511,MF,1206,1%,1/8W,TR
SRES,1M,1206,1%,1/8W,TR(9X0098
SRES,26.7K,THK,1206,1%,1/8W,10
R24 R23
R212 R211
R187 R114 R120 R72
(8.09)
CAPACITORS = MFD/VOLTS
INDUCTANCE = HENRIES
RESISTANCE = OHMS
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.
5-25-2001F
"X" INFO.
DESIGN INFORMATION
REFERENCE:
MANUFACTURING TOLERANCE PER E2056
ON 2 PLACE DECIMALS IS .02
ON 3 PLACE DECIMALS IS .002
ON ALL ANGLES IS .5 OF A DEGREE
EQUIPMENT TYPE:
INVERTER WELDERS
CONPC.ATB.RRODOALS'BLY
4--96
DRAWN BY: F.V.
SUBJECT:
SUPERSEDING:
MATERIAL TOLERANCE (" ") TO AGREE
ENGINEER: T. O'DONNEL
APPROVED:
t
OTHER COMPONENT SIDE (BACKSIDE)
WITH PUBLISHED STANDARDS.
SCALE:
NONE
DRAWING No.:
DATE:
L 11088-1D2
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 WAVE 455/R
Download from Www.Somanuals.com. All Manuals Search And Download.
G-12
G-12
ELECTRICAL DIAGRAMS
SCHEMATIC - DIGITIAL POWER SUPPLY PC BOARD
+5V
Machine Control Power Supply
R50
.13
J42
D18
3
1
2
6A
200V
+
t
D4
6A
200V
60V
LED2
10
T1
+5Volts, .750 Amp
C43
100
16V
C41
100
16V
C39
0.1
50V
T1
C12
.0015
2000V
33.2
33.2
10-55 VDC
Operation
332
3
Vref
1
R9
10.0K
10.0K
10.0K
11
12
D22
10.0
1.0A
30V
R60
10.0
D
S
+15Volts
Q1
21A
G
R61
10.0
200V
.750 Amp
D24
C13
1
200V
7
6
2
1
VCC
OUT
1
5
Vref
1
J41
8
4
5
J42
D3
1A
600V
VREF
RT/CT
GND
VFB
D19
DZ8
18V
3W
Vfb1
OCI1
2
X8
1
DC Input (+)
IN
OUT
CNY17-3
COMP
CS
3A
600V
R10
R5
3
100K
100K
2
6
4
J41
4
X5
Vfb1
ADJ
9
+
t
7
D21
1.0A
30V
C11
22
35V
C14
0.1
50V
C47
1.0
35V
R55
R52
221K
1.21K
.33W
T1
1.82K
T1
OV1
475
Machine Control
Shut Down
Capacitor
4
6
C45
C7
0.1
50V
C6
4.7
35V
150p
R39
R12
5.62K
100V
56.2K
C8
3W
0.05
820p
50V
C42
R13
C32
2700p
50V
10p
10.0K
J41
3
100V
1
J41
1
8
X1
GND
5
REF
DC Input (-)
TL431
6
C44
0.1
50V
C38
4.7
35V
C40
1.0
35V
-15Volts, .100Amp
T1
1.21K
.33W
5
6
J42
J42
8
ADJ
J42
2
IN
OUT
DZ1
24V
3W
X9
14
D8
1A
600V
gnd_mcps
T2
+5V
Operation
30-55 VDC
1
D25
1.00K
Undervoltage
Detect
<30VDC
C31
.0015
2000V
D2
1A
D23
1.0A
30V
5
4
1
600V
OCI2
CNY17-3
D10
X3
D
Q2
J42
6
2
21A
J43
G
4
7
6
2
1
200V
VCC
OUT
R32
15.0
6
S
IN
OUT
Vref 2
8
4
5
VREF
RT/CT
GND
VFB
D9
DZ2
C49
.022
R34
221K
1A
27V
.5W
DZ7
18V
3W
COMP
CS
R31
75K
Vfb2
600V
ADJ
3
3
R29
C53
.1
X4
C27
C23
1.0
35V
100K
C25
0.1
50V
OV2
C24
4.7
35V
C26
1
200V
1.21K
.33W
T2
12
150p
100V
D20
1.0A
30V
C52
150p
DZ3
27V
.5W
15Volts, .250Amps
SPI
gnd_mcps
C2
0.1
50V
C3
4.7
35V
R38
R28
5.62K
56.2K
C4
820p
50V
3W
0.05
Overvoltage
Shutdown
> 55 VDC
C28
249
10p
J43
100V
R40
3
+
t
D16
16A
.13
200V
60V
OV2
OV1
LED1
2
+5Volts, 3 Amps
SPI
D14
D17
C37
100
16V
C36
100
16V
C35
100
16V
C34
0.1
50V
T2
13
150
.33W
150
.33W
150
.33W
D13
Vref 2
332
DZ4
3.3V
3W
C33
4.7
35V
15
J43
D15
X7
5
IN
OUT
1A
600V
4
1
5
4
GND
J43
OCI3
CNY17-3
R17
C5
0.1
50V
C1
4.7
35V
C30
1.0
35V
+5Volts, .100 Amp
CAN
8
150
.33W
T2
11
+
t
D7
2
6
1A
.24
Vfb2
600V
6
J43
10
+20Volts
.200 Amps
Gate Drive
475K
R21
C21
0.1
50V
C17
4.7
35V
C18
4.7
35V
T2
9
2.49K
.33W
C46
150p
100V
J43
2
D12
1.82K
C16
R22
J43
7
R24
.24
2700p
50V
10.0K
J43
4
D1
+
t
D6
X6
1A
1
IN
OUT
600V
7
1A
600V
8
X2
+20Volts
.200 Amps
Gate Drive
5
GND
REF
TL431
6
C22
0.1
50V
C20
4.7
35V
C19
4.7
35V
T2
8
C9
0.1
50V
2.49K
.33W
C10
4.7
35V
C29
1.0
35V
+5Volts, .100 Amp
RS232
T2
10
150
.33W
J43
11
J43
9
J43
1
J43
12
FILENAME: G3631-2D2
GENERAL INFORMATION
ELECTRICAL SYMBOLS PER E1537
LAST NO. USED
R-
C-
D-
MFD
CAPACITORS =
RESISTORS Ohms
DIODES 1A, 400V
(
.022/50V
UNLESS OTHERWISE SPECIFIED)
NOTES :
N.A. SINCE COMPONENTS OR CIRCUITRY ON
LABELS
=
(
1/4W UNLESS OTHERWISE SPECIFIED)
(UNLESS OTHERWISE SPECIFIED)
A
PRINTED CIRCUIT BOARD MAY CHANGE
=
WITHOUT AFFECTING THE INTERCHANGEABILITY OF COMPLETE BOARD, THIS DIAGRAM MAY
A
SUPPLY VOLTAGE NET
NOT SHOW THE EXACT COMPONENTS OR CIRCUITRY OF CONTROLS HAVING
NUMBER.
