Download Lincoln Electric SVM112-B User's Manual
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SVM112-B View Safety Info February, 2001 TM INVERTEC POWER WAVE 450 For use with machines having Code Numbers: 10105 thru 10610 Return to Master TOC View Safety Info View Safety Info Safety Depends on You Return to Master TOC Return to Master TOC RETURN TO MAIN INDEX Lincoln arc welding and cutting equipment is designed and built with safety in mind. However, your overall safety can be increased by proper installation . . . and thoughtful operation on your part. DO NOT INSTALL, OPERATE OR REPAIR THIS EQUIPMENT WITHOUT READING THIS MANUAL AND THE SAFETY PRECAUTIONS CONTAINED THROUGHOUT. And, most importantly, think before you act and be careful. View Safety Info Return to Master TOC 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 Return to Master TOC i i SAFETY WARNING CALIFORNIA PROPOSITION 65 WARNINGS Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm. The Above For Diesel Engines The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm. The Above For Gasoline Engines ARC WELDING CAN BE HAZARDOUS. PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH. KEEP CHILDREN AWAY. PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING. Return to Master TOC Return to Master TOC Return to Master TOC Read and understand the following safety highlights. For additional safety information, it is strongly recommended that you purchase a copy of “Safety in Welding & Cutting - ANSI Standard Z49.1” from the American Welding Society, P.O. Box 351040, Miami, Florida 33135 or CSA Standard W117.2-1974. A Free copy of “Arc Welding Safety” booklet E205 is available from the Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199. BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE AND REPAIR PROCEDURES ARE PERFORMED ONLY BY QUALIFIED INDIVIDUALS. FOR ENGINE powered equipment. 1.h. To avoid scalding, do not remove the radiator pressure cap when the engine is hot. 1.a. Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running. ____________________________________________________ 1.b. Operate engines in open, well-ventilated areas or vent the engine exhaust fumes outdoors. ____________________________________________________ 1.c. Do not add the fuel near an open flame welding arc or when the engine is running. Stop the engine and allow it to cool before refueling to prevent spilled fuel from vaporizing on contact with hot engine parts and igniting. Do not spill fuel when filling tank. If fuel is spilled, wipe it up and do not start engine until fumes have been eliminated. ____________________________________________________ 1.d. Keep all equipment safety guards, covers and devices in position and in good repair.Keep hands, hair, clothing and tools away from V-belts, gears, fans and all other moving parts when starting, operating or repairing equipment. ____________________________________________________ 1.e. In some cases it may be necessary to remove safety guards to perform required maintenance. Remove guards only when necessary and replace them when the maintenance requiring their removal is complete. Always use the greatest care when working near moving parts. ___________________________________________________ 1.f. Do not put your hands near the engine fan. Do not attempt to override the governor or idler by pushing on the throttle control rods while the engine is running. ELECTRIC AND MAGNETIC FIELDS may be dangerous 2.a. Electric current flowing through any conductor causes localized Electric and Magnetic Fields (EMF). Welding current creates EMF fields around welding cables and welding machines 2.b. EMF fields may interfere with some pacemakers, and welders having a pacemaker should consult their physician before welding. 2.c. Exposure to EMF fields in welding may have other health effects which are now not known. 2.d. All welders should use the following procedures in order to minimize exposure to EMF fields from the welding circuit: 2.d.1. Route the electrode and work cables together - Secure them with tape when possible. 2.d.2. Never coil the electrode lead around your body. 2.d.3. Do not place your body between the electrode and work cables. If the electrode cable is on your right side, the work cable should also be on your right side. 2.d.4. Connect the work cable to the workpiece as close as possible to the area being welded. ___________________________________________________ 1.g. To prevent accidentally starting gasoline engines while turning the engine or welding generator during maintenance work, disconnect the spark plug wires, distributor cap or magneto wire as appropriate. 2.d.5. Do not work next to welding power source. Mar ‘95 Return to Master TOC Return to Master TOC ii ELECTRIC SHOCK can kill. ARC RAYS can burn. 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. 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.b. Use suitable clothing made from durable flame-resistant material to protect your skin and that of your helpers from the arc rays. 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: • Semiautomatic DC Constant Voltage (Wire) Welder. • DC Manual (Stick) Welder. • AC Welder with Reduced Voltage Control. 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. 3.c. In semiautomatic or automatic wire welding, the electrode, electrode reel, welding head, nozzle or semiautomatic welding gun are also electrically “hot”. 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. Return to Master TOC ii SAFETY 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. 3.i. When working above floor level, use a safety belt to protect yourself from a fall should you get a shock. 3.j. Also see Items 6.c. and 8. FUMES AND GASES can be dangerous. 5.a. Welding may produce fumes and gases hazardous to health. Avoid breathing these fumes and gases.When welding, keep your head out of the fume. Use enough ventilation and/or exhaust at the arc to keep fumes and gases away from the breathing zone. When welding with electrodes which require special ventilation such as stainless or hard facing (see instructions on container or MSDS) or on lead or cadmium plated steel and other metals or coatings which produce highly toxic fumes, keep exposure as low as possible and below Threshold Limit Values (TLV) using local exhaust or mechanical ventilation. In confined spaces or in some circumstances, outdoors, a respirator may be required. Additional precautions are also required when welding on galvanized steel. 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. 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. 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. 5.e. Also see item 1.b. Return to Master TOC Mar ‘95 Return to Master TOC iii WELDING SPARKS can cause fire or explosion. 6.a. Remove fire hazards from the welding area. If this is not possible, cover them to prevent the welding sparks from starting a fire. Remember that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas. Avoid welding near hydraulic lines. Have a fire extinguisher readily available. 6.b. Where compressed gases are to be used at the job site, special precautions 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. Return to Master TOC 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. 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). 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. Return to Master TOC iii SAFETY 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. 6.h. Also see item 1.c. CYLINDER may explode if damaged. 7.a. Use only compressed gas cylinders containing the correct shielding gas for the process used and properly operating regulators designed for the gas and pressure used. All 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. 7.c. Cylinders should be located: • Away from areas where they may be struck or subjected to physical damage. • 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. 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. FOR ELECTRICALLY powered equipment. 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. 8.c. Ground the equipment in accordance with the U.S. National Electrical Code and the manufacturer’s recommendations. Return to Master TOC Mar ‘95 Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC iv iv SAFETY PRÉCAUTIONS DE SÛRETÉ 6. Eloigner les matériaux inflammables ou les recouvrir afin de prévenir tout risque d’incendie dû aux étincelles. Pour votre propre protection lire et observer toutes les instructions et les précautions de sûreté specifiques qui parraissent dans ce manuel aussi bien que les précautions de sûreté générales suivantes: 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. Sûreté Pour Soudage A L’Arc 1. Protegez-vous contre la secousse électrique: a. Les circuits à l’électrode et à la piéce sont sous tension quand la machine à souder est en marche. Eviter toujours tout contact entre les parties sous tension et la peau nue ou les vétements mouillés. Porter des gants secs et sans trous pour isoler les mains. b. Faire trés attention de bien s’isoler de la masse quand on soude dans des endroits humides, ou sur un plancher 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. 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. e. Ne jamais toucher simultanément les parties sous tension des porte-électrodes connectés à deux machines à souder parce que la tension entre les deux pinces peut être le total de la tension à vide des deux machines. 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. 2. Dans le cas de travail au dessus du niveau du sol, se protéger contre les chutes dans le cas ou on recoit un choc. Ne jamais enrouler le câble-électrode autour de n’importe quelle partie du corps. 8. S’assurer que la masse est connectée le plus prés possible de la zone de travail qu’il est pratique de le faire. Si on place la masse sur la charpente de la construction ou d’autres endroits éloignés de la zone de travail, on augmente le risque de voir passer le courant de soudage par les chaines de levage, câbles de grue, ou autres circuits. Cela peut provoquer des risques d’incendie ou d’echauffement des chaines et des câbles jusqu’à ce qu’ils se rompent. 9. Assurer une ventilation suffisante dans la zone de soudage. Ceci est particuliérement important pour le soudage de tôles galvanisées plombées, ou cadmiées ou tout autre métal qui produit des fumeés toxiques. 10. Ne pas souder en présence de vapeurs de chlore provenant d’opérations de dégraissage, nettoyage ou pistolage. La chaleur ou les rayons de l’arc peuvent réagir avec les vapeurs du solvant pour produire du phosgéne (gas fortement toxique) ou autres produits irritants. 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. PRÉCAUTIONS DE SÛRETÉ POUR LES MACHINES À SOUDER À TRANSFORMATEUR ET À REDRESSEUR 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. c. Protéger l’autre personnel travaillant à proximité au soudage à l’aide d’écrans appropriés et non-inflammables. 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. 1. Relier à la terre le chassis du poste conformement au code de l’électricité et aux recommendations du fabricant. Le dispositif de montage ou la piece à souder doit être branché à une bonne mise à la terre. 2. Autant que possible, I’installation et l’entretien du poste seront effectués par un électricien qualifié. 3. Avant de faires des travaux à l’interieur de poste, la debrancher à l’interrupteur à la boite de fusibles. 4. Garder tous les couvercles et dispositifs de sûreté à leur place. 5. Toujours porter des lunettes de sécurité dans la zone de soudage. Utiliser des lunettes avec écrans lateraux dans les zones où l’on pique le laitier. Mar. ‘93 v v RETURN TO MAIN INDEX MASTER TABLE OF CONTENTS FOR ALL SECTIONS Page Safety.................................................................................................................................................i-iv Installation .............................................................................................................................Section A Operation...............................................................................................................................Section B Accessories...........................................................................................................................Section C Maintenance .........................................................................................................................Section D Theory of Operation .............................................................................................................Section E Troubleshooting and Repair.................................................................................................Section F How To Use Troubleshooting Guide ...........................................................................................F-2 PC Board Troubleshooting Procedures and Replacement.........................................................F-3 Troubleshooting Guide ................................................................................................................F-5 Test Procedures ........................................................................................................................F-27 Removal and Replacement Procedures .................................................................................F-155 Electrical Diagrams ..............................................................................................................Section G Parts Manual................................................................................................................................P-261 POWER WAVE 450 Return to Master TOC Section A-1 TABLE OF CONTENTS - INSTALLATION SECTION - Section A-1 Installation Technical Specifications .............................................................................................................A-2 Safety Precautions......................................................................................................................A-3 Select Suitable Location .............................................................................................................A-3 Stacking................................................................................................................................A-3 Tilting .................................................................................................................................A-3 Lifting .................................................................................................................................A-3 High Frequency Precautions.......................................................................................................A-3 Return to Master TOC Input Connections.......................................................................................................................A-3 Ground Connections...................................................................................................................A-4 Input Power Connections ...........................................................................................................A-4 Input Fuse and Supply Wire Considerations .......................................................................A-4 Input Voltage Reconnect Procedure ....................................................................................A-4 Output Connections....................................................................................................................A-5 Work and Electrode Cable Connections ..............................................................................A-5 Size.................................................................................................................................A-5 Routing............. ..............................................................................................................A-5 Water Cooler Connections ...................................................................................................A-5 Return to Master TOC Return to Master TOC Wire Feeder Connections.....................................................................................................A-5 POWER WAVE 450 Return to Master TOC Return to Section TOC A-2 A-2 INSTALLATION TECHNICAL SPECIFICATIONS - POWER WAVE 450 INPUT -THREE PHASE ONLY Input Voltages: 200 230 400 460 575 Input Currents @ 500A/40 VDC @ 450A/38 VDC 87 75 76 65 44 38 38 32 32 28 Return to Master TOC Return to Section TOC RATED OUTPUT Duty Cycle Amps Volts at Rated Amperes 60% Duty Cycle 100% Duty Cycle 500 450 40 VDC 38 VDC Constant Open Circuit Voltage Continuous Current Range Process Current Ranges 75 Volts 5-540 Amps GMAW 50-540 Amps FCAW 40-540 Amps STICK 30-540 Amps Pulse Current Range Pulse Voltage Range Pulse and Background Time Range Pulse Frequency 5-750 Amps 5-55 Volts 100 Microsec - 3.3 Sec 0.15 - 1000 Hz Return to Master TOC Return to Section TOC RECOMMENDED INPUT WIRE AND FUSE SIZES Input Voltage/ Freqency Duty Cycle Input Ampere Rating on Nameplate 200/50-60 230/50-60 400/50-60 460/50-60 575/50-60 200/50-60 230/50-60 400/50-60 460/50-60 575/50-60 60% 60% 60% 60% 60% 100% 100% 100% 100% 100% 87 76 44 38 32 75 65 38 32 28 Type 75°C Copper Wire in Conduit AWG[IEC] Sizes (MM2) 4 4 8 8 8 4 4 8 8 8 Type 75°C Ground Wire in Conduit AWG[IEC] Sizes (MM2) Type 75°C (Super Lag) or Breaker Size (Amps) 8 (10) 8 (10) 10 (6) 10 (6) 10 (6) 8 (10) 8 (10) 10 (6) 10 (6) 10 (6) 120 100 50 50 50 100 100 50 50 40 (25) (25) (10) (10) (10) (25) (25) (10) (10) (10) Height Width Depth Weight 905 mm 35.6 in. 515 mm 20.3 in. 1010 mm 39.8 in. 137.9 kg 303.5 lbs. OPERATING TEMPERATURE RANGE STORAGE TEMPERATURE RANGE Return to Master TOC Return to Section TOC PHYSICAL DIMENSION 0° to 40°C -50° to 85°C POWER WAVE 450 Return to Master TOC Return to Section TOC A-3 INSTALLATION Read this entire installation section before you start installation. LIFTING SAFETY PRECAUTIONS HIGH FREQUENCY PRECAUTIONS WARNING ELECTRIC SHOCK can kill. • Only qualified personnel should perform this installation. Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC • Turn the input power OFF at the disconnect switch or fuse box before working on this equipment. • Do not touch electrically hot parts. • Always connect the Power Wave grounding terminal (located inside the reconnect input access doors). Lift the machine by the lift bail only. Do not attempt to lift the machine by the push handle. If possible, locate the Power Wave away from radio controlled machinery. The normal operation of the Power Wave may adversely affect the operation of RF controlled equipment, which may result in bodily injury or damage to the equipment. INPUT CONNECTIONS Be sure the voltage, phase, and frequency of the input power is as specified on the rating plate, located on the rear of the machine. See Figure A.1 for the location of the rating plate. FIGURE A.1 - RATING PLATE LOCATION SELECT SUITABLE LOCATION Place the welder where clean cooling air can circulate in through the rear louvers and out through the side and front louvers. Dirt, dust, or any foreign material that can be drawn into the welder should be kept at a minimum. Using filters on the air intake to prevent dirt from building up restricts air flow. Do not use such filters. Failure to observe these precautions can result in excessive operating temperatures and nuisance shutdowns. The Power Wave may be used outdoors. Power Wave power sources carry an IP23 enclosure rating. They are rated for use in damp, dirty environments subject to occasional falling water such as rain. However, the best practice is to keep the machine in a dry, sheltered area, since a wet environment speeds corrosion of parts. Do not place the machine in puddles or otherwise submerge parts of the machine in water. This may cause improper operation and is a possible safety hazard. STACKING 3 1. RATING PLATE 2. RECONNECT/INPUT ACCESS DOOR 3. INPUT CORD ACCESS HOLE WARNING TILTING Return to Master TOC 2 1 Power Wave machines cannot be stacked. Return to Section TOC A-3 Each machine must be placed on a secure, level surface. The machine may topple over if this procedure is not followed. 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. The Power Wave has a 1.375” (35mm) access hole for the input cord, but the input cord is not supplied. POWER WAVE 450 Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC A-4 A-4 INSTALLATION CAUTION Failure to follow these instructions can cause immediate failure of components within the welder. GROUND CONNECTIONS The frame of the welder must be grounded. A ground terminal marked with the symbol is located inside the reconnect/input access door for this purpose. See your local and national electrical codes for proper grounding methods. See Figure A.2 for the location of the reconnect/input access door and related connection diagram. wire sizes. Fuse the input circuit with the recommended super lag fuses or delay type 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. INPUT VOLTAGE RECONNECT PROCEDURE Welders are shipped connected for the highest input voltage listed on the rating plate. To change this connection for a different input voltage, refer to reconnect instructions in Figure A.2 and proceed according to the steps that follow for the appropriate voltage. INPUT POWER CONNECTIONS Connect L1, L2, L3 according to the Input Supply Connection Diagram decal located on the reconnect/input access door. See Figure A.2. INPUT FUSE AND SUPPLY WIRE CONSIDERATIONS Refer to the Technical Specifications at the beginning of this Installation section for recommended fuse and Return to Section TOC Return to Master TOC Return to Master TOC NOTE: Turn main input power to mthe machine OFF before performing reconnect procedure. Failure to do so will result in damage to the machine. DO NOT switch the reconnect bar with machine power ON. LY R N M O OU A E Y GR PL O A M R T DI SA FE FIC E I R EC SP Return to Section TOC FIGURE A.2 - CONNECTION DIAGRAM ON RECONNECT/INPUT ACCESS DOOR Also called “inverse time” or “thermal/magnetic” circuit breakers. These breakers have a delay in tripping action that decreases as the magnitude of the current increases. POWER WAVE 450 A-5 INSTALLATION Return to Master TOC Return to Section TOC A-5 FIGURE A.3 – FRONTPANEL/BACK PANEL 6 5 (IN) 4 Return to Master TOC Return to Section TOC (OUT) 1 3 2 1 WORK TERMINAL 2 ELECTRODE TERMINAL 3 REMOTE CONTROL AMPHENOL RECEPTACLE 4 WATER COOLING FITTINGS (ON BACK PANEL) 5 WIRE FEEDER CONNECTIONS (ON BACK PANEL) 6 ELECTRODE TERMINAL To operate at 200-208 VAC: OUTPUT CONNECTIONS 1. Open the reconnect/input access door. See Figure A.3 for the location of the work terminal, electrode terminal, remote control amphenol receptacle, water cooler fittings and wire feeder connections. 2. Move the input voltage switch to Voltage = 200208V position. Return to Master TOC Return to Section TOC 3. Move “A” lead to the 200-208V terminal. To operate at 220-230 VAC: SIZE 1. Open the reconnect/input access door. To operate at 380-415 VAC: Use the largest welding (electrode and ground) cables possible — at least 70mm2 (#2/0) copper wire — even if the output current does not require it. When pulsing, the pulse current often exceeds 650 amps with the Power Wave 450. Voltage drops can become excessive if undersized welding cables are used. 1. Open the reconnect/input access door. ROUTING 2. Move the input voltage switch to Voltage = 380415V position. To avoid interference problems with other equipment and to achieve the best possible operation, route all cables directly. Avoid excessive lengths, bundle the electrode and ground cables together where practical, and do not coil excess cable. 2. Move the input voltage switch to voltage = 220230V position. 3. Move “A” lead to the 220-230V terminal. Return to Master TOC 3. Move “A” lead to the 380-415 VAC terminal. Return to Section TOC WORK AND ELECTRODE CABLE CONNECTIONS To operate at 440-460 VAC: No setup required. The machine is factory-connected to operate at 440 volts. To verify, do the following: 1. Open the reconnect/input access door. WATER COOLER CONNECTIONS The water cooler fittings are a quick-connect type. Refer to the Accessories section of this manual for water cooler operation and antifreeze mixtures. 2. Check that the input voltage switch is set to Voltage = 440-460V position. WIRE FEEDER CONNECTIONS 3. Check that the “A” lead is at the 440-460V. Refer to the Accessories section for Wire Feeder Connections. Refer to Setup overlay in Operation section for Wire Feeder Configuration. POWER WAVE 450 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Section TOC NOTES POWER WAVE 450 Return to Master TOC Section B-1 Section B-1 TABLE OF CONTENTS - OPERATION SECTION Operation...............................................................................................................................Section B Safety Instructions ......................................................................................................................B-2 Quick Start Reference for Process Selection Overlay................................................................B-3 General Description ....................................................................................................................B-4 Synergic Welding..................................................................................................................B-4 Recommended Processes ...................................................................................................B-4 Operational Features and Controls ......................................................................................B-4 Design Features and Advantages ........................................................................................B-4 Return to Master TOC Welding Capability................................................................................................................B-4 Limitations ............................................................................................................................B-4 Controls and Settings .................................................................................................................B-5 Case Front Controls .............................................................................................................B-5 Operating Overlays .....................................................................................................................B-6 Overview...............................................................................................................................B-6 Installing an Overlay .............................................................................................................B-6 Overlay Types .......................................................................................................................B-7 Pulse, GMAW, FCAW, Stick Overlay ..........................................................................................B-8 Weld from Memory Overlay ......................................................................................................B-11 Weld from Memory, Dual Procedure Overlay ...........................................................................B-12 Return to Master TOC Dual Wire Feeders, Dual Procedure Overlay ............................................................................B-14 Limits Overlay ...........................................................................................................................B-15 Setup Overlay ...........................................................................................................................B-17 Wire Feeder Setup Description ................................................................................................B-18 Overview of Welding Procedures .............................................................................................B-20 FCAW and GMAW..............................................................................................................B-20 Pulse Procedures ...............................................................................................................B-20 Stick/TIG Procedures .........................................................................................................B-20 Wave Control......................................................................................................................B-20 Tables B.3, B.4, B.5, B.6 ....................................................................................................B-21 Pulse Welding.....................................................................................................................B-22 Return to Master TOC Overload Protection..................................................................................................................B-23 Thermal Protection .............................................................................................................B-23 Over Current Protection .....................................................................................................B-23 POWER WAVE 450 Return to Master TOC Return to Section TOC B-2 OPERATION OPERATING INSTRUCTIONS Read and understand this entire section of operating instructions before operating the machine. SAFETY INSTRUCTIONS WARNING ELECTRIC SHOCK can kill. Return to Master TOC Return to Section TOC • 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. Return to Master TOC Return to Section TOC 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 Safety Guidelines detailed in the beginning of this manual. Return to Master TOC Return to Section TOC HOT COOLANT can burn skin. • Always be sure coolant is not hot before doing any work on cooler parts. POWER WAVE 450 B-2 Return to Master TOC Return to Section TOC B-3 OPERATION QUICK START REFERENCE FOR USING THE PROCESS SELECTION OVERLAY Step 2: Adjust the wire feed to speed “WFS” and voltage “V” or arc length “T” (if necessary). a. Press the DISPLAY RECALL key view additional procedure information. Read and understand the “Controls and Settings” and “Operating Overlays” sections of this manual before using the following Quick Start Reference procedure to operate the Power Wave. NOTE: Selection of certain options may limit the selection of subsequent options. Step 3: Save process information (if desired). a. Press the SAVE TO MEMORY key a. Install the desired PROCESS OVERLAY. Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC . You can recall your procedure later by pressing the RECALL FROM MEMORY key RECALL and the appro- priate MEMORY LOCATION key. 1 The electrode class, electrode size, and electrode/ gas type you can select for your process will be limited to the machine’s programmed recommendations. Therefore, selecting certain options may limit other option selections. 2 The wave control scale displayed shows the default setting. (The higher the setting, the softer the arc.) If you change the setting, your new setting will be displayed. d. Select ELECTRODE CLASS. e. Select ELECTRODE SIZE. f. Return to Master TOC SAVE b. Press one of the MEMORY LOCATION keys (1-8). b. Turn the machine ON. c. Select the desired welding PROCESS1. to b. Adjust wire feed speed and voltage or arc length trim through the controls on your wire feeder. The new values appear on both the wire feeder and the Power Wave display. Step 1: Select your process information: Return to Section TOC B-3 Select ELECTRODE/GAS TYPE. g. Press the WAVE CONTROL UP or DOWN keys to see the present setting. Press the WAVE CONTROL UP or WAVE CONTROL DOWN keys to adjust2. POWER WAVE 450 Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC B-4 OPERATION GENERAL DESCRIPTION DESIGN FEATURES AND ADVANTAGES The INVERTEC Power Wave power source is a high performance, digitally controlled inverter welding power source capable of complex, high-speed waveform control. It uses three-phase input power only. The Power Wave is designed to be used as a synergic welding system in conjunction with a wire feeder. • Designed to NEMA Standards. SYNERGIC WELDING • Modular construction for easy servicing. The Power Wave system is designed primarily as a synergic welding system. The word “synergic” comes from the word “synergism,” which means “two or more things working together to achieve an effect which neither can achieve individually.” • Thermostatically protected. The Power Wave and wire feeder operate as a team. Each “knows” what the other is doing at all times. They each also know what process, wire type, wire size, and gas combination are being used. In a synergic system, the wire feeder and power source must “talk” together. This means that only certain wire feeders can work in a synergic setup. A synergic feeder has special circuitry to “talk” with and “listen” to the Power Wave power source. Return to Master TOC Return to Section TOC Welding experts have preprogrammed the system for the best range of process settings according to wire type, wire size, and gas combination. When the wire feed speed is changed, the system automatically adjusts the current and voltage waveforms to give the best weld characteristics. This improves the soundness, appearance, and repeatability of welds. Refer to the Accessories section of this manual for available wire feeders. RECOMMENDED PROCESSES The Power Wave is designed to be used as a multiple process machine. It comes preprogrammed with GMAW pulse, GMAW (short arc and spray) FCAW (Innershield™ and Outershield™), and stick procedures. Return to Master TOC OPERATIONAL FEATURES AND CONTROLS Return to Section TOC B-4 The Power Wave, through use of a keypad overlay system, provides various options and controls such as Multiple Process/Procedure Selection; Memory Storage of Procedures; Weld from Memory Only operation; Dual Process/Dual Feeder capability. • Multiple process output ranges 5 - 540 amps. • 2-line LCD display. • Easy access for input connections. Connections are simple strip and clamp (no lugs required). • Electronic overcurrent protection. • Overvoltage protection. • Digital signal processor and microprocessor control. • RS232 interface for future welding application updates. • Simple, reliable reconnection for various input voltages. • New accessories and wire feeders communicate using a digital current loop to transfer information. • Auto device recognition simplifies accessory cable connections. • Direct support of two wire feeders. • Auto-configurable for either metric or English mode. • Multi-process control: Stick, short arc, GMAW spray, GMAW pulse, and flux cored arc welding (FCAW). • Simple control through use of overlays that limit access to only those keys required for a given application. WELDING CAPABILITY The Power Wave 450 is rated at 500 amps, 40 volts at 60% duty cycle based on a ten minute time period. It is capable of higher duty cycles at lower output currents. If the duty cycles are exceeded, a thermostat will shut off the output until the machine cools to a reasonable operating temperature. LIMITATIONS • The Power Wave is not recommended for processes other than those specified by available overlays. • The Power Wave is not recommended for pipe thawing. POWER WAVE 450 Return to Master TOC Return to Section TOC B-5 B-5 OPERATION CONTROLS AND SETTINGS CASE FRONT CONTROLS All operator controls and adjustments are located on the case front of the Power Wave. Refer to Figure B.1 and corresponding explanations. Refer to Figure B.1 for the location of the following controls: FIGURE B.1 – CASE FRONT CONTROLS 6 3 1 1. LCD DISPLAY: Provides welding procedure information and parameters such as wire type, gas type, WFS, trim, etc. 2. POWER SWITCH: Controls input power to the Power Wave. When the switch is turned to the ON position, the connected wire feeder meters light up and the LCD display on the Power Wave shows the following: Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC 2 Return to Section TOC Return to Section TOC LINCOLN ELECTRIC Version X.X This display is shown for a few seconds followed by another display that depends on the overlay placed on the machine. At this point, the machine is ready for operation. 4 1 2 3 4 5 6 5 LCD DISPLAY POWER SWITCH HIGH TEMPERATURE LIGHT REMOTE CONTROL AMPHENOL RECEPTACLE 5 AMP CIRCUIT BREAKER LCD DISPLAY ADJUSTMENT 3. HIGH TEMPERATURE LIGHT (thermal overload): A yellow light that comes on when an over temperature situation occurs. Output is disabled until the machine cools down. At that point the light goes out and output is enabled again. 4. REMOTE CONTROL AMPHENOL RECEPTACLE: Allows remote current control during stick welding via a hand or foot Amptrol accessory. 5. 5 AMP CIRCUIT BREAKER: Protects two auxiliary power circuits: the 24V supply used by the trigger circuits and the 42V supply used by the internal machine circuits and the wire feeders. 6. LCD DISPLAY ADJUSTMENT: Use a small flat blade screw driver to adjust the viewing angle of the LCD display. POWER WAVE 450 Return to Master TOC Return to Section TOC B-6 B-6 OPERATION OPERATING OVERLAYS INSTALLING AN OVERLAY OVERVIEW 1. Open the ACCESS DOOR by grasping the provided indent on the door and pulling the door forward. See Figure B.3 for door location. The Power Wave is controlled by a panel of keys (keypad) located on the front of the machine. The operator can access controls by placing an overlay over the keys. FIGURE B.3 – OVERLAY ACCESS DOOR An OVERLAY is a special plastic sheet with a number of keys and symbols printed on one side and a bar code printed on the other. See Figure B.2. The printed keys allow the operator to communicate with the machine for a specific set of functions. The bar code allows the machine to identify the overlay. 5 3 1 2 Return to Master TOC Return to Section TOC 4 FIGURE B.2 – TYPICAL POWER WAVE OVERLAY C COPYRIGHT 1994 L9361-2 WELD FROM MEMORY ™ TM R INVERTEC POWER WAVE 350 WARNING HIGH TEMP. PROGRAM LIST MEMORY RECALL 1 M 3 M M 5 M 6 M 7 M 8 M Return to Master TOC M Return to Section TOC THE LINCOLN ELECTRIC COMPANY CLEVELAND, OHIO USA 2 4 1 2 3 4 5 6 7 8 DISPLAY RECALL Before the Power Wave is turned ON, the operator selects the desired overlay and mounts it in the overlay frame on the front of the machine. Then, when the machine is turned ON, it reads the overlay bar code and configures the machine accordingly, allowing the operator to access only certain keys. The machine must be powered up each time an overlay is changed. 1 2 3 4 5 OVERLAY ACCESS DOOR OVERLAY FRAME ACCESS DOOR INDENT TRACKS LOCATING PINS 2. Select the desired overlay from the storage compartment located behind the access door. Return to Master TOC Return to Section TOC 3. Remove any overlay already in the overlay frame and place it in the storage compartment. 4. Slide the new overlay into the overlay frame. Align the overlay with the two tracks on the sides of the frame. Be sure the overlay is seated in the bottom lip of the frame and on the top two locating pins. Close the access door securely. POWER WAVE 450 Return to Master TOC Return to Section TOC B-7 OPERATION OVERLAY TYPES Four types of overlays can be used with the Power Wave. 1. Process Overlays. These overlays are used to create, save and recall specific welding procedures by selecting and adjusting the various welding settings that have been programmed into the Power Wave at the factory. Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC 2. Weld From Memory Overlays. These overlays (also called Shop Overlays) provide a simple way for operators to recall and use any of the welding procedures that have been stored in the memory of the Power Wave. Return to Section TOC B-7 3. Setup Overlays. These overlays provide specific machine setup information, such as operating limits for the welding procedures stored in memory. Overlay Type 1 Overlay Name Figure No. GMAW PULSE, GMAW FCAW, STICK PROCESS SELECTION OVERLAY B.4 WELD FROM MEMORY OVERLAY B.5 WELD FROM MEMORY, DUAL PROCEDURE OVERLAY B.6 *DUAL WIRE FEEDERS, DUAL PROCEDURES OVERLAY B.7 3 *LIMITS OVERLAY B.8 3 SETUP OVERLAY B.9 2 2 2 *These overlays are optional. See Accessories Section for Order Numbers. 4. Special Purpose Overlays. These are custom overlays for specific customer applications. Detailed information on how to use currently available Power Wave overlays follows. POWER WAVE 450 Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC B-8 OPERATION PULSE, GMAW, FCAW, AND STICK/TIG PROCESS SELECTION OVERLAY An operator can use this overlay to create a new welding procedure, save a newly created welding procedure, view an existing welding procedure, recall an existing welding procedure, and clear a memory location. See Figure B.4. The steps for performing each of these functions are given below. FIGURE B.4 – PULSE, GMAW, FCAW, STICK/TIG PROCESS SELECTION OVERLAY 1 11 10 2 8 6 9 Return to Master TOC Return to Section TOC 3 1 2 3 4 5 6 4 LCD DISPLAY WINDOW PROCESS SELECT KEY ELECTRODE CLASS UP/DOWN KEYS ELECTRODE SIZE UP/DOWN KEYS ELECTRODE/GAS TYPE UP/DOWN KEYS WAVE CONTROL UP/DOWN KEYS 1. LCD DISPLAY WINDOW: Power up the machine with this overlay in place. When the Power Wave is turned on, the following message appears on the display for a few seconds: LINCOLN ELECTRIC VERSION X.X Return to Master TOC This display is followed by: Return to Section TOC B-8 OVERLAY ID NUMBER = 1 A welding procedure is made up of seven components: process, material type, wire diameter, program, wire feed speed, voltage or arc length trim, and wave control. A new welding procedure is created by selecting a combination of these components from the ones that have been programmed into the Power Wave. See Figure B.4 for key locations. 5 7 7 8 9 10 11 DISPLAY RECALL KEY SAVE TO MEMORY KEY MEMORY LOCATION NUMBER KEYS RECALL FROM MEMORY KEY HIGH TEMPERATURE LIGHT NOTE: The following four selections should always be performed in this order: process, electrode class, electrode size, electrode/gas type. Selecting a setting for one component narrows your choice of available settings in remaining components. This is why the order of performing the steps is important. However, if you make component selections out of order, the machine will prompt you to make a new selection for any settings that do not apply. 2. PROCESS SELECT KEY: Use the PROCESS SELECT key to select from the processes available in the machine. Press the PROCESS SELECT key until the light by the desired process is lit. POWER WAVE 450 Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC Return to Section TOC B-9 OPERATION 3. ELECTRODE CLASS UP/DOWN: Use the ELECTRODE CLASS UP or DOWN keys to select from the material types available for the selected process. Press the ELECTRODE CLASS UP or DOWN key until the desired material type is displayed. 4. ELECTRODE SIZE UP/DOWN: Use the ELECTRODE SIZE UP or DOWN keys to select from the wire diameters available for the selected process and material type. Press the ELECTRODE SIZE UP or DOWN key until the desired wire diameter is displayed. 5. ELECTRODE/GAS TYPE UP/DOWN KEYS: Use the ELECTRODE/GAS TYPE UP or DOWN keys to select from the programs available for the selected process, material type, and wire diameter. Press the ELECTRODE/GAS TYPE UP or DOWN Key until the desired program is displayed. 6. WAVE CONTROL UP/DOWN KEYS: Press one of the two WAVE CONTROL keys to display the present wave control. This is shown on a scale from LO to HI. Use the WAVE CONTROL UP or WAVE CONTROL DOWN key to change the wave control to the desired level. When this scale is shown, the WAVE CONTROL setting can also be changed while welding (on the fly). Press the DISPLAY RECALL key to exit the wave control function. For a description of how the wave control setting affects the welding procedure, refer to the Overview of Welding Procedures sub-section of the Operation section of this manual. The wire feed speed and voltage or arc length trim desired for the new procedure can be changed from the wire feeder. B-9 7. DISPLAY RECALL KEY: Since not all the information about the procedure can be seen on the 2-line LCD display window at the same time, use the DISPLAY RECALL key to display and verify all of the selected procedure information. The normal default display window shows the Procedure Description, WFS, and preset voltage or arc length trim values. Press and hold the DISPLAY RECALL key, and the window shows the procedure description and gas type for as long as the key is held depressed. Release the DISPLAY RECALL key, and the window shows wire size, material type, and process description. After a few seconds, the window changes back to the default display. 8. SAVE TO MEMORY KEY: This key is used to save a newly created welding procedure. The Power Wave has eight memory locations which can be used to store all the settings of up to eight welding procedures. Once stored in a memory location, a procedure can be recalled for later use with the RECALL FROM MEMORY key. To save a newly created welding procedure: Press the SAVE TO MEMORY key SAVE and then one of the MEMORY LOCATION NUMBER keys. Keep a record of this number for future reference. Any previously created welding procedure stored in that location will be erased. If you press the SAVE TO MEMORY key but decide not to save the procedure, you can exit this function by pressing the DISPLAY RECALL key. 9. MEMORY LOCATION NUMBER KEYS: To view information about any stored welding procedure, simply press its MEMORY LOCATION NUMBER key. As you hold down the selected key, the procedure description and gas type of the procedure appear in the display window. The process type is shown by the indicating light opposite the appropriate process symbol. Return to Master TOC Return to Section TOC When you release the selected key, the wire size, material type and process description appear for a few seconds. This function does not display the wire feed speed and voltage or arc length trim settings. To view these, you must recall the procedure from memory with the RECALL FROM MEMORY key. POWER WAVE 450 B-10 Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC The RECALL FROM MEMORY and SAVE TO MEMORY keys can be used to clear a memory location. Return to Section TOC 10. RECALL FROM MEMORY KEY: This key is used to recall an existing procedure from memory. You can recall and use any of the previously created welding procedures that are stored in one of the eight memory locations. Simply press the RECALL FROM MEMORY key RECALL and then the appropriate MEMORY LOCATION NUMBER key. Return to Section TOC OPERATION If you press the RECALL FROM MEMORY key and then change your mind, you can exit this function by pressing the DISPLAY RECALL key. If the memory location you select does not contain a stored welding procedure, this will be indicated in the display window. Select another memory location. It is not necessary to save a procedure back to memory after it is recalled from memory. When a procedure is saved into a memory location, it can be recalled from there until another procedure is stored in that location or the location is cleared. SAVE Press the SAVE TO MEMORY key and then the RECALL FROM MEMORY key RECALL . (Do not press both keys at the same time.) A message in the display window will ask you to press the MEMORY LOCATION NUMBER key of the memory location you want to clear. If you press the SAVE TO MEMORY and RECALL FROM MEMORY keys and then change your mind, you can exit this function by pressing the DISPLAY RECALL key. 11. HIGH TEMPERATURE LIGHT: The high temperature light comes on when the internal machine temperature exceeds the allowed limit. Output is disabled until the machine cools down and the high temperature light goes out. POWER WAVE 450 B-10 Return to Master TOC Return to Section TOC B-11 B-11 OPERATION WELD FROM MEMORY OVERLAY The Weld From Memory Overlay lets an operator recall and use any welding procedure stored in one of eight memory locations. See Figure B.5. FIGURE B.5 – WELD FROM MEMORY OVERLAY 1 1 2 3 4 5 6 LCD DISPLAY WINDOW MEMORY RECALL KEYS PROGRAM LIST DISPLAY RECALL KEY HIGH TEMPERATURE LIGHT MEMORY LIGHTS 5 6 Return to Master TOC Return to Section TOC 2 3 1. LCD DISPLAY WINDOW: Power up the machine with this overlay in place. When the Power Wave is turned on, the following message appears in the display window for a few seconds: LINCOLN ELECTRIC Version X.X Return to Master TOC OVERLAY ID NUMBER = 2 Return to Section TOC This message is then replaced by the following message: SELECT A MEMORY LOCATION 2. MEMORY RECALL NUMBERS: Select the memory location of the desired welding procedure by pressing the appropriate MEMORY RECALL NUMBER key. If no procedure was saved in the selected memory location, the following message appears: MEMORY LOCATION # IS EMPTY Select another memory location. Return to Master TOC With this overlay in place, the wire feed speed and the preset voltage or arc length trim can be changed from the wire feeder. The new values will replace the previous values and become a permanent part of the procedure. If limits have been set on the wire feed speed, voltage or arc length trim of the selected procedure, these limits will be active when this overlay is in place. They cannot be overridden from this overlay. This display is followed by: Return to Section TOC 4 When a welding procedure is recalled from memory, the display window will show the procedure description, wire feed speed, and arc length trim or preset voltage. 3. PROGRAM LIST: The PROGRAM LIST block in the center of this overlay provides a convenient place to record a brief description of each welding procedure stored in memory. A “Dry Erase” marker should be used for this purpose. 4. DISPLAY RECALL KEY: To view other information about the selected procedure, press the DISPLAY RECALL key. The display window will show the procedure description and gas type of the selected procedure for as long as the key is held depressed. When the key is released, material type, wire size, and process descriptions will be displayed for a few seconds. 