A
COMMON CODE
POWER SUPPLY SOURCE POINT
COMMON CONNECTION
FRAME CONNECTION
EARTH GROUND CONNECTION
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
"X" INFO.
Chg. Sheet No.
6-2-2000A
DESIGN INFORMATION
REFERENCE:
MANUFACTURING TOLERANCE PER E2056
ON 2 PLACE DECIMALS IS .02
ON 3 PLACE DECIMALS IS .002
EQUIPMENT TYPE:
Digital Systems
Schematic, Digital Power Supply
±
DRAWN BY: JP\TK
ENGINEER:
±
ON ALL ANGLES IS ± .5 OF A DEGREE
10-27-2000E
SUBJECT:
MATERIAL TOLERANCE (" ") TO AGREE
t
SUPERSEDING:
WITH PUBLISHED STANDARDS.
11-30-98
DRAWING No.:
APPROVED:
SCALE:
NONE
DATE:
3631
G
DO NOT SCALE THIS DRAWING
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
POWER WAVE 455/R
Download from Www.Somanuals.com. All Manuals Search And Download.
G-13
G-13
ELECTRICAL DIAGRAMS
PC BOARD ASSEMBLY-DIGITAL POWER SUPPLY
ITEM
PART NUMBER
REQ'D.
DESCRIPTION
REFERENCE
DESIGNATOR
1
2
3
4
5
G3632-C
M19436-3
S8025-80
E2527
1
1
POWER PC BOARD BLANK
POTTING TRAY
2
SELF TAPPING SCREW
EPOXY ENCAPSULATIOG RESIN
115g
E2861
AS REQ'D ELECTRICAL INSULATING COMPOUND
FOR ITEMS LISTED BELOW REFER TO ELECTRONIC COMPONENT DATABASE FOR COMPONENT
SPECIFICATIONS
ITEM PART NUMBER
QTY.
1
DESCRIPTION
REFERENCE
N/A
6
PCLIN-503-3
707W04095
A262564400
A262566900
A262569000
A262576200
A262577900
SM100-035
SM100-444
SM100-411
SM100-420
SM100-440
SM100-441
SM100-443
SM100-445
SM100-446
SM100-447
SM100-448
PCB,MTP,DC POWER ASSY,NP
SDIO,MURS120T3,NO PRINT
SRES,1.82K,1206,1%,1/8W,NP
SRES,5.62K,1206,1%,1/8W,TR,NP
SRES,10K,1206,1%,1/4W,(09X-007
SRES,56.2K,1206,1%,1/8W,NP(500
SRES,100K,TKF,1206,1%,1/8W,TR,
SRES,330,1206,5%,1/4W
7
2
D1 D15
8
2
R14 R20
9
3
R12 R28 R45
R4 R13 R22 R2 R27 R56
R38 R39
10
11
12
13
14
15
16
17
18
19
20
21
22
23
6
2
4
R5 R10 R21 R29
R41 R53
2
1
SRES,249,1206,1%,1/4W,TR,NP
SRES,221K,1206,1%,1/8W,TR,NP
SRES,20,1206,1%,1/8W,TR,NP
SRES,0.05,1%,2W,TR,NP
R33
2
R34 R52
1
R32
2
R11 R30
1
SRES,1K,5%,2W,TR,NP
R26
3
SRES,33.2,1206,1%,1/4W,TR,NP
SRES,43.2K,1206,1%,1/4W,TR,NP
SRES,44.2K,1206,1%,1/4W,TR,NP
SRES,THERMISTOR,POS TEMP,TR,NP
SRES,THERMISTOR,POS TEMP,TR,NP
R15 R16 R43
R18 R49
2
2
R42 R51
1
R50
2
R17 R24
C1 C10 C17 C18 C19 C20 C24
C33 C38 C3 C6
C27 C45 C46
C23 C29 C30 C40 C47
C4 C8
24
25
26
27
28
SM200-145
SM200-183
SM200-188
SM200-192
SM200-193
11
3
SCAP,4.7uF,TAN,35V,20%,TR,NP
SCAP,150pF,0805,50V,COG,5%,TR,
SCAP,1uF,TAN,3528,35V,TR,NP
SCAP,820pF,0805,50V,COG,5%,TR,
SCAP,2700pF,0805,5OV,X7R,5%,TR
5
2
2
C16 C42
C2 C5 C7 C9 C14 C21 C22 C25
C34 C39 C44
C28 C32
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
70
71
72
73
74
75
76
77
78
79
SM200-194
SM200-200
SM200-201
SM200-202
SM550-079
SM550-109
SM550-122
SM550-123
SM550-148
SM550-149
SM550-125
SM550-126
SM550-128
703W31526
A262567400
SM550-104
A287245100
SM800-299
SM800-297
707W03410
HW900-379
TH100-160
TH100-161
TH200-132
TH300-023-A
TH300-024-A
TH400-053
TH600-263
TH600-264
TH600-266
PPW-11110-1
PPW-11160-1
707W04224
TH200-219
SM200-220
SM200-221
SM200-522
703W01044
SM100-523
SM400-057
SM400-058
SM400-059
SM100-524
SM100-525
SM100-526
SM100-409
SM900-001
9P7951
11
2
1
5
7
2
2
4
1
1
2
1
2
1
1
6
2
2
2
3
2
1
1
2
1
1
2
1
1
1
2
2
1
2
1
1
4
3
2
1
1
1
2
3
2
1
2
SCAP,0.1uF,0805,50V,X7R,10%,TR
SCAP,10pF,CER,0805,100V,5%,TR,
SCAP,33uF,TAN,7343,25V,10%,TR,LOW ESR C11
SCAP,100uF,TAN,7343,10V,20%,TR
SDIO,1A,400V,DO-214BA,GLS,NP
SLED,RED,1206,TR,NP
C35 C36 C37 C41 C43
D10 D12 D13 D14 D17 D24 D25
LED1 LED2
SDIO,MURD620CT,6A,200V,ULTRA-F
SDIO,MBRA130LT3,1A,30V,SCHOTTK
SDIO,MURB1620CT,16A,200V
SDIO,1SMB5934BT3,24V,3W
SDIO,MMSZ5254BT1,0.5W,27V,5%,T
SDIO,1SMB5913BT3,3W,3.3V,5%,TR
SDIO,1SMB5931BT3,3W,18V,5%,TR,
SRES,15K,FXD,1206,1%,1/8W,TR
SRES,6.19K,1206,1%,1/8W,TR,NP
SDIO,MURS160,1A,600V,FAST RECO
SICS,TL4311D,LIN,V-REF,36V,-40
SICS,PWM CONTROLLER,I-MODE,NP
SICS,MC78M05,V-REG,100mA,5V,NP
TRA,CNY17-3,NP
D4 D18 D16
D20 D21 D22 D23
D16
DZ1
DZ2 DZ3
DZ4
DZ7 DZ8
R1
R3
D2 D3 D6 D7 D8 D9
(3.64)
X1 X2
X4 X5
X6 X7
OCI1 OCI2 OCI3
HSS,MTP,VERT MOUNT,TO220,NP
RES,THERMISTOR,PTC,POS TEMP,TR
RES,THERMISTOR,NTC,NEG TEMP,NP
CAP,1uF,PEMF,200V,10%,NP
TFM,L-5763-3,FLYBACK,NP
TFM,L-5764-3,FLYBACK,NP
TRA,BUZ30A,NMF,21A,200V,T0220,
CON,4P,TIN,MINI,NP
Q1,Q2 HEATSINKS
R40
R55
C13 C26
T1
T2
Q1 Q2
J41
CON,6P,TIN,MINI,NP
J42
CON,12P,TIN,MINI,NP
J43
SCREW
N/A
WASHER
N/A
SDIO,MURS360T3,NP
D19
CAP, 1500pF,200V,MET POLYPROP
SCAP,0.022uF,50v, X7R
C12,31
C49
SCAP,330pF,0805,50V,5%, COG
SRES,47.5,1210,5%,1/2W,TR,NP
SRES,10,TKF,0805,1%,1/10W
SRES,30.1,FXD,1210,5%,1/2W,TR
STRA,78M15C,DPACK
C52
R6 R7 R57 R58
R9 R60 R61
R35 R36
X3
STRA,7815C,DPACK
X8
CR
STRA,79M15C,DPACK
X9
SRES,2.49K,1210,5%,1/2W,T/R
SRES,1.21K,1210,5%,1/2W,TR,NP
SRES,150,1210,5%,1/2W,TR,NP
SRES,475,1206
R19 R23
R46 R48 R37
R25 R44
R8
SHSS,MTP,D2PACK,TO263
X8,D16 HEATSINKS
N/A
AS REQ'D THERMAL JOINT COMPOUND
SM200-194
A262577600
SM100-526
1
1
1
SCAP,0.1uF,0805,50V,X7R,10%,TR
SRES,75K,TKF,1206,1%,1/8W,TR,
SRES,150,1210,5%,1/2W,TR,NP
C53
R31
R62, R63, R64
CAPACITORS = MFD/VOLTS
INDUCTANCE = HENRIES
RESISTANCE = OHMS
(6.14)
INVERTER WELDERS
DIGITAL POWER P.C. BOARD AS'BLY
6-2-2000A
G3632-1
NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your factory warranty. Individual Printed Circuit Board Components are not available from Lincoln Electric. This information is pro-
vided for reference only. Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician. Improper PC board repairs could result in damage to the
machine.
POWER WAVE 455/R
Download from Www.Somanuals.com. All Manuals Search And Download.
G-14
G-14
ELECTRICAL DIAGRAMS
SCHEMATIC - FEEDHEAD PC BOARD #1
COMMON DIGITAL CONTROLS
XA
11-3-2000A
FEEDHEAD PC BOARD SCHEMATIC
1 OF 3
LRW
07/17/2000
3823-1C1/1
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
POWER WAVE 455/R
Download from Www.Somanuals.com. All Manuals Search And Download.
G-15
G-15
ELECTRICAL DIAGRAMS
SCHEMATIC- FEEDHEAD PC BOARD #2
TPD
TPE
COMMON DIGITAL CONTROLS
XA
11-3-2000A
FEEDHEAD PC BOARD SCHEMATIC
2 OF 3
LRW
07/17/2000
3823-1C1/2
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
POWER WAVE 455/R
Download from Www.Somanuals.com. All Manuals Search And Download.
G-16
G-16
ELECTRICAL DIAGRAMS
SCHEMATIC- FEEDHEAD PC BOARD #3
COMMON DIGITAL CONTROLS
XA
11-3-2000A
FEEDHEAD PC BOARD SCHEMATIC
3 OF 3
LRW
07/17/2000
3823-1C1/3
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
POWER WAVE 455/R
Download from Www.Somanuals.com. All Manuals Search And Download.