5. HIGH TEMPERATURE LIGHT: The high temperature light comes on when the internal machine temperature exceeds the allowed limit. Output is disabled until the machine cools down and the high temperature light goes out. 6. MEMORY LIGHTS: A memory light is on when its corresponding memory is selected. This tells you what memory is active at any given time. POWER WAVE 450 Return to Master TOC Return to Section TOC B-12 B-12 OPERATION WELD FROM MEMORY, DUAL PROCEDURE OVERLAY The Weld From Memory, Dual Procedure Overlay lets an operator recall and use dual welding procedures stored in memory. The overlay must be used with a separate dual procedure switch or a gun that has a two position trigger. The switch or trigger selects which procedure will be active. See Figure B.6 FIGURE B.6 – WELD FROM MEMORY, DUAL PROCEDURE OVERLAY Return to Master TOC Return to Section TOC 1 5 6 2 Return to Master TOC Return to Section TOC 3 1 LCD DISPLAY WINDOW 2 MEMORY RECALL KEYS 3 PROGRAM LIST 4 4 DISPLAY RECALL KEY 5 HIGH TEMPERATURE LIGHT 6 MEMORY LIGHTS 1. LCD DISPLAY WINDOW: Power up the machine with this overlay in place. When the Power Wave is turned on, the following message appears in the display window for a few seconds: LINCOLN ELECTRIC Version X.X Select a memory location PAIR for the two desired welding procedures by pressing either of the two corresponding MEMORY RECALL NUMBER keys. If no procedure was saved to one of the memory pair locations, the following message appears: MEMORY LOCATION # IS EMPTY This display is followed by: OVERLAY ID NUMBER = 3 In this case select another memory pair. Return to Master TOC Return to Section TOC This message is then replaced by the following message: SELECT A MEMORY LOCATION 2. MEMORY RECALL KEYS: The following four memory pairs are available on this overlay: Memory 1 and Memory 2 Memory 3 and Memory 4 Memory 5 and Memory 6 Memory 7 and Memory 8 Set the dual procedure switch or gun trigger to the position for PROCEDURE A or PROCEDURE B. Position A activates the welding procedure from the odd numbered memory locations (1, 3, 5 or 7). Position B activates the welding procedure from the corresponding even numbered memory locations (2, 4, 6 or 8). For example, if memory location 3 was selected, Position A activates the procedure from memory location 3; Position B activates the procedure from memory location 4. POWER WAVE 450 Return to Master TOC Return to Section TOC B-13 OPERATION When a pair of welding procedures are recalled from memory, the display window will show the procedure description, wire feed speed, and the preset voltage or arc length trim of the LAST procedure welded with. With this overlay in place, the wire feed speed and the preset voltage or arc length trim can be changed from the wire feeder. The new values will replace the previous values and become a permanent part of the procedure. Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC Return to Section TOC If limits have been set on the wire feed speed, voltage or arc length trim of the selected procedures, these limits will be active when this overlay is in place. They cannot be overridden from this overlay. 3. THE PROGRAM LIST: The PROGRAM LIST block in the center of this overlay provides a convenient place to record a brief description of each welding procedure stored in memory. A “Dry Erase” marker should be used for this purpose. 4. DISPLAY RECALL KEY: To view other information about the active procedure, press the DISPLAY RECALL key. The display window will show the procedure description and gas type of the active procedure for as long as the key is held depressed. When the key is released, the wire size, material type, and process descriptions display for a few seconds. 5. HIGH TEMPERATURE LIGHT: The high temperature light comes on when the internal machine temperature exceeds the allowed limit. Output is disabled until the machine cools down and the high temperature light goes out. 6. MEMORY LIGHTS: A memory light is on when its corresponding memory is selected. This tells you what memory location is active at any given time. POWER WAVE 450 B-13 Return to Master TOC Return to Section TOC B-14 The Dual Wire Feeders, Dual Procedures Overlay is used when the Power Wave is equipped with two wire feeders and two guns with two position switches. Any welding procedure stored in memory locations 1, 2, 3, or 4 can be automatically recalled and used. See Figure B.7. FIGURE B.7 – DUAL WIRE FEEDERS, DUAL PROCEDURE OVERLAY LCD DISPLAY WINDOW WIRE FEEDERS MEMORY CHART DISPLAY RECALL KEY HIGH TEMPERATURE LIGHT MEMORY LIGHTS 1 5 4 Return to Master TOC Return to Section TOC OPERATION DUAL WIRE FEEDERS, DUAL PROCEDURE OVERLAY (OPTIONAL) 1 2 3 4 5 2 1. LCD DISPLAY WINDOW: Power up the machine with this overlay in place. When the Power Wave is turned on, the following message appears in the display window for a few seconds: Return to Master TOC Return to Section TOC LINCOLN ELECTRIC VERSION X.X OVERLAY ID NUMBER = 9 2. WIRE FEEDERS MEMORY CHART: The active welding procedure is determined by the active wire feeder and its gun switch position. The welding procedure recall from memory is as follows: Active Wire Feeder Gun Trigger Memory Location Position of Procedure A B A B 1 2 3 4 Pull the trigger on either wire feeder. Return to Master TOC 3 With this overlay in place, the wire feed speed and the preset voltage or arc length trim can be changed from the wire feeder. The new values replace the previous values and become a permanent part of the procedure. If limits have been set on the wire feed speed, voltage or arc length trim of the selected procedures, these limits will be active when this overlay is in place. They cannot be overridden from this overlay. This display is followed by: #1 #1 #2 #2 Return to Section TOC B-14 Depending on the gun switch position, the corresponding memory location is automatically recalled. The wire feeders memory chart has no keys; it is simply a chart. 3. DISPLAY RECALL KEY:To view other information about the active welding procedure, press the DISPLAY RECALL key. The display window will show the procedure description and gas type of the last active procedure for as long as the key is held depressed. When the key is released, the wire size, material type, and process descriptions will be displayed for a few seconds. 4. HIGH TEMPERATURE LIGHT: The high temperature light comes on when the internal machine temperature exceeds the allowed limit. Output is disabled until the machine cools down and the high temperature light goes out. 5. MEMORY LIGHTS: A memory light is on when its corresponding memory is selected. This tells you what memory location is active at any given time. The display window will show the procedure description, wire feed speed, and the preset voltage or arc length trim of the last active welding procedure. POWER WAVE 450 Return to Master TOC Return to Section TOC B-15 B-15 OPERATION LIMITS OVERLAY (OPTIONAL) The Limits Overlay is used to set the maximum and minimum limits of the wire feed speed and voltage or arc length trim for any welding procedure stored in memory. See Figure B.8. FIGURE B.8 – LIMITS OVERLAY 8 2 6 Return to Master TOC Return to Section TOC 1 3 4 Return to Master TOC Return to Section TOC 1 2 3 4 LCD DISPLAY WINDOW RECALL FROM MEMORY KEY MEMORY LOCATION NUMBER KEYS SET LIMIT KEY 5 6 7 8 5 7 LIMIT UP/DOWN KEYS SAVE TO MEMORY KEY DISPLAY RECALL KEY MEMORY LIGHTS 1. LCD DISPLAY WINDOW: Power up the machine with this overlay in place. When the Power Wave is turned on, the following message appears in the display window for a few seconds: LINCOLN ELECTRIC Version X.X Determine the memory location number of the welding procedure for which you want to set limits.Then press the RECALL FROM MEMORY key RECALL followed by the MEMORY LOCATION NUMBER key for the selected procedure. If no procedure was saved in the selected memory location, the following message appears: This display is followed by: MEMORY LOCATION # IS EMPTY OVERLAY ID NUMBER = 4 This message is then replaced by the following message: Return to Master TOC Return to Section TOC SELECT A MEMORY LOCATION Select another memory location. 4. SET LIMIT KEY: AND 5. LIMIT UP / DOWN KEYS: 2. RECALL FROM MEMORY KEY: AND 3. MEMORY LOCATION NUMBERS: The RECALL FROM MEMORY key RECALL is used to recall a welding procedure from memory. The SET LIMIT key and LIMIT UP / LIMIT DOWN keys are used to set the maximum and minimum allowed wire feed speed, and voltage trim or arc length trim values of the procedure that was recalled from memory. POWER WAVE 450 Return to Master TOC Return to Section TOC B-16 OPERATION Use the LIMIT UP and LIMIT DOWN keys to change the maximum wire feed speed to the desired value. Press the SET LIMIT key again. The new maximum and old minimum wire feed speeds will be displayed. Use the LIMIT UP and LIMIT DOWN keys to change the minimum wire feed speed to the desired value. Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC Return to Section TOC Press the SET LIMIT key. The present maximum and minimum voltage trim or arc length trim will be displayed. (Refer to Table B.3 to see how voltage trim affects preset voltage. Refer to Table B.6 to see how arc length trim affects preset arc length.) B-16 7. DISPLAY RECALL KEY: To view other information about the active welding procedure, press the DISPLAY RECALL key. The display window will show the procedure description and gas type of the last active procedure for as long as the key is held depressed. When the key is released, the wire size, material type, and process descriptions will be displayed for a few seconds. 6. MEMORY LIGHTS: A memory light is on when its corresponding memory is selected. This tells you what memory is active at any given time. Use the LIMIT UP and LIMIT DOWN keys to change the maximum value. The maximum for either type is 1.5. Press the SET LIMIT key. The new maximum and old minimum voltage trim or arc length trim will be displayed. Use the LIMIT UP and LIMIT DOWN keys to change the minimum value. The minimum for either type is 0.5. 6. SAVE TO MEMORY KEY: The SAVE TO MEMORY KEY is used to save the procedure with the newly set limits to memory. Press the SAVE TO MEMORY key SAVE followed by the MEMORY LOCATION NUMBER key of the desired memory location. This does not have to be the original location from which the procedure was recalled. Step 6 can be performed any time during the limitsetting process. You do not have to set all the available limits. When you have set all the desired limits, save the procedure to memory. To clear any previously set limits, recall the procedure from memory and change the limits to the maximum range available. Then save the procedure to memory. POWER WAVE 450 Return to Master TOC Return to Section TOC B-17 B-17 OPERATION SETUP OVERLAY The Setup Overlay is used to control the water cooler operation (on/off and prime the water cooler), and to set up the voltage sensing configuration of the machine and wire feeder(s) connected to the Power Wave. See Figure B.9. FIGURE B.9 – SETUP OVERLAY C COPYRIGHT 1994 THE LINCOLN ELECTRIC COMPANY CLEVELAND, OHIO USA L9660 SETUP OVERLAY R Return to Master TOC Return to Section TOC WARNING Return to Master TOC +POLARITY ELECTRODE SENSE LEAD ENABLED ELECTRODE SENSE LEAD ENABLED WORK SENSE LEAD ENABLED 1 WORK SENSE LEAD ENABLED WATER COOLER ENABLED 5 6 7 WATER COOLER PRESSURE +/ POLARITY +/ POLARITY WATER COOLER ENABLE ELECTRODE SENSE LEAD ELECTRODE SENSE LEAD PRIME WATER COOLER WORK SENSE LEAD WORK SENSE LEAD WIRE FEEDER 1 WIRE FEEDER 2 3 2 WATER COOLER CAN ONLY BE PRIMED WHEN IT IS ENABLED. 4 PRIME THE WATER COOLER UNTIL WATER COOLER PRESSURE LIGHT TURNS ON. WATER COOLER SETUP 1 2 3 4 Return to Section TOC +POLARITY LCD DISPLAY WINDOW WATER COOLER ON/OFF KEY WATER COOLER PRESSURE LIGHT PRIME WATER COOLER KEY 5 WIRE FEEDER 1+/- POLARITY KEY 6 WIRE FEEDER 1 ELECTRODE SENSE LEAD KEY 7 WIRE FEEDER 1 WORK SENSE LEAD KEY 1. LCD DISPLAY WINDOW: Power up the machine with this overlay in place. When the Power Wave is turned on, the following message appears in the display window for a few seconds: LINCOLN ELECTRIC Version X.X 3. WATER COOLER PRESSURE LIGHT: This light indicates whether or not the coolant flow rate is high enough for normal water cooler operation. If the water cooler loses the required flow rate it will shut down within a couple of seconds, the water cooler pressure light will turn off,and the machine sounds a buzzer. This display is followed by: OVERLAY ID NUMBER = 0 Return to Master TOC Return to Section TOC This message is then replaced by the following message: POWER WAVE SETUP 2. WATER COOLER ON/OFF KEY: Press this key to toggle the water cooler between being enabled and disabled. The present status of the water cooler is indicated by the “WATER COOLER ON” light. 4. PRIME WATER COOLER KEY: The water cooler may have to be primed if there is not enough coolant in the system for proper operation. Make sure that the water cooler has been turned on before it is primed. (The “WATER COOLER ON” light should be turned on.) Check reservoir for proper coolant level - See Water Cooler information in ACCESSORIES section. To prime the water cooler, hold the PRIME WATER COOLER key down. While this key is pressed, the display will show: POWER WAVE 450 PRIME WATER COOLER Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC B-18 OPERATION When the “WATER COOLER PRESSURE” light turns on, release the key. If this key has been pressed for 30 seconds and the ‘WATER COOLER PRESSURE’ light still did not turn on, check the water cooler for adequate fluid level. 5. WIRE FEEDER 1 +/- POLARITY KEY: Press this key to change the present voltage sensing polarity of wire feeder 1. The present polarity of wire feeder 1 is indicated by the “WIRE FEEDER 1+ POLARITY” light. If wire feeder 1 is set for positive voltage sensing polarity, this light is turned on. 6. WIRE FEEDER 1 ELECTRODE SENSE LEAD KEY: Press this key to enable or disable the electrode sense lead (lead #67) of wire feeder 1. When enabled, voltage sensing is done by the electrode sense lead. When disabled, voltage sensing is done at the Power Wave output terminal. When enabled, the “WIRE FEEDER 1 ELECTRODE SENSE LEAD ENABLED” light will be illuminated. 7. WIRE FEEDER 1 WORK SENSE LEAD KEY: Press this key to enable or disable the work sense lead (lead #21) of wire feeder 1. When enabled, voltage sensing is done by the work sense lead. When disabled, voltage sensing is done at the Power Wave output terminal. When enabled, the “WIRE FEEDER 1 WORK SENSE LEAD ENABLED” light will be illuminated. Return to Master TOC Return to Section TOC WIRE FEEDER SETUP DESCRIPTION The Power Wave may be set up for either positive or negative arc voltage sensing using any two of the following places: 1. the positive output terminal of the Power Wave 2. the negative output terminal of the Power Wave 3. the electrode sense lead (67 lead) of the wire feeder 4. the work sense lead (21 lead) of the wire feeder Return to Master TOC The SETUP Overlay allows you to select between which two places arc voltage will be sensed. Once the selection is made it is not necessary to reconfirm the selection every time a new overlay is used or a wire feeder is replaced with another one. The selection will remain until it is changed with the SETUP Overlay. Return to Section TOC B-18 When welding with a stick procedure, the arc voltage is automatically measured between the Power Wave’s output studs. I. Select arc voltage sensing polarity first. +/- POLARITY KEY A. Positive Voltage Sensing Polarity: In most welding applications the electrode cable is connected to the + output terminal and the work cable is connected to the - output terminal of the power source. This is the positive voltage sensing polarity, illustrated by Figure B.10. When the Power Wave and the wire feeder(s) are connected in this manner, the arc voltage can be measured in one of four ways. These four ways are shown in Table B.1. Table B.1: Positive Voltage Sensing Options Positive Voltage Reference Negative Voltage Reference + Output Terminal - Output Terminal + Output Terminal Work Sense (21) Lead* Electrode Sense (67) Lead - Output Terminal Electrode Sense (67) Lead Work Sense (21) Lead* * Consult the factory before using this option. Use the ELECTRODE SENSE LEAD KEY to select either the + output terminal or the electrode sense (67) lead for the positive voltage reference. The work sense (21) lead is used only in rare circumstances. For most installations, use the WORK SENSE LEAD KEY to select the - output terminal for negative voltage reference. Consult the factory if use of the work sense (21) lead is desired. B. Negative Voltage Sensing Polarity: In some welding applications (such as Innershield®) the electrode cable is connected to the output terminal and the work cable is connected to the + output terminal of the power source. This is the negative voltage sensing polarity, illustrated by Figure B.11. When the Power Wave and the wire feeder(s) are connected in this manner, the arc voltage can be measured in one of four ways. These four ways are shown in Table B.2. Table B.2: Negative Voltage Sensing Options Positive Voltage Reference Negative Voltage Reference – Output Terminal + Output Terminal – Output Terminal Work Sense (21) Lead* Electrode Sense (67) Lead + Output Terminal Electrode Sense (67) Lead Work Sense (21) Lead* * Consult the factory before using this option. 11/96 POWER WAVE 450 Return to Master TOC Return to Section TOC B-19 OPERATION Use the ELECTRODE SENSE LEAD KEY to select either the - output terminal or the electrode sense (67) lead for the positive voltage reference. The work sense (21) lead is used only in rare circumstances. For most installations, use the WORK SENSE LEAD KEY to select the - output terminal for negative voltage reference. Consult the factory if use of the work sense (21) lead is desired. The two wire feeders can only be connected in the same manner, either by the Positive Polarity or the Negative Polarity setup. FIGURE B.10 Return to Master TOC Return to Section TOC POSITIVE VOLTAGE SENSING POLARITY Power Wave Control Cable (includes 67 lead) Electrode Sense Lead 67 - + Wire Feeder Block Electrode Cable FIGURE 11B Return to Master TOC Return to Section TOC Work Cable FIGURE B.11 NEGATIVE VOLTAGE SENSING POLARITY Power Wave Control Cable (includes 67 lead) Electrode Sense Lead 67 Return to Master TOC Return to Section TOC B-19 + Wire Feeder Block Electrode Cable Work Cable FIGURE 11C POWER WAVE 450 Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC Return to Section TOC B-20 OPERATION OVERVIEW OF WELDING PROCEDURES FLUX CORED ARC WELDING (FCAW) AND GMAW PROCEDURES For each wire feed speed, a corresponding voltage has been preprogrammed into the machine by welding experts. This preprogrammed voltage is the best average voltage for the procedure at the given wire feed speed. If the wire feed speed is changed on the wire feeder, the voltage automatically changes with it. In some cases, the operator may want to change the preprogrammed voltages; for example, to compensate for cable and fixture voltage drops. The preset voltages can be adjusted on the wire feeder’s Voltage display. When a change is made to the voltage at one wire-feed speed, this change is applied to all other wire feed speed settings. For example, if the operator turns up the voltage by 10 percent, the machine automatically increases the preset voltages at all the other wire feed speeds by 10 percent. In the GMAW FCAW process, the display shows the Procedure Description, WFS and Preset Voltage. The preset voltage which was programmed at the factory, may be changed on the wire feeder voltage display. Note that, if you change the default preset voltage up or down, a respective “ ” or “V” sign will be displayed after the preset value. When the gun trigger is pulled, note that the display changes to show WFS, Actual Arc Voltage and Actual Arc Current. See Table B.5 for display summary. Return to Master TOC Return to Section TOC V PULSE PROCEDURES In these procedures, the actual voltage greatly depends on the waveform used. The peak currents, background currents, rise times, fall times, and pulse times all affect the actual voltage. The actual voltage for a given wire feed speed is not directly predictable unless the waveform is known. In this case, it is not practical to preset an actual voltage for the procedure. Instead, an arc length adjustment is provided. The machine “knows” what the best arc length is at the given wire feed speed but allows the operator to change it. The arc length can be adjusted between 0.5 and 1.5 on the wire feeder’s Voltage display. An arc length trim of 1.0 means that no adjustments will be made to the preset arc lengths. An arc length trim greater than 1.0 increases the preset arc lengths. An arc length trim less than 1.0 decreases the preset arc lengths. The arc length adjustment is factored in at all wire feed speed settings. Refer to Table B.6 for summary of arc length trim. B-20 Increasing the arc length by 10 percent at a given wire feed speed also increases all the other arc length settings of the procedure by 10 percent. In the GMAW Pulse process, the display shows the Procedure Description, WFS and Arc Length Trim. Arc length trim is programmed to a default at the factory and may be adjusted on the wire feeder. When the trigger is pulled, the WFS, Actual Arc Voltage and Actual Arc Current are displayed. STICK/TIG PROCEDURES Stick welding can be performed with the Power Wave by attaching a remote control kit to the 6-pin amphenol on the front of the machine. The K941-1 remote control kit is recommended. Select the stick process from either the GMAW Pulse, GMAW FCAW, stick process selection overlay, or recall it from a previously stored memory location with a Weld From Memory overlay. When this process is selected, the Power Wave reads the current (amps) setting from the remote control kit. It also controls the output of the machine based on the position of the Output Terminals switch, which is also located on the remote control kit. When this switch is in the ON position, the output terminals of the Power Wave are electrically hot. When the switch is in the OFF position, the output terminals of the Power Wave are electrically cold and the machine cannot produce an output. In the stick process, the LCD display shows Procedure Description, and Preset Current (SET=). The Current Trim is always equal to 1 (T=1.00). When the trigger is pulled the Preset Current, Actual Arc Voltage and Actual Arc Current are displayed. See Tables B.3 through B.6 for a summary of the information discussed above. WAVE CONTROL The wave control settings of all procedures can be changed on the Power Wave GMAW Pulse, GMAW FCAW, Stick Process Selection Overlay. The wave control is a setup parameter that may be adjusted when the welding procedures are set. This feature provides an easy way to change the arc behavior without creating a new procedure. The wave control setting of a procedure limits the speed at which the current waveform of that procedure can change. Typically, each procedure is programmed to have average wave control (at the center of the scale). POWER WAVE 450 Return to Master TOC Return to Section TOC B-21 OPERATION TABLE B.3 – RELATIONSHIP BETWEEN VOLTAGE TRIM AND PRESET VOLTAGE Voltage Trim Relationship to Preset Voltage 0.6 60% of preset voltage 0.8 80% of preset voltage 1.0 no change to preset voltage 1.2 120% of preset voltage 1.4 140% of preset voltage TABLE B.6 – RELATIONSHIP BETWEEN SELECTED ARC LENGTH TRIM AND PRESET ARC LENGTH AS INDICATED BY ARC LENGTH Arc Length Trim Preset Arc Length 0.6 60% of preset length 0.8 80% of preset length 1.0 no change to preset length 1.2 120% of preset length 1.4 140% of preset length Return to Master TOC If, for example, the minimum voltage trim is set to 0.8 and the maximum voltage trim is set to 1.4, this means that the voltage for a given wire feed speed can be adjusted to be anywhere between 80% and 140% of the preset voltage of that wire feed speed. TABLE B.4 – ADJUSTABLE PARAMETERS Return to Master TOC Return to Section TOC Return to Section TOC Explanation of Table B.3: Adjustable Parameters GMAW Pulse GMAW FCAW Wire Feeder WFS Display Wire Feed Speed Wire Feed Speed — Wire Feeder Voltage Display Arc Length Trim Preset Voltage — Power Wave 450 Display (with GMAW Pulse, GMAW FCAW, Stick Process Selection Overlay) Wave Control (Frequency) Wave Control (Inductance) Wave Control (Arc Force) Return to Master TOC Stick TABLE B.5 – DISPLAYS OF THE POWER WAVE AND WIRE FEEDERS FOR DIFFERENT PROCESSES IN BOTH TRIGGER POSITIONS Wire Feeder Power Wave 450 Trigger Position1 Open Return to Section TOC B-21 Closed GMAW Pulse GMAW FCAW STICK1 WFS and Arc Length Trim WFS and Preset Voltage Preset Current WFS, Actual Arc Voltage, Actual Arc Current WFS, Actual Arc Voltage, Actual Arc Current Preset Current, Actual Arc Voltage, Actual Arc Current GMAW Pulse GMAW FCAW WFS DISPLAY: Wire Feed Speed VOLTAGE DISPLAY: Arc Length Trim WFS DISPLAY: Wire Feed Speed VOLTAGE DISPLAY: Preset Voltage WFS DISPLAY: Wire Feed Speed VOLTAGE DISPLAY: Actual Arc Voltage WFS DISPLAY: Wire Feed Speed2 VOLTAGE DISPLAY: Actual Arc Voltage In Stick, trigger is on Remote Control Kit K941-1. 1 Arc Current, not wire feed speed, is displayed if a Remote Control Kit is attached to the wire feeder. POWER WAVE 450 2 Return to Master TOC Return to Section TOC B-22 OPERATION In Pulse processes: The wave control adjustment allows the frequency setting to vary. Increasing the wave control allows the frequency setting to increase, and decreasing the wave control allows the frequency setting to decrease. Varying the wave control setting affects the droplet transfer and allows fine-tuning for different welding positions. Return to Master TOC Return to Section TOC In GMAW and FCAW processes: The wave control adjusts the inductance. (Inductance is inversely proportional to pinch.) Increasing the wave control setting decreases the inductance, which results in the arc getting colder and pinched tighter. Decreasing the wave control setting increases the inductance, which results in the arc getting wider. In Stick processes: The wave control adjusts the arc force. Increasing the wave control setting increases the arc force, making the arc more harsh but less likely to stick. Decreasing the wave control setting decreases the arc force, making the arc softer and smoother. PULSE WELDING Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC Some people have trouble getting used to the behavior of the pulsing arc. The parameters programmed into the Power Wave have been thoroughly tested for their ability to deliver a sound weld with good appearance. There are, however, a few things to keep in mind when pulse welding. Spatter levels are often very low with the pulse welding process. Pulsing is often used to eliminate cleaning operations necessary when using other welding processes. Fume levels are sometimes lower with the pulsing process. Whether or not you will get lower fume levels depends on the pulsing programs used. Certain waveform characteristics are necessary to get low fume levels. Unfortunately, low fume procedures are harder to weld with than procedures designed to optimize the welding process. B-22 The pulsing process greatly affects the heat input to the workpiece. This can be a valuable tool for either increasing or decreasing the heat input with a given process. For instance, it is possible to greatly increase the heat input when welding steel at high deposition rates. On the other hand, it is possible to reduce the heat input using the pulsing process. For example, heat input is reduced greatly with some of the low current stainless steel procedures using the processes programmed into the Power Wave. In all cases, the Power Wave procedures have been checked for their ability to deliver a sound weld. However, the fusion of the weld metal into the workpiece may be affected. It is the responsibility of the user to determine if the welds produced are suitable and sound. The Power Wave 450 is optimized for use with a 0.75” (1.9 cm) stickout. The adaptive behavior is programmed to support a stickout range from 0.5” to 1.25” (1.3 to 3.2 cm). In the low and high end of the wire feed speed ranges of most processes, the adaptive behavior may be restricted. This is a physical restriction due to reaching the edge of the operating range for the process. It is possible to achieve adaptive behavior for longer stickout lengths. However, shielding gas is often lost when the stickout is too long. A longer electrical stickout is often used with the pulsing process at higher deposition rates. A long stickout will increase the melt-off rate of the wire. In pulse welding, like other wire welding processes, the arc length is determined by the voltage setting. This voltage is programmed at the factory for each process and wire feed speed. It may be changed using the Voltage setting on the wire feeder. When adaptive processes are used, the voltage will vary with stickout. The machine must change the voltage to keep a stable arc. It is very important to recognize this. “Actual” arc voltage when welding will vary because the stickout will seldom be held at the nominal 1.9 cm value. The pulsing process is not slower than other processes. The process is sometimes less forgiving when the arc gets on or ahead of the puddle. More attention must be paid to the weld to avoid losing the puddle. Speed is a matter of deposition rate. All things being equal regarding the joint being welded, the speed will depend on the wire feed speed. The travel speed is maximized by maintaining a very short arc. Often the process is “trimmed” down until the arc “crackles.” The spatter increases slightly, but many of the advantages of pulsing are retained. When welding steel, the Power Wave is designed to run well in this region between pulse and short arc. POWER WAVE 450 Return to Master TOC OPERATION Return to Master TOC Return to Master TOC B-23 OVERLOAD PROTECTION THERMAL PROTECTION OVER CURRENT PROTECTION The Power Wave has thermostatic protection from excessive duty cycles, overloads, loss of cooling, and high ambient temperatures. When the power source is subjected to any of these conditions or any of the conditions mentioned above, a thermostat will open. The yellow high temperature light on the case front comes on. See Figure B.1 for location. Machine output is disabled, and welding is not possible until the machine is allowed to cool and the High Temperature Light goes out. The Power Wave 450 is limited to producing 750 amps peak current. If the average current exceeds 540 amps, then the peak current will be limited to 100 amps until the average current decreases to under 50 amps. Return to Master TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC B-23 POWER WAVE 450 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Section TOC NOTES POWER WAVE 450 Return to Master TOC Section C-1 Section C-1 TABLE OF CONTENTS - ACCESSORIES Accessories...........................................................................................................................Section C Options/Accessories...................................................................................................................C-2 Wire Feeder Setup ...............................................................................................................C-2 Guns and Cables .................................................................................................................C-2 Water Cooler Usage ...................................................................................................................C-2 Recommended Coolants............................................................................................................C-3 Priming the Cooler......................................................................................................................C-3 Return to Master TOC Return to Master TOC Return to Master TOC Cooler Periodic Maintenance .....................................................................................................C-4 POWER WAVE 450 Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC C-2 C-2 ACCESSORIES OPTIONS/ACCESSORIES GUNS AND CABLES • Synergic 7 wire feeder (K632-1) standard speed,or (K632-2) high speed Several MAGNUM guns are recommended for use with the Power Wave as shown in Table C.1. • MAGNUM 400 gun (K471-2) or 550 gun (K598) • Internal water cooler • Undercarriages (Single [K961-1]or Dual [K962-1]Gas Cylinders) • Remote control (stick welding) K941-1 • Amptrols (Hand K963-1 or -2, Foot K870) • Limits Overlay K946-4 • Dual Wire Feeders, Dual Procedures Overlay K946-9 • Dual Feeder, Dual Procedure, Memory Selection Overlay K946-12 • Test and Calibration Overlay Place the proper liner in the gun and connect the gun to the feeder. Consult the specific instructions supplied with the gun for detailed operating instructions. FIGURE C.1 – WIRE FEEDER AND WATER COOLER CONNECTIONS 1 2 3 WIRE FEEDER SETUP 5 The Power Wave must be used with wire feeders listed above. Mount the feeder in a location suitable to your needs. For most applications, connect the electrode cable between the feeder and the positive (+) connection of the power source. When negative electrode polarity is required, such as in some Innershield™ applications, connect the electrode cable between the feeder and the negative (-) connection of the power source. See Figure C.1. Connect the control cable between the feeder and power source. The cable has different connectors on each end and will fit in only one way. If only one feeder is used, it must be connected to the Feeder 1 Amphenol located on the back panel in the upper lefthand corner (as you view the machine from the back). If a second feeder is used, it must be plugged into the Feeder 2 Amphenol receptacle located just to the right of the Feeder 1 Amphenol receptacle. Connect the work cable between the work and the negative (-) connection of the power source. When negative electrode polarity is required, such as in some Innershield™ applications, connect the work cable between the work and the positive (+) connection of the power source. See Figure C.1. • Connect the feeder to a welding gas supply. • Load the wire into the feeder and gun. • Configure wire feeders (Refer to Setup overlay in operation section. 1 2 3 4 5 4 WIRE FEEDER CONNECTIONS (LOCATION) WATER COOLER LINE (IN) WATER COOLER LINE (OUT) CIRCUIT BREAKER (WATER COOLER) FILL SPOUT (WATER COOLER) Using a water-cooled gun is recommended to reduce the size of the gun and improve parts life. The Power Wave comes with a standard internal water cooler. However, an external cooler may also be used. TABLE C.1 – RECOMMENDED GUNS FOR USE WITH POWER WAVE 450 Gun Application Cooling Product No. MAGNUM 400 GMAW Gas K471-2 MAGNUM 550 GMAW Gas K598 WATER COOLER USAGE The Power Wave is equipped with an optional internal water cooler. We recommend using the water cooler when welding above 300 amps with argon blends on a regular basis. The gun heating from pulsing above 300 amps average current is often excessive and leads to reduced consumable life, reduced gun life, and operator discomfort. Water cooling greatly increases the durability of the gun and parts at high current. Use of the Synergic 7 wire feeder requires appropriate input cable assembly, wire stand, and drive roll kit. Refer to Synergic 7 Operators Manual for available options. 1 POWER WAVE 450 Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC C-3 ACCESSORIES There are two water connections on the rear of the Power Wave. See Figure C.1. Connect the water lines between these connectors and those on the wire feeder. The water is fed through the feeder into the gun. When a water cooler is used, the water cooler must be enabled by using the Setup Overlay. a. Install the Set-up overlay. b. Keep accessories’ hose lengths horizontal, either coiled or straight, and no higher than 4 feet of the specified coolant level. c. Switch on the Power Wave machine. The water cooler contains a flow switch, which is closed when there is adequate coolant circulating in the system. If this flow rate drops below the switch manufacturer’s set point, the flow switch opens. A couple of seconds after the flow switch opens the water cooler shuts down. If the water cooler is enabled and the flow switch opens, the machine beeps loudly indicating that there is a problem with the water cooler operation. d. Press the "WATER COOLER ENABLE" button so that the "WATER COOLER ENABLED" light is illuminated. e. Press the "PRIME WATER COOLER" button until the "WATER COOLER PRESSURE" light is steadily illuminated. 4. Check coolant level. Add more if required. Figure C.2 RECOMMENDED COOLANTS Rear Panel of Power Wave 1. The following coolants have been determined to be compatible with the wetted materials used in the G3503-[ ] cooler assembly: • Distilled or deionized water • Potable tap water • Sediment-free mixtures containing a maximum of 50% ethylene glycol or automotivegrade antifreeze and the balance of distilled or deionized water. Reservoir Screen Visible Coolant Level 0.25 to 0.50 inches Return to Master TOC Return to Section TOC 2. Ethylene glycol mixtures should be selected if the cooler may be exposed to a temperature below the freezing point of water. 3. Consult gun, torch, and wire feeder manuals for coolant recommendations and select one from the above list. 4. Pure solutions and mixtures of, or materials (i.e. towels) wetted with ethylene glycol are toxic to humans and animals. They must not be haphazardly discarded, especially by pouring liquids down the drain. Contact the local EPA office for responsible disposal methods or for recycling information. Return to Master TOC 5. The cooler’s reservoir has a nominal liquid capacity of 1.6 gallons. Return to Section TOC C-3 Do Not Use: Any prepacked welding industry coolant mixture, such as those offered by Miller, OKI, Bernhard, or Dynaflux. These coolants contain substances which attack plastic components and may shorten the life of the system. Once added, these substances are virtually impossible to purge from the system. DO NOT USE OIL-BASED COOLANTS OF ANY TYPE. K961-1 Single Cylinder Undercarriage Designed for quick installation in the field. Consists of a front caster assembly, a rear platform assembly, a handle, and an upper cylinder support. PRIMING THE COOLER K962-1 Dual Cylinder Undercarriage - 1. Select a recommended coolant and fill cooler to specified level (see Fig. C.2). Designed for quick installation in the field. Consists of a front caster assembly, a dual bottle rear platform assembly, a handle, and a dual bottle upper cylinder support. 2. Attach desired water-cooled accessory (gun and wire feeder or TIG torch) to cooler’s QDs. 3. Prime the cooler: POWER WAVE 450 Return to Master TOC Return to Section TOC C-4 ACCESSORIES G3503-[ ] COOLER PERIODIC MAINTENANCE 1. Preparation: • Always switch off the Power Wave machine power. • Always disconnect the Power Wave machine from service input power. • Do not remove the pump relief valves' 3/4 in. acorn hex nut or attempt to adjust the relief valve setting. Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC 2. Remove the G3503-[ ] cooler from the Power Wave machine. Return to Section TOC C-4 3. Clean the pump’s inlet strainer: • Drain the reservoir of coolant and dispose of it in an environmentally responsible manner (see Recommended Coolants). • Place absorbent towels underneath pump head. • Hold pump head to apply countertorque when loosening strainer’s 7/8 acorn nut. Do not confuse with 3/4 acorn nut. Remove nut and slide inlet strainer down and out from pump head. • Gently rinse strainer under running water to thoroughly clean it. • Use the mirror to inspect inside of pump for contamination. Carefully remove hardened debris with dental pick if necessary, without scratching inside of the pump. • Reinstall strainer and acorn nut, tightening with 75±15 in.-lbs. of torque. Wipe dry all areas wetted by coolant. Dispose of towels in an environmentally responsible manner (see Recommended Coolants). 4. Gently rinse the reservoir’s strainer under running water to thoroughly clean it. 5. Remove fan shroud and inspect hoses and electrical harnesses for kinking or damage (cut, abrasion, swelling, etc.). Replace if necessary. 6. Remove accumulated dust from cooler, especially from the motor and heat exchanger, by blowing it off with shop air or vacuuming it out. • The heat exchanger fins are sharp but can be easily bent. Treat them with care to avoid personal injury and damaging them. • Remove the cooler from the machine for a more thorough cleaning job. 7. Motor lubrication is recommended once a year: • Remove plug over lube port at top of motor near fan end. • Add 20 drops of electric motor or SAE 10 oil then reinstall plug. 8. Flush coolant from the system and replace with fresh, recommended coolant at least once a year. More frequent flushing may be necessary, depending upon a user’s particular system or its usage. NOTE: Never run the pump dry. Always use a recommended coolant, otherwise pump damage may result. 9. Reinstall the G3503-[ ] cooler into the Power Wave machine. G3503-[ ] COOLER SERVICE 1. Preparation: • Always switch off the Power Wave machine power. • Always disconnect the Power Wave machine from service input power. • Do not remove the pump relief valves' 3/4 in. acorn hex nut or attempt to adjust the relief valve setting. 2. Remove the G3503-[ ] cooler from the Power Wave machine whenever: • replacing major cooler components (i.e. pump, motor, heat exchanger, etc.). • replacing hoses and electrical harnesses that are kinked or damaged (cut, abraded, deteriorated or swollen, etc.). • investigating suspect coolant leakage. 3. Pump replacement: a. Drain the reservoir of coolant and dispose of it in an environmentally responsible manner (see Recommended Coolants). b. Remove fan shroud. c. Place absorbent towels underneath pump head and wherever coolant system is opened. d. Carefully pull pump inlet hose and its elbow from reservoir (bottom). e. Loosen pump outlet hose clamp at QD then carefully remove from fitting. f. Disconnect v-band clamp from motor and remove pump: • Do not drop or lose drive coupling between pump and motor. • Do not discard old pump. Remove both fittings, Keep v-clamp, Seal old pump in a waterproof bag, Package into protective container, and Return to nearest Lincoln Electric FSS center. POWER WAVE 450 C-5 C-5 Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC ACCESSORIES g. Install new pump and v-band clamp: • Do not apply any lubricant to pump’s drive coupling. • Pump body is properly oriented with its strainer at the 6:00 position. • Tighten v-clamp with 15 to 30 in-lbs. of torque. h. Attach coolant lines to QD and reservoir. i. Wipe dry all areas wetted by coolant. Dispose of towels in an environmentally responsible manner (see Recommended Coolants). j. Reinstall cooler into machine. 4. Motor removal or replacement: • Do not reuse the 4 internal-tooth star washers. Replace with new parts. 5. Installing the fan: • Slide onto motor shaft until the fan is located between 0.25 to 0.50 inches from the heat exchanger. • Tighten set screw with 65 to 75 in-lbs of torque against motor shaft’s flat. • Fan rotation is counterclockwise, as viewed from fan-end of motor’s shaft. • Fan pulls air through the heat exchanger, blows it over the motor, then exhausts it through the reservoir. POWER WAVE 450 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Section TOC C-6 C-6 NOTES POWER WAVE 450 Return to Master TOC D-1 D-1 TABLE OF CONTENTS -MAINTENANCEMaintenance .........................................................................................................................Section D Safety Precautions......................................................................................................................D-2 Routine and Periodic Maintenance ............................................................................................D-2 Input Filter Capacitor Discharge.................................................................................................D-2 Preventive Maintenance .............................................................................................................D-5 Return to Master TOC Return to Master TOC Return to Master TOC General Component Locations...................................................................................................D-6 POWER WAVE 450 Return to Master TOC Return to Section TOC D-2 MAINTENANCE SAFETY PRECAUTIONS WARNING ELECTRIC SHOCK can kill. • Only Qualified personnel should perform this maintenance. • Turn the input power OFF at the disconnect switch or fuse box before working on this equipment. Return to Master TOC Return to Section TOC • Do not touch electrically hot parts. ROUTINE AND PERIODIC MAINTENANCE Perform the following preventive maintenance at least once every six months. WARNING Prior to performing preventive maintenance it is important to perform the following capacitor discharge procedure to avoid electric shock. Return to Master TOC Return to Section TOC INPUT FILTER CAPACITOR DISCHARGE PROCEDURE 1. Turn off input power and disconnect input power lines. 2. Remove the hex head screws from the top and the sides of the machine. Remove the handle bar and the wrap-around machine cover. 3. Remove the two case sides. There are hex head screws on each side. CAUTION Return to Master TOC Return to Section TOC TO PREVENT DAMAGE TO MACHINE, AVOID UNNECESSARY MOVEMENT OF FRONT PANEL. 4. Obtain a high resistance and high wattage resistor (25-1000 ohms and 25 watts minimum). This resistor is not supplied with the machine. Secure this resistor to a piece of insulating material such as a glastic board. See Figure D.3. NEVER USE A SHORTING STRAP FOR THIS PROCEDURE. POWER WAVE 450 D-2 Return to Master TOC Return to Section TOC D-3 MAINTENANCE FIGURE D.1 – RESISTOR LOCATIONS Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC 5 PAIRS OF RESISTORS CHECK VOLTAGES BETWEEN EACH TERMINAL AND FROM EACH RESISTOR TO CASE GROUND 5. Locate two sets of two resistors on the left side of the machine and three sets of two resistors on the right side of the machine. See Figure D.1. Do not touch the resistors or any other internal machine component. Using a DC voltmeter, check for any DC voltage that may be present across the terminals of each resistor and from each resistor to case ground (20 measurements in all). If a voltage is present, be careful not to touch these resistors. WARNING Return to Master TOC Return to Section TOC ELECTRIC SHOCK can kill. • Proceed with caution being careful not to touch any internal machine components during the discharge procedure. POWER WAVE 450 D-3 Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC D-4 MAINTENANCE 6. Locate the #9 and #12 terminals, identified by the “Discharge” labels, on each of the four Switch Boards. See Figure D.2. D-4 FIGURE D.3 – RESISTORS WITH LEADS CONNECTED 7. Using insulated, needle nose-type jumper leads and insulated gloves, connect one jumper lead to one end of the resistor obtained in step 4. Connect the other jumper lead to the other end of the resistor. 8. Carefully connect the needle nose end of one of the jumper leads to terminal #9. See Figure D.3. Connect the needle nose end of the other jumper lead to terminal #12. Terminals #9 and #12 are indicated by the “Discharge” label. Leave resistor connected for 10 seconds. DO NOT TOUCH TERMINALS, RESISTORS, OR ANY INTERNAL MACHINE COMPONENT DURING THIS PROCEDURE! FIGURE D.2 – DISCHARGE LABEL D I S C H A R G E D I S C H A R G E D I S C H A R G E D I S C H A R G E D I S C H A R G E 9. Check voltage across terminals (9 and 12) with a DC voltmeter. Terminal 9 has positive polarity and terminal 12 has negative polarity. Voltage should be zero. If any voltage remains, repeat this capacitor discharge procedure. 10. Repeat discharge procedure (steps 7, 8 and 9) for each of the other three Switch Boards. POWER WAVE 450 Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC D-5 MAINTENANCE PREVENTIVE MAINTENANCE Perform the following preventive maintenance procedures at least once every six months. It is good practice to keep a preventive maintenance record; a record tag attached to the machine works best. D-5 8. Reconnect the shunt and wire #467 to the negative (-) output terminal. Make sure the connection is tight. 9. Replace and secure the machine covers and handle bar. 1. Remove the hex head screws from the sides and top of the machine. Remove the handle bar and the machine wrap-around cover. Remove the two case sides. There are hex head screws on each side. 10. Remove the overlay from the front panel of the machine. Clean the plastic case with a low pressure airstream. Wipe the sensors (Fig D.4 Item 8) with a clean, soft cloth. Make sure the sensors are not scratched in the process. 2. Perform the input filter capacitor discharge procedure described at the beginning of the Maintenance Section. 11. Check the back of the overlays. If the bar code (black square(s)) on the back of the overlay is scratched, apply a dull black spray finish to the scratched-off areas only. If a large area of the bar code is scratched off, the machine either will not recognize the overlay or will mistake the overlay for another one. 3. Disconnect the shunt from the negative (-) output terminal. Failure to do this could cause damage to the shunt circuitry. 4. Clean the inside of the machine with a low pressure airstream. Be sure to clean the following components thoroughly (Refer to Figure D.4): • Display, Snubber, and Shunt printed circuit boards • Power Switch • Main Transformer • Auxiliary Transformers • Input Rectifier • Heat Sink Fins • Input Filter Capacitors • Output Terminals • Terminal Strip 12. Inspect gun and cables for good condition. 5. Examine the capacitors for leakage or oozing. Replace if needed. 6. Examine the wrap-around and side covers for dents and breakage. Repair them as needed. The covers must be kept in good condition to assure that high voltage parts are protected and that correct spacings are maintained. 