G-17
G-17
ELECTRICAL DIAGRAMS
PC BOARD ASSEMBLY-FEEDHEAD
PC BOARD REFERENCE
DESIGNATORS
74
75
76
S25001-3320SMT
S25005-1SMT
S25001-4751SMT
6
2
4
R139,R140,R141,R142,R143,R144 RESISTOR,SMD,332ohms,1/4W,1206,1%
ITEM
PART NO.
G3822-D
QTY
DESCRIPTION
FEED HEAD PC BOARD BLANK
R97,R98
R99,R114,R132,R137
R101,R104,R125,R126,R127,
SRES,0.05,3W,1%,TR,NP
SRES,4.75K,1206,1%,1/8W,NP,(SM
1
2
3
1
M19436-5
S8025-80
1
POTTING TRAY
77
S25000-4751SMT
14
R128,R129,R130,R131,R133,
SRES,4.75K,0805,1%,TR,NP
2
195g
6.88 OZ.
AS REQ.
1
SELF TAPPING SCREW
R134,R145,R90,R109
R115
4
E2527
EPOXY ENCAPSULATING RESIN
78
79
80
S25001-1503SMT
S25000-1211SMT
S25000-2002SMT
1
1
3
SRES,150K,1206,1%,1/8W,NP
SRES,1.21K,0805,1%,1/10W,TR,NP
SRES,20K,TKF,0805,1%,01/10W,TR
R135
R146,R147,R76
R2,R3,R4,R5,R6,R7,R9,R16,R17,
5
6
7
E3539
ELECTRICAL INSULATING COMPOUND
SOFTWARE,CPLD
S24822-2
S24823-2
X5
X9
N.D.
N.E.
1
SOFTWARE,FLASH
R18,R19,R20,R21,R22,R23,R53,
81
S25000-1002SMT
24
RESISTOR,SMD,METAL FILM,1/10W,10.0K,1%
FOR ITEMS LISTED BELOW REFER TO ELECTRONIC COMPONENT DATABASE FOR COMPONENT SPECIFICATIONS
R54,R77,R80,R106,R116,R138,
R148,R149
S1
T1
8
9
S25024-2SMT
4
C1,C2,C7,C50
C3,C4,C5,C6,C8,C9,C12,C14,
C15,C19,C20,C22,C25,
C26,C27,C28,C29,C30,C31,
C32,C34,C35,C38,C39,C41,
C43,C45,C46,C47,C48,C49,
C51,C54,C56,C57,C59,C60,
C64,C65,C69,C72,C75,C76,
C77,C78,C81,C82
C10,C11,C17,C18,C80
C13,C16
SCAP,1uF,TAN,3528,35V,TR,NP
SCAP,0.1uF,0805,50V,X7R,10%,TR
82
83
S19869-8
S20375-8
1
1
1
1
1
1
1
1
1
1
1
1
1
2
1
1
1
1
1
3
1
2
1
1
1
1
SWT,78B08S,DIP,SPST,8P,NP
TFM,L5936,Noreast,Switching Pwr
SICS,4.6V,2%,VOLT. DETECTOR
SICS,MC68332,MICRCONTROLLER,TQ
SICS,25128,SERIAL EEPR,NP
84
85
S25068-7SMT
M15101-14SMT
S25069-2SMT
S20353-1SMT
S25070-6SMT
S17900-24SMT
S25069-3SMT
S25066-2SMT
S25057-3SMT
M15105-9SMT
S15128-21SMT
S15128-18SMT
S15128-16SMT
S15018-20SMT
S25069-4SMT
S20353-5
X1
X2
86
87
X3
X4
S25020-3SMT
47
SICS,MC145407,RECEIVER/DRVR,RS
SICS,XC9572-15,CPLD,TQ100,NP
SICS,74HC132,NP
88
89
X5
X7,X29
X9
X10
90
91
SICS,28F800B5B90,FLASH ROM,90n
SICS,AD7862,DUAL,12BIT,250kSPS
SICS,AD8403ARU10,DIGITAL POT,NP
SICS,AD7945,12BIT,PARALLEL,DAC
SICS,LT1016,COMPARATOR,NP
SICS,MC33074,QUAD,OPAMP,S014,T
ICS,SMD,OP-AMP,QUAD,HIGH PERFORMANCE 1014
SICS,HIP4082,H-BRIDGE,FET DRIVE
SICS,128Kx16,20nS,TSOP(II)
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
S25024-8SMT
S25020-13SMT
S25024-5SMT
S25024-10SMT
S25020-2SMT
S25020-10SMT
S25020-9SMT
S25020-15SMT
S24833-1
5
2
6
3
1
3
2
3
2
1
1
1
2
2
4
SCAP,10uF,TAN,6032,16V,10%,TR,NP
SCAP,150pF,CER,0805,100V,COG,5%,TR,NP
SCAP,4.7uF,TAN,7343,35V,10%,TR,NP
SCAP,22uF,TAN,7343,25V,10%,POLAR,TR
SCAP,0.022uF,0805,50V,X7R,10%,
SCAP,4700pF,0805,50V,X7R,10%,T
SCAP,47pF,0805,50V,COG,5%,TR,N
SCAP,22pF,0805,50V,COG,5%,TR,N
CAP,0.27uF,PCF,63V,5%,TR,NP
CAP,1000uF,ALU,35V,20%,NP
92
X11
93
94
X12
X13
C23,C63,C66,C67,C68,C71
C24,C36,C73
95
96
X14,X20
X15
X16
C37
C40,C42,C44
97
98
C52,C79
X17
C55,C58,C83
99
X18
X19
SICS,AN82527,CAN CONTROLLER,PL
SICS,74ACT573,OCTAL,TRANS. LAT
SICS,MAX485,TRANSCEIVER,NP
SICS,79L05,V-REG,-5V,SO8
C61,C62
100
101
102
103
104
105
106
107
S25065-2SMT
S20353-4SMT
S25068-8SMT
S25068-6SMT
S15128-25SMT
S17900-11SMT
S24841-1