7. Remove welding cables and check the electrical ground continuity. Use an ohmmeter to measure the resistance between each output terminal and an unpainted surface of the machine case. The meter reading should be 500,000 ohms or more. If the meter reading is less than 500,000 ohms, check for electrical components that are not properly insulated from the case. Correct component insulation, if needed. POWER WAVE 450 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC D-6 D-6 MAINTENANCE FIGURE D.4 – GENERAL COMPONENT LOCATIONS 1 2 3 4 5 6 7 8 9 DISPLAY BOARD (BACK OF PANEL) POWER SWITCH MAIN TRANSFORMER AUXILIARY TRANSFORMER INPUT RECTIFIER HEAT SINK FINS OUTPUT TERMINALS OVERLAY BAR CODE SENSORS TERMINAL STRIP (LOCATION) 5 4 1 Return to Master TOC Return to Section TOC 9 8 6 2 7 Return to Master TOC Return to Section TOC 3 POWER WAVE 450 Return to Master TOC Section E-1 Section E-1 TABLE OF CONTENTS -THEORY OF OPERATIONTheory of Operation .............................................................................................................Section E General Description ....................................................................................................................E-2 Input Voltage ...............................................................................................................................E-2 Precharge (Soft Start)..................................................................................................................E-3 Switch Boards.............................................................................................................................E-4 Main Transformer ........................................................................................................................E-5 Output Rectifier and Choke ........................................................................................................E-6 Return to Master TOC Control Board..............................................................................................................................E-7 Power Board ...............................................................................................................................E-8 Display Board..............................................................................................................................E-9 Thermal Protection....................................................................................................................E-10 Protective Circuits.....................................................................................................................E-10 Over Current Protection .....................................................................................................E-10 Over Voltage Protection......................................................................................................E-10 Field Effect Transistor (FET) Operation .....................................................................................E-11 Pulse Width Modulation............................................................................................................E-12 Minimum Output.................................................................................................................E-12 Maximum Output................................................................................................................E-12 Return to Master TOC FIGURE E.1 – POWER WAVE BLOCK LOGIC DIAGRAM INPUT CONTACTOR INPUT RECTIFIER AND RECONNECT MAIN TRAMSFORMER OUTPUT RECTIFIER CHOKE THREE PHASE INPUT POWER FET ASSEMBLY CT AUX. TRANS INPUT LINE SWITCH PROTECTION BOARD FAN RIGHT SWITCH BOARD FET ASSEMBLY NEGATIVE SHUNT POWER BOARD Return to Master TOC POSITIVE LEFT SWITCH BOARD CONTROL BOARD WATER COOLER DISPLAY BOARD SNUBBER AND SENSE LEADS LCD DISPLAY KEYPAD PC INTERFACE OVERLAY WF1 WF2 POWER WAVE 450 Return to Master TOC Return to Section TOC E-2 E-2 THEORY OF OPERATION FIGURE E.2 – INPUT VOLTAGE CIRCUIT INPUT CONTACTOR INPUT RECTIFIER AND RECONNECT MAIN TRAMSFORMER OUTPUT RECTIFIER CHOKE POSITIVE LEFT SWITCH BOARD THREE PHASE INPUT POWER FET ASSEMBLY CT AUX. TRANS INPUT LINE SWITCH PROTECTION BOARD FAN RIGHT SWITCH BOARD FET ASSEMBLY NEGATIVE POWER BOARD Return to Master TOC Return to Section TOC SHUNT CONTROL BOARD WATER COOLER DISPLAY BOARD SNUBBER AND SENSE LEADS LCD DISPLAY KEYPAD PC INTERFACE OVERLAY Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC WF1 WF2 GENERAL DESCRIPTION INPUT VOLTAGE The Power Wave is an inverter type power source that can support most welding procedures. It is modeled after a P.C. (Personal Computer). There are no specific welding characteristics designed into the power portion of the machine. All welding characteristics are programmed into the software package. The Power Wave can be connected for a variety of three phase voltages. The initial input power is applied to the Power Wave through a line switch located on the front of the machine. The voltage is connected to the Protection Board where it is current limited before being passed on to the input rectifier and reconnect switches. The reconnect panel allows the user to switch to low or high voltage and connect the Auxiliary Transformer to the appropriate input voltage. The Auxiliary Transformer supplies power to the fan motors and, through the Protection Board, to the printed circuit boards and wire feeder(s). NOTE: Unshaded areas of Block Logic Diagram are the subject of discussion. POWER WAVE 450 Return to Master TOC Return to Section TOC E-3 E-3 THEORY OF OPERATION FIGURE E.3 – PRECHARGE CIRCUIT INPUT CONTACTOR INPUT RECTIFIER AND RECONNECT MAIN TRAMSFORMER OUTPUT RECTIFIER CHOKE THREE PHASE INPUT POWER FET ASSEMBLY CT AUX. TRANS INPUT LINE SWITCH PROTECTION BOARD FAN RIGHT SWITCH BOARD FET ASSEMBLY NEGATIVE Return to Master TOC Return to Section TOC SHUNT POWER BOARD CONTROL BOARD WATER COOLER DISPLAY BOARD SNUBBER AND SENSE LEADS LCD DISPLAY KEYPAD PC INTERFACE OVERLAY WF1 WF2 Return to Section TOC Return to Master TOC Return to Master TOC PRECHARGE (SOFT START) Return to Section TOC POSITIVE LEFT SWITCH BOARD The Protection Board contains a “soft Start” circuit, which is powered by the Auxiliary Transformer. During precharge or “soft start” only two phases of the input power, with current limiting, are connected to the input rectifier. This AC input voltage is rectified, and the DC voltage is applied through the Reconnect Switches to the input capacitors located on the Switch Boards. The Protection Board monitors the voltage across the capacitors. When the capacitors have charged to an acceptable level, the Protection Board energizes the Main Input Contactor, making all three phases of input power available to the input capacitors. At this point the Power Wave is in the “Run Mode” of operation. If the capacitors become under- or overvoltaged, the Protection Board will de-energize the Main Input Contactor, and the machine output will be disabled. NOTE: Unshaded areas of Block Logic Diagram are the subject of discussion. POWER WAVE 450 Return to Master TOC Return to Section TOC E-4 E-4 THEORY OF OPERATION FIGURE E.4 – SWITCH BOARD CIRCUIT INPUT CONTACTOR INPUT RECTIFIER AND RECONNECT MAIN TRAMSFORMER OUTPUT RECTIFIER CHOKE THREE PHASE INPUT POWER FET ASSEMBLY CT AUX. TRANS INPUT LINE SWITCH PROTECTION BOARD FAN RIGHT SWITCH BOARD FET ASSEMBLY NEGATIVE POWER BOARD Return to Master TOC Return to Section TOC SHUNT CONTROL BOARD WATER COOLER DISPLAY BOARD SNUBBER AND SENSE LEADS LCD DISPLAY KEYPAD PC INTERFACE OVERLAY WF1 WF2 Return to Section TOC Return to Master TOC Return to Master TOC SWITCH BOARDS Return to Section TOC POSITIVE LEFT SWITCH BOARD There are four Switch Boards in the Power Wave, each containing an input capacitor. The capacitors on Switch Boards #1 and #2 are always in parallel, and the capacitors on Switch Boards #3 and #4 are always in parallel. When the filter capacitors are fully charged, they act as power supplies for the Switch Boards. The Switch Boards contain the Field Effect Transistors (FETs) which, when switched on, supply the Main Transformer primary windings with DC current flow. See FET operation discussion and diagrams (Figures E.10 and E11). NOTE: Unshaded areas of Block Logic Diagram are the subject of discussion. POWER WAVE 450 Return to Master TOC Return to Section TOC E-5 E-5 THEORY OF OPERATION FIGURE E.5 – MAIN TRANSFORMER INPUT CONTACTOR INPUT RECTIFIER AND RECONNECT MAIN TRAMSFORMER OUTPUT RECTIFIER CHOKE THREE PHASE INPUT POWER FET ASSEMBLY CT AUX. TRANS INPUT LINE SWITCH PROTECTION BOARD FAN RIGHT SWITCH BOARD FET ASSEMBLY NEGATIVE POWER BOARD Return to Master TOC Return to Section TOC SHUNT CONTROL BOARD WATER COOLER DISPLAY BOARD SNUBBER AND SENSE LEADS LCD DISPLAY KEYPAD PC INTERFACE OVERLAY WF1 WF2 Return to Section TOC Return to Master TOC Return to Master TOC MAIN TRANSFORMER Return to Section TOC POSITIVE LEFT SWITCH BOARD Each Switch Board assembly works as a switch pair. Each board feeds current to a primary winding of the Main Transformer. These primary currents are monitored by the Current Transformer (CT). The CT sends a signal through the Protection Board to the Control Board. If the primary currents become abnormally high, the Control Board will shut off the FETs, thus disabling machine output. The right and left sides of the transformer are isolated from each other. The right side of the transformer is supplied from Switch Boards #1 and #2, while the left side of the transformer is supplied from Switch Boards #3 and #4. The DC current flow through each primary winding is clamped back to each respective input capacitor when the FETs are turned off. The firing of the four Switch Board pairs occurs during halves of a 50 microsecond interval, creating two constant 20 kHz square waves on the primary side of the transformer. The current flow through the Main Transformer primaries induces a 20 kHz AC square wave output signal at the secondary of the Main Transformer. NOTE: Unshaded areas of Block Logic Diagram are the subject of discussion. POWER WAVE 450 Return to Master TOC Return to Section TOC E-6 E-6 THEORY OF OPERATION FIGURE E.6 – OUTPUT RECTIFIER AND CHOKE INPUT CONTACTOR INPUT RECTIFIER AND RECONNECT MAIN TRAMSFORMER OUTPUT RECTIFIER CHOKE THREE PHASE INPUT POWER FET ASSEMBLY CT AUX. TRANS INPUT LINE SWITCH PROTECTION BOARD RIGHT SWITCH BOARD FAN FET ASSEMBLY NEGATIVE Return to Master TOC Return to Section TOC SHUNT POWER BOARD CONTROL BOARD WATER COOLER DISPLAY BOARD SNUBBER AND SENSE LEADS LCD DISPLAY KEYPAD PC INTERFACE OVERLAY WF1 WF2 Return to Section TOC Return to Master TOC Return to Master TOC OUTPUT RECTIFIER AND CHOKE Return to Section TOC POSITIVE LEFT SWITCH BOARD The Output Rectifier receives the AC output from the Main Transformer secondary and rectifies it to a DC level with a 40 kHz ripple. Since the Output Choke is in series with the positive leg of the Output Rectifier and also in series with the welding load, a filtered DC output is applied to the machine output terminals. NOTE: Unshaded areas of Block Logic Diagram are the subject of discussion. POWER WAVE 450 Return to Master TOC Return to Section TOC E-7 E-7 THEORY OF OPERATION FIGURE E.7 – CONTROL BOARD INPUT CONTACTOR INPUT RECTIFIER AND RECONNECT MAIN TRAMSFORMER OUTPUT RECTIFIER CHOKE THREE PHASE INPUT POWER FET ASSEMBLY CT AUX. TRANS INPUT LINE SWITCH PROTECTION BOARD FAN RIGHT SWITCH BOARD FET ASSEMBLY NEGATIVE POWER BOARD Return to Master TOC Return to Section TOC SHUNT CONTROL BOARD WATER COOLER DISPLAY BOARD SNUBBER AND SENSE LEADS LCD DISPLAY KEYPAD PC INTERFACE OVERLAY WF1 WF2 Return to Section TOC Return to Master TOC Return to Master TOC CONTROL BOARD Return to Section TOC POSITIVE LEFT SWITCH BOARD The Control Board is at the heart of controlling the output of the machine. With the information it receives from the Shunt (current feedback), the voltage sensing leads, the wire feeder(s), and the other printed circuit boards, the Control Board optimizes the welding results by regulating the FETs’ switching times, which in turn control the output of the machine. The Control Board also monitors the thermal protection devices and the regulation and fault signals produced on the Protection Board. NOTE: Unshaded areas of Block Logic Diagram are the subject of discussion. POWER WAVE 450 Return to Master TOC Return to Section TOC E-8 E-8 THEORY OF OPERATION FIGURE E.8 – POWER BOARD INPUT CONTACTOR INPUT RECTIFIER AND RECONNECT MAIN TRAMSFORMER OUTPUT RECTIFIER CHOKE THREE PHASE INPUT POWER FET ASSEMBLY CT AUX. TRANS INPUT LINE SWITCH PROTECTION BOARD FAN RIGHT SWITCH BOARD FET ASSEMBLY NEGATIVE POWER BOARD Return to Master TOC Return to Section TOC SHUNT CONTROL BOARD WATER COOLER DISPLAY BOARD SNUBBER AND SENSE LEADS LCD DISPLAY KEYPAD PC INTERFACE OVERLAY WF1 WF2 Return to Section TOC Return to Master TOC Return to Master TOC POWER BOARD Return to Section TOC POSITIVE LEFT SWITCH BOARD The Power Board provides gate drives for the FETs on the Switch Boards. It does so based on the “turn-on” signals it receives from the Control Board. One function of the Power Board is to isolate the Control Board from the Switch Boards. The Power Board also provides the other printed circuit boards with the DC voltage supply they require. NOTE: Unshaded areas of Block Logic Diagram are the subject of discussion. POWER WAVE 450 Return to Master TOC Return to Section TOC E-9 E-9 THEORY OF OPERATION FIGURE E.9 – DISPLAY BOARD INPUT CONTACTOR INPUT RECTIFIER AND RECONNECT MAIN TRAMSFORMER OUTPUT RECTIFIER CHOKE THREE PHASE INPUT POWER FET ASSEMBLY CT AUX. TRANS INPUT LINE SWITCH PROTECTION BOARD FAN RIGHT SWITCH BOARD FET ASSEMBLY NEGATIVE Return to Master TOC Return to Section TOC SHUNT POWER BOARD CONTROL BOARD WATER COOLER DISPLAY BOARD SNUBBER AND SENSE LEADS LCD DISPLAY KEYPAD PC INTERFACE OVERLAY WF1 WF2 Return to Section TOC Return to Master TOC Return to Master TOC DISPLAY BOARD Return to Section TOC POSITIVE LEFT SWITCH BOARD The Display Board allows the operator to select from the procedures that are programmed into the machine, and it lets the Control Board know which procedure was selected. These procedures are programmed into the machine’s software package. The Display Board is used to communicate with the operator. It determines what Overlay is installed in the machine and which buttons are active on the keypad. It also controls the LCD display, the lights on the front of the machine, the Piezo Buzzer and the water cooler. Through the use of a current serial loop, the Display Board and Control Board communicate (or talk) to the wire feeder(s). The Display Board can also communicate with a computer through the RS232 interface. NOTE: Unshaded areas of Block Logic Diagram are the subject of discussion. POWER WAVE 450 Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC E-10 THEORY OF OPERATION E-10 THERMAL PROTECTION PROTECTIVE CIRCUITS Two normally closed (NC) thermostats protect the machine from excessive operating temperatures. These thermostats are wired in series and are connected to the Control Board. One of the thermostats is located on the heat sink of a switch board, and the other is located on the main choke. Excessive temperatures may be caused by a lack of cooling air or operating the machine beyond the duty cycle or output rating. If excessive operating temperatures should occur, the thermostats will prevent output from the machine. The displays will remain on during this time; and the yellow Thermal light, located of the front of the machine, will be illuminated. The thermostats are selfresetting once the machine cools sufficiently. If the thermostat shutdown was caused by excessive output or duty cycle and the fans are operating normally, the Power Switch (SW1) may be left on and the reset should occur within a 15-minute period. If one or both of the fans are not turning or the air intake louvers are obstructed, then the power must be removed from the machine, and the fan problem air obstruction must be corrected. Protective circuits are designed into the Power Wave to sense trouble and shut down the machine before damage occurs to the machine’s internal components. OVER CURRENT PROTECTION If the average current exceeds 520 amps, then the peak current will be limited to 100 amps until the average current decreases to under 50 amps. OVER VOLTAGE PROTECTION A protective circuit is included on the Protection Board to monitor the voltage across the input capacitors. In the event that a capacitor voltage is too high, the protection circuit will prevent output. Also, in the event that a capacitor voltage is too low, the machine output is disabled and the “soft start” mode is repeated. The protection circuit may prevent output if any of the following circumstances occur: 1. Capacitor condition is required. (Required if machine has been off for a long period of time and is connected for high input voltage operation.) 2. Voltage across a capacitor exceeds 370 volts. (High line surges or improper input voltage connections.) 3. Voltage across a capacitor is under 170 volts. (Due to improper input voltage connections.) Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC 4. Internal component damage. POWER WAVE 450 Return to Master TOC Return to Section TOC E-11 E-11 THEORY OF OPERATION FIELD EFFECT TRANSISTOR (FET) OPERATION FIGURE E.10 – FIELD EFFECT TRANSISTOR OPERATION SOURCE TERMINAL GATE TERMINAL (0 VOLTS) DRAIN TERMINAL DRAIN (N) SOURCE (N) Return to Master TOC Return to Section TOC N CHANNEL SUBSTRATE (P) A. PASSIVE GATE TERMINAL (+ 6 VOLTS) Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC SOURCE (N) DRAIN (N) ELECTRONS B. ACTIVE An FET is a type of transistor. FETs are semiconductors well suited for high-frequency switching. Drawing A above shows an FET in a passive mode. There is no gate signal (zero volts) from the source and, therefore, no current flow. The drain terminal of the FET may be connected to a voltage supply. But since there is no conduction, the circuit will not supply current to downstream components connected to the source. The circuit is turned off like a light switch in the OFF position. Drawing B above shows the FET in an active mode. When the gate signal, a positive DC voltage relative to the source, is applied to the gate terminal of the FET, it can’t conduct current. A voltage supply connected to the drain terminal will allow the FET to conduct and henceforth supply current to downstream components. Current will flow through the conducting FET to downstream components as long as the gate signal is present. This is similar to turning on a light switch. POWER WAVE 450 Return to Master TOC Return to Section TOC E-12 E-12 THEORY OF OPERATION PULSE WIDTH MODULATION FIGURE E.11 – TYPICAL FET OUTPUTS (+) (–) 48 µsec 50 µsec 1 µsec 1 µsec Return to Master TOC Return to Section TOC MINIMUM OUTPUT (+) (–) 20 µsec 20 µsec 10 µsec 50 µsec The term PULSE WIDTH MODULATION is used to describe how much time is devoted to conduction in the positive and negative portions of the cycle. Changing the pulse width is known as MODULATION. Pulse Width Modulation (PWM) is the varying of the pulse width over the allowed range of a cycle to affect the output of the machine. Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC MAXIMUM OUTPUT MINIMUM OUTPUT MAXIMUM OUTPUT By holding the gate signals on for 20 microseconds each and allowing only 10 microseconds of dwell time (off time) during the 50microsecond cycle, the output is maximized. The darkened area under the top curve can be compared to the area under the bottom curve. The more dark area under the curve, the more power is present. By controlling the duration of the gate signal, the FET is turned on and off for different durations during a cycle. The top drawing above shows the minimum output signal possible over a 50-microsecond time period. The positive portion of the signal represents one FET group1 conducting for 1 microsecond. The negative portion is the other FET group1. The dwell time (off time) is 48 microseconds (both FET groups off). Since only 2 microseconds of the 50-microsecond time period is devoted to conducting, the output power is minimized. A FET group consists of the sets of FET modules grouped onto one switch board. 1 POWER WAVE 450 Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Section F-1 Section F-1 TABLE OF CONTENTS -TROUBLESHOOTING & REPAIR SECTIONTroubleshooting & Repair Section.......................................................................................Section F How to Use Troubleshooting Guide............................................................................................F-2 PC Board Troubleshooting Procedures and Replacement.........................................................F-3 Troubleshooting Guide ................................................................................................................F-5 Test Procedures ........................................................................................................................F-23 Capacitor Discharge Procedure .........................................................................................F-23 Auxiliary Transformer Test 1 ...............................................................................................F-27 Auxiliary Transformer Test 2 ...............................................................................................F-31 Auxiliary Transformer Primary Wiring Harness Test ...........................................................F-35 Auxiliary Transformer #1 Secondary and Wiring Harness Test ..........................................F-39 Input Power and Wiring Harness Test ................................................................................F-43 Input Rectifier Resistance Test ...........................................................................................F-47 Output Shunt/Welding Feedback Test................................................................................F-51 Piezo-Electric Alarm Buzzer Test........................................................................................F-55 Output Rectifier Diodes Test ..............................................................................................F-57 Field Effect Transistor/Switch Board Test...........................................................................F-59 Snubber and Bleeder Resistor Test....................................................................................F-75 Reconnect Switch Test 1....................................................................................................F-81 Reconnect Switch Test 2....................................................................................................F-85 Static Capacitor Balance Test ............................................................................................F-89 Dynamic Capacitor Balance Test .......................................................................................F-93 Internal and Auxiliary Supply Voltage Test .........................................................................F-97 Main Contactor Test .........................................................................................................F-103 Serial Loop Wiring Harness Test ......................................................................................F-107 Wire Feeder 1 Trigger Circuit Test ....................................................................................F-111 Wire Feeder 2 Trigger Circuit Test ....................................................................................F-115 Trigger Circuit and Wiring Harness Test ...........................................................................F-119 Internal Remote Control Test............................................................................................F-123 K941-1 Remote Control Kit Test ......................................................................................F-127 K941-1 Remote Control Kit Trigger Circuit Test ...............................................................F-131 LCD Display Test ..............................................................................................................F-135 Calibration Procedures............................................................................................................F-139 Sensor Calibration Test (For Display Board) ....................................................................F-141 Quick Voltage Calibration .................................................................................................F-143 Full Voltage Calibration.....................................................................................................F-145 Full Voltage Calibration Using A Welding Arc...................................................................F-147 Current Calibration ...........................................................................................................F-151 Replacement Procedures........................................................................................................F-155 T1 Auxiliary Transformer Removal and Replacement ......................................................F-155 Water Cooler Removal and Replacement ........................................................................F-157 Water Cooler Disassembly ...............................................................................................F-161 T2 Auxiliary Transformer Removal and Replacement ......................................................F-165 Fan Motor Removal and Replacement.............................................................................F-167 Input Rectifier Removal and Replacement.......................................................................F-171 Printed Circuit Board Removal and Replacement ...........................................................F-175 Display Board Removal and Replacement.......................................................................F-179 Main Input Contactor (CR1) Removal and Replacement .................................................F-183 Output Rectifier Bridge Removal and Replacement ........................................................F-187 FET Module Removal and Replacement ..........................................................................F-191 Main Transformer Removal and Replacement .................................................................F-197 Pre-Powerup Switch Board Test Procedure.....................................................................F-199 POWER WAVE 450 Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC Return to Section TOC 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 malfunctions. Simply follow the three-step procedure listed below. Step 1. LOCATE PROBLEM (SYMPTOM). Look under the column labeled “PROBLEM (SYMPTOMS). This column describes possible symptoms that the machine may exhibit. Find the listing that best describes the symptom that the machine is exhibiting. Symptoms are grouped into three main categories: Output Problems, Function Problems, and Welding Problems. Step 2. PERFORM EXTERNAL TESTS. The second column, labeled “POSSIBLE AREAS OF MISADJUSTMENT(S),” lists the obvious external possibilities that may contribute to the machine symptom. Perform these tests/checks in the order listed. In general, these tests can be conducted without removing the case wrap-around cover. Step 3. PERFORM COMPONENT TESTS. The last column, labeled “Recommended Course of Action,” lists the most likely components that may have failed in your machine. It also specifies the appropriate test procedure to verify that the subject component is either good or bad. If there are a number of possible components, check the components in the order listed to eliminate one possibility at a time until you locate the cause of your problem. All of the referenced test procedures referred to in the Troubleshooting Guide are described in detail at the end of this chapter. Refer to the Troubleshooting and Repair Table of Contents to locate each specific Test Procedure. All of the referred to test points, components, terminal strips, etc., can be found on the referenced electrical wiring diagrams and schematics. Refer to the Electrical Diagrams Section Table of Contents to locate the appropriate diagram. 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. Return to Master TOC Return to Section TOC CAUTION POWER WAVE 450 F-2 Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC F-3 TROUBLESHOOTING & REPAIR PC BOARD TROUBLESHOOTING PROCEDURES AND REPLACEMENT WARNING ELECTRIC SHOCK can kill. Have an electrician install and service this equipment. Turn the machine OFF before working on equipment. Do not touch electrically hot parts. Sometimes machine failures appear to be due to PC board failures. These problems can sometimes be traced to poor electrical connections. To avoid problems when troubleshooting and replacing PC boards, please use the following procedure: 1. Determine to the best of your technical ability that the PC board is the most likely component causing the failure symptom. 2. Check for loose connections at the PC board to assure that the PC board is properly connected. Return to Master TOC Return to Section TOC 3. If the problem persists, replace the suspect PC board using standard practices to avoid static electrical damage and electrical shock. Read the warning inside the static resistant bag and perform the following procedures. PC Board can be damaged by static electricity. ATTENTION Static-Sensitive Devices Handle only at Static-Safe Workstations Return to Master TOC Reusable Container Do Not Destroy Return to Section TOC F-3 • Remove your body’s static charge before opening the static-shielding bag. Wear an antistatic wrist strap. For safety, use a 1 Meg ohm resistive cord connected to a grounded part of the equipment frame. • If you don’t have a wrist strap, touch an unpainted, grounded, part of the equipment frame. Keep touching the frame to prevent static build-up. Be sure not to touch any electrically live parts at the same time. • 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. • 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 proper failure analysis. 4. Perform any necessary PC Board calibration procedures. See the flow chart on the next page. 5. Test the machine to determine if the failure symptom has been corrected by the replacement PC board. NOTE: Allow the machine to heat up so that all electrical components can reach their operating temperature. 6. Remove the replacement PC board and substitute it with the original PC board to recreate the original problem. Recalibrate if required. a. If the original problem does not reappear by substituting the original board, then the PC board was not the problem. Continue to look for bad connections in the control wiring harness, junction blocks, and terminal strips. b. If the original problem is recreated by the substitution of the original board, then the PC board was the problem. Reinstall the replacement PC board, recalibrate if required, and test the machine. 7. Always indicate that this procedure was followed when warranty reports are to be submitted. NOTE: Following this procedure and write on the warranty report, “INSTALLED AND SWITCHED PC BOARDS TO VERIFY PROBLEM,” 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. POWER WAVE 450 PC BOARD REPLACEMENT CALIBRATION REQUIREMENTS Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Master TOC DISPLAY BOARD REPLACED Return to Section TOC F-4 TROUBLESHOOTING & REPAIR Return to Master TOC Return to Section TOC F-4 SNUBBER BOARD REPLACED SHUNT AMPLIFIER BOARD REPLACED IF POSSIBLE QUICK VOLTAGE CALIBRATION CONTROL BOARD REPLACED CURRENT CALIBRATION FULL VOLTAGE CALIBRATION POWER WAVE 450 Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC F-5 TROUBLESHOOTING & REPAIR TROUBLESHOOTING GUIDE PROBLEMS (SYMPTOMS) F-5 Observe Safety Guidelines detailed in the beginning of this manual. POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION OUTPUT PROBLEMS Major physical or electrical damage is evident when the sheet metal cover(s) are removed. 1. Contact your local authorized Lincoln Electric Field Service Facility for technical assistance. Machine is dead – no output – no fans – no displays. 1. Check the main input fuses. If open, replace. 2. Make certain that the input power switch (S1) is in the “ON” position. 3. Check for proper input voltage – must match the rating on the machine nameplate. 1. If fuse (F1) quickly fails, perform the Auxiliary Transformer Primary Wiring Harness Test. 2. If fuse (F1) does not fail, perform the Auxiliary Transformer Test #1. 4. Make certain the reconnect panel is configured properly for the applied voltage. Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC 5. Check fuse (F1) in the reconnect panel. If faulty, replace with 5-amp slow-blow fuse. 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 1800-833-9353. POWER WAVE 450 Return to Master TOC Return to Section TOC F-6 TROUBLESHOOTING & REPAIR TROUBLESHOOTING GUIDE PROBLEMS (SYMPTOMS) Observe Safety Guidelines detailed in the beginning of this manual. POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION OUTPUT PROBLEMS Machine has no output – fans are running – display is on – a “clicking” sound is heard coming from the machine. 1. Turn power OFF immediately. 2. Check for proper input voltage (per machine nameplate). 3. Make certain the reconnect panel is configured properly for the applied voltage. 1. Perform the Auxiliary Transformer Test #1 2. Perform the Main Contactor Test. 3. Perform the Reconnect Switch Test #1. 4. Perform the Reconnect Switch Test #2. Return to Master TOC Return to Section TOC F-6 5. Perform the Input Rectifier Test. 6. Perform the Switch Board Test. 7. Perform the Snubber and Bleeder Resistor Test. 8. The protection board may be faulty. Replace. Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC 9. The input filter capacitors may be faulty. Replace. 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 1800-833-9353. POWER WAVE 450 Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC F-7 TROUBLESHOOTING & REPAIR TROUBLESHOOTING GUIDE PROBLEMS (SYMPTOMS) F-7 Observe Safety Guidelines detailed in the beginning of this manual. POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION OUTPUT PROBLEMS Fans run slow or intermittently – display is very dim – no weld output. 1. Make certain the reconnect panel and fuse (F1) jumper “A” is configured properly for the input voltage being applied. 1. Perform the Auxiliary Transformer Test #1. Machine has no output – no display – fans run – circuit breaker (5 amp) repeatedly trips. 1. Make sure that not more than 5 amps of auxiliary power are being drawn. 1. The circuit breaker (5 amp) may be faulty. Test or replace. 2. Remove the wire feeder control cable from the Power Wave. If the symptom disappears, the wire feeder or control cable is faulty. 2. Perform the Auxiliary Transformer #1 Secondary and Wiring Harness Test. 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 1800-833-9353. POWER WAVE 450 Return to Master TOC Return to Section TOC F-8 TROUBLESHOOTING & REPAIR TROUBLESHOOTING GUIDE PROBLEMS (SYMPTOMS) Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC Observe Safety Guidelines detailed in the beginning of this manual. POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION OUTPUT PROBLEMS Machine has no output – no fans – no display. Main input fuses are open indicating excessive input current draw. Return to Section TOC F-8 1. Check for proper input voltage connections. 1. Perform the Input Power and Wiring Harness Test. 2. Make certain the reconnect panel is configured properly for the applied voltage. 2. Perform the Input Rectifier Test. 3. Replace the input fuses with proper size and ratings. 3. Perform the Reconnect Switch Test #1. 4. Perform the Switch Board Test. 5. Perform the Snubber and Bleeder Resistor Test. Machine has no output – no display – fans run. Machine has no output – fans run - Display flashes On and Off repeatedly. 1. Check circuit breaker (5 amp) located on the front panel. Reset if necessary. 1. Perform the Auxiliary Transformer Test #1. 1. Check for loose or faulty connections at the Power P.C. Board. See Wiring Diagram. 1. Replace the Power P.C. Board. 2. Perform the Internal and Auxiliary Supply Voltage Test. 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 1800-833-9353. POWER WAVE 450 Return to Master TOC Return to Section TOC F-9 TROUBLESHOOTING & REPAIR TROUBLESHOOTING GUIDE PROBLEMS (SYMPTOMS) Return to Master TOC Observe Safety Guidelines detailed in the beginning of this manual. POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION OUTPUT PROBLEMS Circuit breaker (5 amp) trips when gun trigger is pulled – fans run. Return to Section TOC F-9 1. Make sure that not more than 5 amps of auxiliary power are being used. 2. Remove the wire feeder’s control cable(s) from the Power Wave. If the symptoms disappear, replace the wire feeder and cables with known good equipment. If the problem is solved, the wire feeder or control cable is faulty. The machine intermittently loses output. The wire feeder still feeds wire. 1. If after a few seconds the contactor “pulls” back in, then check for high input line voltage. 1. The 5 amp circuit breaker may be faulty. Test or replace. 2. Perform the Trigger Circuit and Wiring Harness Test. 1. Perform the Static Capacitor Balance Test. 2. Perform the Welding Feedback Test. 3. The control board may be faulty. Replace. Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC 4. The shunt board assembly may be faulty. Replace. 5. Perform the Switch Board Test. 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 1800-833-9353. POWER WAVE 450 Return to Master TOC Return to Section TOC F-10 TROUBLESHOOTING & REPAIR TROUBLESHOOTING GUIDE PROBLEMS (SYMPTOMS) Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC Observe Safety Guidelines detailed in the beginning of this manual. POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION OUTPUT PROBLEMS Machine has no welding output – fans run – display is on. Return to Section TOC F-10 1. Make sure that the machine was powered up with a properly installed overlay. Without an overlay installed in the Power Wave, or an invalid overlay installed, the machine will not have welding output. 2. Check to see if the Limits or Setup overlay is installed on the front panel. These two overlays cannot be used for welding. 3. Check for proper input voltage per machine nameplate. 4. Make certain the reconnect panel is configured properly. 5. Check to see that when the trigger is pulled on the wire feeder the wire feeder’s voltage display changes to indicate arc voltage. If this does not happen, the feeder or control cable may be faulty. 1. Perform the Wire Feeder Trigger Circuit Test (#1 or #2) for the appropriate wire feeder receptacle (amphenol). 2. If a K941-1 Remote Control Kit is attached to the Power Wave, then perform the K941-1 Remote Control Kit Trigger Circuit Test. 3. Perform the Reconnect Switch Test #1. 4. Perform the Output Rectifier Diodes Test. 5. Perform the Switch Board Test. 6. Perform the Snubber and Bleeder Resistor Test. 7. Perform the Static Capacitor Balance Test. 8. Perform the Dynamic Capacitor Balance Test. 6. Check wire feeder control cable for loose or faulty connections. 7. If the machine is connected for 380VAC or higher and has not been used for a long period of time, the capacitors may require “conditioning.” Let the Power Wave run at an idle state for 30 minutes. 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 1800-833-9353. POWER WAVE 450 Return to Master TOC Return to Section TOC F-11 TROUBLESHOOTING & REPAIR TROUBLESHOOTING GUIDE PROBLEMS (SYMPTOMS) Return to Master TOC Return to Section TOC Return to Master TOC Return to Master TOC POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION 1. Welding application may exceed recommended duty cycle. 2. Dirt and dust may have clogged the cooling channels inside the machine. Refer to the Maintenance Section of this manual. 1. One of the thermostats located on the output rectifier or FET heat sink may be faulty. Test or replace. 3. Air intake and exhaust louvers may be blocked due to inadequate clearance around machine. 4. Make sure both fans are functioning correctly. Machine does not appear to overheat, but yellow light turns on and off intermittently. Output is disabled whenever yellow light is on. Return to Section TOC Observe Safety Guidelines detailed in the beginning of this manual. OUTPUT PROBLEMS Machine regularly overheats-yellow light (LED) on the front panel glows, indicating a thermal overload. The display is on. Return to Section TOC F-11 NONE 1. Check thermostats on output rectifier and switch board #1. These thermostats are normally closed. 2. Check leads from thermal switches to molex plug J23 on the control board for loose or faulty connections. 3. The control board may be faulty. Replace, and perform voltage calibration and current calibration procedures. 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 1800-833-9353. POWER WAVE 450 Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC F-12 TROUBLESHOOTING & REPAIR TROUBLESHOOTING GUIDE PROBLEMS (SYMPTOMS) F-12 Observe Safety Guidelines detailed in the beginning of this manual. POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION FUNCTION PROBLEMS The voltage and or wire feed speed will not adjust to user satisfaction. 1. Certain limits may have been imposed on the welding parameters. Refer to the Limits Overlay section of this manual. NONE The voltage and or wire feed speed can be adjusted on the wire feeder, but the changes are not shown on the Power Wave display. 1. When the Limits Overlay or the Setup Overlay is installed in the Power Wave, the machine and wire feeder displays do not match. These overlays cannot be used for welding. 1. Try the other wire feeder receptacle. If the problem is solved, the initial receptacle or associated wiring is faulty. 2. If two wire feeders are connected to the Power Wave, only one of the feeder’s settings can be displayed on the Power Wave at one tme. Pull the trigger of the wire feeder whose settings you want displayed on the Power Wave. 2. If the problem persists with both wire feeder receptacles, check or replace the wire feeder and control cable. 3. If the wire feeder and control cable are OK, then perform the Serial Loop Wiring Harness Test. 4. The display board may be faulty. Replace and perform voltage calibration. 5. The control board may be faulty. Replace and perform voltage calibration and current calibration. The Dual Procedure overlay is installed, and the user cannot change from procedure “A” to procedure “B” or vice versa. 1. Check for proper installation of the Dual Procedure overlay. 1. Perform the Serial Loop Wiring Harness Test. 2. Check the Dual Procedure Gun Trigger or separate dual procedure switch. 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 1800-833-9353. POWER WAVE 450 Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC F-13 TROUBLESHOOTING & REPAIR TROUBLESHOOTING GUIDE PROBLEMS (SYMPTOMS) F-13 Observe Safety Guidelines detailed in the beginning of this manual. POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION FUNCTION PROBLEMS The display cannot be seen clearly or cannot be seen at all. 1. Adjust the viewing angle of the display. Follow the instructions provided in the Operation Section of this manual. (Look under the “LCD DISPLAY ADJUSTMENTS” in the “CONTROLS AND SETTINGS” subsection of the Operation Section.) 1. Perform the LCD Display Test. Machine does not respond to keys being pressed, or the machine has improper displays. 1. Each time an overlay is changed, make certain that the machine is powered-up with the new overlay in place. 1. Using the test and calibration overlay L9660-255, perform the keyboard/LED test. See overlay. 2. Make certain that the correct overlay ID number is displayed on power-up. Refer to the Operation Section of this manual for the overlay description. 2. Perform the Serial Loop Wiring Harness Test. 3. In some cases, some of the keys on the overlay may be locked out. Refer to the Operation Section of this manual for the overlay descriptions. 3. Replace the control board and perform voltage calibration and current calibration. 4. Replace the display board and perform voltage calibration. 5. Replace the power board. 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 1800-833-9353. POWER WAVE 450 Return to Master TOC Return to Section TOC F-14 TROUBLESHOOTING & REPAIR TROUBLESHOOTING GUIDE PROBLEMS (SYMPTOMS) Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC Observe Safety Guidelines detailed in the beginning of this manual. POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION FUNCTION PROBLEMS Machine display reads “Error Invalid Overlay,” or it displays an invalid ID number on power-up. Return to Section TOC F-14 1. Make certain the overlay is installed properly. 1. Perform the Sensor Calibration Test. 2. Inspect the infrared sensors on the front panel. If they are dirty, blow them out with low pressure air and clean with a soft cloth. 3. Inspect for damage to the Bar Code(s) (black squares) on the back of the overlay. Also check for dirt build-up on back of overlay. Wipe off with a soft rag. Machine displays “ERROR: S.L. NOT INITIALIZED” on power-up. 1. Contact your local Lincoln Authorized Field Service Facility for technical assistance. 1. Perform the Serial Loop Wiring Harness Test. 2. The control board may be faulty. Replace and perform voltage calibration and current calibration. 3. The display board may be faulty. Replace and perform voltage calibration. 4. The power board may be faulty. Replace. 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 1800-833-9353. POWER WAVE 450 Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC F-15 TROUBLESHOOTING & REPAIR TROUBLESHOOTING GUIDE PROBLEMS (SYMPTOMS) F-15 Observe Safety Guidelines detailed in the beginning of this manual. POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION FUNCTION PROBLEMS The Beeper (Piezoelectric Buzzer) cannot be heard – machine operating normally. 1. Background noise may be too loud for user to hear beeper. The welding parameters that were saved in memory are different when recalled. 1. Make certain that a remote control unit is NOT connected. When a remote control unit is used, the weld parameters are set by the remote control potentiometers. 1. Check the continuity of wire #445 (8J44 to 8J16). 1. Make sure that the water cooler has been installed and also enabled. Refer to the Setup Overlay description in the Operation Section of the manual. 1. Perform the Auxiliary Transformer #2 Test. The water cooler does not turn on. 1. Perform the Piezoelectric Buzzer Test. 2. The display board may be faulty. Replace and perform voltage calibration. 2. If the water cooler is enabled but there is insufficient flow rate in the water cooler hose, the Power Wave will beep loudly, and the water cooler will shut down. Prime the water cooler. Refer to the Setup Overlay description in the Operation Section of this manual. 2. The power board may be faulty. Replace. 3. The display board may be faulty. Replace. 2. Check the continuity of leads #453, 454, 455 & 456. From plug J3 to J11. See wiring diagram. 3. The display board may be faulty. Replace. 4. The water cooler may be faulty. 3. The coolers circuit breaker may have tripped. Reset if necessary 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 1800-833-9353. POWER WAVE 450 Return to Master TOC Return to Section TOC F-16 TROUBLESHOOTING & REPAIR TROUBLESHOOTING GUIDE PROBLEMS (SYMPTOMS) Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC Observe Safety Guidelines detailed in the beginning of this manual. POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION FUNCTION PROBLEMS The machine beeps without the keys being pressed. Return to Section TOC F-16 If the water cooler is enabled and the flow switch inside the water cooler opens (due to inadequate coolant flow rate), the machine indicates this by beeping. This happens regardless of the overlay placed on the machine. In this case, do the following. 1. Turn the machine off and on a couple of times and see if the beeping continues. If the flow rate dropped momentarily, then turning the machine off and on eliminates the beeping. A momentary drop in flow rate could be due to a temporary restriction in the water cooler hose. 1. Perform the Auxiliary Transformer #2 Test. 2. The water cooler may be defective. Replace. 3. Check the continuity of lead #453, 454, 455 & 456 from plug J3 to J11. See wiring diagram. 4. The display board may be faulty. Replace. 2. Check the water cooler and accessory hoses for kinks, internal obstructions or blockage, or ruptures. If such problems were found then correct them. Turn the machine Off and On to check if the beeping has been eliminated. 3. Check the water cooler fluid level. Low coolant level could cause the flow rate to drop. 4. Prime the water cooler. Refer to the Setup Overlay section of this manual for instructions. 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 1800-833-9353. POWER WAVE 450 Return to Master TOC Return to Section TOC F-17 TROUBLESHOOTING & REPAIR TROUBLESHOOTING GUIDE PROBLEMS (SYMPTOMS) F-17 Observe Safety Guidelines detailed in the beginning of this manual. POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION FUNCTION PROBLEMS Foreign characters are shown on the Power Wave display. Contact your local Lincoln Authorized Field Service Facility. 1. Make sure molex plug J19 is plugged into the Display board securely and the pins are secure in the plug body. Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC Return to Section TOC 2. The display board may be faulty. Replace and perform voltage calibration. 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 1800-833-9353. POWER WAVE 450 Return to Master TOC Return to Section TOC F-18 TROUBLESHOOTING & REPAIR TROUBLESHOOTING GUIDE PROBLEMS (SYMPTOMS) Observe Safety Guidelines detailed in the beginning of this manual. POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION FUNCTION PROBLEMS 1. Make sure that a stick welding procedure is selected on the Power Wave. 1. Perform the (K941-1) Remote Control Kit Test or install a new K941-1. 2. Make certain that the (K941-1) remote control is securely plugged into the Power Wave 6 pin amphenol receptacle. 2. Perform the Internal Remote Control Test. Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Master TOC The control knob on the Remote Control Kit (K941-1) does not change the preset current on the Power Wave display. Return to Section TOC F-18 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 1800-833-9353. POWER WAVE 450 Return to Master TOC Return to Section TOC F-19 TROUBLESHOOTING & REPAIR TROUBLESHOOTING GUIDE PROBLEMS (SYMPTOMS) Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC Observe Safety Guidelines detailed in the beginning of this manual. POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION WELDING PROBLEMS Machine loses output while welding. Fans and display are functioning properly. Return to Section TOC F-19 1. Check the yellow High Temperature light on the frontpanel. If the light is “ON,” then refer to the Output Problems section in this table relating to this condition. 2. Check for proper input voltages (per machine nameplate). 3. Check for balanced threephase input supply voltages. 4. Check electrode and work cables for loose or poor connections. 1. Perform the Welding Feedback Test. 2. Perform the Switch Board Test. 3. Perform the Snubber and Bleeder Resistor Test. 4. Perform the Static Capacitor Balance Test. 5. Perform the Dynamic Capacitor Test. 6. Perform the appropriate Wire Feeder Trigger Circuit Test. If a K941-1 Remote Control Kit is used, perform the K941-1 Remote Control Kit Trigger Circuit Test. 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 1800-833-9353. POWER WAVE 450 Return to Master TOC Return to Section TOC F-20 TROUBLESHOOTING & REPAIR TROUBLESHOOTING GUIDE PROBLEMS (SYMPTOMS) Observe Safety Guidelines detailed in the beginning of this manual. POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION WELDING PROBLEMS Return to Master TOC For no apparent reason the weld characteristics have changed. Return to Section TOC F-20 1. Check for proper wire feed speed setting. In the MIG/MAG and FCAW Modes, check for proper voltage settings. In the MIG/MAG Pulse Modes, check the arc length trim setting. These controls are on the wire feeder. In the Stick Mode, check for proper preset current setting. 2. Check for proper shielding gas and gas flow. 3. Check for loose or faulty welding cables. The arc is “too hot,” and cannot be adjusted. 1. Perform the full voltage calibration. 1. If zero arc voltage is displayed while welding, the voltage sense leads may be broken. Check the following molex plugs and associated wiring for loose or faulty connections: J60, J62 on the snubber board J20 on the control board 2. Perform the Welding Feedback Test. 3. The control board may be faulty. Replace and perform voltage calibration and current calibration. 1. Check plugs J60, J62 and J20 for loose or faulty connections. See Wiring Diagram. Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC 2. The snubber board may be faulty. Replace and perform full voltage calibration. 3. The control board may be faulty. Replace and perform voltage calibration and current calibration. 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 1800-833-9353. POWER WAVE 450 Return to Master TOC Return to Section TOC F-21 TROUBLESHOOTING & REPAIR TROUBLESHOOTING GUIDE PROBLEMS (SYMPTOMS) Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC Observe Safety Guidelines detailed in the beginning of this manual. POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION WELDING PROBLEMS Machine often “noodle welds” with a particular procedure. Return to Section TOC F-21 1. The machine may be trying to deliver too much power. When the average output current exceeds a maximum limit, the peak current is drastically cut back. Lower the welding parameter settings and/or increase the stickout length to eliminate this problem. If problem occurs all the time change the control board. Power Wave 450 – When the average output current exceeds 540 amps, the peak output current is folded back to 100 amps. Erratic output or greater than 6 amps reading on display with no output. Replace shunt and lead assembly. None 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 1800-833-9353. POWER WAVE 450 CONTROL BD GROUND PLANE PROTECTION BD POWER BD 1 1 16 J20 J30 8 1 1 J21 16 1 16 8 J41 1 J31 1 14 POWER WAVE 450 12 J32 J42 6 1 1 4 6 J23 6 J33 1 1 1 1 J24 J34 1 1 1 10 4 J25 6 1 1 4 1 J39 1 1 4 J26 J27 J28 6 1 4 J44 4 12 J35 J36 J37 J38 14 14 1 Return to Master TOC Return to Section TOC J43 TOP VIEW DISPLAY J22 1 12 Return to Master TOC Return to Master TOC J40 Return to Section TOC Return to Section TOC 4 Return to Master TOC Return to Section TOC F-22 TROUBLESHOOTING & REPAIR F-22 PC BOARD CONNECTOR LOCATIONS FIGURE F.1 – PC BOARD CONNECTOR LOCATIONS Return to Master TOC Return to Section TOC F-23 TROUBLESHOOTING & REPAIR 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. Return to Master TOC Return to Section TOC If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-800-833-9353 (WELD). PURPOSE FOR THE PROCEDURE This procedure will drain off any charge stored in the four large capacitors that are part of the FET or IGBT switch board assembly. This procedure MUST be performed, as a safety precaution, before conducting any test or repair procedure that requires you to touch internal components of the machine. Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC MATERIALS NEEDED Volt/Ohmmeter (Multimeter) 5/16" Nut driver 3/8" Nut driver Insulated gloves Jumper wire with insulated leads and needle-nose ends High wattage resistor - 25 to 1000 ohms, 25 watts minimum Piece of glastic board or similar insulating materials on which to secure the resistor This procedure takes approximately 25 minutes to perform. POWER WAVE 450 F-23 F-24 F-24 Return to Master TOC Return to Section TOC TROUBLESHOOTING & REPAIR CAPACITOR DISCHARGE PROCEDURE (continued) TEST PROCEDURE 1. Remove main input supply power to the machine. 2. With the 3/8" nut driver, remove the screws that hold the handle to the machine. 3. Remove the rubber gasket (cover seal) from the lift bail. Return to Master TOC Return to Section TOC 4. With the 5/16" nut driver, remove the sheet metal screws from the case top. 5. With the 5/16" nut driver, remove the screws holding the right and left case sides. Remove the case sides by lifting up and out. 6. Obtain a high resistance and high wattage resistor (25 - 1000 ohms, 25 watts minimum). This resistor is not supplied with the machine. Secure this resistor to a piece of insulating material such as a glastic board. See Figure F.4. NEVER USE A SHORTING STRAP FOR THIS PROCEDURE. 7. Locate the two sets of two resistors on the left side of the machine and three sets of two resistors on the right side of the machine. See Figure F.2. Do not touch the resistors or any other internal machine component. Using a DC voltmeter, check for any DC voltage that may be present across the terminals of each resistor and from each resistor to case ground (20 measurements in all). If a voltage is present, be careful not to touch these resistors. 8. Locate terminals #9 and #12 on the switch boards. They can be identified by the “Discharge” labels, which are located on each of the four switch boards. See Figure F.3. Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC FIGURE F.2 – RESISTOR LOCATIONS 5 PAIRS OF RESISTORS CHECK VOLTAGES BETWEEN EACH TERMINAL AND FROM EACH RESISTOR TO CASE GROUND POWER WAVE 450 F-25 F-25 Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC Return to Section TOC TROUBLESHOOTING & REPAIR CAPACITOR DISCHARGE PROCEDURE (continued) FIGURE F.3 – DISCHARGE LABEL D I S C H A R G E D I S C H A R G E D I S C H A R G E D I S C H A R G E WARNING ELECTRIC SHOCK can kill. Proceed with caution. Be careful not to touch any internal machine components during the discharge procedure. Return to Master TOC 9. Using the insulated, needle nose type jumper leads and insulated gloves, connect one jumper lead to one end of the resistor obtained in step 6. Connect the other jumper lead to the other end of the resistor. Return to Section TOC D I S C H A R G E 10. Carefully connect the needle nose end of one of the jumper leads to terminal #9. See Figure F.5. Connect the needle nose end of the other jumper lead to terminal #12. Terminals #9 and #12 are indicated by the "Discharge" label. Leave the resistor connected for 10 seconds. DO NOT TOUCH TERMINALS, RESISTORS, OR ANY INTERNAL MACHINE COMPONENTS DURING THIS PROCEDURE! POWER WAVE 450 F-26 F-26 Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC TROUBLESHOOTING & REPAIR CAPACITOR DISCHARGE PROCEDURE (continued) FIGURE F.4 - RESISTOR WITH LEADS CONNECTED. 11. Check the voltage across terminals #9 and #12 with the DC voltmeter. Terminal #9 has positive polarity and terminal #12 has negative polarity. Voltage should be zero. If any voltage remains, repeat this capacitor discharge procedure. 12. Repeat discharge procedure steps 9, 10, and 11 for each of the other three switch boards of the FET or IGBT switch board assembly. POWER WAVE 450 Return to Master TOC Return to Section TOC F-27 TROUBLESHOOTING & REPAIR AUXILIARY TRANSFORMER TEST #1 WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual. Return to Master TOC Return to Section TOC If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting 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 #1 and also if the correct voltages are being induced on the secondary windings of the transformer. MATERIALS NEEDED Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Volt/Ohmmeter (Multimeter) 5/16" Nut driver 3/8" Nut driver Input and Auxiliary Circuit Wiring Diagram – Figure F.6. This procedure takes approximately 35 minutes to perform. POWER WAVE 450 F-27 F-28 F-28 Return to Master TOC Return to Section TOC TROUBLESHOOTING & REPAIR AUXILIARY TRANSFORMER TEST #1 (continued) FIGURE F.5 - TRANSFORMER T1 AND T2 LOCATION 3 4 Return to Master TOC Return to Section TOC 2 1 1. AUXILIARY TRANSFORMER T1, PLUG J5 LOCATED IN BASE 2. PROTECTION BOARD 3. PLUG J30 4. AUXILIARY TRANSFORMER T1 TEST PROCEDURE Return to Master TOC Return to Section TOC 1. Remove main input supply power to the machine. 2. With the 3/8" nut driver, remove the 4 screws that hold the handle to the machine. 3. Remove the rubber gasket (cover seal) from the lift bail. 4. With the 5/16" nut driver, remove the sheet metal screws from the case top. 5. With the 5/16" nut driver, remove the screws holding the right and left case sides. Remove the case sides by lifting up and out. Return to Master TOC Return to Section TOC 6. Perform the Capacitor Discharge Procedure described earlier in this section of the manual. WARNING Before continuing with the test procedure, perform the capacitor discharge procedure to avoid electric shock. 7. After you have completed the capacitor discharge procedure for all four switch boards, remove the PC board cover. Use the 5/16" nut driver. 8. Remove plug J5 from the T2 transformer located in the machine base assembly. This is a 6-pin molex plug with 5 wires; see Figure F. 5 for location. T2 is connected in parallel with T1. Leaving the two transformers connected in parallel for the test might result in incorrect readings; therefore plug J5 should be disconnected. 9. Remove plug J30 from the protection board. See Figure F.1 for location of the board and plug J30. 10. Remove the 5 leads ( 3 heavy and 2 small) T1, T2, T3 from main input contactor CR1. This is a safety precaution. It prevents high voltage from being put on the machine during the test. Wrap tape around the lead ends to insulate them and prevent them from touching. POWER WAVE 450 F-29 F-29 Return to Master TOC Return to Section TOC TROUBLESHOOTING & REPAIR AUXILIARY TRANSFORMER TEST #1 (continued) 11. Remove plugs J32 and J33 from the protection board. 12. Turn the main input supply power to the machine back ON. WARNING Return to Master TOC Return to Section TOC ELECTRIC SHOCK can kill. Proceed with caution. Be careful not to touch any internal machine components during the remainder of the test procedure. 13. Check for the correct AC voltage at plugs J32 and J33 as follows. (DO NOT CHECK THE VOLTAGE ON THE PROTECTION BOARD!) Test A: J33 - pin 1 (lead 32A) to J33 - pin 3 (lead 333) = 42 VAC Test B: J33-1 (32A) to J33-4 (334) = 24 VAC If these voltages are wrong or missing, check the associated wiring to the transformer primary. Check the leads at power switch S1. See the Input and Auxiliary Circuit Wiring Diagram, Figure F.6. If the correct voltages are applied to the primary and the secondary voltages are incorrect, the transformer may be faulty. Replace the transformer. Refer to the T1 Auxiliary Transformer Removal and Replacement procedure in this section of the manual. 14. After the test is completed and the problem successfully repaired, reconnect plugs J30, J32 and J33 to the protection board. 15. Reconnect plug J5 to the T2 transformer. 16. Reconnect the 5 leads to the main contactor CR1. 17. Install the PC board cover. 18. Install the machine case sides and top. 19. Install the handle and the lift bail rubber gasket. Return to Master TOC Return to Section TOC Test C: J32-1 (321) to J32-3 (323) = 24 VAC Test D: J33-1 (leads 32A) to J33-6 (lead 336) = 115VAC. If the voltage checks are good, then Auxiliary Transformer #1 is good. If Test C is good but Tests A and B are not correct, check the 5 amp circuit breaker (located on the front panel of the machine). See the Input and Auxiliary Circuit Wiring Diagram, Figure F.6. If all the secondary voltages are wrong or missing, check the associated wiring to the transformer primary. These voltages are most easily checked at the terminal strip. The correct voltages are as follows: Return to Master TOC Return to Section TOC H1 to H2 = 200 - 208 VAC H1 to H3 = 220 - 230 VAC H1 to H4 = 380 - 415 VAC H1 to H5 = 440 - 460 VAC POWER WAVE 450 4 POWER WAVE 450 (T3) W (L3) (324) (T2) V (L2) 24VAC CR1 (T1) (326) MAIN CONTACTOR U (L1) G 1 3 POWER SWITCH SWI (L3A) 2 (L1A) (HIB) (321B) F1 321A FUSE BOT. FAN (220VAC) AC1 POS AC3 NEG 5 2 P5 AUXILIARY TRANF 2 J4 J4 440-460 (H5) JUMPER "A" 380-415 (H4) 220-230 (H3) INPUT RECTIFIER AC2 (H1) 200-208 (H2) TOP FAN Return to Master TOC Return to Master TOC (220VAC) Return to Section TOC Return to Section TOC 2 4 1 H3 220-230V 200-208V H2 H1 H5A 2 4 H3 220-230V H2 200-208V H4 3 380-415V P2 H5 6 440-460V H4A H3A H2A H5 6 H5 440-460V P73 H1A H1 1 H4 3 H4 380-415V H3 H2 H1 1 321 24VAC W N(24V) U(42V) R(115V) AUX. TRANSF. 1 W N(24V) 4 2 1 3 5 6 2 P70 3 33 334 323 4 P71 R(115V) 6 336 333 U(42V) 5 24VAC Return to Master TOC Return to Section TOC 5A CIRCUIT BREAKER 32A J33 J33 J33 J33 J32 J32 CR1 6 J30 J30 (T3) (HIB) 16 R CR1 R CR2 J32 CR2 11 1 6 4 J30 J32 (T1) (321A) PROTECTION BOARD 1 4 3 6 3 1 Return to Master TOC Return to Section TOC F-30 TROUBLESHOOTING & REPAIR F-30 FIGURE F.6 – INPUT AND AUXILIARY CIRCUIT WIRING DIAGRAM Return to Master TOC Return to Section TOC F-31 TROUBLESHOOTING & REPAIR AUXILIARY TRANSFORMER TEST #2 WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual. Return to Master TOC Return to Section TOC If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting 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 #2 and also if the correct voltages are being induced on the secondary windings of the transformer. Note: Transformer #2 is not present on all models. MATERIALS NEEDED Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Volt/Ohmmeter (Multimeter) 5/16" Nut driver 3/8" Nut driver Input and Auxiliary Circuit Wiring Diagram – Figure F.8 This procedure takes approximately 35 minutes to perform. POWER WAVE 450 F-31 F-32 F-32 Return to Master TOC Return to Section TOC TROUBLESHOOTING & REPAIR AUXILIARY TRANSFORMER TEST #2 (continued) FIGURE F.7 - TRANSFORMER T1 AND T2 LOCATION Return to Master TOC Return to Section TOC 2 3 1 1. AUXILIARY TRANSFORMER T1 WITH PLUG J73 2. PLUG J30 3. PROTECTION BOARD TEST PROCEDURE Return to Master TOC Return to Section TOC 1. Remove main input supply power to the machine. 2. With the 3/8" nut driver, remove the 4 screws that hold the handle to the machine. 3. Remove the rubber gasket (cover seal) from the lift bail. 4. With the 5/16" nut driver, remove the sheet metal screws from the case top. 5. With the 5/16" nut driver, remove the screws holding the right and left case sides. Remove the case sides by lifting up and out. Return to Master TOC Return to Section TOC 6. Perform the Capacitor Discharge Procedure described earlier in this section of the manual. WARNING Before continuing with the test procedure, perform the capacitor discharge procedure to avoid electric shock. 7. After you have completed the capacitor discharge procedure for all four switch boards, remove the PC board cover. Use the 5/16" nut driver. 8. Remove plug J73 from the T1 transformer. T2 is connected in parallel with T1. Leaving the two transformers connected in parallel for the test might result in incorrect readings; therefore plug J73 should be disconnected. 9. Remove plug J30 from the protection board. See Figure F.1 for location of the board and plug J30. 10. Remove the 5 leads ( 3 heavy and 2 small) T1, T2, T3 from main input contactor CR1. This is a safety precaution. It prevents high voltage from being put on the machine during the test. Wrap tape around the lead ends to insulate them and prevent them from touching. POWER WAVE 450 F-33 F-33 Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC TROUBLESHOOTING & REPAIR AUXILIARY TRANSFORMER TEST #2 (continued) 11. To conduct this test, you will be measuring the voltage between pin 2 and pin 5 of plug J4. The plug is located in the machine undercarriage and is somewhat difficult to reach. It is probably easiest to disconnect the plug and insert the probes of your voltmeter alongside pins 2 and 5 before turning on input power, which is the next step. If this voltage is wrong or missing, check the associated wiring to the transformer primary. If the correct voltage IS applied to the primary but the voltage at H1A to H3A is not correct, the transformer may be faulty. Replace the transformer. Refer to the T2 Auxiliary Transformer Removal and Replacement Procedure in this section of the manual. 12. Turn the main input supply power to the machine back ON. 14. After the test is completed and the problem successfully repaired, reconnect plug J30 to the protection board. WARNING 15. Reconnect plug J73 to the T1 transformer. ELECTRIC SHOCK can kill. Proceed with caution. Be careful not to touch any internal machine components during the remainder of the test procedure. 16. Reconnect the 5 leads to the main contactor CR1. 17. Install the PC board cover. 18. Install the machine case sides and top. 19. Install the handle and the lift bail rubber gasket. 13. Check for the correct AC voltage between plug J4 - pin 2 and J4 - pin 5. It should be 220 - 230 VAC. Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC If the voltage is correct, then Auxiliary Transformer #2 is good. If the voltage is wrong or missing, check the associated wiring to the transformer primary. See the Input and Auxiliary Circuit Wiring Diagram, Figure F.8. These voltages are most easily checked at the terminal strip. The correct voltages are as follows: H1A to H3A = 220 - 230 VAC POWER WAVE 450 4 POWER WAVE 450 (T3) W (L3) (324) (T2) V (L2) 24VAC CR1 (T1) (326) MAIN CONTACTOR U (L1) G 1 3 POWER SWITCH SWI (L3A) 2 (L1A) (HIB) (321B) F1 321A FUSE BOT. FAN (220VAC) AC1 POS AC3 NEG 5 2 P5 AUXILIARY TRANF 2 J4 J4 440-460 (H5) JUMPER "A" 380-415 (H4) 220-230 (H3) INPUT RECTIFIER AC2 (H1) 200-208 (H2) TOP FAN Return to Master TOC Return to Master TOC (220VAC) Return to Section TOC Return to Section TOC 2 4 1 H3 220-230V 200-208V H2 H1 H5A 2 4 H3 220-230V H2 200-208V H4 3 380-415V P2 H5 6 440-460V H4A H3A H2A H5 6 H5 440-460V P73 H1A H1 1 H4 3 H4 380-415V H3 H2 H1 1 321 24VAC W N(24V) U(42V) R(115V) AUX. TRANSF. 1 W N(24V) 4 2 1 3 5 6 2 P70 3 33 334 323 4 P71 R(115V) 6 336 333 U(42V) 5 24VAC Return to Master TOC Return to Section TOC 5A CIRCUIT BREAKER 32A J33 J33 J33 J33 J32 J32 CR1 6 J30 J30 (T3) (HIB) 16 R CR1 R CR2 J32 CR2 11 1 6 4 J30 J32 (T1) (321A) PROTECTION BOARD 1 4 3 6 3 1 Return to Master TOC Return to Section TOC F-34 F-34 TROUBLESHOOTING & REPAIR FIGURE F.8 – INPUT AND AUXILIARY CIRCUIT WIRING DIAGRAM Return to Master TOC Return to Section TOC F-35 TROUBLESHOOTING & REPAIR AUXILIARY TRANSFORMER PRIMARY WIRING HARNESS TEST WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual. Return to Master TOC Return to Section TOC If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-800-833-9353 (WELD). TEST DESCRIPTION This test will determine if there are any short circuits or other problems in the circuit feeding the primary windings of the auxiliary transformers, which would cause the fuse (F1) on the reconnect panel to blow. Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC MATERIALS NEEDED Volt/Ohmmeter (Multimeter) 5/16" Nut driver 3/8" Nut driver Input and Auxiliary Circuit Wiring Diagram – Figure F.10 Machine Wiring Diagram in the Electrical Diagrams section of this manual Protection PC Board Schematic in the Electrical Diagrams section of this manual This procedure takes approximately 20 minutes to perform. POWER WAVE 450 F-35 F-36 F-36 Return to Master TOC Return to Section TOC TROUBLESHOOTING & REPAIR AUXILIARY TRANSFORMER PRIMARY WIRING HARNESS TEST (continued) FIGURE F.9 - RECONNECT PANEL/TERMINAL STRIP LOCATION 1 Return to Master TOC Return to Section TOC 2 3 4 1. 2. 3. 4. RECONNECT PANEL (ON LEFT SIDE) TERMINAL STRIP FAN MOTORS AUXILIARY TRANSFORMERS Return to Master TOC Return to Section TOC TEST PROCEDURE 1. Remove main input supply power to the machine. 2. With the 3/8" nut driver, remove the 4 screws that hold the handle to the machine. 3. Remove the rubber gasket (cover seal) from the lift bail. 4. With the 5/16" nut driver, remove the sheet metal screws from the case top. Return to Master TOC Return to Section TOC 5. With the 5/16" nut driver, remove the screws holding the right and left case sides. Remove the case sides by lifting up and out. 6. Perform the Capacitor Discharge Procedure described in this section of the manual. WARNING Before continuing with the test procedure, perform the capacitor discharge procedure to avoid electric shock. 7. After you have completed the capacitor discharge procedure for all four switch boards, remove the PC board cover. Use the 5/16" nut driver. 8. Remove the 5 leads ( 3 heavy and 2 small) T1, T2, T3 from main input contactor CR1. This is a safety precaution. It prevents high voltage from being put on the machine during the test. Wrap tape around the lead ends to insulate them and prevent them from touching. 9. Remove plug J30 from the protection board. See Figure F.1 for location of the board and plug J30. NOTE: If removing plug J30 solves the problem, check for a short circuit or a fault in the 24 VAC circuit (plug P71) and the main contactor coil. See the Input and Auxiliary Circuit Wiring Diagram, Figure F.10. POWER WAVE 450 F-37 F-37 Return to Master TOC Return to Section TOC TROUBLESHOOTING & REPAIR AUXILIARY TRANSFORMER PRIMARY WIRING HARNESS TEST (continued) 10. Check the wires that run from the reconnect panel to the terminal strip. Look for shorts between wires caused by broken or burned insulation. See the Input and Auxiliary Circuit Wiring Diagram, Figure F.10. Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC Return to Section TOC 11. Check for shorts in the wires that run from the terminal strip to the auxiliary transformers and to the fan motors. 12. The fan motors or the auxiliary transformer may be faulty. Disconnect these components one at a time and see if fuse F1 blows when input power is applied. The internal resistance of the fan motors should be about 16 ohms. 14. After the test is completed and the problem successfully repaired, reconnect plug J30 to the protection board. 15. Reconnect plugs P70 and P71 to the T1 transformer. 16. Reconnect the 5 leads to the main contactor CR1. 17. Install the PC board cover. 18. Install the machine case sides and top. 19. Install the handle and the lift bail rubber gasket. 13. Remove plug P70 from the transformer. If this solves the problem, check for a short in the secondary circuit. See the machine Wiring Diagram and the Protection PC Board Schematic in the Electrical Diagrams section of this manual. POWER WAVE 450 POWER WAVE 450 (T3) W (L3) (324) (T2) V (L2) 24VAC CR1 (T1) (326) MAIN CONTACTOR U (L1) G 1 3 POWER SWITCH SWI (L3A) 2 (L1A) 4 (HIB) (321B) F1 321A FUSE BOT. FAN (220VAC) AC1 POS AC3 NEG 5 2 P5 AUXILIARY TRANF 2 J4 J4 440-460 (H5) JUMPER "A" 380-415 (H4) 220-230 (H3) INPUT RECTIFIER AC2 (H1) 200-208 (H2) TOP FAN Return to Master TOC Return to Master TOC (220VAC) Return to Section TOC Return to Section TOC 2 4 1 H3 220-230V 200-208V H2 H1 H5A 2 4 H3 220-230V H2 200-208V H4 3 380-415V P2 H5 6 440-460V H4A H3A H2A H5 6 H5 440-460V P73 H1A H1 1 H4 3 H4 380-415V H3 H2 H1 1 321 24VAC W N(24V) U(42V) R(115V) AUX. TRANSF. 1 W N(24V) 4 2 1 3 5 6 2 P70 3 33 334 323 4 P71 R(115V) 6 336 333 U(42V) 5 24VAC Return to Master TOC Return to Section TOC 5A CIRCUIT BREAKER 32A J33 J33 J33 J33 J32 J32 CR1 6 J30 J30 (T3) (HIB) 16 R CR1 R CR2 J32 CR2 11 1 6 4 J30 J32 (T1) (321A) PROTECTION BOARD 1 4 3 6 3 1 Return to Master TOC Return to Section TOC F-38 F-38 TROUBLESHOOTING & REPAIR FIGURE F.10 – INPUT AND AUXILIARY CIRCUIT WIRING DIAGRAM Return to Master TOC Return to Section TOC F-39 TROUBLESHOOTING & REPAIR AUXILIARY TRANSFORMER #1 SECONDARY AND WIRING HARNESS TEST WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual. Return to Master TOC Return to Section TOC If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-800-833-9353 (WELD). TEST DESCRIPTION This test will determine if there are any short circuits or other problems in the load circuits fed by the secondary windings of the auxiliary transformer, which would cause the transformer to overheat or the fuse (F1 - primary side) on the reconnect panel to blow. MATERIALS NEEDED Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Volt/Ohmmeter (Multimeter) 5/16" Nut driver 3/8" Nut driver Auxiliary Transformer #1 Secondary Circuit Wiring Diagram – Figure F.12 This procedure takes approximately 30 minutes to perform. POWER WAVE 450 F-39 F-40 F-40 Return to Master TOC Return to Section TOC TROUBLESHOOTING & REPAIR AUXILIARY TRANSFORMER #1 SECONDARY AND WIRING HARNESS TEST (continued) FIGURE F.11 - PLUG AND RECEPTACLE INSPECTION POINTS 1 6 Return to Master TOC Return to Section TOC 5 4 1. 2. 3. 4. 5. 6. 2 3 TEST PROCEDURE Return to Master TOC Return to Section TOC 1. Remove main input supply power to the machine. 2. With the 3/8" nut driver, remove the 4 screws that hold the handle to the machine. 3. Remove the rubber gasket (cover seal) from the lift bail. 4. With the 5/16" nut driver, remove the sheet metal screws from the case top. 5. With the 5/16" nut driver, remove the screws holding the right and left case sides. Remove the case sides by lifting up and out. 6. Perform the Capacitor Discharge Procedure described earlier in this section of the manual. WIRE FEEDER RECEPTACLES SQUARE WAVE TIG PROTECTION BOARD DISPLAY BOARD PROTECTION BOARD CONTROL BOARD POWER BOARD 7. After you have completed the capacitor discharge procedure for all four switch boards, remove the PC board cover. Use the 5/16" nut driver. 8. Disconnect all plugs and wirefeeder receptacles associated with the auxiliary transformer secondary. This is done to isolate the machine electrically. Inspect all the disconnected plugs and receptacles, looking for shorted pins and wires. See the Auxiliary Transformer #1 Secondary Circuit Wiring Diagram, Figure F.12, for the specific plugs and receptacles to check, which include: • WF2 Receptacle • WF1 Receptacle • Square Wave TIG Protection Board Return to Master TOC Return to Section TOC • Display Board • Power Board WARNING Before continuing with the test procedure, perform the capacitor discharge procedure to avoid electric shock. • Protection Board 9. Check for shorts on the associated PC boards. See the Auxiliary Transformer #1 Secondary Circuit Wiring Diagram, Figure F.12. POWER WAVE 450 F-41 F-41 Return to Master TOC Return to Section TOC TROUBLESHOOTING & REPAIR AUXILIARY TRANSFORMER #1 SECONDARY AND WIRING HARNESS TEST (continued) 10. Check for shorts at plugs J33, J34, J35, J37, and J38 on the protection board. Inspect the board for evidence of arcing. 11. After the test is completed and the problem successfully repaired, reconnect all plugs disconnected for the test. 12. Install the PC board cover. 13. Install the machine case sides and top. Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC Return to Section TOC 14. Install the handle and the lift bail rubber gasket. POWER WAVE 450 POWER WAVE 450 336 *336 J33 334 J33 333 J33 5A C.B. 32A J33 AUXILIARY TRANSFORMER 1 W 2 COMMON U 5 42V N 3 24V R 6 115V 33 Return to Master TOC 6 4 3 1 COMMON A 32D J34 5 Return to Master TOC (P83) WF1 RECEPTACLE Return to Section TOC (P82) WF2 RECEPTACLE COMMON I 32E J34 6 42V 42C J34 24V C 102D K 3 J34 4 115V J 31C 1 J34 TRIG 2 D 106A J34 7 COMMON A 32B COMMON 32C I 42V K 42B 24V C 102B 115V 31B J TRIG 1 D 105A SQUARE WAVE TIG PROTECTION BOARD Return to Master TOC Return to Section TOC PROTECTION BOARD J34 12 J34 13 J34 10 J34 11 J34 8 J34 14 24V J92 6 296 J38 3 TRIG 1 J92 3 293 J38 2 TRIG 1 J12 4 374 DISPLAY BOARD TRIG 2 2 372 J37 2 J37 4 COMMON J13 J12 371 J37 COMMON J13 4 373 2 1 J37 3 POWER BOARD Return to Master TOC Return to Section TOC 3 351 J35 1 J43 COMMON J43 42V 1 356 J35 6 Return to Section TOC F-42 F-42 TROUBLESHOOTING & REPAIR FIGURE F.12 AUXILIARY TRANSFORMER #1 SECONDARY CIRCUIT WIRING DIAGRAM Return to Master TOC Return to Section TOC F-43 TROUBLESHOOTING & REPAIR INPUT POWER AND WIRING HARNESS TEST WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual. Return to Master TOC Return to Section TOC If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-800-833-9353 (WELD). TEST DESCRIPTION This test will determine if there are any short circuits or other problems on the input power circuit that would cause the input fuses to repeatedly blow. MATERIALS NEEDED Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Volt/Ohmmeter (Multimeter) 5/16" Nut driver 3/8" Nut driver Input and Auxiliary Circuit Wiring Diagram – Figure F.14 This procedure takes approximately 20 minutes to perform. POWER WAVE 450 F-43 F-44 F-44 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC TROUBLESHOOTING & REPAIR INPUT POWER AND WIRING HARNESS TEST FIGURE F.13 - INPUT POWER INSPECTION POINTS 2 3 1 1. POWER SWITCH (S1) 2. MAIN CONTACTOR INPUT LEADS (TOP) 3. PROTECTION BOARD TEST PROCEDURE Return to Master TOC Return to Section TOC 1. Remove main input supply power to the machine. 2. With the 3/8" nut driver, remove the 4 screws that hold the handle to the machine. 3. Remove the rubber gasket (cover seal) from the lift bail. 4. With the 5/16" nut driver, remove the sheet metal screws from the case top. 5. With the 5/16" nut driver, remove the screws holding the right and left case sides. Remove the case sides by lifting up and out. Return to Master TOC Return to Section TOC 6. Perform the Capacitor Discharge Procedure described earlier in this section of the manual. 7. After you have completed the capacitor discharge procedure for all four switch boards, remove the PC board cover. Use the 5/16" nut driver. 8. Manually check the power switch (S1) for proper operation by turning it back and forth. At the back of the front panel where the switch is mounted, make a visual inspection. Be sure the input and output leads are not shorted together. Make sure the switch contacts are not fused together or shorted to another phase. (Because of the high input voltage involved, you should be able to see physical evidence if any of these problems exist.) Remove the tape covering the switch and check the switch with an ohmmeter. High resistance should be present. WARNING Before continuing with the test procedure, perform the capacitor discharge procedure to avoid electric shock. POWER WAVE 450 F-45 F-45 Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC TROUBLESHOOTING & REPAIR INPUT POWER AND WIRING HARNESS TEST (continued) 9. Check for shorts or fusing at the input (top) leads to the main contactor. 10. Remove plug J30 from the protection board. Check the resistance on the J30 header (the plug mounted on the board) between pin 1 and pin 6. Resistance should be very high. If resistance is low or zero ohms, the protection board is faulty. 11. Check plug J30 and associated wires for shorts or damaged connections. See the Input and Auxiliary Circuit Wiring Diagram, Figure F.14. 12. If any of the tests reveal signs of heavy current flow, check the switch boards and the input rectifier. Refer to the Switch Board Test and the Input Rectifier Resistance Test in this section of the manual. 13. After the test is completed and the problem successfully repaired, reconnect all plugs disconnected for the test. 14. Install the PC board cover. 15. Install the machine case sides and top. Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC 16. Install the handle and the lift bail rubber gasket. POWER WAVE 450 POWER WAVE 450 (T3) W (L3) (324) (T2) V (L2) 24VAC CR1 (T1) (326) MAIN CONTACTOR U (L1) G 1 3 POWER SWITCH SWI (L3A) 2 (L1A) 4 (HIB) (321B) F1 321A FUSE BOT. FAN (220VAC) AC1 POS AC3 NEG 5 2 P5 AUXILIARY TRANF 2 J4 J4 440-460 (H5) JUMPER "A" 380-415 (H4) 220-230 (H3) INPUT RECTIFIER AC2 (H1) 200-208 (H2) TOP FAN Return to Master TOC Return to Master TOC (220VAC) Return to Section TOC Return to Section TOC 2 4 1 H3 220-230V 200-208V H2 H1 H5A 2 4 H3 220-230V H2 200-208V H4 3 380-415V P2 H5 6 440-460V H4A H3A H2A H5 6 H5 440-460V P73 H1A H1 1 H4 3 H4 380-415V H3 H2 H1 321 24VAC W N(24V) U(42V) R(115V) AUX. TRANSF. 1 W N(24V) 4 2 1 3 5 6 2 P70 3 33 334 323 4 P71 R(115V) 6 336 333 U(42V) 5 24VAC 1 Return to Master TOC Return to Section TOC 5A CIRCUIT BREAKER 32A J33 J33 J33 J33 J32 J32 CR1 6 J30 J30 (T3) (HIB) 16 R CR1 R CR2 J32 CR2 11 1 6 4 J30 J32 (T1) (321A) PROTECTION BOARD 1 4 3 6 3 1 Return to Master TOC Return to Section TOC F-46 TROUBLESHOOTING & REPAIR F-46 FIGURE F.14 – INPUT AND AUXILIARY CIRCUIT WIRING DIAGRAM Return to Master TOC Return to Section TOC F-47 TROUBLESHOOTING & REPAIR INPUT RECTIFIER RESISTANCE TEST WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual. Return to Master TOC Return to Section TOC If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-800-833-9353 (WELD). TEST DESCRIPTION This test will determine if any of the internal diodes in the three-phase rectifier are shorted or open. MATERIALS NEEDED Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Analog Volt/Ohmmeter (Multimeter) 5/16" Nut driver 3/8" Nut driver Machine Wiring Diagram in the Electrical Diagrams section of this manual This procedure takes approximately 35 minutes to perform. POWER WAVE 450 F-47 F-48 F-48 Return to Master TOC Return to Section TOC TROUBLESHOOTING & REPAIR INPUT RECTIFIER RESISTANCE TEST (continued) FIGURE F.15 - RECONNECT SWITCH LOCATION 3 1 Return to Master TOC Return to Section TOC 2 Return to Master TOC Return to Section TOC 1. RECONNECT SWITCH 2. INPUT RECTIFIER 3. MAIN CONTACTOR WARNING TEST PROCEDURE 2. With the 3/8" nut driver, remove the 4 screws that hold the handle to the machine. 3. Remove the rubber gasket (cover seal) from the lift bail. 4. With the 5/16" nut driver, remove the sheet metal screws from the case top. Return to Master TOC 5. With the 5/16" nut driver, remove the screws holding the right and left case sides. Remove the case sides by lifting up and out. Return to Section TOC Before continuing with the test procedure, perform the capacitor discharge procedure to avoid electric shock. 1. Remove main input supply power to the machine. 6. Perform the Capacitor Discharge Procedure described earlier in this section of the manual. 7. After you have completed the capacitor discharge procedure for all four switch boards, use the 5/16" nut driver to remove the two 5/16" sheet metal screws holding the reconnect switch assembly. Twist the reconnect switch out to access the lead connections on the back. 8. Use the 3/8" wrench to disconnect the two negative leads from the reconnect switch. By disconnecting the leads at the reconnect switch, you will not have to disturb the silicon applied to the input rectifier. Electrically isolate the leads from all other leads. POWER WAVE 450 F-49 F-49 Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC TROUBLESHOOTING & REPAIR INPUT RECTIFIER RESISTANCE TEST (continued) 9. Check all leads connected to the input rectifier. Check for looseness or shorted wires. 10. Using an analog type meter, perform the resistance test Steps A through L according to the Table F.1. NOTE: If terminals AC1, AC2, and AC3 of the input rectifier are not easily accessible, use terminals T1, T2, and T3, respectively, of main contactor CR1 for the resistance measurements. Similarly, if terminals POS and NEG of the input rectifier are not easily accessible, use terminals POS and NEG of the reconnect switch for the resistance measurements. 11. After the test is completed and the problem successfully repaired, reconnect the negative leads to the reconnect switch. Fasten the reconnect switch assembly back into position on the machine. NOTE: If input rectifier was shorted, other components may be faulty. Perform Field Effect Transistor/ Switch Board Test and check for “leaky” or “shorted” capacitors. 12. Install the machine case sides and top. 13. Install the handle and the lift bail rubber gasket. TABLE F.1 – INPUT RECTIFIER RESISTANCE VALUES Step (See Note) Test for Place + Lead on . . . Place - Lead on . . . A 1K Ohms POS B 1K Ohms C If . . . Then . . . AC1 >1K Ohms <100 Ohms Go to step B. Tested failed. POS AC2 >1K Ohms <100 Ohms Go to step C. Tested failed. 1K Ohms POS AC3 >1K Ohms <100 Ohms Go to step D. Tested failed. D 1K Ohms AC1 NEG >1K Ohms <100 Ohms Go to step E. Tested failed. E 1K Ohms AC2 NEG >1K Ohms <100 Ohms Go to step F. Tested failed. F 1K Ohms AC3 NEG >1K Ohms <100 Ohms Go to step G. Tested failed. G <100 Ohms AC1 POS <100 Ohms >1K Ohms Go to step H. Test failed. H <100 Ohms AC2 POS <100 Ohms >1K Ohms Go to step I. Test failed. I <100 Ohms AC3 POS <100 Ohms >1K Ohms Go to step J. Test failed. J <100 Ohms NEG AC1 <100 Ohms >1K Ohms Go to step K. Test failed. K <100 Ohms NEG AC2 <100 Ohms >1K Ohms Go to step L. Test failed. L <100 Ohms NEG AC3 <100 Ohms >1K Ohms Input Rectifier OK Test failed. POWER WAVE 450 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Section TOC F-50 F-50 NOTES POWER WAVE 450 Return to Master TOC Return to Section TOC F-51 TROUBLESHOOTING & REPAIR OUTPUT SHUNT/WELDING FEEDBACK TEST WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual. Return to Master TOC Return to Section TOC If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-800-833-9353 (WELD). TEST DESCRIPTION The following procedure will determine whether the shunt amplifier board is receiving the correct supply voltage from the control board and providing the correct feedback voltage. MATERIALS NEEDED Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Volt/Ohmmeter (Multimeter) 5/16" Nut driver 3/8" Nut driver Machine Wiring Diagram in the Electrical Diagrams section of this manual Load Bank This procedure takes approximately 40 minutes to perform. POWER WAVE 450 F-51 F-52 F-52 Return to Master TOC Return to Section TOC TROUBLESHOOTING & REPAIR QUICK SHUNT TEST TEST PROCEDURE 1. Remove main input supply power to the Power Wave 450. 2. Disconnect the Output leads from the machine. Return to Master TOC Return to Section TOC 3. If a wire feeder is connected to the Power Wave 450, release the drive roll tension so the unit will not feed wire when the trigger is activated. 4. Turn on the Power Wave 450 and activate the gun trigger and hold for several seconds. Trigger the machine on and off several times in this manner and observe the display. The “I=” reading should be less than five amps when the machine is triggered and NOT welding. 5. If after several trigger cycles the “I=” value is at or above 5 amps the shunt assembly is suspect and should be replaced. 6. If the “I=” value is below 5 amps when the trigger is activated and not welding, the stability of the shunt assembly is at an acceptable level. Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC 7. To further test the shunt assembly, continue with the output shunt/welding feedback test. POWER WAVE 450 F-53 F-53 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC TROUBLESHOOTING & REPAIR OUTPUT SHUNT/WELDING FEEDBACK TEST (continued) FIGURE F.16 - SHUNT AMPLIFIER BOARD LOCATION 1 Return to Master TOC Return to Section TOC 1. SHUNT AMPLIFIER BOARD TEST PROCEDURE 3. Remove the rubber gasket (cover seal) from the lift bail. 4. With the 5/16" nut driver, remove the sheet metal screws from the case top. Return to Master TOC Before continuing with the test procedure, perform the capacitor discharge procedure to avoid electric shock. 2. With the 3/8" nut driver, remove the 4 screws that hold the handle to the machine. 5. With the 5/16" nut driver, remove the screws holding the right and left case sides. Remove the case sides by lifting up and out. Return to Section TOC WARNING 1. Remove main input supply power to the machine. 6. Perform the Capacitor Discharge Procedure described earlier in this section of the manual. 7. After you have completed the capacitor discharge procedure for all four switch boards, locate plug J50 at the shunt amplifier board. Locate the plug and insert your voltmeter positive (+) probe into pin 3 and negative probe (-) into pin 1. Right-angle probes are recommended. 8. Turn supply power to the machine ON. POWER WAVE 450 F-54 F-54 Return to Master TOC Return to Section TOC TROUBLESHOOTING & REPAIR OUTPUT SHUNT/WELDING FEEDBACK TEST (continued) WARNING ELECTRIC SHOCK can kill. Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC Return to Section TOC Proceed with caution. Be careful not to touch any internal machine components during the remainder of the test procedure. 9. Check for +15 VDC between plug J50 pin 3+ and J50 - pin 1-. 10. Carefully move the probes, placing the negative probe (-) at plug J50 - pin 6 and the positive (+) probe at J50 - pin 1. Check for -15 VDC. 11. If the voltage readings are NOT correct, check the associated wiring to the control board. If the wiring is okay, the control board may be faulty. Replace the control board. Refer to the Printed Circuit Board Removal and Replacement Procedure in this section of the manual. 12. If the supply voltage readings are correct, load the machine to 400 amps. CAUTION Do not run the machine under load for more than 15 sec. with case removed. 13. Use a current probe to check for 5 ma of current through lead #218 (plug J50 - pin 4). This also reads approximately 1 VDC if you use a voltmeter. 14. If the current reading is NOT correct, the shunt amplifier board may be faulty. Replace the shunt amplifier assembly and perform current calibration. 15. If the current reading IS correct, the control board may be faulty. Replace the control board. Refer to the Printed Circuit Board Removal and Replacement procedure in this section of the manual. 16. After the test is completed and the problem successfully repaired, install the machine case sides and top. 17. Install the handle and the lift bail rubber gasket. Return to Master TOC Return to Section TOC F-55 TROUBLESHOOTING & REPAIR PIEZO-ELECTRIC ALARM BUZZER TEST WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual. Return to Master TOC Return to Section TOC If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-800-833-9353 (WELD). DESCRIPTION The following procedure will determine whether the piezo-electric alarm buzzer is functioning properly. MATERIALS NEEDED Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Volt/Ohmmeter (Multimeter) 5/16" Nut driver 3/8" Nut driver Machine Wiring Diagram in the Electrical Diagrams section of this manual This procedure takes approximately 30 minutes to perform. POWER WAVE 450 F-55 F-56 F-56 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC TROUBLESHOOTING & REPAIR PIEZO-ELECTRIC ALARM BUZZER TEST FIGURE F.17 - ALARM BUZZER LOCATION 2 1. LEADS 300, 301 TO PLUG J15 ON DISPLAY BOARD 2. PIEZO-ELECTRIC ALARM BUZZER 1 TEST PROCEDURE Return to Master TOC Return to Section TOC 1. Remove main input supply power to the machine. 2. With the 3/8" nut driver, remove the 4 screws that hold the handle to the machine. 3. Remove the rubber gasket (cover seal) from the lift bail. 4. With the 5/16" nut driver, remove the sheet metal screws from the case top. 5. With the 5/16" nut driver, remove the screws holding the right and left case sides. Remove the case sides by lifting up and out. Return to Master TOC Return to Section TOC 6. Perform the Capacitor Discharge Procedure described earlier in this section of the manual. 7. After you have completed the capacitor discharge procedure for all four switch boards, locate and remove plug J15 from the display board. See Figure F.17 for location. 8. Using lead #300 as positive (+) and lead #301 as negative (-), apply 12 to 15 VDC to the piezo-electric buzzer. 9. If the buzzer does not work, replace it. 10. If the buzzer does work, the display board may be faulty. Replace the display board. Refer to the Display Board Replacement procedure in this section of the manual. 11. After the test is completed and the problem successfully repaired, reconnect plug J15 to the display board. 12. Install the machine case sides and top. 13. Install the handle and the lift bail rubber gasket. WARNING Before continuing with the test procedure, perform the capacitor discharge procedure to avoid electric shock. POWER WAVE 450 Return to Master TOC Return to Section TOC F-57 TROUBLESHOOTING & REPAIR OUTPUT RECTIFIER DIODES TEST WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual. Return to Master TOC Return to Section TOC If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-800-833-9353 (WELD). TEST DESCRIPTION The following procedure will determine whether one of the output rectifier diodes is shorted. If one of the diodes is shorted, the output rectifier assembly must be replaced. MATERIALS NEEDED Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Analog Volt/Ohmmeter (Multimeter) 5/16" Nut driver 3/8" Nut driver Machine Wiring Diagram in the Electrical Diagrams section of this manual This procedure takes approximately 15 minutes to perform. POWER WAVE 450 F-57 F-58 F-58 Return to Master TOC Return to Section TOC TROUBLESHOOTING & REPAIR OUTPUT RECTIFIER DIODES TEST FIGURE F.18 - SNUBBER BOARD, OUTPUT TERMINAL LOCATION Return to Master TOC Return to Section TOC 1 2 1. 2. 3. 4. PC BOARD FRONT/BOTTOM COVER SNUBBER PC BOARD NEGATIVE OUTPUT TERMINAL POSITIVE OUTPUT TERMINAL 3 TEST PROCEDURE Return to Master TOC Return to Section TOC 1. Remove main input supply power to the machine. 2. With the 3/8" nut driver, remove the 4 screws that hold the handle to the machine. 3. Remove the rubber gasket (cover seal) from the lift bail. 4. With the 5/16" nut driver, remove the sheet metal screws from the case top. 5. With the 5/16" nut driver, remove the screws holding the right and left case sides. Remove the case sides by lifting up and out. 6. Perform the Capacitor Discharge Procedure described earlier in this section of the manual. Return to Master TOC Return to Section TOC WARNING Before continuing with the test procedure, perform the capacitor discharge procedure to avoid electric shock. 4 7. After you have completed the capacitor discharge procedure for all four switch boards, disconnect plug J62 from the snubber board. See Figure F.18 for location. 8. Remove any output load that may be connected to the machine. 9. With the volt/ohmmeter, measure the resistance between the positive and negative output terminals. IMPORTANT: The positive (+) probe must be attached to the positive (+) output terminal and the negative probe (-) must be attached to the negative (-) output terminal. 10. If the reading is 40 ohms, the output rectifier diodes are good. If the reading is less than 40 ohms, replace the output rectifier. Refer to the Output Rectifier Replacement Procedure in this section of the manual. 11. After the test is completed and the problem successfully repaired, reconnect plug J62 to the snubber board. 12. Install the machine case sides and top. 13. Install the handle and the lift bail rubber gasket. POWER WAVE 450 Return to Master TOC Return to Section TOC F-59 TROUBLESHOOTING & REPAIR FIELD EFFECT TRANSISTOR/SWITCH BOARD TEST OR IGBT/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. Return to Master TOC Return to Section TOC If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-800-833-9353 (WELD). DESCRIPTION The following procedure will determine if the four switch boards and their related circuitry are functioning properly. This is a resistance test, not a voltage test. The machine does not have to be powered up to perform the test, which is both safer for the technician and less likely to result in accidental damage to the switch boards. Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC MATERIALS NEEDED Analog Volt/Ohmmeter (Multimeter) 5/16" Nut driver 3/8" Nut driver Machine Wiring Diagram in the Electrical Diagrams section of this manual This procedure takes approximately 60 minutes to perform. POWER WAVE 450 F-59 F-60 F-60 Return to Master TOC FIELD EFFECT TRANSISTOR/SWITCH BOARD TEST FIGURE F.19 – F.E.T. SWITCH BOARD LOCATION 1 Return to Master TOC Return to Section TOC Return to Section TOC TROUBLESHOOTING & REPAIR 1. FET OR IGBT SWITCH BOARD ASSEMBLY Return to Master TOC Return to Section TOC TEST PROCEDURE Return to Master TOC Before continuing with the test procedure, perform the following capacitor discharge procedure to avoid electric shock. 2. With the 3/8" nut driver, remove the screws that hold the handle to the machine. 3. Remove the rubber gasket (cover seal) from the lift bail. 4. With the 5/16" nut driver, remove the sheet metal screws from the case top. 5. With the 5/16" nut driver, remove the screws holding the right and left case sides. Remove the case sides by lifting up and out. Return to Section TOC WARNING 1. Remove main input supply power to the machine. 6. Obtain a high resistance and high wattage resistor (25 - 1000 ohms and 25 watts minimum). This resistor is not supplied with the machine. Secure this resistor to a piece of insulating material such as a glastic board. See Figure F.22. NEVER USE A SHORTING STRAP FOR THIS PROCEDURE. POWER WAVE 450 F-61 F-61 Return to Master TOC FIELD EFFECT TRANSISTOR/SWITCH BOARD TEST (continued) FIGURE F.20 - RESISTOR LOCATIONS 5 PAIRS OF RESISTORS CHECK VOLTAGES BETWEEN EACH TERMINAL AND FROM EACH RESISTOR TO CASE GROUND Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC Return to Section TOC TROUBLESHOOTING & REPAIR 7. Locate the two sets of two resistors on the left side of the machine and three sets of two resistors on the right side of the machine. See Figure F.20. Do not touch the resistors or any other internal machine component. Using a DC voltmeter, check for any DC voltage that may be present across the terminals of each resistor and from each resistor to case ground (20 measurements in all). If a voltage is present, be careful not to touch these resistors. 8. Locate terminals #9 and #12 on the switch boards. They can be identified by the “Discharge” labels, which are located on each of the four switch boards. See Figure F.21. WARNING Return to Master TOC Return to Section TOC ELECTRIC SHOCK can kill. Proceed with caution. Be careful not to touch any internal machine components during the discharge procedure. POWER WAVE 450 F-62 F-62 Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC TROUBLESHOOTING & REPAIR FIELD EFFECT TRANSISTOR/SWITCH BOARD TEST (continued) FIGURE F.21 - DISCHARGE LABEL D I S C H A R G E D I S C H A R G E D I S C H A R G E D I S C H A R G E FIGURE F.22 RESISTOR WITH LEADS CONNECTED D I S C H A R G E 9. Using insulated, needle nose type jumper leads and insulated gloves, connect one jumper lead to one end of the resistor obtained in step 6. Connect the other jumper lead to the other end of the resistor. 10. Carefully connect the needle nose end of one of the jumper leads to terminal #9. See Figure F.22. Connect the needle nose end of the other jumper lead to terminal #12. Terminals #9 and #12 are indicated by the "Discharge" label. Leave the resistor connected for 10 seconds. DO NOT TOUCH TERMINALS, RESISTORS, OR ANY INTERNAL MACHINE COMPONENTS DURING THIS PROCEDURE! 11. Check the voltage across terminals #9 and #12 with the DC voltmeter. Terminal #9 has positive polarity and terminal #12 has negative polarity. Voltage should be zero. If any voltage remains, repeat this capacitor discharge procedure. 12. Repeat discharge procedure steps 9, 10, and 11 for each of the other three switch boards. 13. After you have completed the capacitor discharge procedure for all four switch boards, Visually inspect the switch boards. If any of them appear burned or overheated, replace all four switch boards and input filter capacitors C1, C2, C3, and C4. Refer to the FET Module Assembly Removal and Replacement Procedure in this section of the manual. 