S13490-179
C70
X21,X26,X27
X22
S13490-182
C74
CAP,3300uF,ALU,63V,20%,NP
S13490-184
C84
CAP,330uF,100V
X23,X24
X25
SICS,78L05,V-REG,+5V,SO8
S25020-4SMT
S25040-12SMT
S25040-2SMT
C85,C86
CAPACITOR ,SMD CERAMIC,820PF,50V,5%COG,S0805
SDIO,MURS320T3,3A,200V,ULTRAFA
SDIO,400V,0.8A,NP
SICS,LM2576HVS-5.0,VREG,60V,SWI
SICS,74HC245,SOL20,HCMOS,NP
ICS,DC/DC,5V 3A OUT,36-75V IN
SXTL,16MHz,HC40,20pF,NP
D1,D12
X28
X30
D2,D17,D20,D27
D3,D4,D5,D6,D9,D18,D21,D28,D29,
D31
S25082-1SMT
Y1
25
S25040-5SMT
10
SDIO,BAV99LT1,SOT23,DUAL SWITC
26
27
28
29
30
31
32
33
S25049-4SMT
S25040-4SMT
S25040-11SMT
S25040-9SMT
S25040-10SMT
S25046-3SMT
S25046-1SMT
S25044-9SMT
4
5
4
1
1
4
3
6
D7,D8,D10,D19
D11,D13,D14,D15,D16
D22,D23,D24,D25
D26
SDIO,BAT54S,DUAL/SERIES,30V,20
SDIO,BAW56LT1,SOT23,DUAL SWT,T
SDIO,MURS160,1A,600V,FAST RECO
SDIO,3A,200V,D0-214AB,UFR
DIODE,SMD,3A,400V
D30
DZ1,DZ2,DZ3,DZ4
DZ5,DZ28,DZ29
DZ6,DZ7,DZ8,DZ9,DZ26,DZ27
DZ10,DZ11,DZ12,DZ13,DZ14,
DZ15,DZ16,DZ17,DZ18
DZ20,DZ21,DZ22,DZ23
F1,F2
SDIO,MMSZ5248B,18V,ZENER,TR,NP
SDIO,MMSZ5231BT1,5.1V,NP
SDIO,1SMB5920BT3,6.2V,NP
(6.34)
34
S25044-1SMT
9
SDIO,1SMB5918BT3,3W,5.1V,5%,TR,NP
35
36
S25046-2SMT
S18380-5
4
2
SDIO,MMSZ5240BT1,10V,500mW,ZEN
RES,50,VAR,PTC,NP
F3,F4,F5,F6,F7,F8,F9,F10,
F11,F12,F13,F14
J81,J82
37
S18380-14
12
RES,500,PTC,265V
38
39
40
41
42
43
44
45
46
47
S24020-4
2
1
1
1
1
1
4
1
5
5
CON,MOLEX,15-97-7042,MINI,PCB,4 PIN,TIN
CON,MOLEX,15-97-7062,MINI,PCB,6 PIN,TIN
CON,MOLEX,15-97-7082,MINI,PCB,8 PIN,TIN
CON,MOLEX,15-97-7162,MINI,PCB,16 PIN,TIN
CON,10P,MINI,NP
S24020-6
J83
S24020-8
J84
S24020-16
J85
S18248-10
J86
S18248-16
J87
CON,MOLEX,39-28-1163,PCB,16 PIN,TIN
SICS,Optocoupler, HCPL-0601 (SO-8)
SICS,HCPL-0201,OPTOCOUPLE
S15000-28SMT
S15000-26SMT
S25051-4SMT
S25050-2SMT
OCI1,OCI2,OCI3,OCI4
OCI5
Q1,Q12,Q13,Q15,Q16
STRA,2N7002,TR,NP, (SM400-020)
STRA,2N4403,SO23,TR,(500475),N
Q2,Q3,Q7,Q14,Q17
Q4,Q5,Q6,Q19,Q20,Q21,Q22,Q23,Q2
4
48
S25050-1SMT
9
STRA,2N4401,SOT-23,NPN,TR,
49
50
S25051-5SMT
S23060-1SMT
4
1
Q8,Q9,Q10,Q11
Q18
STRA,75A,55V,0.007 OHM FET,N-CHAN
IC,SMD,SWITCH,LO-SIDE,2.2A60V,
R2,R3,R4,R5,R6,R7,R9,R16,
R17,R18,R19,R20,R21,R22,
R23,R53,R54,R77,R80,R106,
R116,R138,R148,R149
R8,R10,R13,R83,R100,R118
R84,R85,R86,R152
R11,R12
51
S25000-1002SMT
24
SRES,10K,0805,1%,1/10W,TR,NP
52
53
54
S25001-1002SMT
S25001-4752
S25003-2000SMT
6
4
2
SRES,10K,MF,1206,1%,1/8W,TR
RESISTOR,SMD,47.5K,1/4W,1206,1%
SRES,200,2512,5%,1W,TR,NP
R14,R15,R62,R68,R78,R102,
R103,R107,R112
R24,R25,R55,R105,R113,
R136,R153,R154
R26,R27
55
S25001-4750SMT
9
SRES,475,1206,1%,1/8W,TR,NP
56
57
58
S25000-1001SMT
S25000-4750SMT
S25004-2430SMT
8
2
SRES,1K,0805,1%,1/10W,TR,NP
SRES,475,0805,1%,TR,NP
(5.84)
R28,R29,R30,R31,R32,R33,
R34,R35,R36,R37,R38,R39
R41,R42,R48,R49,R50,R51,
R52,R121,R123
R43,R44,R45,R46,R47,R65,
R108,R122,R124
R56,R57,R58,R61,R64,R66,
R110,R111
12
SRES,243,WSC-1,1%,1W,TR,NP
59
60
61
S25000-3320SMT
S25000-2210SMT
S25001-2000SMT
9
9
8
SRES,332,0805,1%,1/10W,TR,NP
SRES,221,TKF,0805,1%,1/10W,TR
SRES,200,1206,1%,1/8W,TR,NP
62
63
64
65
66
67
68
69
70
71
72
73
S25001-7500SMT
S25000-2213SMT
S25000-4752SMT
S25000-1003SMT
S25001-1001SMT
S25000-9092SMT
S25000-3921SMT
S25001-4753SMT
S25001-4752SMT
S25001-1000SMT
S25001-15R0SMT
S25001-1500SMT
1
1
2
6
1
2
1
2
2
9
2
4
R1
RESISTOR,SMD,750ohms,1/4W,1206,1%
SRES,221K,TKF,0805,1%,01/10W,TR
SRES,47.5K,TKF,0805,1%,01/10W,TR
SRES,100K,TKF,0805,1%,01/10W,TR
SRES,1K,1206,1%,1/8W,TR,NP,(09
SRES,90.9K,TKF,0805,1%,1/10W
SRES,3.92K,TKF,0805,1%,1/10W,TR
SRES,475K,1206,1%,1/8W,TR,NP
SRES,47.5K,1206,1%,1/8W,TR,NP
SRES,100,1206,1%,1/8W,TR,NP
SRES,15,1206,1%,1/8W,TR,NP
R63
R67,R72
R69,R71,R73,R75,R82,R117
R70
R74,R81
R79
R87,R120
R88,R119
R89,R93,R96,R155,R156,R157,
R91,R92
R94,R95,R150,R151
SRES,150,1206,1%,1/8W,TR,NP
UNLESS OTHERWISE SPECIFIED:
RESISTANCE = OHMS
COMMON DIGITAL CONTROLS
FEED HEAD PC BOARD ASSEMBLY
4-20-2001C
L11087-2
NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your factory warranty. Individual Printed Circuit Board Components are not available from Lincoln Electric. This information is pro-
vided for reference only. Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician. Improper PC board repairs could result in damage to the
machine.
POWER WAVE 455/R
Download from Www.Somanuals.com. All Manuals Search And Download.
G-18
G-18
ELECTRICAL DIAGRAMS
SCHEMATIC - INPUT PC BOARD
M
1 9 5 2 8
PRE-CHARGE CONNECTIONS
CONTACTOR OUTPUT
2
10
J60
2
4
3
4
CONTACTOR
J61
J61
J61
CR1
COIL CONNECT
TP1
TP3
1
660V
250J
660V
250J
J60
J60
TP2
CONTACTOR CONTROL
+13V FROM CONTROL BOARD
PRE-CHARGE CONTROL
5
R9
R8
3
4
660V
250J
5
6
CR2
CR2
100
10W
100
10W
+13V
J61
CR1
R2
R1
6
100
10W
100
10W
VAC
Input
TP4
660V
250J
3
J60
J60
J61
CR2
R7
R10
8
100
10W
100
10W
4
R6
R3
100
10W
100
10W
+13V
475
1
5
4
D2
1A
D3
D1
OCI1
CNY17-3V
1500V
2
6
SINGLE PHASE DETECT
8
J60
CENTER LEG TO OUTSIDE LEG OF INPUT
C1
.022
50V
GENERAL INFORMATION
ELECTRICAL SYMBOLS PER E1537
LAST NO. USED
UNUSED PINS
R- 25
OCI-
CR-
TP-
1
C-
D-
1
2
J61
J61
J60
CAPACITORS
RESISTORS
DIODES
=
MFD
(
.022/50V
1/4W
UNLESS OTHERWISE SPECIFIED)
UNLESS OTHERWISE SPECIFIED)
3
4
6
7
1
LABELS
=
Ohms
(
NOTES :
=
1A, 400V
(UNLESS OTHERWISE SPECIFIED)
SUPPLY
VOLTAGE NET
J60
N.A. SINCE COMPONENTS OR CIRCUITRY ON
A
PRINTED CIRCUIT BOARD MAY CHANGE
3
POWER SUPPLY SOURCE POINT
COMMON CONNECTION
WITHOUT AFFECTING THE INTERCHANGEABILITY OF
A
COMPLETE BOARD, THIS DIAGRAM MAY
J61
J61
J61
NOT SHOW THE EXACT COMPONENTS OR CIRCUITRY OF CONTROLS HAVING A COMMON CODE
NUMBER.
5
7
9
FRAME CONNECTION
EARTH GROUND CONNECTION
THIS SHEET CONTAINS PROPRIETARY INFORMATION OWNED BY
THE LINCOLN ELECTRIC CO.
FILENAME: M19528-1AA
AND IS NOT TO BE REPRODUCED, DISCLOSED OR USED WITHOUT THE EXPRESS PERMISSION OF
THE LINCOLN ELECTRIC CO.
UNLESS OTHERWISE SPECIFIED TOLERANCE
ON HOLES SIZES PER E-2056
Ch’ge.Sht.No.
XA
EQUIP.
TYPE
INVERTEC 450 - 650
INPUT P.C. BOARD SCHEMATIC
THE LINCOLN ELECTRIC CO.
CLEVELAND, OHIO U.S.A.
ON
ON
2
3
PLACE DECIMALS IS
PLACE DECIMALS IS
+
+
.O2
.OO2
11-3-2000A
SUBJECT
ON ALL ANGLES IS
+
.5 OF
A
DEGREE
NONE
SCALE
MATERIAL TOLERANCE ("t") TO AGREE
WITH PUBLISHED STANDARDS
SHT.
19528
MAB
5-25-99
CHK.
SUP’S’D’G.
M
DR.
DATE
NO.
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
POWER WAVE 455/R
Download from Www.Somanuals.com. All Manuals Search And Download.
G-19
G-19
ELECTRICAL DIAGRAMS
PC BOARD ASSEMBLY-INPUT
ITEM
REQ’D
PART NO.