14. If none of the switch boards shows physical damage, test each switch board according to the procedures given below. If any test shows that one of the switch boards is damaged, replace all four switch boards and input filter capacitors C1, C2, C3, and C4. Refer to the FET Module Assembly Removal and Replacement Procedure in this section of the manual. POWER WAVE 450 F-63 F-63 FIELD EFFECT TRANSISTOR/SWITCH BOARD TEST (continued) FIGURE F.23 - SWITCH BOARD ASSEMBLY CONNECTION DECAL 2W 3W TOP 2R 406 401 3T 2T 12C 9A 12A 4T 1T 405 402 4R 1R 4W 1W 3W 2W 3R 2R 408 403 3B 2B 12D 9B CAP 2 9C CAP 4 Return to Master TOC Return to Section TOC CAP 1 3R CAP 3 Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC Return to Section TOC TROUBLESHOOTING & REPAIR 9D 12B 4B 1B 407 404 4R 1R 4W M16740 1W POWER WAVE 450 4/98 F-64 F-64 Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC TROUBLESHOOTING & REPAIR FIELD EFFECT TRANSISTOR/SWITCH BOARD TEST (continued) Switch Board Test 1: (For Switch Board Marked CAP 1 on the Switch Board Assembly Connection Decal - See Figure F.23.) A. Disconnect all wiring harness leads from switch board 1. Fold the leads up so that they do not interfere with the exposed PC board terminals. B. With the volt/ohmmeter, measure the resistance between terminals according to Table F. 2. See Figure F.23 for the locations of the terminals. If any test fails, replace all four switch boards. Refer to the FET Module Assembly Removal and Replacement procedure in this section of the manual. If none of the tests fails, reconnect the wiring harness leads to switch board 1 and perform switch board test 2. Switch Board Test 2: (For Switch Board Marked CAP 2 on the Switch Board Assembly Connection Decal - See Figure F.23.) Return to Master TOC Return to Section TOC A. Disconnect all wiring harness leads from switch board 2. Fold the leads up so that they do not interfere with the exposed PC board terminals. B. With the volt/ohmmeter, measure the resistance between terminals according to Table F. 3. If any test fails, replace all four switch boards. Refer to the FET Module Assembly Removal and Replacement procedure in this section of the manual. If none of the tests fails, reconnect the wiring harness leads to switch board 2 and perform switch board test 3. Return to Master TOC Return to Section TOC Switch Board Test 3: (For Switch Board Marked CAP 3 on the Switch Board Assembly Connection Decal - See Figure F.23.) A. Disconnect all wiring harness leads from switch board 3. Fold the leads up so that they do not interfere with the exposed PC board terminals. B. With the volt/ohmmeter, measure the resistance between terminals according to Table F. 4. If any test fails, replace all four switch boards. Refer to the FET Module Assembly Removal and Replacement procedure in this section of the manual. If none of the tests fails, reconnect the wiring harness leads to switch board 3 and perform switch board test 4. Switch Board Test 4: (For Switch Board Marked CAP 4 on the Switch Board Assembly Connection Decal - See Figure F.23.) A. Disconnect all wiring harness leads from switch board 4. Fold the leads up so that they do not interfere with the exposed PC board terminals. B. With the volt/ohmmeter, measure the resistance between terminals according to Table F. 5. If any test fails, replace all four switch boards. Refer to the FET Module Assembly Removal and Replacement procedure in this section of the manual. If none of the tests fails, reconnect the wiring harness leads to switch board 4. IGBT Switch Board Test (G3165-1) See Table F.6. A. Disconnect all wiring harness leads from the switch boards. Fold the leads up so that they do not interfere with the exposed PC board terminals. B. With the Volt/Ohmmeter, measure the resistance between terminals according to Table F.6. If any test fails, replace all four switch boards. Refer to the FET Module Assembly Removal and Replacement procedure in this section of the manual. If none of the tests fail, reconnect the wiring harness leads to the switch boards. 15. After the test is completed and the problem successfully repaired, install the machine case sides and top. 16. Install the handle and the lift bail rubber gasket. POWER WAVE 450 F-65 F-65 Return to Master TOC Return to Section TOC TROUBLESHOOTING & REPAIR FIELD EFFECT TRANSISTOR/SWITCH BOARD TEST (continued) TABLE F.2 – SWITCH BOARD 1 RESISTANCE TEST TABLE Apply Positive Test Probe to Terminal Apply Negative Test Probe to Terminal 2T 12A Test Result Conclusion Repair Action Next Procedure OK None Continue Shorted Replace 4 Switch Boards Snubber Resistor Test Less than 100 ohms OK None Continue Greater than 1K ohm Open Replace 4 Switch Boards Snubber Resistor Test Greater than 1K ohm OK None Continue Less than 100 ohms Shorted Replace 4 Switch Boards Snubber Resistor Test Less than 100 ohms OK None Continue Greater than 1K ohm Open Replace 4 Switch Boards Snubber Resistor Test Less than 100 ohms OK None Continue Greater than 1K ohm Open Replace 4 Switch Boards Snubber Resistor Test Greater than 1K ohm OK None Continue Less than 100 ohms Shorted Replace 4 Switch boards Snubber Resistor Test Greater than 1K ohm Return to Master TOC Return to Section TOC Less than 100 ohms 12A 9A Return to Master TOC Return to Section TOC 1T 2T Return to Master TOC Return to Section TOC 9A 2T 1T 9A 9A 2T NOTE: K ohm = ohm reading multiplied by 1000. NOTE: Always make sure that all four Switch Boards are changed at the same time. Never mix an old style (different part number) Switch Board with a new style (new part number). POWER WAVE 450 F-66 F-66 Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC TROUBLESHOOTING & REPAIR FIELD EFFECT TRANSISTOR/SWITCH BOARD TEST (continued) TABLE F.2 – SWITCH BOARD 1 RESISTANCE TEST TABLE (Continued) Apply Positive Test Probe to Terminal Apply Negative Test Probe to Terminal 12A 1T 1T 12A Return to Master TOC Return to Section TOC 401 9A Return to Master TOC Return to Section TOC 402 12A 401 12A 402 9A Test Result Conclusion Repair Action Next Procedure Less than 100 ohms OK None Continue Greater than 1K ohm Open Replace 4 Switch Boards Snubber Resistor Test Greater than 1K ohm OK None Continue Less than 100 ohms Shorted Replace 4 Switch Boards Snubber Resistor Test Greater than 1K ohm OK None Continue Less than 100 ohms Shorted Replace 4 Switch Boards Snubber Resistor Test Less than 100 ohms OK None Continue Greater than 1K ohm Open Replace 4 Switch Boards Snubber Resistor Test Less than 100 ohms OK None Continue Greater than 1K ohm Open Replace 4 Switch Boards Snubber Resistor Test Greater than 1K ohm OK None Continue Less than 100 ohms Shorted Replace 4 Switch boards Snubber Resistor Test NOTE: K ohm = ohm reading multiplied by 1000. NOTE: Always make sure that all four Switch Boards are changed at the same time. Never mix an old style (different part number) Switch Board with a new style (new part number). POWER WAVE 450 F-67 F-67 Return to Master TOC Return to Section TOC TROUBLESHOOTING & REPAIR FIELD EFFECT TRANSISTOR/SWITCH BOARD TEST (continued) TABLE F.3 – SWITCH BOARD 2 RESISTANCE TEST TABLE Apply Positive Test Probe to Terminal Apply Negative Test Probe to Terminal 2B 12B Test Result Conclusion Repair Action Next Procedure OK None Continue Shorted Replace 4 Switch Boards Snubber Resistor Test Less than 100 ohms OK None Continue Greater than 1K ohm Open Replace 4 Switch Boards Snubber Resistor Test Greater than 1K ohm OK None Continue Less than 100 ohms Shorted Replace 4 Switch Boards Snubber Resistor Test Less than 100 ohms OK None Continue Greater than 1K ohm Open Replace 4 Switch Boards Snubber Resistor Test Less than 100 ohms OK None Continue Greater than 1K ohm Open Replace 4 Switch Boards Snubber Resistor Test Greater than 1K ohm OK None Continue Less than 100 ohms Shorted Replace 4 Switch boards Snubber Resistor Test Greater than 1K ohm Return to Master TOC Return to Section TOC Less than 100 ohms 12B 9B Return to Master TOC Return to Section TOC 1B 2B Return to Master TOC Return to Section TOC 9B 2B 1B 9B 9B 2B NOTE: K ohm = ohm reading multiplied by 1000. NOTE: Always make sure that all four Switch Boards are changed at the same time. Never mix an old style (different part number) Switch Board with a new style (new part number). POWER WAVE 450 F-68 F-68 Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC TROUBLESHOOTING & REPAIR FIELD EFFECT TRANSISTOR/SWITCH BOARD TEST (continued) TABLE F.3 – SWITCH BOARD 2 RESISTANCE TEST TABLE (Continued) Apply Positive Test Probe to Terminal Apply Negative Test Probe to Terminal 12B 1B 1B 12B Return to Master TOC Return to Section TOC 403 9B Return to Master TOC Return to Section TOC 404 12B 403 12B 404 9B Test Result Conclusion Repair Action Next Procedure Less than 100 ohms OK None Continue Greater than 1K ohm Open Replace 4 Switch Boards Snubber Resistor Test Greater than 1K ohm OK None Continue Less than 100 ohms Shorted Replace 4 Switch Boards Snubber Resistor Test Greater than 1K ohm OK None Continue Less than 100 ohms Shorted Replace 4 Switch Boards Snubber Resistor Test Less than 100 ohms OK None Continue Greater than 1K ohm Open Replace 4 Switch Boards Snubber Resistor Test Less than 100 ohms OK None Continue Greater than 1K ohm Open Replace 4 Switch Boards Snubber Resistor Test Greater than 1K ohm OK None Continue Less than 100 ohms Shorted Replace 4 Switch boards Snubber Resistor Test NOTE: K ohm = ohm reading multiplied by 1000. NOTE: Always make sure that all four Switch Boards are changed at the same time. Never mix an old style (different part number) Switch Board with a new style (new part number). POWER WAVE 450 F-69 F-69 Return to Master TOC Return to Section TOC TROUBLESHOOTING & REPAIR FIELD EFFECT TRANSISTOR/SWITCH BOARD TEST (continued) TABLE F.4 – SWITCH BOARD 3 RESISTANCE TEST TABLE Apply Positive Test Probe to Terminal Apply Negative Test Probe to Terminal 4T 12C Test Result Conclusion Repair Action Next Procedure OK None Continue Shorted Replace 4 Switch Boards Snubber Resistor Test Less than 100 ohms OK None Continue Greater than 1K ohm Open Replace 4 Switch Boards Snubber Resistor Test Greater than 1K ohm OK None Continue Less than 100 ohms Shorted Replace 4 Switch Boards Snubber Resistor Test Less than 100 ohms OK None Continue Greater than 1K ohm Open Replace 4 Switch Boards Snubber Resistor Test Less than 100 ohms OK None Continue Greater than 1K ohm Open Replace 4 Switch Boards Snubber Resistor Test Greater than 1K ohm OK None Continue Less than 100 ohms Shorted Replace 4 Switch boards Snubber Resistor Test Greater than 1K ohm Return to Master TOC Return to Section TOC Less than 100 ohms 12C 9C Return to Master TOC Return to Section TOC 3T 4T Return to Master TOC Return to Section TOC 9C 4T 3T 9C 9C 4T NOTE: K ohm = ohm reading multiplied by 1000. NOTE: Always make sure that all four Switch Boards are changed at the same time. Never mix an old style (different part number) Switch Board with a new style (new part number). POWER WAVE 450 F-70 F-70 Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC TROUBLESHOOTING & REPAIR FIELD EFFECT TRANSISTOR/SWITCH BOARD TEST (continued) TABLE F.4 – SWITCH BOARD 3 RESISTANCE TEST TABLE (Continued) Apply Positive Test Probe to Terminal Apply Negative Test Probe to Terminal 12C 3T 3T 12C Return to Master TOC Return to Section TOC 405 9C Return to Master TOC Return to Section TOC 406 12C 405 12C 406 9C Test Result Conclusion Repair Action Next Procedure Less than 100 ohms OK None Continue Greater than 1K ohm Open Replace 4 Switch Boards Snubber Resistor Test Greater than 1K ohm OK None Continue Less than 100 ohms Shorted Replace 4 Switch Boards Snubber Resistor Test Greater than 1K ohm OK None Continue Less than 100 ohms Shorted Replace 4 Switch Boards Snubber Resistor Test Less than 100 ohms OK None Continue Greater than 1K ohm Open Replace 4 Switch Boards Snubber Resistor Test Less than 100 ohms OK None Continue Greater than 1K ohm Open Replace 4 Switch Boards Snubber Resistor Test Greater than 1K ohm OK None Continue Less than 100 ohms Shorted Replace 4 Switch boards Snubber Resistor Test NOTE: K ohm = ohm reading multiplied by 1000. NOTE: Always make sure that all four Switch Boards are changed at the same time. Never mix an old style (different part number) Switch Board with a new style (new part number). POWER WAVE 450 F-71 F-71 Return to Master TOC Return to Section TOC TROUBLESHOOTING & REPAIR FIELD EFFECT TRANSISTOR/SWITCH BOARD TEST (continued) TABLE F.5 – SWITCH BOARD 4 RESISTANCE TEST TABLE Apply Positive Test Probe to Terminal Apply Negative Test Probe to Terminal 4B 12D Test Result Conclusion Repair Action Next Procedure OK None Continue Shorted Replace 4 Switch Boards Snubber Resistor Test Less than 100 ohms OK None Continue Greater than 1K ohm Open Replace 4 Switch Boards Snubber Resistor Test Greater than 1K ohm OK None Continue Less than 100 ohms Shorted Replace 4 Switch Boards Snubber Resistor Test Less than 100 ohms OK None Continue Greater than 1K ohm Open Replace 4 Switch Boards Snubber Resistor Test Less than 100 ohms OK None Continue Greater than 1K ohm Open Replace 4 Switch Boards Snubber Resistor Test Greater than 1K ohm OK None Continue Less than 100 ohms Shorted Replace 4 Switch boards Snubber Resistor Test Greater than 1K ohm Return to Master TOC Return to Section TOC Less than 100 ohms 12D 9D Return to Master TOC Return to Section TOC 3B 4B Return to Master TOC Return to Section TOC 9D 4B 3B 9D 9D 4B NOTE: K ohm = ohm reading multiplied by 1000. NOTE: Always make sure that all four Switch Boards are changed at the same time. Never mix an old style (different part number) Switch Board with a new style (new part number). POWER WAVE 450 F-72 F-72 Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC TROUBLESHOOTING & REPAIR FIELD EFFECT TRANSISTOR/SWITCH BOARD TEST (continued) TABLE F.5 – SWITCH BOARD 4 RESISTANCE TEST TABLE (Continued) Apply Positive Test Probe to Terminal Apply Negative Test Probe to Terminal 12D 3B 3B 12D Return to Master TOC Return to Section TOC 407 9D Return to Master TOC Return to Section TOC 408 12D 407 12D 408 9D Test Result Conclusion Repair Action Next Procedure Less than 100 ohms OK None Continue Greater than 1K ohm Open Replace 4 Switch Boards Snubber Resistor Test Greater than 1K ohm OK None Continue Less than 100 ohms Shorted Replace 4 Switch Boards Snubber Resistor Test Greater than 1K ohm OK None Continue Less than 100 ohms Shorted Replace 4 Switch Boards Snubber Resistor Test Less than 100 ohms OK None Continue Greater than 1K ohm Open Replace 4 Switch Boards Snubber Resistor Test Less than 100 ohms OK None Continue Greater than 1K ohm Open Replace 4 Switch Boards Snubber Resistor Test Greater than 1K ohm OK None Continue Less than 100 ohms Shorted Replace 4 Switch boards Snubber Resistor Test NOTE: K ohm = ohm reading multiplied by 1000. NOTE: Always make sure that all four Switch Boards are changed at the same time. Never mix an old style (different part number) Switch Board with a new style (new part number). POWER WAVE 450 F-73 F-73 Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC TROUBLESHOOTING & REPAIR IGBT/SWITCH BOARD TEST (G3165-1) TABLE F.6 – NOTE: This test will NOT determine if an individual IGBT device is open. Apply Positive Test Probe to Terminal Apply Negative Test Probe to Terminal 2/4 12 9 2/4 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC 9 1/3 9 2/4 Test Result Repair Action Next Procedure Greater than OK 1k ohms None Continue Less than 1K ohms Shorted Replace Switch Boards Snubber Resistor Test Greater than 1K ohms OK None Continue Less than 1k ohms Shorted Replace Switch Boards Snubber Resistor Test Less than 100 ohms OK None Continue Greater than Open 1k ohms Replace Switch Boards Snubber Resistor Test Greater than OK 1k ohms None Continue Less than 1K ohms Replace Switch Boards Snubber Resistor Test Conclusion Shorted NOTE: K ohm = ohm reading multiplied by 1000. NOTE: Always make sure that all four Switch Boards are changed at the same time. Never mix an old style (different part number) Switch Board with a new style (new part number). POWER WAVE 450 F-74 F-74 Return to Master TOC Return to Section TOC TROUBLESHOOTING & REPAIR IGBT/SWITCH BOARD TEST (Continued) TABLE F.6 (Continued) Apply Positive Test Probe to Terminal Apply Negative Test Probe to Terminal 12 1/3 Return to Master TOC Return to Section TOC 1/3 12 Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC 401/403 405/407 9 402/404 406/408 12 401/403 405/407 12 402/404 406/408 9 Test Result Conclusion Repair Action Next Procedure Less than 100 ohms OK None Continue Greater than 1K ohms Open Replace Switch Boards Snubber Resistor Test Greater than 1K ohms OK None Continue Less than 1k ohms Shorted Replace Switch Boards Snubber Resistor Test Greater than 1K ohms OK None Continue Less than 1k ohms Shorted Replace Switch Boards Snubber Resistor Test Less than 100 ohms OK None Continue Greater than 1K ohms Open Replace Switch Boards Snubber Resistor Test Less than 100 ohms OK None Continue Greater than 1K ohms Open Replace Switch Boards Snubber Resistor Test Greater than 1K ohms OK None Continue Less than 1k ohms Shorted Replace Switch boards Snubber Resistor Test NOTE: K ohm = ohm reading multiplied by 1000. NOTE: Always make sure that all four Switch Boards are changed at the same time. Never mix an old style (different part number) Switch Board with a new style (new part number). POWER WAVE 450 Return to Master TOC Return to Section TOC F-75 TROUBLESHOOTING & REPAIR SNUBBER AND BLEEDER RESISTOR TEST WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual. Return to Master TOC Return to Section TOC If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-800-833-9353 (WELD). TEST DESCRIPTION This test will determine if the eight snubber resistors and two bleeder resistors are of the proper value and their associated leads intact. MATERIALS NEEDED Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Volt/Ohmmeter (Multimeter) 5/16" Nut driver 3/8" Nut driver Snubber and Bleeder Resistor Wiring Diagram – Figure F.25 This procedure takes approximately 30 minutes to perform. POWER WAVE 450 F-75 F-76 F-76 SNUBBER AND BLEEDER RESISTOR TEST FIGURE F.24 - SWITCH BOARD ASSEMBLY CONNECTION DECAL 2W 3W TOP 2R 406 401 3T 2T 12C 9A 12A 4T 1T 405 402 4R 1R 4W 1W 3W 2W 3R 2R 408 403 3B 2B 12D 9B CAP 2 9C CAP 4 Return to Master TOC Return to Section TOC CAP 1 3R CAP 3 Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC Return to Section TOC TROUBLESHOOTING & REPAIR 9D 12B 4B 1B 407 404 4R 1R 4W M16740 1W POWER WAVE 450 4/98 F-77 F-77 Return to Master TOC Return to Section TOC TROUBLESHOOTING & REPAIR SNUBBER AND BLEEDER RESISTOR TEST (continued) TEST PROCEDURE 1. Remove main input supply power to the machine. 2. With the 3/8" nut driver, remove the 4 screws that hold the handle to the machine. 3. Remove the rubber gasket (cover seal) from the lift bail. Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC Return to Section TOC 4. With the 5/16" nut driver, remove the sheet metal screws from the case top. 5. With the 5/16" nut driver, remove the screws holding the right and left case sides. Remove the case sides by lifting up and out. 6. Perform the Capacitor Discharge Procedure described earlier in this section of the manual. WARNING C. With the volt/ohmmeter, check for 25 ohms resistance between lead #402 and #9E. If the measurement reads between 20 and 30 ohms, resistor R2 and leads #402 and #9E are okay. Go to step D. If the measurement does not read between 20 and 30 ohms, check for continuity in leads #402 and #9E. Then test for 25 ohms resistance across R2 directly. If the measurement does not read between 20 and 30 ohms, replace resistor R2. D. With the volt/ohmmeter, check for 7.5 Kohms resistance between lead #12L (12E) and #9L (9E). If the measurement reads between 6.75 and 8.25 K-ohms, resistor R9 and leads #12L(12E) and #9L (9E) are okay. Go to step E. Before continuing with the test procedure, perform the capacitor discharge procedure to avoid electric shock. If the measurement does not read between 6.75 and 30 K-ohms, check for continuity in leads #12L (12E) and #9L(9E). Then test for 7.5 K-ohms resistance across R9 directly. If the measurement does not read between 6.75 and 8.25 K-ohms, replace resistor R9. 7. Perform the following tests on the four switch boards: E. Reconnect quick connect terminals #401, #402, #9, and #12 on switch board 1. Switch Board 1: (Switch Board 1 is Marked CAP 1 on the Switch Board Assembly Connection Decal - See Figure F.24.) Switch Board 2: (Switch Board 2 is Marked CAP 2 on the Switch Board Assembly Connection Decal - See Figure F.24.) A. Remove quick connect terminals #401, #402, #9, and #12 from switch board 1. A. Remove quick connect terminals #403, #404, #9, and #12. B. With the volt/ohmmeter, check for 25 ohms resistance between lead #401 and #12E. B. With the volt/ohmmeter, check for 25 ohms resistance between lead #403 and #12F. If the measurement reads between 20 and 30 ohms, resistor R1 and leads #401 and #12E are okay. Go to step C. If the measurement reads between 20 and 30 ohms, resistor R3 and leads #403 and #12F are okay. Go to step C. If the measurement does not read between 20 and 30 ohms, check for continuity in leads #401 and #12E. Then test for 25 ohms resistance across R1 directly. If the measurement does not read between 20 and 30 ohms, replace resistor R1. If the measurement does not read between 20 and 30 ohms, check for continuity in leads #403 and #12F. Then test for 25 ohms resistance across R3 directly. If the measurement does not read between 20 and 30 ohms, replace resistor R3. POWER WAVE 450 F-78 F-78 Return to Master TOC Return to Section TOC TROUBLESHOOTING & REPAIR SNUBBER AND BLEEDER RESISTOR TEST (continued) C. With the volt/ohmmeter, check for 25 ohms resistance between lead #404 and #9F. If the measurement reads between 20 and 30 ohms, resistor R4 and leads #404 and #9F are okay. Go to step D. Return to Master TOC Return to Section TOC If the measurement does not read between 20 and 30 ohms, check for continuity in leads #404 and #9F. Then test for 25 ohms resistance across R4 directly. If the measurement does not read between 20 and 30 ohms, replace resistor R4. D. Reconnect quick connect terminals #403, #404, #9, and #12 on switch board 2. Switch Board 3: (Switch Board 3 is Marked CAP 1 on the Switch Board Assembly Connection Decal - See Figure F.24.) A. Remove quick connect terminals #405, #406, #9, and #12 from switch board 3. B. With the volt/ohmmeter, check for 25 ohms resistance between lead #405 and #12G. Return to Master TOC Return to Section TOC If the measurement reads between 20 and 30 ohms, resistor R5 and leads #405 and #12G are okay. Go to step C. If the measurement does not read between 20 and 30 ohms, check for continuity in leads #405 and #12G. Then test for 25 ohms resistance across R5 directly. If the measurement does not read between 20 and 30 ohms, replace resistor R5. C. With the volt/ohmmeter, check for 25 ohms resistance between lead #406 and #9G. Return to Master TOC Return to Section TOC If the measurement reads between 20 and 30 ohms, resistor R6 and leads #406 and #9G are okay. Go to step D. If the measurement does not read between 20 and 30 ohms, check for continuity in leads #406 and #9G. Then test for 25 ohms resistance across R5 directly. If the measurement does not read between 20 and 30 ohms, replace resistor R5. D. With the volt/ohmmeter, check for 7.5 Kohms resistance between lead #12G (12M) and #9G (9M). If the measurement reads between 6.75 and 8.25 K-ohms, resistor R10 and leads #12G (12M) and #9G (9M) are okay. Go to step E. If the measurement does not read between 6.75 and 30 K-ohms, check for continuity in leads #12G (12M) and #9G (9M). Then test for 7.5 K-ohms resistance across R10 directly. If the measurement does not read between 6.75 and 8.25 K-ohms, replace resistor R10. E. Reconnect quick connect terminals #405, #406, #9, and #12 on switch board 3. Switch Board 4: (Switch Board 4 is Marked CAP 4 on the Switch Board Assembly Connection Label - See Figure F.24.) A. Remove quick connect terminals #407, #408, #9, and #12 from switch board 4. B. With the volt/ohmmeter, check for 25 ohms resistance between lead #407 and #12H. If the measurement reads between 20 and 30 ohms, resistor R7 and leads #407 and #12H are okay. Go to step C. If the measurement does not read between 20 and 30 ohms, check for continuity in leads #407 and #12H. Then test for 25 ohms resistance across R3 directly. If the measurement does not read between 20 and 30 ohms, replace resistor R7. C. With the volt/ohmmeter, check for 25 ohms resistance between lead #408 and #9H. If the measurement reads between 20 and 30 ohms, resistor R8 and leads #408 and #9H are okay. Go to step D. If the measurement does not read between 20 and 30 ohms, check for continuity in leads #408 and #9H. Then test for 25 ohms resistance across R8 directly. If the measurement does not read between 20 and 30 ohms, replace resistor R8. D. Reconnect quick connect terminals #407, #408, #9, and #12 on switch board 4. 8. Install the machine case sides and top. 9. Install the handle and the lift bail rubber gasket. POWER WAVE 450 Return to Master TOC Return to Section TOC F-79 FIGURE F.25 – SNUBBER AND BLEEDER RESISTOR WIRING DIAGRAM (401) SWITCH BOARD #1 401 12A Return to Master TOC Return to Section TOC 402 9A 403 12B Return to Master TOC (12L) TO RECONNECT SWITCH R9 R2 (9E) (9A) 25Ω ( 25W ) ( 7.5KΩ 25W ) (9L) TO RECONNECT SWITCH (12F) (12B) R3 25Ω ( 25W ) TO RECONNECT SWITCH (404) 404 9B R4 (9F) (9B) 25Ω ( 25W ) TO RECONNECT SWITCH (405) SWITCH BOARD #3 405 12C (12G) (12C) R5 25Ω ( 25W ) (12M) TO RECONNECT SWITCH (406) C3 406 9C R10 R6 (9G) (9C) 25Ω ( 25W ) TO RECONNECT SWITCH (407) SWITCH BOARD #4 Return to Master TOC (12A) 25Ω ( 25W ) (403) SWITCH BOARD #2 C2 Return to Section TOC (12E) R1 (402) C1 Return to Section TOC F-79 TROUBLESHOOTING & REPAIR 407 12D (12H) (12D) R7 25Ω ( 25W ) TO RECONNECT SWITCH (408) C4 408 9D R8 (9H) (9D) 25Ω ( 25W ) TO RECONNECT SWITCH POWER WAVE 450 (9M) ( 7.5KΩ 25W ) Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Section TOC F-80 F-80 NOTES POWER WAVE 450 Return to Master TOC Return to Section TOC F-81 TROUBLESHOOTING & REPAIR RECONNECT SWITCH TEST 1 WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual. Return to Master TOC Return to Section TOC If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-800-833-9353 (WELD). TEST DESCRIPTION This test will determine if there are any short circuits between the leads connected to the reconnect switch. MATERIALS NEEDED Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Volt/Ohmmeter (Multimeter) 5/16" Nut driver 3/8" Nut driver Phillips head screw driver Input and Reconnect Wiring Diagram – Figure F.27 This procedure takes approximately 40 minutes to perform. POWER WAVE 450 F-81 F-82 F-82 Return to Master TOC Return to Section TOC TROUBLESHOOTING & REPAIR RECONNECT SWITCH TEST 1 FIGURE F.26 - RECONNECT SWITCH 1 Return to Master TOC Return to Section TOC 1. RECONNECT PANEL 2. RECONNECT SWITCH 3. LEAD CONNECTIONS 3 2 Return to Master TOC Return to Section TOC TEST PROCEDURE WARNING 1. Remove main input supply power to the machine. 2. With the 3/8" nut driver, remove the 4 screws that hold the handle to the machine. 3. Remove the rubber gasket (cover seal) from the lift bail. 4. With the 5/16" nut driver, remove the sheet metal screws from the case top. Return to Master TOC 5. With the 5/16" nut driver, remove the screws holding the right and left case sides. Remove the case sides by lifting up and out. Return to Section TOC Before continuing with the test procedure, perform the capacitor discharge procedure to avoid electric shock. 6. Perform the Capacitor Discharge Procedure described earlier in this section of the manual. 7. Test the reconnect switch for short circuits according to the voltage for which the machine is wired: For 230 VAC: A. Check that the following leads are connected together at the reconnect switch: #9A, #9B, #9C, #9D, #9K, #9J, and POS. B. Check that the following leads are connected together at the reconnect switch: #12A, #12B, #12C, #12D, #12K, #12J, and NEG. C. With the volt/ohmmeter, check that there is no continuity between the two groups of leads in A and B above. POWER WAVE 450 F-83 F-83 Return to Master TOC Return to Section TOC TROUBLESHOOTING & REPAIR RECONNECT SWITCH TEST 1 (continued) For 380 or 460 VAC: A. Check that the following leads are connected together at the reconnect switch: #9A, #9B, #9K, and POS. B. Check that the following leads are connected together at the reconnect switch: #9C, #9D, #9J, #12A, #12B, and #12J. Return to Master TOC Return to Section TOC C. Check that the following leads are connected together at the reconnect switch: #12C, #12D, #12K and NEG. D. With the volt/ohmmeter, check that there is no continuity between the three groups of leads in A, B, and C above. 8. If any of the leads tested above are shorted, go to step 9. If none of the leads are shorted, the test is complete. Install the machine case sides, top, handle and the lift bail rubber gasket. D. Remove leads #9A, #9B, #9C, #9D, #12A, #12B, #12C, and #12D from the four switch boards. If this eliminates the short, check these leads to make sure they are not exposed, damaged, or shorted. If the leads are okay, perform the Switch Board Test and the Snubber and Bleeder Resistor Test to find the cause of the short. Reconnect leads #9A, #9B, #9C, #9D, #12A, #12B, #12C, and #12D to the four switch boards before conduction these tests. 10. Replace the PC board cover and install the machine case sides and top. 11. Install the handle and the lift bail rubber gasket. 9. Perform the following steps: Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC A. With the 5/16" nut driver, remove the screws that hold the PC board cover. Remove the cover. B. Disconnect plug J31 from the protection board. If this eliminates the short, the protection board may be faulty. Replace the protection board. If the short persists, go to step 9C. C. With the Phillips head screw driver, remove the POS and NEG leads from the reconnect switch. If this eliminates the short, either the input rectifier or the harness (leads POS and NEG) between the input rectifier and the reconnect switch is faulty. Check the harness and if it is not faulty, perform the Input Rectifier Test. Reconnect leads POS and NEG to the input rectifier. If the short persists, go to step 9D. POWER WAVE 450 G U V W (324) CR1 (326) L1 L2 L3 POWER WAVE 450 12B SWITCH BOARD #2 9B SWITCH BOARD #1 12A - NEG + POS C3 12C SWITCH BOARD #3 9C R10 ON OFF OFF ON 380V 230V 460V ON OFF TO WATER COOLER F1 C2 R9 AC1 AC2 AC3 LOAD 1 (H1) (321B) C1 9A T1 T2 T3 (L1A) 4 LINE (L3A) 2 3 BOT. FAN C4 12D SWITCH BOARD #4 9D H5 H4 H3 H2 H1 2 J4 J4 5 H1 Return to Master TOC Return to Master TOC TOP FAN Return to Section TOC Return to Section TOC (329) (326) J31 J31 J32 CONTROL BOARD 4 6 24VAC OPTOTRAIAC J32 J31 10 9J 1 1 T1 11 1 3 6 429 24V 115V 4 CR2 R J23 4 234 2 J39 J30 J30 J30 J30 J33 J33 J33 J33 6 HIB 321A 16 323 321 32A 5A CIRCUIT BREAKER 33 334 333 336 R CR1 12K T3 2 3 5 6 4 1 J31 4 1 2 3 5 6 PROTECTION BD 14 9K 12 12J 24VAC (R) 115 (U)42 115 (N)24 115 (W) 115 (W) (N) 24VAC (U) 42VAC (R) P70115V 24VAC P71 P2 AUX 1 HIA P5 1 H2A 4 H3A 2 H4A 3 H5A 6 AUX 2 6 3 2 4 1 P73 Return to Master TOC Return to Section TOC 2 3 J23 232 J39 3 CR2 CR1 J32 FREQUENCY MEASUREMENT 1 Return to Master TOC Return to Section TOC F-84 TROUBLESHOOTING & REPAIR F-84 FIGURE F.27 – INPUT AND RECONNECT WIRING DIAGRAM Return to Master TOC Return to Section TOC F-85 TROUBLESHOOTING & REPAIR RECONNECT SWITCH TEST 2 WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual. Return to Master TOC Return to Section TOC If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-800-833-9353 (WELD). TEST DESCRIPTION This test will determine if any leads connected to the reconnect switch are damaged. MATERIALS NEEDED Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Volt/Ohmmeter (Multimeter) 5/16" Nut driver 3/8" Nut driver Input and Reconnect Wiring Diagram – Figure F.29 This procedure takes approximately 40 minutes to perform. POWER WAVE 450 F-85 F-86 F-86 Return to Section TOC Return to Master TOC Return to Master TOC RECONNECT SWITCH TEST 2 (continued) FIGURE F.28 - RECONNECT SWITCH 1 1. RECONNECT PANEL 2. RECONNECT SWITCH 3. LEAD CONNECTIONS 3 2 Return to Master TOC Return to Section TOC Return to Section TOC TROUBLESHOOTING & REPAIR TEST PROCEDURE WARNING 1. Remove main input supply power to the machine. 3. Remove the rubber gasket (cover seal) from the lift bail. 4. With the 5/16" nut driver, remove the sheet metal screws from the case top. Return to Master TOC 5. With the 5/16" nut driver, remove the screws holding the right and left case sides. Remove the case sides by lifting up and out. Return to Section TOC Before continuing with the test procedure, perform the capacitor discharge procedure to avoid electric shock. 2. With the 3/8" nut driver, remove the 4 screws that hold the handle to the machine. 7. Visually check that the following leads are not damaged or exposed. With the volt/ohmmeter, also test the leads for continuity: 6. Perform the Capacitor Discharge Procedure described earlier in this section of the manual. POWER WAVE 450 F-87 F-87 Return to Master TOC Return to Section TOC TROUBLESHOOTING & REPAIR RECONNECT SWITCH TEST 2 (continued) • Lead #9A between the reconnect switch and switch board #1. • Lead #9B between the reconnect switch and switch board #2. • Lead #9C between the reconnect switch and switch board #3. • Lead #9D between the reconnect switch and switch board #4. Return to Master TOC Return to Section TOC • Lead #9J between the reconnect switch and plug J31 - pin 10 of the protection board. • Lead #9K between the reconnect switch and plug J31 - pin 14 of the protection board. Return to Master TOC B. Test for continuity between leads #12A, #12B, #12C, #12D, #12K, #12J, and NEG connected together at the reconnect switch. • Lead #12B between the reconnect switch and switch board #2. A. Test for continuity between leads #9A, #9B, #9K, and POS connected together at the reconnect switch. • Lead #12J between the reconnect switch and plug J31 - pin 12 of the protection board. Return to Master TOC A. Test for continuity between leads #9A, #9B, #9C, #9D, #9K, #9J, and POS connected together at the reconnect switch. For 380 - 460 VAC: • Lead #12D between the reconnect switch and switch board #4. Return to Section TOC For 200-230 VAC: • Lead #12A between the reconnect switch and switch board #1. • Lead #12C between the reconnect switch and switch board #3. Return to Section TOC 8. With the volt/ohmmeter, test THAT THERE IS CONTINUITY between the leads in the following groups according to the voltage for which the machine is wired: • Lead #12K between the reconnect switch and plug J31 - pin 1 of the protection board. B. Test for continuity between leads #9C, #9D, #9J, #12A, #12B, and #12J connected together at the reconnect switch. C. Test for continuity between leads #12C, #12D, #12K and NEG connected together at the reconnect switch. 9. If there is continuity within the groups of leads tested, the test is complete. Install the machine case sides, top, handle and the lift bail rubber gasket. • Lead POS between the reconnect switch and the input rectifier. • Lead NEG between the reconnect switch and the input rectifier. POWER WAVE 450 G U V W (324) CR1 (326) L1 L2 L3 POWER WAVE 450 12B SWITCH BOARD #2 9B SWITCH BOARD #1 12A - NEG + POS C3 12C SWITCH BOARD #3 9C R10 ON OFF OFF ON 380V 230V 460V ON OFF TO WATER COOLER F1 C2 R9 AC1 AC2 AC3 LOAD 1 (H1) (321B) C1 9A T1 T2 T3 (L1A) 4 LINE (L3A) 2 3 BOT. FAN C4 12D SWITCH BOARD #4 9D H5 H4 H3 H2 H1 2 J4 J4 5 H1 Return to Master TOC Return to Master TOC TOP FAN Return to Section TOC Return to Section TOC (329) (326) J31 J31 J32 CONTROL BOARD 4 6 24VAC OPTOTRAIAC J32 J31 10 9J 1 1 T1 11 1 3 6 429 24V 115V 4 CR2 R J23 4 234 2 J39 J30 J30 J30 J30 J33 J33 J33 J33 6 HIB 321A 16 323 321 32A 5A CIRCUIT BREAKER 33 334 333 336 R CR1 12K T3 2 3 5 6 4 1 J31 4 1 2 3 5 6 PROTECTION BD 14 9K 12 12J 24VAC (R) 115 (U)42 115 (N)24 115 (W) 115 (W) (N) 24VAC (U) 42VAC (R) P70115V 24VAC P71 P2 AUX 1 HIA P5 1 H2A 4 H3A 2 H4A 3 H5A 6 AUX 2 6 3 2 4 1 P73 Return to Master TOC Return to Section TOC 2 3 J23 232 J39 3 CR2 CR1 J32 FREQUENCY MEASUREMENT 1 Return to Master TOC Return to Section TOC F-88 TROUBLESHOOTING & REPAIR F-88 FIGURE F.29 – INPUT AND RECONNECT WIRING DIAGRAM Return to Master TOC Return to Section TOC F-89 TROUBLESHOOTING & REPAIR STATIC CAPACITOR BALANCE TEST WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual. Return to Master TOC Return to Section TOC If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-800-833-9353 (WELD). TEST DESCRIPTION This test will determine if, with no machine output, the input capacitors are balanced. Before conducting this test, perform the following tests: Switch Board Test - to ensure that none of the switch boards are faulty. Snubber and Bleeder Resistance Test - to ensure that the bleeder resistors are properly connected to the switch boards. Return to Master TOC Return to Section TOC Reconnect Switch Test 1 and Reconnect Switch Test 2 - to ensure that input power is properly connected to the switch boards. MATERIALS NEEDED Volt/Ohmmeter (Multimeter) 5/16" Nut driver 3/8" Nut driver Snubber and Bleeder Resistor Wiring Diagram – Figure F.31 Return to Master TOC Return to Section TOC This procedure takes approximately 30 minutes to perform. POWER WAVE 450 F-89 F-90 F-90 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC TROUBLESHOOTING & REPAIR STATIC CAPACITOR BALANCE TEST (continued) FIGURE F.30 - BLEEDER RESISTORS R9 AND R10 LOCATION 1 Return to Master TOC Return to Section TOC 1. RESISTORS R9 AND R10 (BLEEDER RESISTORS) TEST PROCEDURE WARNING 1. Remove main input supply power to the machine. 2. With the 3/8" nut driver, remove the 4 screws that hold the handle to the machine. 3. Remove the rubber gasket (cover seal) from the lift bail. 4. With the 5/16" nut driver, remove the sheet metal screws from the case top. Return to Master TOC 5. With the 5/16" nut driver, remove the screws holding the right and left case sides. Remove the case sides by lifting up and out. Return to Section TOC Before continuing with the test procedure, perform the capacitor discharge procedure to avoid electric shock. 6. Perform the Capacitor Discharge Procedure described earlier in this section of the manual. 7. After you have completed the capacitor discharge procedure for all four switch boards, use the 5/16" nut driver to remove the two screws holding the PC board cover. Remove the cover. 8. If possible, set the machine up for 380 VAC or above by setting the reconnect switch and Jumper A to 380 VAC. If only 220 VAC is available, perform the test that way. Turn the machine on but have no output. POWER WAVE 450 F-91 F-91 Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC TROUBLESHOOTING & REPAIR STATIC CAPACITOR BALANCE TEST (continued) For 380 VAC Input Voltage or Higher: WARNING ELECTRIC SHOCK can kill. With input supply power ON, there are high voltages inside the machine. Do not reach into the machine or touch any internal part of the machine, including resistors R9 and R10. Use insulated gloves to measure the resistance across these resistors. 9. Turn input supply power to the machine ON. Machine output must be OFF. If the difference is less than 75 VDC, static capacitive balance is okay. If the difference is more than 75 VDC, static capacitive balance is not okay. Perform the Input Rectifier Test. Also visually check input filter capacitors C1, C2, C3, and C4 for any signs of damage; replace the FET or IGBT assembly. For 220 VAC Input Voltage: The two resistance measurements should be the same. If one or both is less than 175 VDC, perform the Main Contactor Test and the Input Rectifier Test. Also visually check input filter capacitors C1, C2, C3, and C4 for any signs of damage; replace the FET or IGBT assembly. 10. Measure and record the DC voltage across bleeder resistors R9 and R10. Compare the voltage recorded to the desired values in Table F.7, depending on the input supply voltage setup. 12. After the test is completed and the problem successfully repaired, install the machine case sides and top. 11. Determine the difference between the two bleeder resistor voltages. 13. Install the handle and the lift bail rubber gasket. TABLE F.7 BLEEDER RESISTOR R9 AND R10 VOLTAGE VALUES VAC INPUT VDC ACROSS BLEEDER RESISTORS R9 AND R10 460 VAC 325 VDC 440 VAC 311 VDC 415 VAC 293 VDC 380 VAC 269 VDC 230 VAC 325 VDC 208 VAC 294 VDC POWER WAVE 450 Return to Master TOC Return to Section TOC F-92 Figure F.31 – SNUBBER AND BLEEDER RESISTOR WIRING DIAGRAM SNUBBER AND BLEEDER RESISTOR WIRING DIAGRAM (401) SWITCH BOARD #1 401 12A Return to Master TOC Return to Section TOC 402 9A 403 12B Return to Master TOC (12L) TO RECONNECT SWITCH R9 R2 (9E) (9A) 25Ω ( 25W ) ( 7.5KΩ 25W ) (9L) TO RECONNECT SWITCH (12F) (12B) R3 25Ω ( 25W ) TO RECONNECT SWITCH (404) 404 9B R4 (9F) (9B) 25Ω ( 25W ) TO RECONNECT SWITCH (405) SWITCH BOARD #3 405 12C (12G) (12C) R5 25Ω ( 25W ) (12M) TO RECONNECT SWITCH (406) C3 406 9C R10 R6 (9G) (9C) 25Ω ( 25W ) TO RECONNECT SWITCH (407) SWITCH BOARD #4 Return to Master TOC (12A) 25Ω ( 25W ) (403) SWITCH BOARD #2 C2 Return to Section TOC (12E) R1 (402) C1 Return to Section TOC F-92 TROUBLESHOOTING & REPAIR 407 12D (12H) (12D) R7 25Ω ( 25W ) TO RECONNECT SWITCH (408) C4 408 9D R8 (9H) (9D) 25Ω ( 25W ) TO RECONNECT SWITCH POWER WAVE 450 (9M) ( 7.5KΩ 25W ) Return to Master TOC Return to Section TOC F-93 TROUBLESHOOTING & REPAIR DYNAMIC CAPACITOR BALANCE TEST WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual. Return to Master TOC Return to Section TOC If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-800-833-9353 (WELD). TEST DESCRIPTION This test will determine if, with no machine output, the control board is receiving the correct frequency signal from the protection board. NOTE: Conduct this test after the Static Capacitor Balance Test has been performed successfully. The reconnect switch and Jumper A must be set for 380 VAC input voltage or higher. The selected input voltage must be the actual voltage applied. Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC MATERIALS NEEDED Volt/Ohmmeter (Multimeter) Oscilloscope 5/16" Nut driver 3/8" Nut driver Input and Reconnect Wiring Diagram – Figure F.33 This procedure takes approximately 45 minutes to perform. POWER WAVE 450 F-93 F-94 F-94 Return to Master TOC Return to Section TOC TROUBLESHOOTING & REPAIR DYNAMIC CAPACITOR BALANCE TEST (continued) FIGURE F.32- CONTROL BOARD PLUG LOCATIONS TOP VIEW PROTECTION BD 1 1 1 16 Return to Master TOC 1 1 1 1 4 4 1 2 J31 4 3 14 J30 Return to Section TOC 1 1 6 J32 J33 6 14 J34 6 4 J35 J36 J37 J38 J39 GROUND PLANE CONTROL BD 2 1 8 1 8 1 1 1 12 14 6 J20 J21 1 1 1 6 4 1 4 J22 J23 J24 10 J25 4 J26 J27 J28 DISPLAY Return to Master TOC Return to Section TOC TEST PROCEDURE 3. Remove the rubber gasket (cover seal) from the lift bail. 4. With the 5/16" nut driver, remove the sheet metal screws from the case top. 6. Perform the Capacitor Discharge Procedure described earlier in this section of the manual. Return to Master TOC Before continuing with the test procedure, perform the capacitor discharge procedure to avoid electric shock. 2. With the 3/8" nut driver, remove the 4 screws that hold the handle to the machine. 5. With the 5/16" nut driver, remove the screws holding the right and left case sides. Remove the case sides by lifting up and out. Return to Section TOC WARNING 1. Remove main input supply power to the machine. 7. After you have completed the capacitor discharge procedure for all four switch boards, use the 5/16" nut driver to remove the two screws that hold the PC board cover. Remove the cover. 8. Connect the machine negative (-) output terminal to earth ground. Connect the oscilloscope case ground to earth ground. 9. Connect the oscilloscope to plug J23 - pin 4 (positive side) and plug J23 - pin 2 (negative side) on the control board. See Figure F.32 for location If these connections are reversed, you will not be able to see the frequency train on the oscilloscope. Set the oscilloscope to be DC coupled with 2 volts/division and 0.2 milliseconds/division. POWER WAVE 450 F-95 F-95 Return to Master TOC Return to Section TOC TROUBLESHOOTING & REPAIR DYNAMIC CAPACITOR BALANCE TEST (continued) WARNING ELECTRIC SHOCK can kill. Return to Master TOC Return to Section TOC With input power ON, there are high voltages inside the machine, including the protection board. Do not reach into the machine or touch any internal part of the machine while power is ON. 10. Turn input power ON. must be OFF. Machine output 11. Measure the frequency between J23 - pin 4 and J23 - pin 2 on the control board. You should see between 3.2 and 5.3 divisions per cycle (950 to 1550 Hz.). If you do see this, the test is completed. If you do not see this, go to the next step. Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC 12. Turn the power switch SW1 to the OFF position, disconnect input power to the machine, and perform the Capacitor Discharge Procedure. 14. Test leads #232 and #234 for continuity. These leads are between the protection board and the control board. Lead #232 is between J39 - pin 3 and J23 - pin 2. Lead #234 is between J39 - pin 2 and J23 - pin 4. These leads must be intact for the frequency signal to be measured, because the transistor side of the optocoupler needs the power from the control board. 15. If all the leads tested in step 14 are okay, make sure that the molex plugs are all plugged in correctly and pushed far enough into their headers. Check the frequency again on the oscilloscope. 16. If the frequency is still incorrect, the protection board may be faulty. Replace the protection board and perform the Dynamic Capacitor Balance Test again. 17. If the frequency is still incorrect, the control board may be faulty. Replace the control board. 18. Install the machine case sides and top. 19. Install the handle and the lift bail rubber gasket. WARNING Before continuing with the test procedure, perform the capacitor discharge procedure to avoid electric shock. 13. After you have completed the capacitor discharge procedure for all four switch boards, with the volt/ohmmeter, test leads 9J, 9K, 12J, and 12K for continuity between the between the reconnect switch and the protection board. POWER WAVE 450 G U V W (324) CR1 (326) L1 L2 L3 POWER WAVE 450 12B SWITCH BOARD #2 9B SWITCH BOARD #1 12A - NEG + POS C3 R10 12C SWITCH BOARD #3 9C ON OFF OFF ON 380V 230V 460V ON OFF TO WATER COOLER F1 C2 R9 AC1 AC2 AC3 (321B) LOAD 1 (H1) 3 C1 9A T1 T2 T3 (L1A) 4 LINE (L3A) 2 BOT. FAN C4 12D SWITCH BOARD #4 9D H5 H4 H3 H2 H1 2 J4 J4 5 H1 Return to Master TOC Return to Master TOC TOP FAN Return to Section TOC Return to Section TOC (329) (326) J31 J31 J32 CONTROL BOARD 4 6 24VAC OPTOTRAIAC J32 J31 10 9J 1 1 T1 11 1 4 3 6 429 24V 115V CR2 R J23 4 234 2 J39 J30 J30 J30 J30 J33 J33 J33 J33 6 HIB 321A 16 323 321 32A 5A CIRCUIT BREAKER 33 334 333 336 R CR1 12K T3 2 3 5 6 4 1 J31 4 1 2 3 5 6 PROTECTION BD 14 9K 12 12J 24VAC (R) 115 (U)42 115 (N)24 115 (W) 115 (W) (N) 24VAC (U) 42VAC (R) P70115V 24VAC P71 P2 AUX 1 HIA P5 1 H2A 4 H3A 2 H4A 3 H5A 6 AUX 2 6 3 2 4 1 P73 Return to Master TOC Return to Section TOC 2 3 J23 232 J39 3 CR2 CR1 J32 FREQUENCY MEASUREMENT 1 Return to Master TOC Return to Section TOC F-96 TROUBLESHOOTING & REPAIR F-96 FIGURE F.33 – INPUT AND RECONNECT WIRING DIAGRAM Return to Master TOC Return to Section TOC F-97 TROUBLESHOOTING & REPAIR INTERNAL AND AUXILIARY SUPPLY VOLTAGE TEST WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual. Return to Master TOC Return to Section TOC If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-800-833-9353 (WELD). TEST DESCRIPTION This test will determine if the proper voltages are present at the protection board, the power board, the control board, and the display board. MATERIALS NEEDED Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Volt/Ohmmeter (Multimeter) 5/16" Nut driver 3/8" Nut driver Internal Auxiliary Supply Wiring Diagram – Figure F.34 This procedure takes approximately 45 minutes to perform. POWER WAVE 450 F-97 F-98 F-98 Return to Master TOC Return to Section TOC TROUBLESHOOTING & REPAIR INTERNAL AND AUXILIARY SUPPLY VOLTAGE TEST (continued) TEST PROCEDURE WARNING 1. Remove main input supply power to the machine. 2. With the 3/8" nut driver, remove the 4 screws that hold the handle to the machine. 3. Remove the rubber gasket (cover seal) from the lift bail. Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC 4. With the 5/16" nut driver, remove the sheet metal screws from the case top. 5. With the 5/16" nut driver, remove the screws holding the right and left case sides. Remove the case sides by lifting up and out. 6. Perform the Capacitor Discharge Procedure described earlier in this section of the manual. Return to Master TOC With input power ON, there are high voltages inside the machine, including plug J30 and the protection board. Do not reach into the machine or touch any internal part of the machine while power is ON. 11. Turn input power ON. must be OFF. Machine output 12. Verify the following voltage measurements: A. Protection Board: WARNING 115 VAC Between J33 - pin 6 and J33 pin 1 (Power Wave 450 only) Before continuing with the test procedure, perform the capacitor discharge procedure to avoid electric shock. 42 VAC Between J33 - pin 3 and J33 pin 1 24 VAC Between J33 - pin 4 and J33 pin 1 7. After you have completed the capacitor discharge procedure for all four switch boards, remove the PC board cover. Use the 5/16" nut driver. 8. Remove the 5 leads ( 3 heavy and 2 small) T1, T2, T3 from main input contactor CR1. This is a safety precaution. It prevents high voltage from being put on the machine during the test. Wrap tape around the lead ends to insulate them and prevent them from touching. 9. Remove plug J30 from the protection board. See Figure F.1 for location of the board and plug J30. Return to Section TOC ELECTRIC SHOCK can kill. 10. Make sure that none of the pins are loose or open on the following molex plugs: J33, J34, J35, J37, J38 (on the protection board), J12, J13, J16 (on the display board), J22 (on the control board), J42, J43, and J44 (on the power board). See the Internal Auxiliary Supply Wiring Diagram, Figure F.34. If any of these voltages are not present on the protection board, and the Auxiliary Transformer 1 Test has been completed successfully, do the following: Turn the power switch SW1 OFF and disconnect input power to the machine. Check the pins of plug J33 to be sure they are not loose or broken. Since Auxiliary Transformer 1 Test determined that voltages are present at plug J33, the fault must be that these signals are not getting to header J33. B. Protection Board: 115 VAC Between J34 - pin 1 and J34 pin 5 (Power Wave 450 only) 42 VAC Between J34 - pin 3 and J34 pin 5 24 VAC Between J34 - pin 4 and J34 pin 5 If any of these voltages are not present on the protection board (and the voltages in part A, above, were present, replace the protection board. POWER WAVE 450 F-99 F-99 Return to Master TOC Return to Section TOC TROUBLESHOOTING & REPAIR INTERNAL AND AUXILIARY SUPPLY VOLTAGE TEST (continued) C. Protection Board: 115 VAC 42 VAC Between J34 - pin 8 and J34 pin 12 (Power Wave 450 only) Between J44 - pin 11 and J44 - pin 12 -5 VDC Between J34 - pin 10 and J34 - pin 12 Between J44 - pin 9 and J44 pin 12 -8 VDC Between J44 - pin 6 and J44 pin 12 Between J34 - pin 11 and J34 - pin 12 Return to Master TOC Return to Master TOC If any of these voltages are not present on the protection board (and the voltages in part A, above, were present, replace the protection board. Return to Master TOC Return to Section TOC Return to Section TOC Return to Section TOC 24 VAC +5 VDC If any of these voltages are NOT present, replace the power board. If these voltages ARE present, check the wiring first. Then replace the display board. F. Control Board: D. Power Board: 42 VAC Between J43 - pin 1 and J43 pin 3 If this voltage is not present (and the voltages in part A, above, were present), disconnect plug J35 from the protection board and check for 42 VAC at header J35 between pin 1 and pin 6. If this voltage is NOT present, replace the protection board. If this voltage IS present, check the wiring between the boards. Then replace the power board. +15 VDC Between J22 - pin 10 and J22 - pin 12 -15 VDC Between J22 - pin 6 and J22pin 12 +5 VDC Between J22 - pin 11 and J22 - pin 12 If any of these voltages are not present (and the voltages in part D, above, were present), disconnect plug J42 from the power board and check the following voltages at header J42 on the power board: +15 VDC Between J42 - pin 10 and J42 - pin 12 E. Display Board: +5 VDC Between J16 - pin 2 and J16 pin 3 -15 VDC Between J42 - pin 6 and J42 pin 12 +15 VDC Between J16 - pin 10 and J16 - pin 7 +5 VDC Between J42 - pin 11 and J42 - pin 12 +5 VDC Between J16 - pin 1 and J16 pin 7 -5 VDC Between J16 - pin 9 and J16 pin 7 -8 VDC Between J16 - pin 6 and J16 pin 7 If any of these voltages are NOT present, replace the power board. If these voltages ARE present, check the wiring. Then replace the control board. If any of these voltages are not present (and the voltages in part D, above, were present), disconnect plug J44 from the power board and check the following voltages at header J44 on the power board: +5 VDC Between J44 - pin 3 and J44 pin 2 +15 VDC Between J44 - pin 10 and J44 - pin 12 POWER WAVE 450 F-100 F-100 Return to Master TOC Return to Section TOC TROUBLESHOOTING & REPAIR INTERNAL AND AUXILIARY SUPPLY VOLTAGE TEST (continued) 13. With the Volt/ohmmeter, check the following leads for continuity: A. Between the Protection Board and Wire Feeder 2 Receptacle: Lead #32D Between J34 - pin 5 and P82 - pin A Lead #32E Between J34 - pin 6 and P82 - pin I Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC Return to Section TOC Lead #42C Between J34 - pin 3 and P82 - pin K Lead #102D Between J34 - pin 4 and P82 - pin C Lead #31C Between J34 - pin 1 and P82 - pin J C. Between the protection board and the square wave TIG protection board: Lead #296 14. After the test is completed and the problem successfully repaired, disconnect input power to the machine. 15. Connect the five leads to main input contactor CR1 and insert plug J30 into the protection board. 16. Install the machine case sides and top. 17. Install the handle and the lift bail rubber gasket. Lead #106A Between J34 - pin 7 and P82 - pin D B. Between the Protection Board and Wire Feeder 1 Receptacle: Lead #32B Between J34 - pin 12 and P83 - pin A Lead #32C Between J34 - pin 13 and P83 - pin I Lead #42B Between J34 - pin 10 and P83 - pin K Lead #102B Between J34 - pin 11 and P83 - pin C Lead #31B Between J38 - pin 3 and J92 - pin 6 Between J34 - pin 8 and P83 - pin J Lead #105A Between J34 - pin 14 and P83 - pin D POWER WAVE 450 6 3 5 2 (115V) (24V) (42V) 336 334 333 5A C.B. 32A POWER WAVE 450 INTERNAL AUXILIARY SUPPLY WIRING DIAGRAM AUXILIARY TRANFORMER 1 R N U W 33 6 J33 4 3 1 Return to Master TOC Return to Master TOC P82 WF2 RECEPTACLE Return to Section TOC COMMON 32D COMMON I 42V 42C A 5 32E 6 115V J 24V 102D K 3 C 4 TRIG 2 TRIG 1 CONTROL BOARD POWER DISPLAY BOARD POWER RS232 POWER 12 11 10 6 7 1 10 9 6 2 3 J22 J16 CONTROL BOARD DISPLAY BOARD 225 224 223 226 449 448 447 446 444 443 442 6 J35 1 PROTECTION BOARD SQUARE WAVE TIG PROTECTION BD 356 351 12 11 10 6 12 11 10 9 6 3 2 J42 COMMON +5VDC +15VDC -15VDC COMMON +5VDC +15VDC -5VDC -8VDC +5VDC COMMON OUTPUTS: 42V COMMON J44 1 J43 3 INPUTS: POWER BOARD Return to Master TOC Return to Master TOC P83 WF1 RECEPTACLE Return to Section TOC Return to Section TOC TRIG 1 Return to Section TOC 372 31C 1 P82 TRIG 2 D 106A 2 J37 2 J13 7 J34 3 J37 1 J37 373 4 J13 371 2 J12 COMMON A 12 32B COMMON I 13 32C 42V K 10 42B 24V 102B 115V C 8 31B J 11 P83 TRIG 1 374 296 D 105A 14 J34 4 J37 4 J12 24V J92 6 3 J92 3 293 2 J38 F-101 TROUBLESHOOTING & REPAIR F-101 FIGURE F.34 – INTERNAL AUXILIARY SUPPLY WIRING DIAGRAM Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Section TOC F-102 F-102 NOTES POWER WAVE 450 Return to Master TOC Return to Section TOC F-103 TROUBLESHOOTING & REPAIR MAIN CONTACTOR TEST WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual. Return to Master TOC Return to Section TOC If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-800-833-9353 (WELD). TEST DESCRIPTION This test will determine if main input contactor CR1 and its associated wiring and components are faulty or damaged. MATERIALS NEEDED Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Volt/Ohmmeter (Multimeter) 5/16" Nut driver 3/8" Nut driver Slot head screw driver Input and Reconnect Wiring Diagram – Figure F.36 This procedure takes approximately 45 minutes to perform. POWER WAVE 450 F-103 F-104 F-104 Return to Master TOC MAIN CONTACTOR TEST (continued) L3 L1 L1 L2 T1 T2 T3 L3 CR1 TEST PROCEDURE WARNING 1. Remove main input supply power to the machine. 3. Remove the rubber gasket (cover seal) from the lift bail. 5. With the 5/16" nut driver, remove the screws holding the right and left case sides. Remove the case sides by lifting up and out. Return to Master TOC Before continuing with the test procedure, perform the capacitor discharge procedure to avoid electric shock. 2. With the 3/8" nut driver, remove the 4 screws that hold the handle to the machine. 4. With the 5/16" nut driver, remove the sheet metal screws from the case top. Return to Section TOC A A FIGURE F.35 - MAIN CONTACTOR Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC Return to Section TOC TROUBLESHOOTING & REPAIR 6. Perform the Capacitor Discharge Procedure described earlier in this section of the manual. 7. After you have completed the capacitor discharge procedure for all four switch boards, visually inspect the input terminals L1, L2, and L3 of the main contactor. Make sure they are not shorted together. If they are shorted, go to step 8. If they are not shorted, go to step 9. 8. With the slot head screw driver, remove leads L1A and L3A from the main contactor. POWER WAVE 450 F-105 F-105 Return to Master TOC MAIN CONTACTOR TEST (continued) A. With the power switch SW1 OFF, check to see if leads L1A and L3A are shorted together. If they are shorted, visually inspect the leads. If the leads are okay, then power switch SW1 is faulty and must be replaced. Return to Master TOC Return to Master TOC B. Remove leads L1, L2, and L3 from the main contactor. Check if the terminals of the main contactor are still shorted. If they are, the main contactor is faulty and must be replaced. If the terminals are not shorted, the input lines themselves are shorted. Reconnect leads L1, L2, L3, L1A, and L3A to the main contactor. Return to Master TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC TROUBLESHOOTING & REPAIR If any of these measurements shows continuity, replace the main contactor. If no continuity is shown, go to step 12. 12. Visually check the following leads for damage, then check for continuity as described: Lead #324 Between the main contactor and plug J32 - pin 4 of the protection board Lead #326 Between the main contactor and plug J32 - pin 6 of the protection board Lead #321 Between plug J71 - pin 1 of auxiliary Transformer 1 and plug J32 - pin 1 of the protection board Lead #323 Between plug J71 - pin 4 of auxiliary Transformer 1 and plug J32 - pin 3 of the protection board A. Check if the terminals of the main contactor are still shorted. If they are, the main contactor is faulty and must be replaced. Lead T1 Between the main contactor and the protection board plug J30 - pin 11 B. Reconnect leads T1, T2, and T3 to the main contactor. Remove plug J30 from the protection board. Make sure that leads T1 and T3 of plug J30 between the main contactor and the protection board are not damaged, exposed, or shorted together. Check again for shorts across the contacts of the main contactor. If the terminals are not shorted now, the protection board is faulty. Replace the protection board. Lead T3 Between the main contactor and the protection board plug J30 - pin 16 9. Visually inspect terminals T1, T2, and T3 of the main contactor. Make sure they are not shorted together in any way. If they are not shorted, go to step 11. If they are shorted, go to step 10. 10. Remove leads T1, T2, and T3 from the main contactor. C. Visually inspect leads T1, T2, and T3 between the main contactor and the input rectifier and between the main contactor and the protection board. If these leads are not damaged or exposed, then the input rectifier may be faulty and should be checked. Perform the Input Rectifier Test described in this section of the manual. 11. With the volt/ohmmeter, check for continuity between the following terminals of the main contactor: L1 and T1 L2 and T2 L3 and T3 Put the power switch SW1 in the ON position for the next two continuity tests: Lead H1B Between terminal L3 of the main contactor and plug J30 - pin 6 of the protection board Lead #321A Between terminal L1 of the main contactor and plug J30 - pin 1 of the protection board Put the power switch SW1 in the OFF position. Replace any broken or damaged leads discovered by these tests. 13. Connect any plugs disconnected for the tests. Replace the PC board cover with two sheet metal screws. 14. Install the machine case sides and top. 15. Install the handle and the lift bail rubber gasket. POWER WAVE 450 G U V W (324) CR1 (326) L1 L2 L3 POWER WAVE 450 12B SWITCH BOARD #2 9B SWITCH BOARD #1 12A - NEG + POS BOT. FAN C3 12C SWITCH BOARD #3 9C R10 ON OFF OFF ON 380V 230V 460V ON OFF TO WATER COOLER F1 C2 R9 AC1 AC2 AC3 LOAD 1 (H1) (321B) C1 9A T1 T2 T3 (L1A) 4 LINE (L3A) 2 3 H5 H4 H3 H2 H1 C4 12D 2 J4 J4 5 H1 SWITCH BOARD #4 9D Return to Master TOC Return to Master TOC TOP FAN Return to Section TOC Return to Section TOC (329) (326) J31 J31 J32 CONTROL BOARD 4 6 24VAC OPTOTRAIAC J32 J31 10 9J 1 1 T1 11 1 3 6 429 24V 115V 4 CR2 R J23 4 234 2 J39 J30 J30 J30 J30 J33 J33 J33 J33 6 HIB 321A 16 323 321 32A 5A CIRCUIT BREAKER 33 334 333 336 R CR1 12K T3 2 3 5 6 4 1 J31 4 1 2 3 5 6 PROTECTION BD 14 9K 12 12J 24VAC (R) 115 (U)42 115 (N)24 115 (W) 115 (W) (N) 24VAC (U) 42VAC (R) P70115V 24VAC P71 P2 AUX 1 HIA P5 1 H2A 4 H3A 2 H4A 3 H5A 6 AUX 2 6 3 2 4 1 P73 Return to Master TOC Return to Section TOC 2 3 J23 232 J39 3 CR2 CR1 J32 FREQUENCY MEASUREMENT 1 Return to Master TOC Return to Section TOC F-106 TROUBLESHOOTING & REPAIR F-106 FIGURE F.36 – INPUT AND RECONNECT WIRING DIAGRAM Return to Master TOC Return to Section TOC F-107 TROUBLESHOOTING & REPAIR SERIAL LOOP WIRING HARNESS TEST WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual. Return to Master TOC Return to Section TOC If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-800-833-9353 (WELD). TEST DESCRIPTION This test will determine if there are any short circuits or other problems in the serial loop wiring between the power board, the control board, the display board, wire feeder 1 amphenol (P83) and wire feeder 2 amphenol (P82). MATERIALS NEEDED Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Volt/Ohmmeter (Multimeter) 5/16" Nut driver 3/8" Nut driver Serial Loop Wiring Diagram Figure – F.38 This procedure takes approximately 30 minutes to perform. POWER WAVE 450 F-107 F-108 F-108 Return to Master TOC Return to Section TOC TROUBLESHOOTING & REPAIR SERIAL LOOP WIRING HARNESS TEST (continued) FIGURE F.37 - WIRE FEEDER AMPHENOL LOCATIONS Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC 1 1. WIRE FEEDER CONNECTIONS (ON BACK PANEL) TEST PROCEDURE 3. Remove the rubber gasket (cover seal) from the lift bail. 4. With the 5/16" nut driver, remove the sheet metal screws from the case top. Return to Master TOC Before continuing with the test procedure, perform the capacitor discharge procedure to avoid electric shock. 2. With the 3/8" nut driver, remove the 4 screws that hold the handle to the machine. 5. With the 5/16" nut driver, remove the screws holding the right and left case sides. Remove the case sides by lifting up and out. Return to Section TOC WARNING 1. Remove main input supply power to the machine. 6. Perform the Capacitor Discharge Procedure described earlier in this section of the manual. 7. After you have completed the capacitor discharge procedure for all four switch boards, remove the PC board cover. Use the 5/16" nut driver. 8. Perform the following test for faults on the serial loop circuitry between wire feeder 1 amphenol (P83) and the control board. A. Disconnect the wire feeder from the wire feeder 1 amphenol (P83). POWER WAVE 450 F-109 F-109 Return to Master TOC Return to Section TOC TROUBLESHOOTING & REPAIR SERIAL LOOP WIRING HARNESS TEST (continued) B. Check for loose or broken leads between the following pins: A. Check for loose or broken leads between the following pins: P83 - pin L and J27 - pin 1 on the control board (lead #111A) J22 - pin 5 on the control board and J44 pin 5 on the power board (lead #5R) P83 - pin M and J27 - pin 4 on the control board (lead #112A) J22 - pin 4 on the control board and J44 pin 4 on the power board (lead #5W) C. Make sure that plug J27 is plugged into the control board securely and that none of its pins are loose. B. Make sure that plug J22 is plugged into the control board securely and that none of its pins are loose. Also make sure that plug J44 is securely plugged into the power board and that none of its pins are loose. Return to Master TOC Return to Section TOC D. Reconnect the wire feeder to the wire feeder 1 amphenol (P83). 9. Perform the following test for faults on the serial loop circuitry between wire feeder 2 amphenol (P82) and the control board. A. Disconnect the wire feeder from the wire feeder 2 amphenol (P82). B. Check for loose or broken leads between the following pins: P82 - pin L and J28 - pin 1 on the control board (lead #117A) P82 - pin M and J28 - pin 4 on the control board (lead #118A) Return to Master TOC Return to Section TOC C. Make sure that plug J28 is plugged into the control board securely and that none of its pins are loose. With the DC voltmeter, check for at least 30 VDC between plug J44 - pin 5 and pin 4 on the power board. This is the voltage source for the 40 mA current for the serial loop. If the voltage is low or not present, the power board may be faulty. Replace the power board. 12. After the test is completed and the problem successfully repaired, replace the PC board cover with two sheet metal screws. 13. Install the machine case sides and top. 14. Install the handle and the lift bail rubber gasket. D. Reconnect the wire feeder to the wire feeder 2 amphenol (P82). 10. Perform the following test for faults on the serial loop circuitry between the display board and the control board. A. Check for loose or broken leads between the following pins: J26 - pin 3 on the control board and J14 pin 6 on the display board (lead #263) Return to Master TOC Return to Section TOC J26 - pin 4 on the control board and J14 pin 3 on the display board (lead #264) B. Make sure that plug J26 is plugged into the control board securely and that none of its pins are loose. Also make sure that plug J14 is securely plugged into the display board and that none of its pins are loose. 11. Perform the following test for faults on the serial loop circuitry 40 mA current supply. POWER WAVE 450 1/96 FIGURE F.38 – SERIAL LOOP WIRING DIAGRAM J22 (5R) J44 5 40mA current supply 5 Return to Master TOC Return to Section TOC Serial Loop Master Transmit & Receive Lines TxD DISPLAY BOARD RxD DK+ J26 3 Return to Master TOC Return to Master TOC Return to Section TOC (263) POWER BOARD J14 6 TRN Display Board Port Switch Open: DK Board S.L. Comunication enabled Closed: DK Board S.L. Comunication disabled REC DK- J26 (264) J14 3 4 WF1 14-pin WF1 WF+ J27 1 Return to Section TOC F-110 TROUBLESHOOTING & REPAIR Return to Master TOC Return to Section TOC F-110 (111A) L 8-pin P83 82(+) H TRN WF1 Port Switch Open: WF1 S.L. Comunication enabled Closed: WF1 S.L. Comunication disabled REC WF- J27 4 (112A) M P83 14-pin WF2 OPT+ J28 1 (117A) L 81(-) G WF2 8-pin P82 82(+) H TRN WF2 Port Switch Open: WF2 S.L. Comunication enabled Closed: WF2 S.L. Comunication disabled REC OPT- J28 4 (118A) M P82 81(-) G POWER BOARD J22 4 (5W) 4 J44 40mA current path CONTROL BOARD POWER WAVE 450 Return to Master TOC Return to Section TOC F-111 TROUBLESHOOTING & REPAIR WIRE FEEDER 1 TRIGGER CIRCUIT TEST WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual. Return to Master TOC Return to Section TOC If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-800-833-9353 (WELD). TEST DESCRIPTION This test will determine if there are any faults in the 24 VAC trigger circuit integral to the Power Wave and the wire feeder 1 amphenol (P83). MATERIALS NEEDED Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Volt/Ohmmeter (Multimeter) 5/16" Nut driver 3/8" Nut driver Short piece of jumper wire Trigger Circuit Wiring Diagram – Figure F.40 This procedure takes approximately 30 minutes to perform. POWER WAVE 450 F-111 F-112 F-112 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC TROUBLESHOOTING & REPAIR WIRE FEEDER 1 TRIGGER CIRCUIT TEST (continued) FIGURE F.39 - DISPLAY BOARD PLUG LOCATIONS J17 J16 J15 J14 J13 J12 J11 Return to Master TOC Return to Section TOC TEST PROCEDURE Return to Master TOC Before continuing with the test procedure, perform the capacitor discharge procedure to avoid electric shock. 2. With the 3/8" nut driver, remove the 4 screws that hold the handle to the machine. 3. Remove the rubber gasket (cover seal) from the lift bail. 5. With the 5/16" nut driver, remove the screws holding the right and left case sides. Remove the case sides by lifting up and out. Return to Section TOC WARNING 1. Remove main input supply power to the machine. 4. With the 5/16" nut driver, remove the sheet metal screws from the case top. 6. Perform the Capacitor Discharge Procedure described earlier in this section of the manual. J10 7. After you have completed the capacitor discharge procedure for all four switch boards, remove the PC board cover. Use the 5/16" nut driver. 8. Remove plug J12 from the display board. 9. Place a jumper wire between pins C and D of wire feeder receptacle #1. 10. Remove the 5 leads ( 3 heavy and 2 small) T1, T2, T3 from main input contactor CR1. This is a safety precaution. It prevents high voltage from being put on the machine during the test. Wrap tape around the lead ends to insulate them and prevent them from touching. POWER WAVE 450 F-113 F-113 Return to Master TOC Return to Section TOC TROUBLESHOOTING & REPAIR WIRE FEEDER 1 TRIGGER CIRCUIT TEST (continued) 11. Remove plug J30 from the protection board. See Figure F.1 for location of the board and plug J30. ELECTRIC SHOCK can kill. WARNING Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC ELECTRIC SHOCK can kill. Return to Master TOC With the input power ON, there are high voltages inside the machine, including the protection board. Do not reach into the machine or touch any internal parts. With the input power ON, there are high voltages inside the machine. Do not reach into the machine or touch any internal parts. 17. Turn input power ON. The LCD display will read: ERROR: S.L. NOT INITIALIZED. Disregard this; the test can still be performed. 12. Turn input power ON. 18. Remove the jumper between pins C and D of wire feeder #1 receptacle. 13. With the volt/ohmmeter, check for 24 VAC between plug J12 - pin 2 and pin 4. A. If 24 VAC IS present, go to step 14. NOTE: A voltage of 5 to 10 VDC is normal between these pins without the C to D jumper installed in the wirefeeder receptacle. B. If 24 VAC is NOT present, check for 24 VAC between plug J33 - pin 4 and pin 1. See the Trigger Circuit Wiring Diagram, Figure F.40. C. If 24 VAC IS present between plug J33 pin 4 and pin 1, check the continuity and integrity of leads #371, 374, 102B, and 105A and their associated pin connectors. See the Trigger Circuit Wiring Diagram. If the continuity checks are good, the protection board may be faulty. Replace the protection board. D. If 24 VAC is NOT present between plug J33 pin 4 and pin 1, check Auxiliary Transformer #1, the 5 amp circuit breaker, and the associated wiring. See the Trigger Circuit Wiring Diagram, Figure F.40. Return to Section TOC WARNING 19. With the volt/ohmmeter, measure the voltage drop across the 150 ohm resistor between J26 - pins 1 and 2. With the jumper removed, the reading should be zero volts (NO voltage drop). 20. Replace the jumper between pins C and D of wire feeder #1 receptacle. Measure the voltage drop with the jumper installed. The reading should be about 2 VDC across the resistor. A. If 2 VDC is NOT present, check the continuity and integrity of leads #262 and 261 and their associated pins and connectors. The display board may be faulty -- replace the display board. B. If 2 VDC IS present across the resistor, the control board may be faulty -- replace the control board. 21. Turn input power to the machine OFF and connect the five leads to the main contactor. Connect all molex plugs to the PC boards and replace the cover with two sheet metal screws. Install the machine case sides, top, handle, and lift bail rubber gasket. 14. Turn input power to the machine OFF and perform the Capacitor Discharge Procedure. 15. Remove plug J26 from the control board. Attach a 150 ohm resistor between plug J26 - pin 1 and J26 - pin 2 (the J26 plug, not the header on the control board). 16. Replace plug J12 into the display board. POWER WAVE 450 FEEDER 1 FEEDER 2 POWER WAVE 450 (77) A B C D EXTERNAL AUXILIARY EQUIPMENT P1 P83 (175A) (176A) (177A) (105B) (102C) (106A) (102D) "Amphenol 2" 4 3 2 7 5 2 1 9 3 J92 6 POWER WAVE SQUARE WAVE TIG PROTECTION BD J93 (105A) (102B) "Amphenol 1" INTERNAL 6-pin Amphenols A C B D E F F E D C D C P82 14-pin Amphenols D C D C Remote Control Kit K941-1 R (76) (4) (75) (2) (4) (2) (4) (2) 8-pin Amphenols J38 J38 J34 J34 J34 J34 14 2 3 P70 (334) 11 7 4 AUXILIARY TRANSFORMER 1 Return to Master TOC Return to Master TOC Amphenols Return to Section TOC (293) (296) 4 3 J33 24VAC 5A C.B. (32A) (292) (291) (294) J10 7 J10 6 J10 10 J37 (374) J12 4 4 J37 (371) J12 1 2 J37 (372) J13 2 2 J37 (373) J13 3 4 J33 +10V - +5V TO MICRO PROCESOR DISPLAY BD AC TO DC AC TO DC +5V J14 (261) 1 J14 (262) 2 J14 (265) 5 J14 (266) 4 J26 J26 J26 J26 CONTROL BD 2 1 6 5 Return to Master TOC Return to Master TOC 1 Return to Section TOC Return to Section TOC PROTECTION BD (33) 2 P70 Return to Section TOC F-114 TROUBLESHOOTING & REPAIR F-114 FIGURE F.40 – TRIGGER CIRCUIT WIRING DIAGRAM Return to Master TOC Return to Section TOC F-115 TROUBLESHOOTING & REPAIR WIRE FEEDER 2 TRIGGER CIRCUIT TEST WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual. Return to Master TOC Return to Section TOC If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-800-833-9353 (WELD). TEST DESCRIPTION This test will determine if there are any faults in the 24 VAC trigger circuit integral to the Power Wave and the wire feeder 2 amphenol (P82). MATERIALS NEEDED Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Volt/Ohmmeter (Multimeter) 5/16" Nut driver 3/8" Nut driver Short piece of jumper wire Trigger Circuit Wiring Diagram – Figure F.42. This procedure takes approximately 30 minutes to perform. POWER WAVE 450 F-115 F-116 F-116 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC TROUBLESHOOTING & REPAIR WIRE FEEDER 2 TRIGGER CIRCUIT TEST (continued) FIGURE F.41 - DISPLAY BOARD PLUG LOCATIONS J17 J16 J15 J14 J13 J12 J11 Return to Master TOC Return to Section TOC TEST PROCEDURE Return to Master TOC Before continuing with the test procedure, perform the capacitor discharge procedure to avoid electric shock. 2. With the 3/8" nut driver, remove the 4 screws that hold the handle to the machine. 3. Remove the rubber gasket (cover seal) from the lift bail. 5. With the 5/16" nut driver, remove the screws holding the right and left case sides. Remove the case sides by lifting up and out. Return to Section TOC WARNING 1. Remove main input supply power to the machine. 4. With the 5/16" nut driver, remove the sheet metal screws from the case top. 6. Perform the Capacitor Discharge Procedure described earlier in this section of the manual. J10 7. After you have completed the capacitor discharge procedure for all four switch boards, remove the PC board cover. Use the 5/16" nut driver. 8. Remove plug J13 from the display board. 9. Place a jumper wire between pins C and D of wire feeder receptacle #2. 10. Remove the 5 leads ( 3 heavy and 2 small) T1, T2, T3 from main input contactor CR1. This is a safety precaution. It prevents high voltage from being put on the machine during the test. Wrap tape around the lead ends to insulate them and prevent them from touching. POWER WAVE 450 F-117 F-117 Return to Master TOC Return to Section TOC TROUBLESHOOTING & REPAIR WIRE FEEDER 2 TRIGGER CIRCUIT TEST (continued) 11. Remove plug J30 from the protection board. See Figure F.1 for location of the board and plug J30. ELECTRIC SHOCK can kill. WARNING ELECTRIC SHOCK can kill. Return to Master TOC Return to Section TOC With the input power ON, there are high voltages inside the machine. Do not reach into the machine or touch any internal parts. 12. Turn input power ON. 13. With the volt/ohmmeter, check for 24 VAC between plug J13 - pin 2 and pin 4. A. If 24 VAC IS present, go to step 14. NOTE: A voltage of 5 to 10 VDC is normal between these pins without the C to D jumper installed in the wirefeeder receptacle. Return to Master TOC Return to Master TOC Return to Section TOC B. If 24 VAC is NOT present, check for 24 VAC between plug J33 - pin 4 and pin 1. See the Trigger Circuit Wiring Diagram, Figure F.42. Return to Section TOC WARNING C. If 24 VAC IS present between plug J33 pin 4 and pin 1, check the continuity and integrity of leads #373, 372, 102D, and 106A and their associated pin connectors. See the Trigger Circuit Wiring Diagram. If the continuity checks are good, the protection board may be faulty. Replace the protection board. D. If 24 VAC is NOT present between plug J33 pin 4 and pin 1, check Auxiliary Transformer #1, the 5 amp circuit breaker, and the associated wiring. See the Trigger Circuit Wiring Diagram, Figure F.42. 14. Turn input power to the machine OFF and perform the Capacitor Discharge Procedure. With the input power ON, there are high voltages inside the machine, including the protection board. Do not reach into the machine or touch any internal parts. 17. Turn input power ON. The LCD display will read: ERROR: S.L. NOT INITIALIZED. Disregard this; the test can still be performed. 18. Remove the jumper between pins C and D of wire feeder #2 receptacle. 19. With the volt/ohmmeter, measure the voltage drop across the 150 ohm resistor between J26 - pins 1 and 2. With the jumper removed, the reading should be zero volts (NO voltage drop). 20. Replace the jumper between pins C and D of wire feeder #2 receptacle. Measure the voltage drop with the jumper installed. The reading should be about 2 VDC across the resistor. A. If 2 VDC is NOT present, check the continuity and integrity of leads #265 and 266 and their associated pins and connectors. The display board may be faulty -- replace the display board. B. If 2 VDC IS present across the resistor, the control board may be faulty -- replace the control board. 21. Turn input power to the machine OFF and connect the five leads to the main contactor. Connect all molex plugs to the PC boards and replace the cover with two sheet metal screws. Install the machine case sides, top, handle, and lift bail rubber gasket. 15. Remove plug J26 from the ProtectionControl board. Attach a 150 ohm resistor between plug J26 - pin 5 and J26 - pin 6 (the J26 plug, not the header on the control board). 16. Replace plug J13 into the display board, POWER WAVE 450 FEEDER 1 FEEDER 2 POWER WAVE 450 (77) (76) A B C D EXTERNAL AUXILIARY EQUIPMENT P1 P83 (175A) (176A) (177A) (105B) (102C) (106A) (102D) "Amphenol 2" 4 3 2 7 5 2 1 9 3 J92 6 POWER WAVE SQUARE WAVE TIG PROTECTION BD J93 (105A) (102B) "Amphenol 1" INTERNAL 6-pin Amphenols A C B D E F F E D C D C P82 14-pin Amphenols D C D C Remote Control Kit K941-1 R (4) (75) (2) (4) (2) (4) (2) 8-pin Amphenols J38 J38 J34 J34 J34 J34 14 2 3 P70 (334) 11 7 4 AUXILIARY TRANSFORMER 1 Return to Master TOC Return to Master TOC Amphenols Return to Section TOC (293) (296) 4 3 J33 24VAC 5A C.B. (32A) (292) (291) (294) J10 7 J10 6 J10 10 J37 (374) J12 4 4 J37 (371) J12 1 2 J37 (372) J13 2 2 J37 (373) J13 3 4 J33 +10V - +5V TO MICRO PROCESOR DISPLAY BD AC TO DC AC TO DC +5V J14 (261) 1 J14 (262) 2 J14 (265) 5 J14 (266) 4 J26 J26 J26 J26 CONTROL BD 2 1 6 5 Return to Master TOC Return to Master TOC 1 Return to Section TOC Return to Section TOC PROTECTION BD (33) 2 P70 Return to Section TOC F-118 TROUBLESHOOTING & REPAIR F-118 FIGURE F.42 – TRIGGER CIRCUIT WIRING DIAGRAM Return to Master TOC Return to Section TOC F-119 TROUBLESHOOTING & REPAIR TRIGGER CIRCUIT AND WIRING HARNESS TEST WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual. Return to Master TOC Return to Section TOC If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-800-833-9353 (WELD). TEST DESCRIPTION This test will determine if there are any short circuits or other problems in the trigger circuit wiring or if there are any faulty PC boards, which would cause the 5 amp circuit breaker to trip repeatedly. MATERIALS NEEDED Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Volt/Ohmmeter (Multimeter) 5/16" Nut driver 3/8" Nut driver Short piece of jumper wire Auxiliary Transformer #1 Secondary Circuit Wiring Diagram – Figure F.44. This procedure takes approximately 25 minutes to perform. POWER WAVE 450 F-119 F-120 F-120 Return to Master TOC Return to Section TOC TROUBLESHOOTING & REPAIR TRIGGER CIRCUIT AND WIRING HARNESS TEST (continued) FIGURE F.43 - PROTECTION BOARD PLUG/HEADER LOCATIONS PROTECTION BD 1 1 1 16 J30 J31 Return to Master TOC 2. With the 3/8" nut driver, remove the 4 screws that hold the handle to the machine. Return to Section TOC 3. Remove the rubber gasket (cover seal) from the lift bail. 4. With the 5/16" nut driver, remove the sheet metal screws from the case top. 5. With the 5/16" nut driver, remove the screws holding the right and left case sides. Remove the case sides by lifting up and out. 6. Perform the Capacitor Discharge Procedure described earlier in this section of the manual. Return to Master TOC 1 12 1 6 J32 J33 6 11 J34 14 6 4 4 4 J35 J36 J37 J38 J39 C. With the volt/ohmmeter, check for continuity again between J37 - pin 1 and J37 - pin 4 of header J37. There should be continuity now. Remove the jumper. D. With the volt/ohmmeter, check for continuity between J37 - pin 2 and J37 - pin 3 of header J37. There should be no continuity. E. Connect a jumper between J34 - pin 4 and J34 - pin 7 of header J34 on the protection board. This simulates the closing of the trigger on wire feeder 2. F. With the volt/ohmmeter, check for continuity again between J37 - pin 2 and J37 - pin 3 of header J37. There should be continuity now. Remove the jumper and connect plugs J34, J37, and J38 back into the protection board. If the continuity tests above detect a fault, replace the protection board. WARNING Before continuing with the test procedure, perform the capacitor discharge procedure to avoid electric shock. 7. After you have completed the capacitor discharge procedure for all four switch boards, remove the PC board cover. Use the 5/16" nut driver. 8. Remove plugs J34, J37, and J38 from the protection board. See Figure F.1 for location. Continue with the following checks: NOTE: Do not remove plug J33 from the protection board. Return to Master TOC 1 3 1. Remove main input supply power to the machine. Return to Section TOC 7 1 4 14 TEST PROCEDURE Return to Section TOC 1 4 1 A. With the volt/ohmmeter, check for continuity between J37 - pin 1 and J37 - pin 4 of header J37. There should be no continuity. B. Connect a jumper between J34 - pin 11 and J34 - pin 14 of header J34 of the protection board. This simulates the closing of the trigger on wire feeder 1 or the remote. 9. Remove plug J37 from the protection board and inspect its pins and leads. Make sure that the TRIG 1, TRIG 2, and COMMON pins of plug J37 are not shorted together (pins 1, 2, 3, 4, respectively). Make sure that leads #371, #372, #373, and #374 are not exposed. See the Auxiliary Transformer #1 Secondary Circuit Wiring Diagram, Figure F.44. 10. Connect plug J37 to the Protection board. If you found no problem with plug J37 pins and leads, replace the display board. 11. After the tests are completed and the problem successfully repaired, reconnect all plugs to their respective boards. Replace the PC board cover with the two sheet metal screws. 12. Install the machine case sides and top. 13. Install the handle and the lift bail rubber gasket. POWER WAVE 450 POWER WAVE 450 J33 334 J33 333 J33 336 *336 AUXILIARY TRANSFORMER 1 W 2 COMMON U 5 42V N 3 24V R 6 115V 5A C.B. 33 32A J33 Return to Master TOC Return to Section TOC 6 4 3 1 (P82) WF2 RECEPTACLE (P83) WF1 RECEPTACLE Return to Master TOC Return to Section TOC COMMON A 5 J34 32D COMMON I J34 6 J34 32E 42V K J34 4 42C 24V C 3 102D 115V J 1 J34 31C TRIG 2 D 7 J34 106A COMMON A 32B COMMON I 32C 42V K 42B 24V C 102B 115V J 31B TRIG 1 D 105A SQUARE WAVE TIG PROTECTION BOARD Return to Master TOC Return to Section TOC PROTECTION BOARD J34 12 J34 13 J34 10 J34 11 J34 8 J34 14 24V J92 6 296 J38 3 TRIG 1 J92 3 293 J38 2 TRIG 1 J12 4 374 DISPLAY BOARD TRIG 2 2 372 J37 2 J37 4 COMMON J13 J12 371 J37 COMMON J13 4 373 2 1 J37 3 POWER BOARD Return to Master TOC Return to Section TOC 3 351 J35 1 J43 COMMON J43 42V 1 356 J35 6 F-121 TROUBLESHOOTING & REPAIR F-121 FIGURE F.44 AUXILIARY TRANSFORMER #1 SECONDARY CIRCUIT WIRING DIAGRAM Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Section TOC F-122 F-122 NOTES POWER WAVE 450 Return to Master TOC Return to Section TOC F-123 TROUBLESHOOTING & REPAIR INTERNAL REMOTE CONTROL TEST WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual. Return to Master TOC Return to Section TOC If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-800-833-9353 (WELD). TEST DESCRIPTION This test will determine if there is a fault in the circuitry that reads the control knob commands of the K941-1 Remote Control Kit. MATERIALS NEEDED Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Volt/Ohmmeter (Multimeter) 5/16" Nut driver 3/8" Nut driver Trigger Circuit Wiring Diagram – Figure F.46 This procedure takes approximately 45 minutes to perform. POWER WAVE 450 F-123 F-124 F-124 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC TROUBLESHOOTING & REPAIR INTERNAL REMOTE CONTROL TEST (continued) FIGURE F.45 - DISPLAY BOARD PLUG LOCATIONS Return to Master TOC Return to Section TOC J17 J16 J15 J14 J13 J12 J11 TEST PROCEDURE Return to Master TOC Before continuing with the test procedure, perform the capacitor discharge procedure to avoid electric shock. 2. With the 3/8" nut driver, remove the 4 screws that hold the handle to the machine. 3. Remove the rubber gasket (cover seal) from the lift bail. 5. With the 5/16" nut driver, remove the screws holding the right and left case sides. Remove the case sides by lifting up and out. Return to Section TOC WARNING 1. Remove main input supply power to the machine. 4. With the 5/16" nut driver, remove the sheet metal screws from the case top. 6. Perform the Capacitor Discharge Procedure described earlier in this section of the manual. J10 7. After you have completed the capacitor discharge procedure for all four switch boards, remove the PC board cover. Use the 5/16" nut driver. 8. Remove the 5 leads (3 heavy and 2 small) T1, T2, T3 from main input contactor CR1. This is a safety precaution. It prevents high voltage from being put on the machine during the test. Wrap tape around the lead ends to insulate them and prevent them from touching. 9. Remove plug J30 from the protection board. See Figure F.1 for location of the board and plug J30. POWER WAVE 450 Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC F-125 TROUBLESHOOTING & REPAIR INTERNAL REMOTE CONTROL TEST (continued) WARNING ELECTRIC SHOCK can kill. With input power ON, there are high voltages inside the machine, including the protection board. Do not reach into the machine or touch any internal part. Return to Master TOC Return to Master TOC Return to Section TOC • Check lead #177A between the remote amphenol and the square wave TIG protection board for continuity. • Check lead #294 between the square wave TIG protection board and the display board for continuity. 10. Turn input power ON. • Check plugs J10, J92, and J93 to make sure the pins are seated properly and not opened up or loose. 11. Turn the knob on the Remote Control Kit all the way counterclockwise. • Replace the square wave TIG protection board. 12. With the volt/ohmmeter, check the voltage between plug J10 - pin 6 (positive) and J10 - pin 7 (negative) on the display board. It should be about zero volts. B. No continuity between J10 - pin 6 and P1 - pin B (of the remote amphenol) 13. With the Power Wave set in the SMAW (CC) mode of operation, turn the knob on the Remote Control Kit clockwise. The voltage between plug J10 - pin 6 and J10 - pin 7 should increase smoothly to about 10.25 volts. If this happens but the display shows no change in the preset current value (SET = ), replace the display board. If the voltage between pins 6 and 7 does not increase smoothly, test the associated wiring as follows: A. Return to Section TOC A. No continuity between J10 - pin 10 and P1 - pin A (of the remote amphenol): Turn power switch SW1 to the OFF position and disconnect input power to the machine. B. Perform the Capacitor Discharge Procedure described earlier in this section of the manual. WARNING Before continuing with the test procedure, perform the capacitor discharge procedure to avoid electric shock. • Check lead #176A between the remote amphenol and the square wave TIG protection board for continuity. • Check lead #291 between the square wave TIG protection board and the display board for continuity. • Check plugs J10, J92, and J93 to make sure the pins are seated properly and not opened up or loose. • Replace the square wave TIG protection board. C. No continuity between J10 - pin 7 and P1 - pin C (of the remote amphenol) • Check lead #175A between the remote amphenol and the square wave TIG protection board for continuity. • Check lead #292 between the square wave TIG protection board and the display board for continuity. • Check plugs J10, J92, and J93 to make sure the pins are seated properly and not opened up or loose. • Replace the square wave TIG protection board. C. Remove plug J10 from the display board. Check for continuity between the following pins: 15. Connect all the plugs disconnected for the tests above. J10 - pin 10 and P1 - pin A (of the remote amphenol) 16. Connect plug J30 into the protection board and replace the PC board cover with two sheet metal screws. J10 - pin 6 and P1 - pin B (of the remote amphenol) J10 - pin 7 and P1 - pin C (of the remote amphenol) 14. If you find no continuity between any of these pins, do the following: 17. Connect the five leads to the main contactor. 18. Install the machine case sides and top. 19. Install the handle and the lift bail rubber gasket. POWER WAVE 450 F-125 FEEDER 1 FEEDER 2 POWER WAVE 450 (77) A B C D EXTERNAL AUXILIARY EQUIPMENT P1 P83 (175A) (176A) (177A) (105B) (102C) (106A) (102D) "Amphenol 2" 4 3 2 7 5 2 1 9 3 J92 6 POWER WAVE SQUARE WAVE TIG PROTECTION BD J93 (105A) (102B) "Amphenol 1" INTERNAL 6-pin Amphenols A C B D E F F E D C D C P82 14-pin Amphenols D C D C Remote Control Kit K941-1 R (76) (4) (75) (2) (4) (2) (4) (2) 8-pin Amphenols J38 J38 J34 J34 J34 J34 14 2 3 P70 (334) 11 7 4 AUXILIARY TRANSFORMER 1 Return to Master TOC Return to Master TOC Amphenols Return to Section TOC (293) (296) 4 3 J33 24VAC 5A C.B. 1 (292) (291) (294) J10 7 J10 6 J10 10 J37 (374) J12 4 4 J37 (371) J12 1 2 J37 (372) J13 2 2 J37 (373) J13 3 4 J33 +10V - +5V TO MICRO PROCESOR DISPLAY BD AC TO DC AC TO DC +5V J14 (261) 1 J14 (262) 2 J14 (265) 5 J14 (266) 4 J26 J26 J26 J26 CONTROL BD 2 1 6 5 Return to Master TOC Return to Master TOC (32A) Return to Section TOC Return to Section TOC PROTECTION BD (33) 2 P70 Return to Section TOC F-126 TROUBLESHOOTING & REPAIR F-126 FIGURE F.46 – TRIGGER CIRCUIT WIRING DIAGRAM Return to Master TOC Return to Section TOC F-127 TROUBLESHOOTING & REPAIR K941-1 REMOTE CONTROL KIT TEST WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual. Return to Master TOC Return to Section TOC If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-800-833-9353 (WELD). TEST DESCRIPTION This test will determine if the K941-1 Remote Control Kit is faulty. MATERIALS NEEDED Volt/Ohmmeter (Multimeter) Trigger Circuit Wiring Diagram – Figure F.48 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC This procedure takes approximately 20 minutes to perform. POWER WAVE 450 F-127 F-128 F-128 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC TROUBLESHOOTING & REPAIR K941-1 REMOTE CONTROL KIT TEST (continued) FIGURE F.47 - 6-PIN AMPHENOL LOCATION 1 1. MACHINE FRONT PANEL 2. REMOTE CONTROL AMPHENOL RECEPTACLE (6-PIN) TEST PROCEDURE Return to Master TOC Return to Section TOC 2 1. Remove the Remote Control Kit from the power source. 2. Perform the following tests. If any test fails, the Remote Control Kit is faulty and should be replaced. A. With the volt/ohmmeter, check the continuity between pin F of the 6-pin amphenol and the case of the Remote Control Kit. The reading should be zero ohms. Return to Master TOC Return to Section TOC B. With the volt/ohmmeter, check the continuity between pin F and the other five pins of the 6-pin amphenol. The reading should be open (no continuity). C. Set the Output Terminals switch to the ON position. With the volt/ohmmeter, check the continuity between pins D and E of the amphenol. There SHOULD BE continuity (zero ohms). D. Set the Output Terminals switch to the OFF position. With the volt/ohmmeter, check the continuity between pins D and E of the amphenol. There should be NO continuity. E. With the volt/ohmmeter, check the resistance between pins A and C of the amphenol. There should be 10 Kohm (+/- 10%) resistance between these pins at all times. F. Turn the knob of the Remote Control Kit all the way counterclockwise. With the volt/ohmmeter, check the resistance between pins A and B of the amphenol. There should be 10 Kohm (+/- 10%) resistance between these pins now. Turn the knob clockwise. The resistance between pins A and B should smoothly decrease to zero ohms (+/- 10%). POWER WAVE 450 FEEDER 1 FEEDER 2 POWER WAVE 450 (77) (76) A B C D EXTERNAL AUXILIARY EQUIPMENT P1 P83 (175A) (176A) (177A) (105B) (102C) (106A) (102D) "Amphenol 2" 4 3 2 7 5 2 1 9 3 J92 6 POWER WAVE SQUARE WAVE TIG PROTECTION BD J93 (105A) (102B) "Amphenol 1" INTERNAL 6-pin Amphenols A C B D E F F E D C D C P82 14-pin Amphenols D C D C Remote Control Kit K941-1 R (4) (75) (2) (4) (2) (4) (2) 8-pin Amphenols J38 J38 J34 J34 J34 J34 14 2 3 P70 (334) 11 7 4 AUXILIARY TRANSFORMER 1 Return to Master TOC Return to Master TOC Amphenols Return to Section TOC (293) (296) 4 3 J33 24VAC 5A C.B. 1 (292) (291) (294) J10 7 J10 6 J10 10 J37 (374) J12 4 4 J37 (371) J12 1 2 J37 (372) J13 2 2 J37 (373) J13 3 4 J33 +10V - +5V TO MICRO PROCESOR DISPLAY BD AC TO DC AC TO DC +5V J14 (261) 1 J14 (262) 2 J14 (265) 5 J14 (266) 4 J26 J26 J26 J26 CONTROL BD 2 1 6 5 Return to Master TOC Return to Master TOC (32A) Return to Section TOC Return to Section TOC PROTECTION BD (33) 2 P70 Return to Section TOC F-129 TROUBLESHOOTING & REPAIR F-129 FIGURE F.48 – TRIGGER CIRCUIT WIRING DIAGRAM Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Section TOC F-130 F-130 NOTES POWER WAVE 450 Return to Master TOC Return to Section TOC F-131 TROUBLESHOOTING & REPAIR K941-1 REMOTE CONTROL KIT TRIGGER CIRCUIT TEST WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual. Return to Master TOC Return to Section TOC If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-800-833-9353 (WELD). TEST DESCRIPTION This test will determine if there are any faults in the 24 VAC trigger circuit between the Power Wave and the K941-1 Remote Control Kit. MATERIALS NEEDED Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Volt/Ohmmeter (Multimeter) 5/16" Nut driver 3/8" Nut driver Short piece of jumper wire Trigger Circuit Wiring Diagram – Figure F.50 This procedure takes approximately 30 minutes to perform. POWER WAVE 450 F-131 F-132 F-132 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC TROUBLESHOOTING & REPAIR K941-1 REMOTE CONTROL KIT TRIGGER CIRCUIT TEST (continued) FIGURE F.49 - DISPLAY BOARD PLUG LOCATIONS J17 J16 J15 J14 J13 J12 J11 Return to Master TOC Return to Section TOC TEST PROCEDURE WARNING NOTE: Before troubleshooting the remote control trigger circuit, troubleshoot the remote control kit itself. Refer to the K941-1 Remote Control Kit Test in this section of the manual. If that test is successful, perform the trigger circuit test below. 1. Remove main input supply power to the machine. 2. With the 3/8" nut driver, remove the 4 screws that hold the handle to the machine. 3. Remove the rubber gasket (cover seal) from the lift bail. Return to Master TOC 4. With the 5/16" nut driver, remove the sheet metal screws from the case top. Return to Section TOC J10 5. With the 5/16" nut driver, remove the screws holding the right and left case sides. Remove the case sides by lifting up and out. 6. Perform the Capacitor Discharge Procedure described earlier in this section of the manual. Before continuing with the test procedure, perform the capacitor discharge procedure to avoid electric shock. 7. After you have completed the capacitor discharge procedure for all four switch boards, remove the PC board cover. Use the 5/16" nut driver. 8. Remove plug J12 from the display board. 9. Place a jumper wire between pins D and E of the six-pin amphenol. 10. Remove the 5 leads ( 3 heavy and 2 small) T1, T2, T3 from main input contactor CR1. This is a safety precaution. It prevents high voltage from being put on the machine during the test. Wrap tape around the lead ends to insulate them and prevent them from touching. POWER WAVE 450 Return to Master TOC Return to Section TOC F-133 TROUBLESHOOTING & REPAIR K941-1 REMOTE CONTROL KIT TRIGGER CIRCUIT TEST (continued) 11. Remove plug J30 from the protection board. See Figure F.1 for location of the board and plug J30. WARNING 15. Remove plug J26 from the protection board. Attach a 150 ohm resistor between plug J26 - pin 1 and J26 - pin 2 (the J26 plug, not the header on the control board). 16. Replace plug J12 into the display board, ELECTRIC SHOCK can kill. WARNING With the input power ON, there are high voltages inside the machine. Do not reach into the machine or touch any internal parts. ELECTRIC SHOCK can kill. With the input power ON, there are high voltages inside the machine, including the protection board. Do not reach into the machine or touch any internal parts. Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC 12. Turn input power ON. 13. With the volt/ohmmeter, check for 24 VAC between plug J12 - pin 2 and pin 4. A. If 24 VAC IS present, go to step 14. NOTE: A voltage of 5 to 10 VDC is normal between these pins without the D to E jumper installed in the six-pin amphenol receptacle. 17. Turn input power ON. The LCD display will read: ERROR: S.L. NOT INITIALIZED. Disregard this; the test can still be performed. B. If 24 VAC is NOT present, check for 24 VAC between plug J33 - pin 4 and pin 1. See the Trigger Circuit Wiring Diagram, Figure F.50. 18. Remove the jumper between pins D and E of the six-pin amphenol receptacle. C. If 24 VAC IS present between plug J33 pin 4 and pin 1, check the continuity and integrity of leads #371, 374, 102C, 105B, 296, and 293 and their associated pin connectors. See the Trigger Circuit Wiring Diagram. If the continuity checks are good, check the square wave TIG protection board by checking the continuity through the following pins. See the Trigger Circuit Wiring Diagram, Figure F.50. Plug J92 - pin 6 to plug J93 - pin 5. Normal resistance is 4 ohms. Plug J92 - pin 3 to plug J93 - pin 7. Normal resistance is 4 ohms. Return to Master TOC Return to Section TOC If the square wave TIG protection board is good, then the protection board may be faulty. Replace the protection board. D. If 24 VAC is NOT present between plug J33 pin 4 and pin 1, check Auxiliary Transformer #1, the 5 amp circuit breaker, and the associated wiring. See the Trigger Circuit Wiring Diagram, Figure F.50. 14. Turn input power to the machine OFF and perform the capacitor discharge procedure. 19. With the volt/ohmmeter, measure the voltage drop across the 150 ohm resistor between J26 - pins 1 and 2. With the jumper removed, the reading should be zero volts (NO voltage drop). 20. Replace the jumper between pins D and E of the six-pin amphenol receptacle. Measure the voltage drop with the jumper installed. The reading should be about 2 VDC across the resistor. A. If 2 VDC is NOT present, check the continuity and integrity of leads #262 and 261 and their associated pins and connectors. The display board may be faulty -- replace the display board. B. If 2 VDC IS present across the resistor, the control board may be faulty -- replace the control board. 21. Turn input power to the machine OFF and connect the five leads to the main contactor. Connect all molex plugs to the PC boards and replace the cover with two sheet metal screws. Install the machine case sides, top, handle, and lift bail rubber gasket. POWER WAVE 450 F-133 FEEDER 1 FEEDER 2 POWER WAVE 450 (77) A B C D EXTERNAL AUXILIARY EQUIPMENT P1 P83 (175A) (176A) (177A) (105B) (102C) (106A) (102D) "Amphenol 2" 4 3 2 7 5 2 1 9 3 J92 6 POWER WAVE SQUARE WAVE TIG PROTECTION BD J93 (105A) (102B) "Amphenol 1" INTERNAL 6-pin Amphenols A C B D E F F E D C D C P82 14-pin Amphenols D C D C Remote Control Kit K941-1 R (76) (4) (75) (2) (4) (2) (4) (2) 8-pin Amphenols J38 J38 J34 J34 J34 J34 14 2 3 P70 (334) 11 7 4 AUXILIARY TRANSFORMER 1 Return to Master TOC Return to Master TOC Amphenols Return to Section TOC (293) (296) 4 3 J33 24VAC 5A C.B. (32A) (292) (291) (294) J10 7 J10 6 J10 10 J37 (374) J12 4 4 J37 (371) J12 1 2 J37 (372) J13 2 2 J37 (373) J13 3 4 J33 +10V - +5V TO MICRO PROCESOR DISPLAY BD AC TO DC AC TO DC +5V J14 (261) 1 J14 (262) 2 J14 (265) 5 J14 (266) 4 J26 J26 J26 J26 CONTROL BD 2 1 6 5 Return to Master TOC Return to Master TOC 1 Return to Section TOC Return to Section TOC PROTECTION BD (33) 2 P70 Return to Section TOC F-134 TROUBLESHOOTING & REPAIR F-134 FIGURE F.50 – TRIGGER CIRCUIT WIRING DIAGRAM Return to Master TOC Return to Section TOC F-135 TROUBLESHOOTING & REPAIR LCD DISPLAY TEST WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual. Return to Master TOC Return to Section TOC If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-800-833-9353 (WELD). TEST DESCRIPTION This test will determine if there are any faults in the LCD display on the front panel or in the associated hardware and wiring harness. MATERIALS NEEDED Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Volt/Ohmmeter (Multimeter) 5/16" Nut driver 3/8" Nut driver Internal Auxiliary Supply Wiring Diagram – Figure F.52 This procedure takes approximately 30 minutes to perform. POWER WAVE 450 F-135 F-136 F-136 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC TROUBLESHOOTING & REPAIR LCD DISPLAY TEST (continued) FIGURE F.51 - DISPLAY BOARD PLUG LOCATIONS J17 J16 J15 J14 J13 J12 J11 Return to Master TOC Return to Section TOC TEST PROCEDURE WARNING 1. Remove main input supply power to the machine. Return to Master TOC Before continuing with the test procedure, perform the capacitor discharge procedure to avoid electric shock. 