IDENTIFICATION
2.80
RESISTORS = OHMS/WATTS
CAPACITORS = MFD/VOLTS
~.04
4.50
INVERTEC 455-655 INPUT
xxxxx
xxxxx
4.25
J61
J60
D1
R22
TP4
D2
TP3
TP2
R24
R25
R23
R21
R20
R19
R18
OCI1
R11
R12
R13
R14
R15
R16
R17
TP1
xxx
R9
x
x
R7
CR1
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
CR2
R6
R8
R3
x
x
x
x
x
x
R1
R2
x
x
x
x
xxx
R10
.25
L11396-1
0
~.04
6.00
0
.25
3.00
5.75
INVERTER WELDERS
INPUT P.C. BOARD ASSEMBLY
11-3-2000A
L11396-1
NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your factory warranty. Individual Printed Circuit Board Components are not available from Lincoln Electric. This information is pro-
vided for reference only. Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician. Improper PC board repairs could result in damage to the
machine.
POWER WAVE 455/R
Download from Www.Somanuals.com. All Manuals Search And Download.
G-20
G-20
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.
Download from Www.Somanuals.com. All Manuals Search And Download.
G-21
G-21
ELECTRICAL DIAGRAMS
PC BOARD ASSEMBLY-SWITCH
ITEM
REQ'D
PART NO
IDENTIFICATION
C1
1
1
S2 0500-14 CAPACITOR,PPMF,.022,100V,BOX,5%
C2
CAPACITOR,CEMO,0.1, 50V,10%
CAPACITOR,CEMO,.022, 50V,20%
CAPACITOR,CEMO,4700p,50V,10%
CAPACITOR,TAEL,27,35V,10%
S16668-11
S16668-5
S16668-6
S13490-93
S20500-1
C3
1
C4,C6,C7
C5
3
1
C8,C9,C10,C11,C12,C13,C14
CAPACITOR,PPMF,0.1,1000V,10%,BOX
10
C15,C16,C17
D1,D2
DIODE,AXLDS,1A,1000V,FR, 818
2
T12705-44
T12705-32
D3,D4,D5,D6,D7,D8,D9,D10
DIODE,T220,15A,600V,FR,MUR1560
10
D11,D12
6.00 .04
DZ1
ZENER DIODE, 1W,20V,5% 1N4747A
ZENER DIODE, 1W,15V,5% 1N4744A
ZENER DIODE, 1W,6.2V,5% 1N4735A
CONNECTOR,MOLEX,MINI,PCB,6-PIN,TIN
CHOKE,RF,FERRITE BEAD,180 OHM
1
4
T12702-4
T12702-29
T12702-40
S24020-6
+.12
-.00
DZ2,DZ3,DZ5,DZ6
.30
DZ4,DZ7
2
C5
J40
1
C1
X1
L1,L2,L3,L4,L5,L6,L7,L8,L9
10
T 12218-15
L10
OCI1
OPTOCOUPLER,PHOTO-Q,70V,CNY17-3/VDE
TRIMMER,MT,1/2W,10K, 10%,LINEAR
RESISTOR,MF,1/4W,6.81K,1%
1
1
S15000-22
S16296-5
X2
R1
R2
1
S19400-6811
S19400-1002
S19400-10R0
R3,R8
RESISTOR,MF,1/4W,10.0K,1%
2
R9
R10
R4,R13,R14,R17,R18,R19,R20
RESISTOR,MF,1/4W,10.0,1%
13
R2
C3
R21,R23,R24,R25,R26,R27
R5,R9
RESISTOR,MF,1/4W,2.00K,1%
RESISTOR,MF,1/4W,221K,1%
RESISTOR,MF,1/4W,100,1%
2
1
1
3
1
2
5
1
1
1
1
S19400-2001
S19400-2213
S19400-1000
S19400-1003
S19400-6191
S19400-1001
T14648-9
R6
R7
R11
R10,R12,R15
RESISTOR,MF,1/4W,100K,1%
RESISTOR,MF,1/4W,6.19K,1%
RESISTOR,MF,1/4W,1.00K,1%
RESISTOR,WW,5W,2.5K,5%,SQ
TRANSFORMER,PULSE,3-WINDING
CURRENT-TRANSDUCER,125-TURN
IC,CONVERTER,V/F,654
R11
R16,R22
A1
R28,R29,R30,R31,R32
R5
T1
T2
X1
X2
T12737-7
OCI1
M19612
DZ3
C6
DZ2
M13552-3
VOLTAGE REF,ADJ, PECISION,431I
S15128-10
DZ4
R16
R13
L5
R21
L4
R20
L3
R19
L2
L1
R18
R17
DZ5
R 1.62
C7
DZ6
3.00
R30
R29
R28
R14
DZ7
J40
2
R27
L10
R26
L9
R25
L8
R24
L7
R23
L6
1
A2
+.12
-.00
.30
0
+.12
-.00
.00
1.20
1.38
N.T.,N.U.,N.V.
2.00 .12
11.15 .04
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
"X" INFO.
XD-RW
Chg. Sheet No.
5-11-2001F
DESIGN INFORMATION
REFERENCE:
MANUFACTURING TOLERANCE PER E2056
EQUIPMENT TYPE:
INVERTER WELDERS
SWITCH P.C. BOARD AS'BLY
ON
ON
2
3
PLACEDECIMALS IS .02
PLACE DECIMALS IS .002
DRAWN BY: F.V
ENGINEER: L. C.
APPROVED:
G3734-1
ON ALL ANGLES IS .5 OF ADEGREE
SUBJECT:
MATERIAL TOLERANCE (" ") TO AGREE
SUPERSEDING:
t
WITH PUBLISHED STANDARDS.
DATE:
10-3-2000
DRAWING No.:
SCALE:1:1
3734-2
G
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 WAVE 455/R
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G-22
G-22
ELECTRICAL DIAGRAMS
SCHEMATIC - VOLTAGE SENSE PC BOARD
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
POWER WAVE 455/R
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G-23
G-23
ELECTRICAL DIAGRAMS
PC BOARD ASSEMBLY-VOLTAGE SENSE
ITEM
D1
REQD
1
PART NO. IDENTIFICATION
T12199-1
1N4004
J1
J2
L1
1
1
1
S24020-6
S24020-2G
T12218-7
HEADER
HEADER
330uH
.
.
.20
1.80
OCI1,OCI2
R1,R2
2
2
1
2
S15000-20
S19400-4750
S18380-1
PHOTO FET
475 1/4W
R3
THERMISTOR,PTC
160J
TP1,TP2
T13640-18
.04
1.75
M19540-1
CAPACITORS = MFD/VOLTS
RESISTORS = OHMS
INDUCTANCE = HENRYS
1.55
J1
J2
R3
L1
TP2
TP1
.20
0
RA
A
.04
0
1.00
2.00
COMMON DIGITAL CONTROLS
VOLTAGE SENSE SELECT P.C. BD AS'BLY
1-3-2000A
M19540-1
NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your factory warranty. Individual Printed Circuit Board Components are not available from Lincoln Electric. This information is pro-
vided for reference only. Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician. Improper PC board repairs could result in damage to the
machine.
POWER WAVE 455/R
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G-24
G-24
ELECTRICAL DIAGRAMS
SCHEMATIC - 40 VDC BUS PC BOARD
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
POWER WAVE 455/R
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G-25
G-25
ELECTRICAL DIAGRAMS
PC BOARD ASSEMBLY-40 VDC BUS
ITEM
REQ’D
PART NO
M15458-4
IDENTIFICATION
X1
1
3
1
1
1
1
1
1
2
4
2
2
5
2
1
2
1
IC,PWM-CONTROLLER,IMODE,2842A
CAPACITOR,TAEL,4.7,35V 10%
CAPACITOR,TAEL,1.0,35V,10%
CAPACITOR,TAEL,47,35V 10%
CAPACITOR,TAEL,27,35V,10%
CAPACITOR,ALEL,470,100V,+50/-10%
IC,CMOS,DRIVER,MOSFET,2110(SS)
CAPACITOR,CEMO,100P, 100V,5%
CAPACITOR,CEMO,4700P, 50V,2%
CAPACITOR,CEMO,0.1, 50V,10%
RESISTOR,MF,1/4W,47.5,1%
C2,C3,C5
C16
S13490-25
S13490-42
S13490-66
S13490-93
S13490-174
S15018-16
S16668-3
S16668-10
S16668-11
S19400-47R5
S19400-1000
S19400-1002
S19400-1821
S19400-2213
S19400-2672
S19400-3323
C6
C1
C15
X2
C14
C11,C17
C7,C8,C9,C10
R15,R16
R12,R13
R3,R4,R5,R7,R8
R14,R22
R23
RESISTOR,MF,1/4W,100,1%
RESISTOR,MF,1/4W,10.0K,1%
RESISTOR,MF,1/4W,1.82K,1%
RESISTOR,MF,1/4W,221K,1%
RESISTOR,MF,1/4W,26.7K,1%
RESISTOR,MF,1/4W,332K,1%
R20,R21
R29
4.30
R28
R19
R9,R10,R11
C13
J46
J47
D2
D1
L1
1
1
3
1
1
1
1
1
1
S19400-4752
S19400-5622
S19400-8251
S20500-2
S24020-4
S24020-8
T12199-1
T12199-2
T12218-16
RESISTOR,MF,1/4W,47.5K ,1%
RESISTOR,MF,1/4W,56.2K,1%
RESISTOR,MF,1/4W,8.25K,1%
CAPACITOR,PPMF,0.47,630V,10%,BOX
CONNECTOR,MOLEX,MINI,PCB,4-PIN,TIN
CONNECTOR,MOLEX,MINI,PCB,8-PIN,TIN
DIODE,AXLDS,1A,400V
DIODE,AXLDS,1A,1000V
CHOKE,HIGH-CURRENT,100UH,10A,10%, LOW
3.85~.04
3.65
R26,R27
DZ4
2
1
T12300-86
T12702-25
RESISTOR,WW,3W,0.05,1%
ZENER DIODE,5W,20V,5% 1N5357B
MOV2
J47
J46
DZ5,DZ6
2
T12702-45
ZENER DIODE, 1W,18V,5% 1N4746A
D4
D5
D3
1
1
1
T12705-23
T12705-34
T12705-59
DIODE,AXLDS,1A,30V,SCHOTTKY,1N5818
DIODE,AXLDS,1A,400V,FR,1N4936
DIODE,AXLDS,3A,600V,UFR
LED1
R4
R5
R7
R8
MOV1
MOV2
LED1
1
1
1
T13640-15
T13640-24
T13657-2
MOV,50VRMS,15J,14MM
MOV,175VRMS,120J,20MM
LED,T-1,3/4,RED,HLMP-3003
R25
1
T14648-17
RESISTOR,WW,5W,270,5%,SQ
A 1
R11
D1
CAPACITORS = MFD/VOLTS
RESISTORS = OHMS, 1/4 WATT (UNLESS OTHERWISE SPECIFIED)
R27
C16
R28
D5
DZ5
R15
R16
DZ6
C1
C3
R9
D3
R23
X1
R25
C6
C7
C8
C9
X2
C10
R29
D4
R14
R13
C5
.20
0
.20
4.50~.04
0
MULTI-WELD 350
40V DC BUS P.C. BOARD ASSEMBLY
9-22-2000
L11078-1
NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your factory warranty. Individual Printed Circuit Board Components are not available from Lincoln Electric. This information is pro-
vided for reference only. Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician. Improper PC board repairs could result in damage to the
machine.
POWER WAVE 455/R
Download from Www.Somanuals.com. All Manuals Search And Download.
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:
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
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___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
SD287 01/99
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