2. With the 3/8" nut driver, remove the 4 screws that hold the handle to the machine. 3. Remove the rubber gasket (cover seal) from the lift bail. 4. With the 5/16" nut driver, remove the sheet metal screws from the case top. 5. With the 5/16" nut driver, remove the screws holding the right and left case sides. Remove the case sides by lifting up and out. Return to Section TOC J10 6. Perform the Capacitor Discharge Procedure described earlier in this section of the manual. 7. After you have completed the capacitor discharge procedure for all four switch boards, remove the PC board cover. Use the 5/16" nut driver. 8. Remove the 5 leads ( 3 heavy and 2 small) T1, T2, T3 from main input contactor CR1. This is a safety precaution. It prevents high voltage from being put on the machine during the test. Wrap tape around the lead ends to insulate them and prevent them from touching. 9. Remove plug J30 from the protection board. See Figure F.1 for location of the board and plug J30. POWER WAVE 450 F-137 F-137 Return to Master TOC Return to Section TOC TROUBLESHOOTING & REPAIR LCD DISPLAY TEST (continued) WARNING ELECTRIC SHOCK can kill. With input power ON, there are high voltages inside the machine. Do not reach into the machine or touch any internal part. 13. Perform the following tests to locate the problem: Auxiliary Transformer 1 Test and Internal and Auxiliary Voltage Supply Test. If these tests show no component failures, go to step 14. 14. Make sure plug J19 is plugged into the display board securely and that none of its pins are loose or broken. If the pins are all okay, replace the LCD display. Return to Master TOC 10. Turn input power ON. Return to Master TOC Return to Section TOC Return to Section TOC 15. If the problem persists after replacing the LCD display, replace the display board. 11. With the volt/ohmmeter, check the following voltages between plug J16 pins at the display board (without removing plug J16 from the display board): +5 VDC Between J16 - pin 2 and J16 pin 3 +15 VDC Between J16 - pin 10 and J16 - pin 7 +5 VDC Between J16 - pin 1 and J16 pin 7 -5 VDC Between J16 - pin 9 and J16 pin 7 -8 VDC Between J16 - pin 6 and J16 pin 7 16. After the problem has be repaired, install the machine case sides and top. Install the handle and the lift bail rubber gasket. 12. Turn power switch SW1 to the OFF position and disconnect input power to the machine. Connect plug J30 into the protection board. Connect the five leads to the main contactor. If the voltages checked in step 11 were correct, go to step 14. Return to Master TOC Return to Section TOC If any of the voltages in step 11 were not correct, go to step 13. POWER WAVE 450 POWER WAVE 450 6 3 5 2 (115V) (24V) (42V) 336 334 333 5A C.B. 32A AUXILIARY TRANFORMER 1 R N U W 33 INTERNAL AUXILIARY SUPPLY WIRING DIAGRAM Return to Master TOC 6 J33 4 3 1 P82 WF2 RECEPTACLE Return to Master TOC Return to Section TOC COMMON I COMMON 32D A 5 32E 6 42V 42C 115V J 24V 102D K 3 C 4 TRIG 2 P83 WF1 RECEPTACLE TRIG 1 CONTROL BOARD POWER DISPLAY BOARD POWER RS232 POWER 12 11 10 6 7 1 10 9 6 2 3 J22 J16 CONTROL BOARD DISPLAY BOARD 225 224 223 226 449 448 447 446 444 443 442 6 J35 1 PROTECTION BOARD 356 351 12 11 10 6 12 11 10 9 6 3 2 J42 COMMON +5VDC +15VDC -15VDC COMMON +5VDC +15VDC -5VDC -8VDC +5VDC COMMON OUTPUTS: 42V COMMON J44 1 J43 3 INPUTS: POWER BOARD Return to Master TOC Return to Master TOC SQUARE WAVE TIG PROTECTION BD Return to Section TOC Return to Section TOC TRIG 1 Return to Section TOC 372 31C 1 P82 TRIG 2 D 106A 2 J37 2 J13 7 J34 3 J37 1 J37 373 4 J13 371 2 J12 COMMON A 12 32B COMMON I 13 32C 42V K 10 42B 24V 102B 115V C 8 31B J 11 P83 TRIG 1 374 296 D 105A 14 J34 4 J37 4 J12 24V J92 6 3 J92 3 293 2 J38 F-138 TROUBLESHOOTING & REPAIR F-138 FIGURE F.52 – INTERNAL AUXILIARY SUPPLY WIRING DIAGRAM Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC F-139 TROUBLESHOOTING & REPAIR CALIBRATION PROCEDURES POWER WAVE PC BOARD REPLACEMENT CALIBRATION PROCEDURES If the display board is replaced, the display sensor calibration and a voltage calibration must be performed for optimum performance. If the calibration is not done the voltage may be accurate only to within 3 volts. If the sensor calibration is not done, the display board may have some problems sensing the correct overlay on power up. WARNING The display is shipped with the water cooler disabled. If an internal water cooler is being used with the Power Wave, you must use the Setup Overlay L9770-0 to enable the water cooler before using the system. If the control board is replaced, the voltage calibration and current calibration must be performed for optimum performance. If the calibration is not done, the voltage may be accurate only to within 3 volts and the current will be accurate only to within 15 amps. POWER WAVE 450 F-139 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Section TOC F-140 F-140 NOTES POWER WAVE 450 Return to Master TOC Return to Section TOC F-141 TROUBLESHOOTING & REPAIR SENSOR CALIBRATION TEST (FOR DISPLAY BOARD) WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual. Return to Master TOC Return to Section TOC If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-800-833-9353 (WELD). TEST DESCRIPTION This procedure recalibrates the eight overlay sensors of the Power Wave. MATERIALS NEEDED Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Power Wave Test and Calibration Overlay – L9660-255 Set-Up Overlay – L9660 This procedure takes approximately 15 minutes to perform. POWER WAVE 450 F-141 F-142 F-142 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC TROUBLESHOOTING & REPAIR SENSOR CALIBRATION TEST (FOR DISPLAY BOARD) (continued) FIGURE F.53 - SENSOR LOCATION BEHIND OVERLAY 1. LEADS 300, 301 TO PLUG J15 ON DISPLAY BOARD 2. PIEZO-ELECTRIC ALARM BUZZER PROCEDURE 1. Turn the machine ON with no overlay in place. The overlay ID number displayed should be 255. Return to Master TOC Return to Section TOC 2. When the display reads SELECT A FUNCTION, place the TEST overlay on the machine. 3. Press key #34 - OVERLAY CALIBRATE. The OVERLAY CALIBRATE light turns on and for a few seconds the display reads: OVERLAY SENSOR CALIBRATION Then the display changes to read: Insert set-up overlay 5. If one of the sensors could not be calibrated, the display reads: SENSOR X FAILED ENTER TO RETRY Return to Master TOC CALIBRATION SUCCESSFUL After a few seconds the display changes to read: INSERT CAL OVRLY PRESS ENTER . . . 7. Press key #133 - ENTER. the OVERLAY CALIBRATE LED turns off, the machine exits the OVERLAY CALIBRATE function and the display reads: SELECT A FUNCTION INSERT REF OVRLY PRESS ENTER . . . 4. Press key #133 - ENTER. The machine will begin to calibrate the eight overlay sensors. Return to Section TOC 6. If the calibration procedure is successful, the display reads: Make sure the overlay is lined up properly and press key #133 - ENTER. This will cause the machine to try to calibrate the sensor again. If a particular sensor continues to fail. Clean sensor or replace display board. 8. Turn the power switch SW1 to the OFF position. To use the machine, place the appropriate overlay in position and turn power switch SW1 to the ON position. NOTE: Turn power switch SW1 to the OFF position and get the overlay that was not recognized by the power wave. Replace the TEST overlay with this overlay and turn the machine ON. The machine should recognize the overlay now. If it does not, the overlay is faulty. POWER WAVE 450 Return to Master TOC Return to Section TOC F-143 TROUBLESHOOTING & REPAIR QUICK VOLTAGE CALIBRATION WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual. Return to Master TOC Return to Section TOC If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-800-833-9353 (WELD). PROCEDURE DESCRIPTION This procedure is a quick way of calibrating the voltage sensing points (leads), provided that the existing display board is capable of displaying the calibration numbers that are stored in the display board. MATERIALS NEEDED Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC A known “good” replacement display board A Test and Calibration overlay L9660-255 This procedure takes approximately 15 minutes to perform. POWER WAVE 450 F-143 F-144 F-144 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC TROUBLESHOOTING & REPAIR QUICK VOLTAGE CALIBRATION (continued) FIGURE F.54 - TEST AND CALIBRATION OVERLAY PROCEDURE 1. Before changing or disturbing the display board, power up the machine with the L9660-255 Test and Calibration overlay in place. See Figure F.54. 2. Press the Voltage Calibration function (32). The machine should display the following: 5. Repeat the process by pressing the Voltage Calibration function again. The next sensing lead may be selected by pressing the down Arrow Key (101). The above procedure must be repeated six times to obtain and record the calibration number for six different voltage sensing points. These points are the following: 3. Press the Enter Key (133) on the lower right side of the overlay. The machine should display the following: + Polarity (+67A) + Polarity (+67B) - Polarity (+21A) - Polarity (+21B) + Polarity - Polarity ADJUST TO 30V CALIBRATION #=XX 6. Install the “new” replacement display board. NOTE: Here “XX” indicates a particular calibration number for a given voltage sensing point. 7. With the L9660-255 overlay installed, apply power to the machine. Press the Voltage Calibration function (32). Enter the recorded calibration numbers for each of the six voltage sensing points. The calibration numbers are entered by selecting the proper sensing point (lead), pressing the Enter Key (133) and obtaining the display that reads: Return to Master TOC Return to Section TOC VOLTAGE WIRE + POLARITY (+67A) WARNING The machine’s output terminals will be electrically “HOT” when the Enter Key is pressed. Return to Master TOC Return to Section TOC 4. Record the number displayed for the +67 wire and press the Enter Key (133) again. ADJUST TO 30V CALIBRATION #=XX The calibration number is changed using the up/down Arrow Keys (100, 101). Press the Enter Key when the desired number is displayed. 8. Repeat the process for all six sensing points (leads). 9. Perform the Sensor Calibration Test. POWER WAVE 450 Return to Master TOC Return to Section TOC F-145 TROUBLESHOOTING & REPAIR FULL VOLTAGE CALIBRATION WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual. Return to Master TOC Return to Section TOC If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-800-833-9353 (WELD). PROCEDURE DESCRIPTION This procedure is necessary if the display board is replaced and the Quick Voltage Calibration is NOT possible. The Full Voltage Calibration is also necessary if the snubber and/or control boards are replaced. Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC MATERIALS NEEDED A Test and Calibration Overlay L9660-255 A 300 amp, 30 volt resistive grid load. (A MIG welding load may be used if a grid load is not available. Choose an argon rich 30 volt spray procedure.) See the topic Full Voltage Calibration Using a Welding Arc in this section of the manual. A calibrated DC voltmeter accurate to 30.0 volts +/- 0.1 volt. A set of jumper leads to access the remote voltage sensing leads in the wire feeder amphenol receptacles. SETUP PROCEDURE 1. Using the jumper leads, connect 21A (H) and 67A (N), located in wire feeder receptacle #1, to the machine’s positive output terminal. 2. Using the jumper leads, connect 21B (H) and 67B (N), located in wire feeder receptacle #2, to the machine’s positive output terminal. 3. Connect the resistive grid load (or wire feeder) to the machine’s output terminals. 4. Connect the DC voltmeter to the machine’s output terminals. Do not connect the voltmeter to the load. This avoids erroneous readings due to cable drop. This procedure takes approximately 45 minutes to perform. POWER WAVE 450 F-145 F-146 F-146 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC TROUBLESHOOTING & REPAIR FULL VOLTAGE CALIBRATION(continued) FIGURE F.55 - TEST AND CALIBRATION OVERLAY PROCEDURE 1. The voltage calibration numbers are stored in the display board. They are programmable from the front panel using the Test and Calibration Overlay. Return to Master TOC Return to Section TOC 2. Change the PC board in question. 3. Install the Test and Calibration Overlay L9660-255 and power up the machine. See Figure F.55. 6a. If using a synergic 7 wire feeder, press enter then adjust to the desired w.f.s Note the gun will be electrically “hot” at this time. 4. Press the Voltage Calibration function (32). The machine should display the following: CAUTION VOLTAGE WIRE + POLARITY (+67A) WHEN LOADING THE MACHINE WITH THE CASE PARTS REMOVED, BE CAREFUL NOT TO OVERHEAT THE MACHINE. 5. Press the Enter Key (133) on the lower right side of the overlay. The machine should display the following: ADJUST TO 30V CALIBRATION #=XX Return to Master TOC NOTE: Here “XX” indicates a particular calibration number for a given voltage sensing point. Return to Section TOC 6. With the machine loaded, monitor the reference voltage only (external voltmeter). It is the only important reading. Adjust the voltage using the Arrow Keys (100 and 101) until the reference voltmeter reads 30.0 volts. Press the Enter Key. 7. Repeat the process by pressing the Voltage Calibration function again. The next voltage sensing point (lead) may be selected by pressing the down Arrow Key (101). The above procedure must be repeated six times to set the six sensing points (leads) to 30.0 volts. The six test points (leads) are the following: + Polarity (+67A) + Polarity (+67B) - Polarity (+21A) - Polarity (+21B) + Polarity - Polarity WARNING The machine’s output terminals will be electrically “HOT” when the Enter Key is pressed. 8. If the display board is replaced or disturbed, perform the Sensor Calibration Test. POWER WAVE 450 Return to Master TOC Return to Section TOC F-147 TROUBLESHOOTING & REPAIR FULL VOLTAGE CALIBRATION USING A WELDING ARC WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual. Return to Master TOC Return to Section TOC If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-800-833-9353 (WELD). PROCEDURE DESCRIPTION This procedure is necessary if the display board is replaced and the Quick Voltage Calibration or the Normal Full Voltage Calibration is NOT possible. MATERIALS NEEDED Return to Master TOC Return to Section TOC A Test and Calibration overlay L9660-255 (the test procedure can be done within this) A Synergic 7 wire feeder. A calibrated DC voltmeter accurate to 0.1 volts at 30.0 volts. The proper welding wire and gas combination to produce a Spray Arc. For example, 0.035 L-50 wire with a 90% Argon and 10% CO2 blend of gas. SETUP PROCEDURE 1. Connect a DC voltmeter to the machine’s negative output terminal and the conductor block of the wire feeder. 2. Connect the Synergic 7 wire feeder to the Wire Feeder 1 amphenol on the back of the Power Wave. Return to Master TOC Return to Section TOC This procedure takes approximately 45 minutes to perform. POWER WAVE 450 F-147 F-148 F-148 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC TROUBLESHOOTING & REPAIR FULL VOLTAGE CALIBRATION(continued) FIGURE F.55a - TEST AND CALIBRATION OVERLAY PROCEDURE 1. The voltage calibration numbers are stored in the display board. They are programmable from the front panel using the Test and Calibration Overlay. Return to Master TOC Return to Section TOC 2. Change the display board in question. 3. Install the Test and Calibration overlay L9660-255 (or do not insert any overlay into the machine) and power up the machine. See Figure F.55a. If the -255 overlay is not available, use Figure F.55a as a guide to see which keys to press. 4. Press the Voltage Calibration function (32). The machine should display the following: VOLTAGE WIRE + POLARITY (+67A) 5. Press the Enter Key (133) on the lower right side of the overlay. The machine should display the following: ADJUST TO 30V CALIBRATION# = XX Return to Master TOC Return to Section TOC NOTE: Here “xx” indicates a particular calibration number for a given voltage sense point. 6. Adjust the wire feed speed on the Synergic 7 to 500 IPM (some wire feed speed to get into the spray range). NOTE: When the Enter Key is pressed it will clear the wire feed speed to 200 IPM. The wire feed speed must be adjusted after pressing the Enter Key but before starting to weld. 7. Pull the trigger on the torch and start to weld. Hold a long stick out. This is not normally a welding technique. The starting will be poor. The welding may be poor. Maintain a long, steady welding arc. While welding, monitor the reference voltage only (external voltmeter). It is the only important reading. Adjust the voltage using the Arrow Keys (100 and 101) until the reference voltmeter reads 30.0 volts. Record the number on the display, “xx”. Press the Enter Key. Release the trigger on the torch. 8. Repeat the process by pressing the Voltage Calibration function (32) again. The next voltage sensing point may be selected by pressing the down Arrow Key (101). Repeat steps 5, 6, and 7 for the following test points. WARNING The machine’s output terminals will be electrically “HOT” when the Enter Key is pressed. POWER WAVE 450 F-149 F-149 Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC TROUBLESHOOTING & REPAIR FULL VOLTAGE CALIBRATION(continued) – POLARITY (+21A) + POLARITY – POLARITY NOTE: Do not attempt to weld for –Polarity (+21A). Set the number to the same as recorded for +Polarity (+67A). Also for +Polarity and –Polarity, move the voltmeter sense lead from the conductor block of the wire feeder to the positive output terminal on the front of the machine. 9. Turn the machine off. Connect the Synergic 7 to the Wire feeder 2 amphenol on the back of the Power Wave machine. 10. Put the voltmeter sense lead back on the wire feeder conductor block and repeat the calibration process steps 5, 6, and 7 for the following test points: +POLARITY (+67B) –POLARITY (+21B) Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC NOTE: Do not attempt to weld for –Polarity (+21B). Set the number to the same as recorded for +Polarity (+67B). POWER WAVE 450 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Section TOC F-150 F-150 NOTES POWER WAVE 450 Return to Master TOC Return to Section TOC F-151 TROUBLESHOOTING & REPAIR CURRENT CALIBRATION WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual. Return to Master TOC Return to Section TOC If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-800-833-9353 (WELD). PROCEDURE DESCRIPTION This procedure is necessary if the control and/or the shunt amplifier boards are replaced. The current control is the most critical function in the Power Wave machine. MATERIALS NEEDED Test and Calibration Overlay L9660-255 A 300 amp, 30 volt resistance grid load A small trimmer screwdriver A calibrated DC ammeter accurate to read 300.0 amps +/- 1.0 amps. A machine output triggering device such as the K941-1 Remote Control Kit. SETUP PROCEDURE Return to Master TOC Return to Section TOC 1. Remove and install the replacement board in question. This procedure takes approximately 45 minutes to perform. FIGURE F.56 – PC BOARD REMOVED BUT STILL CONNECTED Lay Control Board on top of machine. Make sure it is snapped into the ground plane assembly and insulated from the case and other components. Return to Master TOC Return to Section TOC Leads POWER WAVE 450 F-151 F-152 F-152 Return to Master TOC CURRENT CALIBRATION (continued) 2. Locate the 10 turn trimmer potentiometer located on the control board. It is the only trimmer on the board. If the trimmer is not accessible with the control board installed, then the board must be removed and laid on the top of the PC board compartment. Be sure the control board is insulated from the other boards and the case parts. All wiring plugs must be connected to the control board. See Figure F.56. Return to Section TOC Return to Master TOC Return to Master TOC WARNING Return to Section TOC Return to Section TOC TROUBLESHOOTING & REPAIR WHEN THE MACHINE CASE IS REMOVED HIGH VOLTAGE POINTS ARE EXPOSED. CAUTION WHEN LOADING THE MACHINE WITH THE CASE PARTS REMOVED. BE CAREFUL NOT TO OVER HEAT THE MACHINE. 3. NOTE: If a wire feeder is NOT connected to the Power Wave the machine may not display output volts. 4. Connect the resistance grid load to the machine’s output terminals. Connect the reference ammeter in series with the grid load. See Figure F.57. STAND DIRECTLY IN FRONT OF MACHINE UNDER TEST. EXPLODING PARTS CAN CAUSE INJURY. FAILED PARTS CAN EXPLODE OR CAUSE OTHER PARTS TO EXPLODE WHEN POWER IS APPLIED. ALWAYS WEAR A FACE SHIELD AND LONG SLEEVES WHEN SERVICING. FIGURE F.57 – RESISTANCE GRID LOAD CONNECTIONS POWER WAVE – + AMMETER Return to Master TOC Return to Section TOC VOLT METER RESISTANCE GRID LOAD POWER WAVE 450 F-153 F-153 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC TROUBLESHOOTING & REPAIR CURRENT CALIBRATION (continued) FIGURE F.58 – TEST AND CALIBRATION OVERLAY PROCEDURE WARNING Return to Master TOC Return to Section TOC 1. Install the Test and Calibration Overlay and apply power to the machine. See Figure F.58. 2. Press the Manual Procedure Entry Key (64). The machine should display the following: PROCESS 1 SETUP 1-0 3. Toggle the Arrow Keys (100 and 101) until the display reads: Return to Master TOC Return to Section TOC 5. Adjust the potentiometer until the reference (external ammeter) reads 304 amps +/- 1.0 amps. The load voltage should be greater than 15 volts but less than 35 volts. 6. Remove power to the machine. PROCESS 1 SETUP 1-6 4. Activate the external trigger (K941-1) and load the machine. The machine’s output terminals will be electrically “HOT” when the trigger circuit is activated. 7. If necessary re-install the control board. device. 8. Replace the machine case parts. POWER WAVE 450 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Section TOC F-154 F-154 NOTES POWER WAVE 450 Return to Master TOC Return to Section TOC F-155 TROUBLESHOOTING & REPAIR T1 AUXILIARY TRANSFORMER REMOVAL AND REPLACEMENT WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual. Return to Master TOC Return to Section TOC If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-800-833-9353 (WELD). DESCRIPTION The following procedure will aid the technician in removing the T1 auxiliary transformer for maintenance or replacement. MATERIALS NEEDED Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC 5/16" Nut driver 3/8" Nut driver or socket wrench Wire cutters Machine Wiring Diagram in the Electrical Diagrams section of this manual This procedure takes approximately 35 minutes to perform. POWER WAVE 450 F-155 F-156 F-156 Return to Master TOC Return to Section TOC TROUBLESHOOTING & REPAIR T1 AUXILIARY TRANSFORMER REMOVAL AND REPLACEMENT (continued) FIGURE F.59 - T1 AUXILIARY TRANSFORMER LOCATION 1. AUXILIARY TRANSFORMER T1 2. MOUNTING SCREW (2) Return to Master TOC Return to Section TOC 2 1 PROCEDURE Return to Master TOC Return to Section TOC 1. Remove main input supply power to the machine. 2. With the 3/8" nut driver, remove the 4 screws that hold the handle to the machine. 3. Remove the rubber gasket (cover seal) from the lift bail. 4. With the 5/16" nut driver, remove the sheet metal screws from the case top. 5. With the 5/16" nut driver, remove the screws holding the right and left case sides. Remove the case sides by lifting up and out. 6. Perform the Capacitor Discharge Procedure described earlier in this section of the manual. Return to Master TOC Return to Section TOC WARNING 7. After you have completed the capacitor discharge procedure for all four switch boards, disconnect plugs P70, P71, and P73 that attach to the transformer. See Figure F.59 for location. 8. With the wire cutters, cut any necessary cable ties (necessary for removal of the transformer). Note the location of these cable ties for reassembly. 9. With the 3/8" nut driver or socket wrench, remove the two screws that mount the transformer to the machine base. Remove the T1 auxiliary transformer. 10. To install the T1 auxiliary transformer, carefully position it onto the machine base and tighten the two mounting screws. Connect plugs P70, P71, and P73 to their respective receptacles on the transformer. 11. Install the machine case sides and top. Before continuing with the test procedure, perform the capacitor discharge procedure to avoid electric shock. 12. Install the handle and the lift bail rubber gasket. POWER WAVE 450 Return to Master TOC Return to Section TOC F-157 TROUBLESHOOTING & REPAIR WATER COOLER REMOVAL AND REPLACEMENT For later model coolers (Inlet & Outlet on lower left of machine back) Refer to IM645-A WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual. Return to Master TOC Return to Section TOC If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-800-833-9353 (WELD). DESCRIPTION The following procedure will aid the technician in removing the machine water cooler assembly for maintenance or replacement. Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC MATERIALS NEEDED 5/16" Nut driver 9/16" Open end or box wrench 3/8" Nut driver or socket wrench 3/4" Open end wrench 11/16" Open end wrench Machine Wiring Diagram in the Electrical Diagrams section of this manual This procedure takes approximately 60 minutes to perform. POWER WAVE 450 F-157 F-158 F-158 Return to Master TOC WATER COOLER REMOVAL AND REPLACEMENT (continued) FIGURE F.60 - WATER COOLER LOCATION 2 Return to Master TOC Return to Section TOC Return to Section TOC TROUBLESHOOTING & REPAIR 1 3 1. WATER COOLER ACCESS DOOR (ON BACK PANEL) 2. WATER COOLING FITTINGS 3. CIRCUIT BREAKER Return to Master TOC Return to Section TOC PROCEDURE WARNING NOTE: These instructions may vary slightly with later model coolers. See instructions included with cooler kit. 1. Remove main input supply power to the machine. 2. With the 3/8" nut driver, remove the 4 screws that hold the handle to the machine. 3. Remove the rubber gasket (cover seal) from the lift bail. Return to Master TOC 4. With the 5/16" nut driver, remove the sheet metal screws from the case top. Return to Section TOC Before continuing with the test procedure, perform the capacitor discharge procedure to avoid electric shock. 7. After you have completed the capacitor discharge procedure for all four switch boards, use the 5/16" nut driver to remove the water cooler access door. See Figure F.60 for location. 5. With the 5/16" nut driver, remove the screws holding the right and left case sides. Remove the case sides by lifting up and out. 8. With the 3/8" open end or socket wrench, remove the two water cooler assembly mounting screws. Slide the assembly to the left to better access the circuit breaker, which will be removed in a moment. 6. Perform the Capacitor Discharge Procedure described earlier in this section of the manual. 9. With the 5/16" nut driver, remove the two sheet metal screws holding the lower case back panel. POWER WAVE 450 Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC F-159 TROUBLESHOOTING & REPAIR WATER COOLER REMOVAL AND REPLACEMENT (continued) 10. With the 9/16" open end wrench, remove the circuit breaker. 11. Locate and disconnect plug J4, behind the water cooler. Plug J 4, a large molex plug, has two leads (H1A and H3A). Double-check that these are the leads feeding the plug; there is another large molex plug in the same area that is not connected to the water cooler. 12. Disconnect Plug 3, a small molex plug with four leads. This plug is also located behind the water cooler. 13. Slide out the water cooler assembly. Take care not to damage the reservoir tank and cooling coils. 14. If complete removal is required, with the 3/4" and 11/16" open end wrenches, disconnect the water cooler lines from the machine back panel. Disconnect the plastic strain relievers that hold the water lines to the subframe. Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC If disassembly of the water cooler is required, refer to the Water Cooler Disassembly Procedure in this section of the manual. 15. To install the water cooler, slide the assembly into the machine base. Make sure the cooler fits under the retaining clips. Connect the water lines to the back panel and connect the plastic strain relievers where they hold the water lines to the subframe. 16. Connect plugs 3 and 4, behind the water cooler assembly. 17. Attach the circuit breaker. Use the 9/16" open end wrench. 18. Install the two 5/16" sheet metal screws that hold the lower case back panel. 19. Install the two 3/8" water cooler assembly mounting screws. 20. Connect the water cooler lines to the back panel using the 3/4" and 11/16" wrenches. 21. Set the tabs of the water cooler access door in place and secure the door with the two 5/16" screws. 22. Install the machine case sides and top. 23. Install the handle and the lift bail rubber gasket. POWER WAVE 450 F-159 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Section TOC F-160 F-160 NOTES POWER WAVE 450 Return to Master TOC Return to Section TOC F-161 TROUBLESHOOTING & REPAIR WATER COOLER DISASSEMBLY WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual. Return to Master TOC Return to Section TOC If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-800-833-9353 (WELD). DESCRIPTION The following procedure will aid the technician in disassembly of the machine water cooler assembly for maintenance or part replacement for early model coolers. MATERIALS NEEDED Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Phillips head screw driver Pliers 3/4" Open end wrench 5/16" Box wrench This procedure takes approximately 60 minutes to perform. POWER WAVE 450 F-161 F-162 F-162 Return to Master TOC Return to Section TOC TROUBLESHOOTING & REPAIR WATER COOLER DISASSEMBLY (continued) FIGURE F.61 - WATER COOLER DISASSEMBLY (EARLY MODEL) 1 Return to Master TOC Return to Section TOC 2 PROCEDURE Return to Master TOC Return to Section TOC 3 WARNING 1. Remove main input supply power to the machine. 2. With the 3/8" nut driver, remove the 4 screws that hold the handle to the machine. 3. Remove the rubber gasket (cover seal) from the lift bail. 4. With the 5/16" nut driver, remove the sheet metal screws from the case top. Return to Master TOC 5. With the 5/16" nut driver, remove the screws holding the right and left case sides. Remove the case sides by lifting up and out. Return to Section TOC 1. RESERVOIR 2. TUBE SUPPORT BRACKET 3. ASSEMBLY FLOOR 6. Perform the Capacitor Discharge Procedure described earlier in this section of the manual. POWER WAVE 450 Before continuing with the test procedure, perform the capacitor discharge procedure to avoid electric shock. Return to Master TOC Return to Section TOC F-163 TROUBLESHOOTING & REPAIR WATER COOLER DISASSEMBLY (continued) Reservoir Removal Motor/Pump/Fan Assembly Removal A. After you have completed the capacitor discharge procedure for all four switch boards, remove the water cooler assembly. Refer to the Water Cooler Removal and Replacement Procedure in this section of the manual. A. Perform the Reservoir Removal procedure. Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC Return to Section TOC B. Empty the coolant from the reservoir. Dispose of the coolant in a proper and approved manner. C. With the Phillips head screw driver, remove the two screws holding the reservoir to the cooling tube support bracket. D. With the Phillips head screw driver, remove the four screws holding the reservoir to the floor of the assembly. E. With the pliers, carefully remove the two coolant hoses from the reservoir. F. Carefully slide out and lift the reservoir free from the motor and fan blade. G. After repair, install the reservoir by carefully setting it in place around the motor and fan blade. With the pliers, install the two coolant hoses to the reservoir. With the Phillips head screw driver, install the four screws holding the reservoir to the floor of the assembly and the two screws that hold it to the cooling tube support bracket. Replace the old coolant with fresh coolant and install the water cooler assembly into the machine according to the Water Cooler Removal and Replacement Procedure in this section of the manual. B. With the 3/4" open end wrench, remove the two coolant hoses attached to the motor/pump assembly. C. Remove the four wires leading from the motor to the terminal block. Note the lead numbers and locations for reassembly. D. With the Phillips head screw driver and the 5/16" box wrench, remove the four screws and nuts mounting the motor/pump/fan assembly to the mounting platform. E. Carefully lift out the motor/pump/fan assembly. F. Install the motor/pump/fan assembly by carefully setting in onto the mounting platform and attaching it with the four screws and nuts. Connect the four wire leads from the motor to the terminal block. Attach the two coolant hoses to the motor/pump assembly using the 3/4" open end wrench. 7. Install the reservoir according to the directions in the Reservoir Removal procedure. Install the water cooler assembly according to the Water Cooler Removal and Replacement procedure in this section of the manual. 8. Install the machine case sides and top. 9. Install the handle and the lift bail rubber gasket. POWER WAVE 450 F-163 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Section TOC F-164 F-164 NOTES POWER WAVE 450 Return to Master TOC Return to Section TOC F-165 TROUBLESHOOTING & REPAIR T2 AUXILIARY TRANSFORMER REMOVAL AND REPLACEMENT WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual. Return to Master TOC Return to Section TOC If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-800-833-9353 (WELD). DESCRIPTION The following procedure will aid the technician in removing the T2 auxiliary transformer for maintenance or replacement. MATERIALS NEEDED Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC 5/16" Nut driver 3/8" Nut driver or socket wrench Machine Wiring Diagram in the Electrical Diagrams section of this manual This procedure takes approximately 30 minutes to perform. POWER WAVE 450 F-165 F-166 F-166 Return to Master TOC Return to Section TOC TROUBLESHOOTING & REPAIR T2 AUXILIARY TRANSFORMER REMOVAL AND REPLACEMENT (continued) FIGURE F.62 - T2 AUXILIARY TRANSFORMER LOCATION 1. BASE 2. AUXILIARY TRANSFORMER T2 3. MOUNTING SCREW (2) 3 Return to Master TOC Return to Section TOC 2 1 Return to Master TOC 1. Remove main input supply power to the machine. Return to Master TOC Return to Section TOC Return to Section TOC PROCEDURE 2. With the 3/8" nut driver, remove the 4 screws that hold the handle to the machine. 3. Remove the rubber gasket (cover seal) from the lift bail. 4. With the 5/16" nut driver, remove the sheet metal screws from the case top. 5. With the 5/16" nut driver, remove the screws holding the right and left case sides. Remove the case sides by lifting up and out. 7. After you have completed the capacitor discharge procedure for all four switch boards, proceed to remove the T2 auxiliary transformer. First you will have to remove the water cooler; follow the Water Cooler Removal and Replacement Procedure in this section of the manual. 8. Disconnect the single molex plug attached to the transformer. See Figure F.62 for location. 9. The 3/8" nut driver or socket wrench, remove the two screws that mount the transformer to the machine base. Remove the T2 auxiliary transformer. 6. Perform the Capacitor Discharge Procedure described earlier in this section of the manual. 10. To install the T2 auxiliary transformer, carefully position it onto the machine base and tighten the two mounting screws. Connect the molex plug to its receptacle on the transformer. WARNING 11. Install the water cooler. Refer to the Water Cooler Removal and Replacement Procedure in this section of the manual. Before continuing with the test procedure, perform the capacitor discharge procedure to avoid electric shock. 12. Install the machine case sides and top. 13. Install the handle and the lift bail rubber gasket. POWER WAVE 450 Return to Master TOC Return to Section TOC F-167 TROUBLESHOOTING & REPAIR FAN MOTOR REMOVAL AND REPLACEMENT WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual. Return to Master TOC Return to Section TOC If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-800-833-9353 (WELD). DESCRIPTION The following procedure will aid the technician in removing the machine fan motor for maintenance or replacement. MATERIALS NEEDED Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC 5/16" Nut driver 3/8" Nut driver 3/4" Open or box end wrench Wire cutters Slot head screw driver Machine Wiring Diagram in the Electrical Diagrams section of this manual This procedure takes approximately 30 minutes to perform. POWER WAVE 450 F-167 F-168 F-168 Return to Master TOC Return to Section TOC TROUBLESHOOTING & REPAIR FAN MOTOR REMOVAL AND REPLACEMENT (continued) FIGURE F.63 - FAN MOTOR LOCATION Return to Master TOC Return to Section TOC 1 2 3 Return to Master TOC Return to Section TOC 1. MACHINE BACK 2. TERMINAL STRIP 3. FAN MOTOR AND MOUNTING BRACKET PROCEDURE WARNING 1. Remove main input supply power to the machine. 2. With the 3/8" nut driver, remove the 4 screws that hold the handle to the machine. 3. Remove the rubber gasket (cover seal) from the lift bail. 4. With the 5/16" nut driver, remove the sheet metal screws from the case top. Return to Master TOC 5. With the 5/16" nut driver, remove the screws holding the right and left case sides. Remove the case sides by lifting up and out. Return to Section TOC Before continuing with the test procedure, perform the capacitor discharge procedure to avoid electric shock. 6. Perform the Capacitor Discharge Procedure described earlier in this section of the manual. 7. After you have completed the capacitor discharge procedure for all four switch boards, use the wire cutters to cut any necessary cable ties (necessary for removal of the fan motor) holding the fan motor leads together. Note the location of these cable ties for reassembly. 8. Remove the fan motor leads from the terminal strip. 9. With the 5/16" nut driver, remove the water cooler access door. Then remove the four screws from the lower rear panel. POWER WAVE 450 F-169 F-169 Return to Master TOC Return to Section TOC TROUBLESHOOTING & REPAIR FAN MOTOR REMOVAL AND REPLACEMENT (continued) FIGURE F.64 - MACHINE BACK SECURED TO LIFT BAIL. Return to Master TOC Return to Section TOC 2 1 11. With the 3/4" wrench, remove the lead connected to the rear positive (+) output terminal. Return to Master TOC Return to Section TOC 1. MACHINE BACK 2. LIFT BAIL 12. Swing the back panel up and secure it to the lift bail. See Figure F.64. Use heavy string or wire. BE CAREFUL NOT TO DAMAGE THE RS232 CONNECTOR OR THE WIREFEEDER RECEPTACLES. 13. With the slot head screw driver, remove the clip holding the fan blade onto the motor shaft. 14. Remove the fan blade by carefully sliding it off the motor shaft. Return to Master TOC Return to Section TOC 15. With the 11/32" nut driver or socket wrench, remove the two fan motor mounting nuts. Remove the split-ring lock washers and flat washers. 16. Remove the fan motor by sliding it out of the mounting bracket and free of the machine. NOTE: Repeat this procedure to remove the second fan motor if necessary. 17. To install the fan motor, do the following: Carefully position the fan motor into place on the mounting bracket with the leads toward the terminal strip. Install the flat washers, split-ring lock washers, and nuts to the motor mounting bolts. Carefully slide the fan blade all the way onto the motor shaft. The side of the hub with the metal clip goes toward the motor. Install the clip so that it grips the rounded side of the D-shaped shaft, not the flat. Swing the back panel back down, being careful not to damage the RS232 connector or the wire feeder receptacles. Install the lead to the rear positive (+) output terminal. Install the case back lower sides and the lower rear panel with the 5/16" screws. Attach the fan motor leads to the terminal strip and replace the tie wraps cut during removal so that the motor leads are held away from the fan blades. 18. Install the machine case sides and top. 19. Install the handle and the lift bail rubber gasket. POWER WAVE 450 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Section TOC F-170 F-170 NOTES POWER WAVE 450 Return to Master TOC Return to Section TOC F-171 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. Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC Return to Section TOC If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-800-833-9353 (WELD). DESCRIPTION The following procedure will aid the technician in removing the input rectifier for maintenance or replacement. MATERIALS NEEDED 5 mm Allen wrench Phillips head screw driver 10 mm Open end wrench RTV Silicone sealant (Lincoln E2861) Dow Corning 340 Joint Compound (Lincoln E1868) S18491 M.O.V. Assembly (if necessary) Machine Wiring Diagram in the Electrical Diagrams section of this manual This procedure takes approximately 45 minutes to perform. POWER WAVE 450 F-171 F-172 F-172 Return to Master TOC Return to Section TOC TROUBLESHOOTING & REPAIR INPUT RECTIFIER REMOVAL AND REPLACEMENT (continued) FIGURE F.65 - INPUT RECTIFIER LOCATION 1 Return to Master TOC Return to Section TOC CR1 2 3 4 5 6 Return to Master TOC PROCEDURE Return to Master TOC Return to Section TOC Return to Section TOC 1. 2. 3. 4. 5. 6. MAIN CONTACTOR M.O.V. ASSEMBLY SILICONE SEALANT INPUT RECTIFIER 5MM ALLEN SCREW HEAT SINK PANEL WARNING 1. Remove main input supply power to the machine. Before continuing with the test procedure, perform the capacitor discharge procedure to avoid electric shock. 2. With the 3/8" nut driver, remove the 4 screws that hold the handle to the machine. 3. Remove the rubber gasket (cover seal) from the lift bail. 5. With the 5/16" nut driver, remove the screws holding the right and left case sides. Remove the case sides by lifting up and out. 7. After you have completed the capacitor discharge procedure for all four switch boards, peel the silicone sealant away from the M.O.V. assembly in order to expose the heads of the screws that attach the three heavy leads from the main input contactor to the input rectifier. See Figure F.65. 6. Perform the Capacitor Discharge Procedure described earlier in this section of the manual. 8. With the Phillips head screw driver, remove the three heavy leads from the input rectifier. 4. With the 5/16" nut driver, remove the sheet metal screws from the case top. 9. With the Phillips head screw driver, remove the positive (+) and negative (-) leads from the input rectifier. POWER WAVE 450 Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC F-173 TROUBLESHOOTING & REPAIR INPUT RECTIFIER REMOVAL AND REPLACEMENT (continued) 10. With the 5 mm Allen wrench and the 10 mm open end wrench, remove the two screws mounting the input rectifier to the heat sink panel. 11. When replacing the input rectifier, apply a thin, even coating of Dow Corning 340 Joint Compound (Lincoln T12837) to the mating surfaces between the input rectifier and the heat sink panel. Avoid applying the compound to either the mounting holes or the mounting hardware. 12. Mount the input rectifier to the heat sink panel and tighten the two mounting screws with the 5 mm Allen wrench and the 10 mm open end wrench. Be sure to tighten the screws evenly. 13. With the Phillips head screw driver, attach the positive (+) and negative (-) leads to the input rectifier. Attach the three heavy leads and the M.O.V. assembly to the input rectifier. Replace the M.O.V. assembly if it appears damaged. 14. Apply silicone sealant to the M.O.V. assembly connections. 15. Install the machine case sides and top. 16. Install the handle and the lift bail rubber gasket. POWER WAVE 450 F-173 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Section TOC F-174 F-174 NOTES POWER WAVE 450 Return to Master TOC Return to Section TOC F-175 TROUBLESHOOTING & REPAIR PRINTED CIRCUIT BOARD REMOVAL AND REPLACEMENT (CONTROL BOARD, POWER BOARD, AND PROTECTION BOARD) WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual. Return to Master TOC Return to Section TOC If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-800-833-9353 (WELD). DESCRIPTION The following procedure will aid the technician in removing the control, power, or protection printed circuit boards for maintenance or replacement. MATERIALS NEEDED Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC 5/16" Nut driver 3/8" Nut driver Machine Wiring Diagram in the Electrical Diagrams section of this manual This procedure takes approximately 30 minutes to perform. POWER WAVE 450 F-175 F-176 F-176 Return to Master TOC Return to Section TOC TROUBLESHOOTING & REPAIR PRINTED CIRCUIT BOARD REMOVAL AND REPLACEMENT (CONTROL BOARD, POWER BOARD, AND PROTECTION BOARD) (continued) FIGURE F.66 - PC BOARD REMOVAL Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC 1 2 1. PC BOARD COVER 2. PC BOARD ASSEMBLY 3. RETAINER CLIPS 3 PROCEDURE WARNING 1. Remove main input supply power to the machine. Before continuing with the test procedure, perform the capacitor discharge procedure to avoid electric shock. 2. With the 3/8" nut driver, remove the 4 screws that hold the handle to the machine. 3. Remove the rubber gasket (cover seal) from the lift bail. Return to Master TOC Return to Section TOC 4. With the 5/16" nut driver, remove the sheet metal screws from the case top. 5. With the 5/16" nut driver, remove the screws holding the right and left case sides. Remove the case sides by lifting up and out. 7. After you have completed the capacitor discharge procedure for all four switch boards, use the 5/16" nut driver to remove the two screws holding the printed circuit board cover in place. Slide the cover forward and lift up to remove it. 6. Perform the Capacitor Discharge Procedure described earlier in this section of the manual. POWER WAVE 450 Return to Master TOC Return to Section TOC F-177 PRINTED CIRCUIT BOARD REMOVAL AND REPLACEMENT (CONTROL BOARD, POWER BOARD, AND PROTECTION BOARD) (continued) CAUTION Be sure to follow the recommended static-free methods for handling printed circuit boards. Failure to do so can result in permanent damage to the equipment. Return to Master TOC 8. Remove the molex plugs from the PC board you are removing. Return to Section TOC F-177 TROUBLESHOOTING & REPAIR NOTE: The plugs are numbered in order from left to right. 9. Depress the two PC board retainer clips located on the left and right sides of the board. Lift the board by the clips to remove it. 10. When reinstalling the PC board, make certain the tabs at the bottom of the board fit into the slots on the compartment floor. When the board is properly seated, the retainer clips will snap into the locked position. 11. Install the molex plugs removed earlier. Be sure to fit the each plug into its respective receptacle on the board. 12. Perform appropriate calibration procedure per flowchart in Figure F.67. 13. Install the PC board cover and tighten the two screws with the 5/16" nut driver. 14. Install the machine case sides and top. 15. Install the handle and the lift bail rubber gasket. Return to Master TOC Return to Section TOC FIGURE F.67 – PC BOARD REPLACEMENT CALIBRATION REQUIREMENTS DISPLAY BOARD REPLACED SNUBBER BOARD REPLACED SHUNT AMPLIFIER BOARD REPLACED Return to Master TOC Return to Section TOC IF POSSIBLE QUICK VOLTAGE CALIBRATION CONTROL BOARD REPLACED CURRENT CALIBRATION FULL VOLTAGE CALIBRATION POWER WAVE 450 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Section TOC F-178 F-178 NOTES POWER WAVE 450 Return to Master TOC Return to Section TOC F-179 TROUBLESHOOTING & REPAIR DISPLAY 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. Return to Master TOC Return to Section TOC If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-800-833-9353 (WELD). DESCRIPTION The following procedure will aid the technician in removing the display board for maintenance or replacement. MATERIALS NEEDED Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC 5/16" Nut driver 3/8" Nut driver This procedure takes approximately 45 minutes to perform. POWER WAVE 450 F-179 F-180 F-180 Return to Master TOC Return to Section TOC TROUBLESHOOTING & REPAIR DISPLAY BOARD REMOVAL AND REPLACEMENT (continued) FIGURE F.68 - DISPLAY BOARD REMOVAL 3 Return to Master TOC Return to Section TOC 2 4 1 5 1. 2. 3. 4. 5. MOLEX PLUG HEADERS (8) KEY PAD RIBBON CONNECTOR LCD DISPLAY WINDOW LCD CONNECTOR MOUNTING PIN HOLE Return to Master TOC Return to Section TOC NOTE: Before changing or disturbing the dis- 1. Remove main input supply power to the machine. 2. With the 3/8" nut driver, remove the 4 screws that hold the handle to the machine. 4. With the 5/16" nut driver, remove the sheet metal screws from the case top. Return to Master TOC Before continuing with the test procedure, perform the capacitor discharge procedure to avoid electric shock. PROCEDURE 3. Remove the rubber gasket (cover seal) from the lift bail. Return to Section TOC WARNING play board follow the procedure outlined under QUICK VOLTAGE CALIBRATION (Fig. F.54) in this section. 5. With the 5/16" nut driver, remove the screws holding the right and left case sides. Remove the case sides by lifting up and out. 6. Perform the Capacitor Discharge Procedure described earlier in this section of the manual. CAUTION Be sure to follow the recommended static-free methods for handling printed circuit boards. Failure to do so can result in permanent damage to the equipment. 7. After you have completed the capacitor discharge procedure for all four switch boards, carefully remove the eight molex plugs from the lower portion of the display board. POWER WAVE 450 Return to Master TOC Return to Section TOC F-181 TROUBLESHOOTING & REPAIR DISPLAY BOARD REMOVAL AND REPLACEMENT (continued) 8. Carefully remove the key pad ribbon connector from the right side of the display board. 9. Carefully remove the connector to the LCD display. Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC Return to Section TOC CAUTION Do not touch the sensors located on the left side of the display board when you handle it for removal or replacement. Failure to do so can result in permanent damage to the sensors. 10. Carefully remove the display board from the its mounting pins. Remove the display board by lifting up and out. 11. Reinstall the display board by carefully pressing it onto its mounting pins. Install the LCD display connector, the key pad connector, and the eight molex plugs that fit along the bottom portion of the display board. 12. After you have installed the display board (a new one or the old one), you must perform the Display Board Sensor Calibration Test and necessary voltage calibration. Refer to this test in the test portion of this section of the manual. 13. After performing the Display Board Sensor Calibration Test, install the machine case sides and top. 14. Install the handle and the lift bail rubber gasket. POWER WAVE 450 F-181 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Section TOC F-182 F-182 NOTES POWER WAVE 450 Return to Master TOC Return to Section TOC F-183 TROUBLESHOOTING & REPAIR MAIN INPUT CONTACTOR (CR1) REMOVAL AND REPLACEMENT WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual. Return to Master TOC Return to Section TOC If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-800-833-9353 (WELD). DESCRIPTION The following procedure will aid the technician in removing the main input contactor for maintenance or replacement. MATERIALS NEEDED Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Slot head screw driver 5/16" Nut driver 3/8" Open end wrench Machine Wiring Diagram in the Electrical Diagrams section of this manual This procedure takes approximately 45 minutes to perform. POWER WAVE 450 F-183 F-184 F-184 MAIN INPUT CONTACTOR (CR1) REMOVAL AND REPLACEMENT (continued) L3 T2 T3 T1 Return to Master TOC L3 CR1 324 326 PROCEDURE Return to Master TOC Return to Section TOC Return to Section TOC T1 L2 T3 L1 WARNING 1. Remove main input supply power to the machine. Return to Master TOC Before continuing with the test procedure, perform the capacitor discharge procedure to avoid electric shock. 2. With the 3/8" nut driver, remove the 4 screws that hold the handle to the machine. 3. Remove the rubber gasket (cover seal) from the lift bail. 4. With the 5/16" nut driver, remove the sheet metal screws from the case top. 5. With the 5/16" nut driver, remove the screws holding the right and left case sides. Remove the case sides by lifting up and out. Return to Section TOC A A FIGURE F.69 - MAIN CONTACTOR L1 Return to Master TOC Return to Section TOC TROUBLESHOOTING & REPAIR 6. Perform the Capacitor Discharge Procedure described earlier in this section of the manual. 7. After you have completed the capacitor discharge procedure for all four switch boards, with the slot head screw driver, remove the three heavy leads from the output side of the contactor. 8. With the slot head screw driver, remove the two small leads (L1A and L3A) from the input side of the contactor. POWER WAVE 450 Return to Master TOC Return to Section TOC F-185 TROUBLESHOOTING & REPAIR MAIN INPUT CONTACTOR (CR1) REMOVAL AND REPLACEMENT (continued) 9. With the slot head screw driver, remove the two small leads (T1 and T3) from the output side of the contactor. 13. For replacement, mount the contactor to the vertical mounting panel with the two 3/8" mounting screws and nuts. 10. With the slot head screw driver, remove the two contactor coil leads (#324 and #326) from the contactor. 14. Attach all the contactor leads: coil leads #324 and #326; small leads T1 and T3 to the output side; three heavy leads to the output side; small leads L1A and L3A and three input leads to the input side. Tighten all evenly with the slot head screw driver. 11. With the slot head screw driver and 3/8" wrench, loosen the two mounting screws and nuts holding the contactor to the vertical mounting panel. 16. Install the handle and the lift bail rubber gasket. Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC Return to Section TOC 12. Remove the contactor by lifting up and out. 15. Install the machine case sides and top. POWER WAVE 450 F-185 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Section TOC F-186 F-186 NOTES POWER WAVE 450 Return to Master TOC Return to Section TOC F-187 TROUBLESHOOTING & REPAIR OUTPUT RECTIFIER BRIDGE REMOVAL AND REPLACEMENT WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual. Return to Master TOC Return to Section TOC If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-800-833-9353 (WELD). DESCRIPTION The following procedure will aid the technician in removing the output rectifier bridge for maintenance or replacement. Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC MATERIALS NEEDED Slot head screw driver 5/16" Nut driver 3/8" Nut driver 7/16" Open end wrench Wire cutters Machine Wiring Diagram in the Electrical Diagrams section of this manual This procedure takes approximately 1 hour 30 minutes to perform. POWER WAVE 450 F-187 F-188 F-188 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC TROUBLESHOOTING & REPAIR OUTPUT RECTIFIER BRIDGE REMOVAL AND REPLACEMENT (continued) FIGURE F.70 - OUTPUT RECTIFIER BRIDGE LOCATION 1 Return to Master TOC Return to Section TOC 1. OUTPUT RECTIFIER BRIDGE PROCEDURE WARNING 1. Remove main input supply power to the machine. Before continuing with the test procedure, perform the capacitor discharge procedure to avoid electric shock. 2. With the 3/8" nut driver, remove the 4 screws that hold the handle to the machine. 3. Remove the rubber gasket (cover seal) from the lift bail. Return to Master TOC Return to Section TOC 4. With the 5/16" nut driver, remove the sheet metal screws from the case top. 5. With the 5/16" nut driver, remove the screws holding the right and left case sides. Remove the case sides by lifting up and out. 6. Perform the Capacitor Discharge Procedure described earlier in this section of the manual. 7. After you have completed the capacitor discharge procedure for all four switch boards, cut all necessary cable ties (necessary for removal of the output rectifier bridge) on the left side of the machine. 8. Disconnect all necessary leads from the left side of the output rectifier bridge (two heavy and two small leads). Place the fastener hardware back together to avoid loss. POWER WAVE 450 Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC F-189 F-189 TROUBLESHOOTING & REPAIR OUTPUT RECTIFIER BRIDGE REMOVAL AND REPLACEMENT (continued) 9. Cut all necessary cable ties on the right side of the machine and disconnect all necessary leads (two heavy and two small leads) from the right side of the output rectifier bridge. Place the fastener hardware back together onto the lead ends to avoid loss. 10. On the right side of the machine, use the 7/16" open end wrench to remove the bolt that connects the heat sink at the top to the glastic insulated angle mounting piece. Then remove the carriage bolt that holds the glastic insulated angle mounting piece at the bottom to the subframe. Repeat the same procedure on the left side of the machine. Save the shakeproof washers and nuts for reassembly. 11. With the 7/16" wrench, remove the bolts, top and bottom, that connect the heat sink and glastic insulated angle mounting piece at the middle. With the side bolts already removed, it is easier to access the middle bolts. 12. With the 7/16" wrench, remove the bolt, nut, and split-ring lock washer from the tab connection at the bottom of the heat sink. The input rectifier bridge can now be removed. You may have to bend the bottom tab slightly in order to get it past the main transformer. FIGURE F.71 – HEAT SINK REMOVAL Return to Master TOC Return to Section TOC 1 4 Return to Master TOC Return to Section TOC 2 3 1. GLASTIC INSULATED ANGLE MOUNTING PIECE (TOP) 2. BOTTOM TAB CONNECTION 3. GLASTIC INSULATED ANGLE MOUNTING PIECE (BOTTOM) 4. HEAT SINK POWER WAVE 450 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC F-190 TROUBLESHOOTING & REPAIR OUTPUT RECTIFIER BRIDGE REMOVAL AND REPLACEMENT (continued) FIGURE F.72 – CABLE TIE LOCATIONS SECONDARY HARNESS ASSEMBLY (WHITE) Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC PRIMARY HARNESS ASSEMBLY (BLACK) 13. For reassembly, attach the glastic insulated angle mounting pieces to the heat sink first. Slide the bridge into position and then fasten the bottom tab to the subframe with the bolt, split-ring lock washer and nut. Then attach and tighten down the top and bottom bolts that hold the heat sink on both sides of the machine. 15. Install the machine case sides and top. 16. Install the handle and the lift bail rubber gasket. 14. Reconnect the leads on both sides of the bridge. Install new cable ties according to Figure F.72. POWER WAVE 450 F-190 Return to Master TOC Return to Section TOC F-191 TROUBLESHOOTING & REPAIR FET 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. Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC Return to Section TOC If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-800-833-9353 (WELD). DESCRIPTION The following procedure will aid the technician in removing the FET modules and main transformer for maintenance or replacement. MATERIALS NEEDED Slot head screw driver Phillips head screw driver 5/16" Nut driver 3/8" Nut driver 5/16" Open end or box wrench 7/16" Open end or box wrench 3/8" Socket wrench 1/2" Socket wrench Wire cutters Machine Wiring Diagram in the Electrical Diagrams section of this manual This procedure takes approximately 3 hours 30 minutes to perform. POWER WAVE 450 F-191 Return to Master TOC Return to Section TOC F-192 TROUBLESHOOTING & REPAIR FET MODULE REMOVAL AND REPLACEMENT (continued) FIGURE F.73 - FET MODULE LOCATION 4 Return to Master TOC Return to Section TOC 3 1 1. 2. 3. 4. FET MODULE PIEZO ALARM BUZZER FET MODULE LOCKING BAR RESISTORS 2 Return to Master TOC Return to Section TOC PROCEDURE WARNING 1. Remove main input supply power to the machine. 3. Remove the rubber gasket (cover seal) from the lift bail. 4. With the 5/16" nut driver, remove the sheet metal screws from the case top. Return to Master TOC 5. With the 5/16" nut driver, remove the screws holding the right and left case sides. Remove the case sides by lifting up and out. Return to Section TOC Before continuing with the test procedure, perform the capacitor discharge procedure to avoid electric shock. 2. With the 3/8" nut driver, remove the 4 screws that hold the handle to the machine. 6. Perform the Capacitor Discharge Procedure described earlier in this section of the manual. 7. After you have completed the capacitor discharge procedure for all four switch boards, use the 5/16" nut driver to remove the two screws holding the printed circuit board cover in place. Slide the cover forward and lift up to remove it. CAUTION Be sure to follow the recommended static-free methods for handling printed circuit boards. Failure to do so can result in permanent damage to the equipment. 8. Remove the molex plugs from the PC boards except the display board. POWER WAVE 450 F-192 Return to Master TOC Return to Section TOC F-193 F-193 TROUBLESHOOTING & REPAIR FET MODULE REMOVAL AND REPLACEMENT (continued) FIGURE F.74 - LIFT BAFFLE/BAIL REMOVAL 1 Return to Master TOC Return to Section TOC 2 1. LIFT BAIL 2. LIFT BAIL BAFFLE 3. SUBFRAME STAND 3 Return to Master TOC Return to Section TOC 9. With the wire cutters, cut all necessary cable ties. 10. Disconnect the leads to the output rectifier bridge. Cut all necessary cable ties. 11. Disconnect two plugs from the snubber board. 12. Disconnect the output cable strap and pull it through and free from the lift bail baffle eyelet hole. Cut any necessary cable ties. 13. With the 3/8" nut driver, remove the two screws that hold the lift bail baffle. See Figure F.74. Remove the baffle. Return to Master TOC Return to Section TOC 14. With the 1/2" socket wrench, remove the four bolts (two on each side of the machine) from the lift bail. See Figure F.74. Slide the lift bail up and free of the machine. 17. With the 3/8" wrench, remove the six resistors that are attached to the top of the subframe (four on the top right, two on the top left). Note the physical placement and wiring for reassembly; labeling is recommended. Also loosen the bottom resistors closest to the FET module assembly. This will allow the capacitors to clear the resistors when the FET module assembly slides forward for removal. 18. With the 5/16" nut driver, remove the sheet metal screw holding the ground leads to the right rear of the subframe. On the left side, unclip the cable tie holding the leads. Let the back of the subframe swing out carefully; the harness will support it. 15. On the right side of the machine, cut any necessary cable ties to free the wiring harness from the subframe. 19. With the 5/16" wrench, remove the two sheet metal screws holding the subframe bottom support section. Note the green ground lead on the left side; be sure to reconnect it during reassembly. 16. With the Phillips head screw driver, remove the screw that holds the piezoelectric alarm buzzer in place. Cut the cable tie that holds the wire. 20. With the 7/16" wrench, disconnect the heavy current-carrying flat copper strap running from the shunt amplifier to the output rectifier bridge. POWER WAVE 450 Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC F-194 TROUBLESHOOTING & REPAIR FET MODULE REMOVAL AND REPLACEMENT (continued) 21. Remove the water cooler assembly in order to access the retainer clips that hold the bottom of the FET module assembly in place. (Complete removal of the unit should not be necessary.) Refer to the Water Cooler Removal and Replacement Procedure in this section of the module. 22. Remove the locking bar from the top of the subframe where it secures the FET module assembly. Depress the top and bottom retainer clips with the slot head screw driver so that the FET module assembly can slide forward. 23. Slowly lift and remove the subframe, making sure no clips, cable ties, or lead connections are still holding it. Replacement of the FET Module Assembly: 27. Carefully set the assembly into the bottom of the machine. The terminal label should face the front (toward the main transformer). 28. Connect all leads to their appropriate terminals on the assembly. Use the Wiring Diagram for reference. 29. Carefully position the subframe on top of the FET module assembly. Slide the assembly into place so that the retainer clips snap into their slots, top and bottom. Fit the locking bar into place on top of the subframe to secure the FET module assembly. 24. With the wire cutters, cut all necessary cable ties holding the FET module assembly to the wiring harness. Using needle nose pliers, disconnect the leads attached to the FET module assembly (all red and white leads should remain connected). Refer to the Wiring Diagram to determine which leads should be disconnected. The main transformer and the reconnect module must be free of the FET module assembly. Also disconnect the thermostat lead. 25. Carefully lift the FET module assembly and remove it from the machine. 26. With the FET module assembly removed, the main transformer, background choke, and output choke are now easily accessible. Refer to the Main Transformer Removal and Replacement Procedure in this section of the module. POWER WAVE 450 F-194 Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC F-195 TROUBLESHOOTING & REPAIR FET MODULE REMOVAL AND REPLACEMENT (continued) 30. Install the water cooler assembly. Refer to the Water Cooler Removal and Replacement Procedure in this section of the module. 31. With the 7/16" wrench, connect the heavy current-carrying flat copper strap running from the shunt amplifier to the output rectifier bridge. With a 5/16" wrench, install the two sheet metal screws holding the subframe bottom support section. Connect the green ground lead on the left side. 32. Swing the back of the subframe into place. With the 5/16" nut driver, install the sheet metal screw holding the ground leads to the right rear of the subframe. On the left side, clip the cable tie to hold the leads. 35. Slide the lift bail into place. With the 1/2" socket wrench, install the four bolts (two on each side of the machine) to secure the lift bail. With the 3/8" nut driver, install the two screws to secure the lift bail baffle. Feed the output cable strap through the lift bail baffle eyelet hole. Replace any necessary cable ties. 36. Connect the two plugs to the snubber board. 37. Connect the leads to the output rectifier bridge. Replace all necessary cable ties. 38. Install the molex plugs to the PC boards. Refer to Figure F.1, PC Board Connector Locations in this section of the manual. 39. Install the printed circuit board cover with two 5/16" screws. 33. With the 3/8" wrench, install the six resistors that are attached to the top of the subframe (four on the top right, two on the top left) according to the markings you made during disassembly. Also tighten the bottom resistors closest to the FET module assembly. 40. Replace any necessary cable ties for the wiring harness and other leads that were cut during disassembly. 34. With the Phillips head screw driver, install the screw that holds the piezo-electric alarm buzzer in place. Replace the cable tie that holds the wire. 43. Prior to applying full input power perform the Pre-Power Up Switch Board Test. 41. Install the machine case sides and top. 42. Install the handle and the lift bail rubber gasket. POWER WAVE 450 F-195 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Section TOC F-196 F-196 NOTES POWER WAVE 450 Return to Master TOC Return to Section TOC F-197 TROUBLESHOOTING & REPAIR MAIN TRANSFORMER REMOVAL AND REPLACEMENT WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual. Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC Return to Section TOC If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-800-833-9353 (WELD). DESCRIPTION The following procedure will aid the technician in removing the main transformer for maintenance or replacement. MATERIALS NEEDED Slot head screw driver Phillips head screw driver 5/16" Nut driver 3/8" Nut driver 5/16" Open end or box wrench 7/16" Open end or box wrench 3/8" Socket wrench 1/2" Socket wrench Wire cutters Machine Wiring Diagram in the Electrical Diagrams section of this manual This procedure takes approximately 2 hours 30 minutes to perform. POWER WAVE 450 F-197 F-198 F-198 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC TROUBLESHOOTING & REPAIR MAIN TRANSFORMER/CHOKE REMOVAL AND REPLACEMENT (continued) FIGURE F.75 - MAIN TRANSFORMER LOCATION 1. MAIN TRANSFORMER 1 Return to Master TOC Return to Section TOC PROCEDURE 1. Remove main input supply power to the machine. 2. With the 3/8" nut driver, remove the 4 screws that hold the handle to the machine. 3. Remove the rubber gasket (cover seal) from the lift bail. 4. With the 5/16" nut driver, remove the sheet metal screws from the case top. 5. With the 5/16" nut driver, remove the screws holding the right and left case sides. Remove the case sides by lifting up and out. Return to Master TOC Return to Section TOC 6. Perform the Capacitor Discharge Procedure described earlier in this section of the manual. WARNING Before continuing with the test procedure, perform the capacitor discharge procedure to avoid electric shock. 7. After you have completed the capacitor discharge procedure for all four switch boards, perform the FET Module Assembly Removal Procedure. Refer to the procedure in this section of the manual. After the FET module assembly has been removed, the main transformer and chokes are easily accessible. 8. With the 3/8" socket wrench, remove the four main transformer mounting bolts. 9. Disconnect the heavy leads between the main transformer and the choke assembly. You will need to cut the cable ties on the insulating sleeve and slide the sleeve forward to access the connection. 10. Lift the main transformer out. Remove the background or output chokes if necessary by removing any mounting bolts holding the chokes to the machine frame bottom. 11. After reassembly test on high voltage input and reconnect. POWER WAVE 450 Return to Master TOC Return to Section TOC F-199 TROUBLESHOOTING & REPAIR PRE-POWERUP SWITCH BOARD TEST PROCEDURE FOR REPLACEMENT OF SWITCH ASSEMBLY G2402-2 WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual. Return to Master TOC Return to Section TOC If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-800-833-9353 (WELD). DESCRIPTION The following tests and procedures must be performed if the main power FET module has been replaced in the Power Wave. These tests are necessary to ensure that the FET module has been installed and connected properly. This procedure takes approximately 2 hours to perform. BEWARE: Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC ISOLATED POWER SUPPLIES AND METERING MUST BE USED: CATASTROPHIC PC BOARD DAMAGE WILL OCCUR IF THE VOLTAGE SUPPLIES AND METERING ARE NOT COMPLETELY ELECTRICALLY ISOLATED. MATERIALS NEEDED Calibration and Test Overlay Isolation transformer (for oscilloscope) Isolation transformer 115vac @ 3 amps (min) Isolation transformer 115vac @ 2 amps (min) Variable transformer 3 amps (min) Oscilloscope *Current probe Voltmeters Fuse 5 amps (2). P70 adapter Female connector Male connector Male pin Female pin P23 adapter Male connector Female pin Toggle switch (SPST) L9660-255 circuit of figure #1 circuit of figure #3 Tektronic P6201 or equivalent S18247-6 S18249-6 S8053-122 S8053-123 S18247-6 S8053-123 *An alternate method of testing using an isolated oscilloscope may be used. POWER WAVE 450 F-199 Return to Master TOC Return to Section TOC F-200 TROUBLESHOOTING & REPAIR F-200 PRE-POWERUP SWITCH BOARD TEST PROCEDURE FOR REPLACEMENT OF SWITCH ASSEMBLY G2402-2 (continued) across one of the 7.5K ohm bleeder resistors (R9 or R10). See wiring diagram. FILTER CAPACITOR POLARITY TEST 1. Perform this procedure with the input power removed. Perform the CAPACITOR DISCHARGE Procedure to remove any charge from the input filter capacitors. 2. Configure the machine for 230VAC operation. 4. Attach the positive meter probe to wire #9 and the negative meter probe to lead #12. The resistance should slowly increase to a value between 3K ohms and 3.5K ohms. 5. Repeat the procedure for the other bleeder (7.5K ohm) resistor. Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC Return to Section TOC 3. Attach the ohmmeter (set to 1 K ohm range) FIGURE F.76 - AC SUPPLY LEADS ISOLATED 115 VAC FUSE 5A PRIMARY VOLTAGE VARIABLE 0 SETUP THE POWER WAVE FOR PRETEST 1. Turn the input power switch to the OFF position. 2. Unplug P73. See wiring diagram. 115 VAC INPUT RECTIFIER: AC1 (T1) INPUT RECTIFIER: AC3 (T3) WARNING ALL AC SUPPLIES MUST BE ELECTRICALLY ISOLATED (Isolation transformers). THE PRINTED CIRCUIT BOARDS WILL BE DAMAGED IF THE AC SUPPLIES ARE NOT ISOLATED. 3. Install the L9660-255 Calibration & Test overlay into the Power Wave. 4. Construct an isolated variable AC supply circuit as shown in Figure F.76 using the following equipment: Isolation transformer 115vac @ 3 amps. 5 amp Variac. 5 amp Fuse. 5. Connect the variable AC supply leads to the Power Wave input rectifier terminals AC1 (T1), and AC3 (T3). See Figure F.76. Make certain the variac is at zero volts output. 6. Monitor the filter capacitor voltage as per Figure F.77. WARNING WARNING: ALL METERS AND OSCILLOSCOPES MUST BE ELECTRICALLY ISOLATED (Isolation transformers). POWER WAVE 450 Return to Master TOC Return to Section TOC F-201 TROUBLESHOOTING & REPAIR PRE-POWERUP SWITCH BOARD TEST PROCEDURE FOR REPLACEMENT OF SWITCH ASSEMBLY G2402-2 (continued) FIGURE F.77 - FILTER CAPACITOR VOLTAGE + 9L Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC 400 VDC VOLTMETER + 9M 400 VDC VOLTMETER R 10 12M WARNING WARNING MAKE SURE FILTER CAPACITORS ARE DISCHARGED ALL AC SUPPLIES MUST BE ELECTRICALLY ISOLATED (isolation transformers). THE PRINTED CIRCUIT BOARDS WILL BE DAMAGED IF THE AC SUPPLIES ARE NOT ISOLATED. Switch (SPST) Fuse (5 amp max) P70 adapter Return to Master TOC R9 12L 1. Construct a 115VAC pretest power supply as per Figure F.78 using the following: Return to Section TOC F-201 POWER WAVE 450 Return to Master TOC Return to Section TOC F-202 F-202 TROUBLESHOOTING & REPAIR PRE-POWERUP SWITCH BOARD TEST PROCEDURE FOR REPLACEMENT OF SWITCH ASSEMBLY G2402-2 (continued) FIGURE F.78 - PRETEST POWER SUPPLY PRETEST POWER SWITCH 5A FUSE Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC Return to Section TOC ISOLATED 115 VAC P70 P70 2 2 3 3 5 5 6 6 Connect the pretest power supply to plug P70 as per Figure F.78. See wiring diagram. ARC START PW450 WITH WIREFEEDER The arc start may be initiated by any of the following methods: 1. Release wire tension and pull gun trigger. 2. Jumper pins C and D on wire feeder input connector. 3. Jumper pins D and E on front panel amphenol connector near welding output terminals. POWER WAVE 450 Return to Master TOC Return to Section TOC F-203 F-203 TROUBLESHOOTING & REPAIR PRE-POWERUP SWITCH BOARD TEST PROCEDURE FOR REPLACEMENT OF SWITCH ASSEMBLY G2402-2 (continued) ARC START FOR PW450 ROBOTIC 1. Construct and connect an arc start circuit as per Figure F.79. 3. Leave plug J103 connected to the interface board. 2. Install leads and an arc start switch into plug J103 pin 10 to pin 11 on the interface PC board. Make sure the arc start switch leads are long enough to reach outside of the machine case. 1 500 2 501 3 542 4 543 5 R 6 U 7 B 8 539 J103 9 541 INTERFACE BOARD 10 544 11 545 12 512 13 522 14 67 Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC FIGURE F.79 - SHUNT CONNECTIONS Return to Master TOC INTERFACE RECEPTACLE INSTALL LEADS AND SWITCH ARC START SWITCH 15 16 PRETEST MACHINE CONNECTIONS 1. Make sure the machine shunt connections are tight. 2. Connect the Power Wave output terminals to a grid load. Return to Section TOC TO J34 P83 2. Remove one wire from the output diode heat sink thermostat. The thermostat LED should turn ON. See Wiring Diagram 3. Turn the grid OFF. 3. Reconnect the wire to the output diode heat sink thermostat. The thermostat LED should turn back OFF. PRETEST POWERUP 1. Turn on the pretest power switch. See Figure F.78. The Power Wave should beep and display “SELECT A FUNCTION”. 4. Turn off the pretest power switch See Figure F.78. THERMOSTAT TEST 1. Check the thermostat LED (upper right hand corner of the Power Wave Display Panel) it should be OFF. FET DRIVE TEST Construct plug jumper as per Figure F80. POWER WAVE 450 Return to Master TOC Return to Section TOC F-204 TROUBLESHOOTING & REPAIR F-204 PRE-POWERUP SWITCH BOARD TEST PROCEDURE FOR REPLACEMENT OF SWITCH ASSEMBLY G2402-2 (continued) FIGURE F.80 - PC BOARD RECEPTACLE P 23 2 3 Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC Return to Section TOC 5 6 1. Unplug P23 and insert jumper plug into PC board receptacle. See Figure F.80. 5. Turn ON the arc start switch. See Arc Start PW450 with wire Feeder or Figure F.79. 2. Turn ON the preset power switch. Figure F.78. 6. Attach the oscilloscope probes to each of the following eight test points. Each test point should look like the oscilloscope picture in Figure F.81. See 3. Press the MANUAL PROCEDURE ENTRY (64) key on the Calibration & Test overlay and using the arrow keys (100) and (101) change the Power Wave to “Process 1 Setup 1-1” mode. 4. Set the Oscilloscope for: 20 V/div. 20 uS/div. WARNING ALL METERS AND OSCILLOSCOPES MUST BE ELECTRICALLY ISOLATED (isolation transformer). POSITIVE PROBE #1 P40 pin 14 #2 P40 pin 9 #3 P40 pin 6 #4 P40 pin 1 #5 P41 pin 15 #6 P41 pin 9 #7 P41 pin 7 #8 P41 pin 1 NEGATIVE PROBE P40 pin 16 P40 pin 11 P40 pin 8 P40 pin 3 P41 pin 16 P41 pin 10 P41 pin 8 P41 pin 2 POWER WAVE 450 Return to Master TOC Return to Section TOC F-205 TROUBLESHOOTING & REPAIR F-205 PRE-POWERUP SWITCH BOARD TEST PROCEDURE FOR REPLACEMENT OF SWITCH ASSEMBLY G2402-2 (continued) FIGURE F.81 - FET DRIVE SIGNAL Return to Master TOC Return to Section TOC 0V 20uS/Div 20V/Div SNUBBER SIGNAL TEST 1. Adjust the grid for a “light” load. 2. Turn ON the variable AC supply applied to the primary circuit. See Figure F.76. 6. Attach the oscilloscope to each of the following eight test points. Each test point should look like the oscilloscope picture in Figure F.82. WARNING Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC 3. Slowly increase the voltage until the filter capacitor voltage is 25VDC. See Figure F.77. 4. Adjust the grid load to get 5 amps output from the Power Wave. DO NOT PULL MORE THAN 7-8 AMPS OUTPUT FROM THE POWER WAVE. ALL METERS AND OSCILLOSCOPES MUST BE ELECTRICALLY ISOLATED Isolated Transformer). 5. Set the Oscilloscope for: 5 V/div/ 20 uS/div. POSITIVE PROBE R1 12E or 12L R2 402 R3 12F R4 404 R5 405 R6 406 R7 12H R8 408 NEGATIVE PROBE 401 9E or 9L 403 9F 12G or 12M 9G or 9M 407 9H Turn the variable AC primary supply to zero volts and then turn it OFF. See Figure F.76. Once the filter capacitor voltage drops to zero, turn the arc start switch OFF. See Figure F.79. POWER WAVE 450 Return to Master TOC Return to Section TOC F-206 TROUBLESHOOTING & REPAIR F-206 PRE-POWERUP SWITCH BOARD TEST PROCEDURE FOR REPLACEMENT OF SWITCH ASSEMBLY G2402-2 (continued) FIGURE F.82 - SNUBBER SIGNAL Return to Master TOC Return to Section TOC 0V 20uS/Div 5V/Div 460VAC RECONNECT 1. Reconfigure the machine for 460VAC operation. 2. Turn ON the variable AC supply applied to the primary circuit. See Figure F.76. Return to Master TOC Return to Section TOC 3. Turn on the arc start switch. See Arc Start PW450 or Figure F.79. 4. Slowly increase the voltage until filter capacitor voltage is 25VDC. NOTE: Monitor both capacitor voltages. If the two voltages are not within 5 to 8 VDC of each other STOP and check wiring to the FET switch board assembly and also the individual switch boards. See Figure F.77. 5. Adjust the grid load to get 5 amps output from the Power Source. DO NOT PULL MORE THAN 7-8 AMPS OUTPUT FROM THE POWER WAVE. 6. Repeat the previous Snubber Signal Test by checking the eight test points. Return to Master TOC Return to Section TOC OUTPUT SIGNAL TEST 1. Make certain the machine is configured for 460VAC operation. 4. Slowly increase the voltage until the filter capacitor voltage is 25VDC. See Figure F.77. 5. Adjust the grid load to get 5 amps output from the Power Wave. DO NOT DRAW MORE THAN 7-8 AMPS OUTPUT FROM THE POWER WAVE. 6. Set the Oscilloscope for: 5 V/div. 10 uS/div. WARNING ALL METERS AND OSCILLOSCOPES MUST BE ELECTRICALLY ISOLATED. 7. Connect the positive oscilloscope probe to the Power Wave positive welding output terminal and the negative probe to the negative welding output terminal. The output should look like the oscilloscope picture in Figure F.83. 2. Turn ON the variable AC supply applied to the primary circuit. See Figure F.76. 3. Turn ON the arc start switch. See Arc Start PW450 or Figure F.79. POWER WAVE 450 Return to Master TOC Return to Section TOC F-207 F-207 TROUBLESHOOTING & REPAIR PRE-POWERUP SWITCH BOARD TEST PROCEDURE FOR REPLACEMENT OF SWITCH ASSEMBLY G2402-2 (continued) FIGURE F.83 - OUTPUT SIGNAL Return to Master TOC Return to Section TOC 0V 10uS/Div 5V/Div 8. Turn the variable AC primary supply to zero volts and then turn it OFF. See Figure F.76. Return to Master TOC Return to Section TOC 9. Once the filter capacitor voltage drops to zero, turn the arc start switch OFF. See Arc Start PW450 or Figure F.79. PREPARE MACHINE FOR NORMAL OPERATION 1. Turn OFF the 115VAC pretest power circuit. See Figure F.78 2. Make certain the filter capacitors are completely discharged. Remove the variable AC primary supply. See Figure F.76. 3. Remove the 115VAC pretest power circuit. See Figure F.78. 4. Reconnect plug P70. 5. Remove the jumper plug in P23. See Figure F.80 6. Reconnect P23. OUTPUT TESTS SETUP The filter capacitors must be discharged before continuing. Make sure the Power Wave is configured for 460VAC operation. 1. Connect a power input cable to CR1. DO NOT APPLY INPUT VOLTAGE AT THIS TIME. 2. Connect the grid load to the Power Wave output terminals. Make sure the grid load is OFF. PRIMARY OVER CURRENT TEST 1. Connect a current probe to the oscilloscope and set it for: 10 mV/div. (should be equal 10 mA/div.) 10 uS/div. 2. Put the current probe on lead 221 at J21 pin 1. See Wiring Diagram 3. Loosely assemble the sheet metal case to the Power Wave. 4. Apply input power to the machine and turn the Power Wave power switch ON. Return to Master TOC Return to Section TOC 7. Reconnect P73. POWER WAVE 450 Return to Master TOC Return to Section TOC F-208 F-208 TROUBLESHOOTING & REPAIR PRE-POWERUP SWITCH BOARD TEST PROCEDURE FOR REPLACEMENT OF SWITCH ASSEMBLY G2402-2 (continued) FIGURE F.84 - PRIMARY CURRENT SIGNAL Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC 0V 10uS/Div 10V/Div 5. Press the MANUAL PROCEDURE ENTRY Key on the Calibration and Test Overlay and change the Power Wave to “Process 1 Setup 1 -8” mode. PREPARE MACHINE FOR NORMAL OPERATION. 1. Turn the power switch OFF and remove input power to the machine. 6. Turn the arc start switch ON. See Arc Start PW450 or Figure F.79. 2. The input capacitors must be discharged before continuing. 7. Adjust the output grid load to get 400 amps at 36VDC. The oscilloscope picture should look like Figure F.84. 3. Remove the capacitor voltage monitoring leads. See Figure F.77. *ALTERNATE TEST (without current probe) 1. Connect a transformer isolated oscilloscope as follows: Set oscilloscope for .2v/div and 10us/div Probe J21 pin 1 wire #211 Common J21 pin 5 wire #215 5. Remove the output cables from the Power Wave. 4. Remove the power input cable from CR1. 6. Remove the arc start switch circuit. 7. Enable the water cooler if it was enabled at the start of this test. 3. Check the capacitor voltages. The capacitor voltages must be within eight volts of each other. Return to Master TOC Return to Section TOC 2. Observe a waveform similar to Figure F.84. Equal amplitude and symmetry of the pulses is important. 4. Turn the arc start switch OFF. See Arc Start PW450 or Figure F.79 5. Turn OFF the Power Wave and remove the input power. Make sure the filter capacitors are completely discharged. See Figure F.77. POWER WAVE 450 Return to Master TOC G-1 TABLE OF CONTENTS ELECTRICAL DIAGRAMS Electrical Diagrams Section................................................................................................Section G Wiring Diagram ...........................................................................................................................G-2 Schematic Complete Machine ..................................................................................................G-3 Control PC Board Schematic (1 of 4).........................................................................................G-4 Control PC Board Schematic (2 of 4).........................................................................................G-5 Control PC Board Schematic (3 of 4).........................................................................................G-6 Control PC Board Schematic (4 of 4).........................................................................................G-7 Control PC Board Assembly ......................................................................................................G-8 Return to Master TOC Display PC Board Schematic (1 of 2).........................................................................................G-9 Display PC Board Schematic (2 of 2).......................................................................................G-10 Display PC Board Assembly ....................................................................................................G-11 Power PC Board Schematic ....................................................................................................G-12 Power PC Board Assembly ......................................................................................................G-13 Protection PC Board Schematic ..............................................................................................G-14 Protection PC Board Assembly................................................................................................G-15 Square Wave Protection PC Board Schematic........................................................................G-16 Square Wave Protection PC Board Assembly .........................................................................G-17 Shunt PC Board Schematic .....................................................................................................G-18 Shunt PC Board Assembly.......................................................................................................G-19 Snubber PC Board Assembly ..................................................................................................G-21 Switch PC Board Schematic....................................................................................................G-22 Switch PC Board Assembly .....................................................................................................G-23 RS232 Connections..................................................................................................................G-24 Return to Master TOC Return to Master TOC Snubber PC Board Schematic .................................................................................................G-20 POWER WAVE 450 1/96 G-1 LEFT SIDE OF MACHINE 204 5 76 5 205 TO 6 206 6 7 207 7 8 208 6 291 7 292 8 276 P82 9 275 10 294 P83 J92 11 12 321A 13 TO J30 14 1 3 4 L3A 7 455 8 456 J22 4 5W 5 5R 4 6 226 7 227 TO 10 223 J37 11 224 12 225 372 TO 2 232 3 LCD DISPLAY 233 J14 4 373 1 261 2 262 3 264 4 266 5 265 6 263 J37 J23 15 15 J15 1 300 2 301 PIEZO 1 448 443 3 442 J16 7 449 J44 8 445 9 446 10 447 J32 234 RECT. THERM 5 235 6 236 SWITCH THERM 333 334 303 TO P81 7 306 8 307 P70 10 2 11 3 42C 12 4 102D 5 32D TO 106A 8 31B P82 10 42B 11 102B 12 32B 13 32C 14 105A 9 1 351 2 1 261 2 262 3 263 4 264 3 TO 7 5 265 6 266 4 6 J36 J22 111A TO 4 112A 1 117A P83 2 J28 3 8 J37 TO 361 362 211 4 215 223 224 356 351 373 4 374 J38 9 2 293 3 296 J92 J39 3 4 234 TO 3 232 4 233 J23 POS TO INPUT RECT. POS TO INPUT RECT. 12A TO SWITCH BD #1 12B TO SWITCH BD #2 7 8 TO 9 LCD 9J TO J31 408 T3 167A 3 443 TO SWITCH BD #3 4 5W 5 5R 6 TO 444 7 8 445 9 446 10 447 11 448 12 449 J40 TO R6 F3 CONN. D5 D6 TO SWITCH BD #4 S4 D7 D8 TO S3,S4 CONN. D10 D11 BUS BAR #1 D12 TO D13 SHUNT TO SECONDARY PRIMARY (BOTTOM) (BOTTOM) 3R 3R 406 406 3T 3T 12C 9C TO R6 9G S3,S4 D7-D10 LEAD 461 - TO J62 TO CHOKE 3W TO REC. SWITCH TO CT CONNECTION FOR 3W TO PRIMARY TO REC. SWITCH TO R5 3B TO R5 9C 4T 4T 405 405 TO J40 NEG A 32B B D 105A E 77 J34 NEG C 102B TO 76 F 75 G 121A H I 32C 31B J 42B K 111A (R) L M 4R 4R 4W 4W 3W 3W 3R CONN. TO J40 4B TO R8 D11-D14 TO PRIMARY TO REC. SWITCH D16 D18 F1,F2 CONNECTION FOR F1,F2 CONN. D15-D20 TO R7 TO REC. SWITCH CURRENT TO R8 TRANSFORMER 4T TO R7 4B 3R TO SWITCH BD #1 12L TO R9 9L TO R9 9L TO R2 + 1T TO 1B J40 TO TERM STRIP SWITCH BOARD #3 TO TERM STRIP LEFT BOTTOM BOTTOM FAN TERMINAL STRIP TOP FAN 12D 12D 12H 9D 9D 9H - 4B 4B 407 407 TO TO J36 J41 H1 TO SW1 TO P4 H1 H1A C4 N.D. TO P73 H2 H2 4R 4R 4W 4W SWITCH BOARD #4 2W 2W RIGHT TOP 2R TO R1 TO PRIMARY TOP FAN TO P73 TO REC. SWITCH 4B TO R2 1T TO REC. SWITCH 1B 10 2W 401 2T 2T 9A 9A TO R1 12E 1T 1T TO R2 402 402 TO R6 TO J41 TO CT S1 12A TO P4 H3 HXA N.C. N.D. SWITCH TO P73 TO REC. SWITCH THERM H4 H4 TO J23 C1 9E 12A H3 TO REC. SWITCH 2R 401 P4 TO P73 BOTTOM FAN N.C. 3B 3B 361 4T 467 TOP FAN TO TERM STRIP BOTTOM FAN RECT. THERM TO J23 9M ELECTRODE C3 408 408 (TO SWITCH BDS) 237 (FROM TRANSFORMER) 9E - TO REC. SWITCH TO CT D19 TO SWITCH BD #1 RECEPTACLE #1 N.C. F4 CONNECTION FOR S1,S2 TO P83 N WIRE FEEDER LEFT TOP TO TERM STRIP TO CT D14 12E 12C 12G CONNECTION FOR F3,F4 D1-D6 S1,S2 .0047/400V 8 NEG 112A (W) TO CT 7 5 6 POS (TOP) 4T F3,F4 D4 J16 J22 467 GROUND 464 462 201 203 207 461 1 4 3 2 10 9 8 7 6 1 5 4 3 2 15 14 13 16 9 8 11 12 7 10 5 6 1 4 3 2 6 5 1 4 3 2 AC3 PRIMARY SHUNT - AC2 J60 235 TO J62 AC1 J10 TO C15 400A RECEPTACLE #2 TP6 INPUT TO CT D3 P82 N WIRE FEEDER 67 TO F3,F4, R11, WORK 206 202 205 204 208 221A 167A 67 499 121A 212 213 ELECTRODE R W RECTIFIER L M RECTIFIER R15 TO P82, P83, J K 117A (R) 118A (W) TP4 362 TO OUTPUT I 31C 42C VOLTAGE=380-460V 14 BUS BAR #1 H 32E 12D TO SWITCH BD #4 TO 13 TO F G 221A J60 TO J30 E 275 J34 POS R16 J20 D 276 TO SWITCH BD #4 (TOP) 11 TO J28 10 2W 12 J21 T3 277 12K TO J31 TO SWITCH THERM 15 T2 C 106A J10 3T C16 16 T1 TO J30 102D TO TO J32 9D TO SWITCH BD #4 12C TO SWITCH BD #3 D20 10 9C TO SWITCH BD #3 T1 TO J31 D1 442 5 FRONT OF MACHINE TO J31 D2 2 6 J19 9K A B 326 MAIN TRANSFORMER LEFT SIDE D17 2 TO SWITCH BD #2 SECONDARY J13 TO 1 2 TO SWITCH BD #4 D15 4 1 R8 25 25W TO CT J12 3 9B J35 TO 372 324 CR1 J27 J21 2 TO J32 32D S3 D9 TO TO SWITCH BD #1 R13 1 J44 371 L3 CONNECTOR 225 3 P83 1 1 P82 118A 4 1 3 R7 C13 356 2 TO SWITCH BD #4 R12 J43 5 TO 10 236 TO P73 TO REC. SWITCH 1R 1R 1W 1W SWITCH BOARD #1 2W 2R RIGHT BOTTOM H5 TO RECT. THERM H5 237 1T J60 SNUBBER BD J61 J62 SHUNT AMPLIFIER AMPTROL/ B REMOTE CONTROL P1 TO J62 177A 176A C 175A D 105B E 102C 462 TO J93 1 291 2 292 3 J92 TO 25W 401 TO J10,J38 294 TO SWITCH BD #1 402 TO SWITCH BD #1 12L TO R1 12M 40 100W TO J15 TO PRIMARY TO R5 TO REC. SWITCH 300 + PIEZO 301 - BUZZER TO J62 J93 2 177A 3 176A 4 175A 5 102C 2T F1 TO P1 12F TO SWITCH BD #2 9F TO CT TO R4 TO SWITCH BD #2 TO J41 8 PROTECTION BD (SQUARE WAVE) N.D. COOLER CIRCUIT BREAKER 453 454 455 456 3 4 5 6 454A 455A 456A 403 TO SWITCH BD #2 404 6 5 4 1 3 2B 2B 9B 9B 9F 12B 12B 12F 1B 1B 404 404 N.C. 1R 1R 1W SECONDARY PRIMARY (BOTTOM) (BOTTOM) TO SWITCH BD #2 P3 TO SWITCH BD #2 33 2 334 3 F2 6 H5 3 H4 2 H3 4 H2 1 H1 (380-415) TO SWITCH BOARD #2 N 333 5 336 6 P70 U J14,J23,J26 J37,J38,J39 J32,J33,J35 J11,J20,J21 J43 J50,J92 J62,J93 3 4 4 3 6 J16,J22,J42,J44 1 TERM STRIP (200-208) R J27,J28,J36 1 H2 (42V) J32 TO (220-230) H1 (115V) J3,J4 2 H3 (24V) J12,J13,J15 1 H4 W C. BREAKER N.B. D1 THRU D6 OUTPUT DIODES ARE A MATCHED SET. D7 THRU D14 OUTPUT DIODES ARE A MATCHED SET. D15 THRU D20 OUTPUT DIODES ARE A MATCHED SET. 321 323 P71 H5 N.A. SINCE COMPONENTS OR CIRCUITRY OF A PRINTED CIRCUIT BOARD MAY CHANGE WITHOUT AFFECTING THE INTERCHANGEABILITY OF A COMPLETE BOARD, THIS DIAGRAM MAY NOT SHOW THE EXACT COMPONENTS OR CIRCUITRY HAVING A COMMON CODE NUMBER. 1 4 (440-460) C2 J33 1W TO (24V) NOTES : 2B 2 AUXILIARY TRANSFORMER 403 1B 6 5 4 3 2 1 TO MAIN CHOKE 453A HXB H1A WATER COOLER GND HXA HXB TO 2R 403 TO CT S2 25 25W TO J11 P4 PROTECTION BD (SQUARE WAVE) R4 R3 25 25W TO S3, S4 CONNECTION N.D. P73 J17,J18,J25,J61 1 4 5 8 1 5 6 J24,J31,J34 10 J10,J19,J30,J40,J41,J60 6 1 7 1 8 12 8 14 9 16 N.C. C1, C2, C3, C4 CAPACITORS ARE A MATCHED SET. TERM STRIP J4 RIGHT SIDE J3 WATER COOLER 499 TO R3 105B 7 TO P70 TO J60 TO REC. SWITCH 6 464 32A + TO R4 TO SWITCH BD #1 CIRCUIT 33 TO R3 (TOP) 296 1 2W J41 PRIMARY R11 TO J33 ELECTRODE R10 7.5K 5 RECEPTACLE BREAKER R9 7.5K 25W (TOP) 293 4 6 F 5A R2 25 25W SECONDARY BOARD A R1 25 25W + J50 WORK FOOT Return to Master TOC 227 11 2 TO 3 9H 9A VOLTAGE=200-230V J14 3 2 KEYPAD 9 10 4 32E 7 10 2 J27 5 226 1 6 9 1 4 6 12 J43 L2 TO SWITCH BD #3 25 25W 407 TO 8 C. BREAKER L1 BLOW FUSE 440-460V C12 221 7 31C 1 5 J26 406 RECTIFIER 4 J42 'A' P81 RS232 F1 5A SLOW TP5 5 8 20 NEG TO INPUT RECT. OUTPUT 3 336 9 10 6 2W 2R 2 TO 380-415V NEG TO INPUT RECT. .0047/400V J35 5 15 16 1 P71 220-230V H3 TO TERM STRIP N.B. TO CR1 TO SWITCH BD #4 1 & 2 14 8 1 Return to Master TOC 32A 5 3 9 Return to Section TOC 324 4 2 302 4 J18 12 326 3 6 3 TO J18 12J 321 6 4 6 BDS 1R 2 2 J17 SWITCH 11 1 7 1 2R 1W 5 J33 2W 8 9 323 H2 TO TERM STRIP 12J 13 4 1 11 TO SWITCH BD #3 TO 7 10 7 307 TO A SYSTEM GROUND PER L3A RECONNECT SWITCH 8 J25 R6 25 25W 12H 9J 9K 6 7 12 KEYPAD J41 303 TO SW1 200-208V R5 25 25W 405 6 TO SWITCH 6 L1A 321B REAR OF MACHINE N.E. 5 3 J34 TO 5 2 14 444 4 1 J39 13 5 4 11 4 6 1R 3 14 6 4 2 2 RECONNECT TO SW1 TO SW1 5 H5 TO TERM STRIP 4R 3 13 3 BUZZER 3 TO SWITCH BD #3 TO R10 H4 TO TERM STRIP 2 12 2 J24 9G 9M 4W 1W 9 4 TO TO SWITCH BD #3 TO R10 3 & 4 3R 1 10 1 J26 16 12K 8 5 TO J19 T3 7 TO 4 TO 11 14 J42 1 3 BDS 13 J31 TO J44 371 1 2 SWITCH 3W 12 6 374 3 4R 9 14 221 9 1 2 J12 8 10 13 16 12G 12M R 8 J13 Return to Master TOC J50 T1 J40 3 NATIONAL ELECTRICAL CODE. TO 7 12 3 J3 6 TO CR1 CR1 2 TO 5 N.D. Return to Section TOC W 1 454 TO CR1 POWER SW1 1 L1A SW1 215 9 3R 4W 6 2 TO J17 5 TO 8 (MACHINE SHOWN CONNECTED FOR 440-460V) 3W 4 H1B 10 453 2 J11 5 11 7 1 TERM STRIP 2 TO J36 8 TO LINE 213 5 16 H1 LOAD 211 212 6 H1B (TOP) 1 3 1 3 PLANE #2 4 1 302 306 4 2 GROUND 3 PLANE #1 J30 2 321A 2 GROUND TO J61 4 J21 15 TO J30 4 203 4 G + 321B 201 202 3 J20 W + J10 TO FUSE 77 1 1 2 750 277 4 V + 75 3 U THIS AREA VIEWED FROM LEFT SIDE OF MACHINE POWER BOARD OFF 1 2 PROTECTION BOARD ON CONTROL BOARD OFF DISPLAY BOARD - Return to Master TOC WIRING DIAGRAM - POWER WAVE 450 3 Return to Section TOC G-2 ELECTRICAL DIAGRAMS - Return to Section TOC G-2 N.D. THESE ITEMS ARE ONLY USED ON A 450 MACHINE RIGHT SIDE OF MACHINE 7 WITH A WATER COOLER. N.E. TOROID DOES NOT APPEAR ON EARLIER MODELS. CONNECTOR CAVITY NUMBERING SEQUENCE (VIEWED FROM COMPONENT SIDE OF BOARD) ELECTRICAL SYMBOLS PER E1537 8-28-98B G3617-1 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 450 SCHEMATIC - COMPLETE MACHINE TRIGGER 24V, 42V, & 115V FROM PROTECTION BD. TX 303 4J17 2J17 203 3J40 3R 202 11J40 3R 206 +5 Vb 2J14 262 2J26 5J14 265 5J26 24V TRIGGER CIRCUIT 24V GD SERIAL COMM. 6J14 263 3J26 3J14 264 4J26 40mA 223 10J42 +15 Va -15 Va 6J22 226 6J42 -15 Va 11J22 224 11J42 +5 Va 12J22 225 12J42 +5 Va 373 4J13 0V 372 2J13 24V 9D 208-230V 1J31 CAP.VOLTAGE NOISE_GND 3J39 9J 12J31 12J 12B 12D 9J 12A 12K 12J NEG 12K 10J31 14J31 OUTPUT DISABLE ARC & WORK VOLTAGES FROM WIRE FEEDER RECEPTACLES 203 202 206 201 207 6J61 7J61 8J61 WF2 ARC VOLT.FEEDBACK WF2 WORK VOLT.FEEDBACK WF1 ARC VOLT.FEEDBACK WF1 WORK VOLT.FEEDBACK FROM CONTROL BD. 320V 160J 3B 9D 3500uF 450V .047/1200 (+)CAP3,4 9K MAIN CHOKE + 4B (-)CAP1,2 R7 POS ELECTRODE 12D FEEDED 25/25 4B THRU CT 407 4J39 (OV = RUN 1K 5V = DISABLE) 4R R11 40/100 4W GA OUTPUT DISABE 4J23 234 2J23 232 3J23 233 448 1J16 +5 Vb 446 9J16 -5 Vb 1J21 211 RECTIFIED CT VOLT. (-) 5J21 215 3J21 213 +15 Va -15 Va SHUNT CURRENT FROM SHUNT BD. -8 Vb +5 Vc 6J21 216 2J21 212 8J21 218 PWR_DN ( 5mA AT 400A WELDING CURRENT) D (RS232) DISPLAY BD.GND GA GD A 7J41 2W 15J41 2W 8J41 2R 2R NOISE_GND b GRS232 15V 5J23 CONTROL BOARD DISPLAY BOARD +5 Vb 11J44 448 -5 Vb 9J44 446 +5 Vc c_GND 6J23 POWER BOARD c PIEZO BUZZER 237 SWITCH BD. OUTPUT RECTIFIER TSTAT TSTAT 445 10J44 b_GND PWR_DN 8J44 ISOLATED DC SUPPLIES,TO DISPLAY BD. 6J44 447 444 12J44 449 3J44 443 2J44 442 220-230V 380-415V 467 SLOW BLOW FUSE (+) (-) 440-460V H5 211 3J36 215 4J36 361 1J36 (-) 362 2J36 (+) SHUNT BD. GND Iout H3 H4 WORK "A" 4J50 1R +15 Vb -8 Vb (XIRQ) (-) 1W 1R NOISE_GND +15 Vb (+) 9J41 2J41 10J41 GATE SIGNAL F1 5A 1W TOP FAN SWITCH BOARD #1 BOTTOM 2W (RIGHT TOP) FAN 218 9J42 RECTIFIED CT VOLT. (+) SHUNT BOARD 200-208V H2 1J41 16J41 FREQ.MODULATED RECONNECT PANEL PROTECTION BD. GND e -15 Va e_GND +15 Va 4J44 40mA CURRENT SOURCE d - + RECONNECT PANEL 2J39 232 15 V 10J16 2J15 2.7/10 3B FREQ.MODULATED 233 VB 447 301 0 VAC,FROM 1J33 42VAC,FROM 3J33 DIFFERENTIAL CAP.VOLT. A WHEN WF2 TRIGGER CLOSE 1J15 1J35 6J35 .047/1200 D1-D6 IN PARALLEL R8 25/25 2R 402 H1 H2 H3 H4 H5 R2 TERMINAL STRIP FEEDED 25/25 1T 9A 9A 1T THRU CT .047/1200 371 1J37 374 4J37 373 3J37 372 2J37 H1 H1A 24VAC WHEN WF1 OR FOOT AMPTROL TRIGGER CLOSE H2 H2A H3 H3A H5 H5A H4 H4A R9 7.5K/25 C1 3500uF 450V .047/1200 AUXILIARY TRANSFORMER #1 24VAC WHEN WF2 TRIGGER 321 1J32 CLOSE PROTECTION BD. 3J32 293 2J38 296 3J38 24VAC WHEN FOOT AMPTROL CLOSE,TO 4J37 24VAC FROM 4J33 H5 24VAC SUPPLY P71 FOR 115V (N.E.) 323 336 6J33 12A (24V) 4 6 42V 3J33 333 5 24V 4J33 334 3 0 1J33 33 2 6 H4 R (115V) U (42V) P70 N (24V) W R1 H5 12A 2T 25/25 (440-460) 5 401 (380-415) OUTPUT 1R RECTIFIER 1W H3 H4 (220-230) H2 H3 PROTECTION BOARD 2T 1 2 3 H2 1 H1 (200-208) H1 SWITCH BOARD #2 (RIGHT BOTTOM) P73 10/2 2W DC SUPPLIES FROM CONTROL BD. 24V 8J16 .047/400 SHUNT BD.GND 227 7J22 WHEN WF1 TRIGGER OR FOOT AMPTROL CLOSE 3J16 351 356 (1250Hz WHEN CAP.BALANCED) VB d FET BANK B DRIVER 235 ISOLATED DC SUPPLIES FROM POWER BOARD 0V 300 42VAC SUPPLY, FROM PROTECTION BD. a_GND +18 Vd FET BANK B CAP.DIFFERENTIAL VOLT. 2J12 445 6J62 .0047/400 2.7/10 50uS +15 Va PRESSURE 4J12 442 121A 67 3R 1J50 5R 5W CURRENT 10V 371 2J16 .047/400 3W (LEFT BOTTOM) V A WIPER 374 443 167A 9J60 8J60 320V 160J 6J50 5R 5W 10V (-) 6J16 320V 160J 216 5J22 4J22 5J44 SERIAL LOOP WIPER (+) 7J16 SNUBBER BOARD OUTPUT 213 40mA WIPER 1J11 449 221A 15J60 RECTIFIER 321B FROM 4J28 3J11 444 13J60 11J60 212 WF1 WF2 40mA COUPLED TO 3J26 454 8J11 & BUFFER SWITCH BOARD #4 SENSING CIRCUIT a 10V 453 456 4R 234 10J22 GA 7J11 AC3 NEG DIVIDER SHUNT CURRENT TO CONTROL BD. 7J10 AC2 NEG INPUT RECTIFIER 24VAC WHEN WF2 GND (Io = 5mA AT 400A WELDING CURRENT) 292 AC1 POS 4W SNUBBER BD. 3J50 6J10 455 WATER COOLER CONTROL 24VAC TRIGGER VOLTAGES FOOT AMPTROL REMOTE CONTROL POT.MIN Return to Master TOC 9J10 10J10 4R 24VAC,FROM 4J33 4T NATIONAL ELECTRICAL CODE. 275 291 4R < 25uS +15 Va GA 294 FEEDED THRU CT 405 TP6 .047/1200 GA POT.MAX 0VAC,FROM 1J33 12C DEAD TIME 16J19 POT.WIPER 4W 8J40 1J43 5J42 NOISE_GND 40mA 15J19 8J10 6J34 380-460V 14J19 1J10 .047/1200 25/25 TP5 GATE SIGNAL COUPLED TO 1J27 13J19 3J10 32E R5 TP4 9B 6J26 CIRCUIT 10J19 277 14J40 A 266 4J14 11J19 276 42VAC,FROM 3J33 0VAC 9A 5V=OPEN 1.5V=CLOSE GD ISOLATED WF2 TRIGGER 12J19 75 326 C3 3500uF 450V 9K GD +5Vb 9J19 76 6J32 7.5K/25 C4 8J19 5J10 324 R10 T3 4W 16J40 3J43 FET BANK A 221 1J22 DRIVER WF2 7J19 4J10 4J32 T2 TRIGGER 6J19 77 T3 10/2 236 CONNECTOR 4J19 5J19 0VAC,FROM 1J33 3J34 7J34 T1 T3 408 FET BANK A CIRCUIT 5J34 4J34 T1 4T 115VAC,FROM 6J33 32D 102D T1 11J30 16J30 TRIGGER CLOSE,TO 4J37 42C 106A .047/1200 125/40 125/40 24VAC d ISOLATED WF1 TRIGGER 1J34 3T 9C 9C +15 Va TRIGGER 8J17 1J19 3J19 P81 V 5V=OPEN 1.5V=CLOSE 2J19 RS232 207 1J26 WF1 24VAC WHEN WF1 3T CR1 326 .0047/400 2R D15-D20 IN PARALLEL 404 32A 307 261 1J14 5 Vc (RS232) 24VAC,FROM 4J33 H1B 201 1J20 7J20 A GRS232 0VAC,FROM 1J33 14J34 321A RELAYS TRIGGER CLOSE,TO 2J37 AC VOLTAGE FROM CT 8 20 6J40 13J34 11J34 105A 31C FOOT AMPTROL TRIGGER 5V 3W 6J20 +5 Vb 9J17 GND 3W 2J20 FROM POWER BD. 5 7 1J40 9J40 3J20 ISOLATED DC SUPPLIES 4 6 +18 Vd 32C 102B 1J30 6J30 SOFT START 464 8J18 9J18 10J18 5J18 6J18 7J18 4J18 1J18 3J18 2J18 RX 7J17 WIRE FEEDER REMOTE CONTROL Return to Master TOC 1J17 306 204 ELECT.VOLT.FEEDBACK WF2 WORK VOLT.FEEDBACK 302 3 205 4J20 WF1 ARC VOLT.FEEDBACK WF2 ARC VOLT.FEEDBACK 1 2 5J20 WF1 WORK VOLT.FEEDBACK NOISE_GND Return to Section TOC TO SNUBBER BOARD 42V,FROM 3J33 499 +15 Va 208 8J20 TO SNUBBER BOARD 0VAC,FROM 1J33 10J34 25/25 4J62 -15 Va 8J34 12J34 42B R6 324 115VAC,FROM 6J33 31B 32B 406 L3 L2 7J62 40mA 40mA KEYPAD GROUND PLANE #1 118A(W) 117A(R) 1J28 4J28 40mA TO 4J22 111A(R) 112A(W) 4J27 1J27 LCD DISPLAY 3R MAIN TRANSFORMER LEFT SIDE L1 10J61 FOR WIRE FEEDERS P83 WF1 RECEPTACLE 3W (LEFT TOP) L1A ELECT.VOLT.FEEDBACK SERIAL LOOP COMMUNICATION SWITCH BOARD #3 -15 Va B G 208 275 9J61 G 2J61 75 NATIONAL ELECTRICAL CODE. L3A 1J62 G TO A SYSTEM GROUND PER S1 POWER SWITCH 461 276 FROM CONTROL BD. 277 F DC SUPPLIES E 76 TO CONTROL BD. 77 F L3A FROM CONTROL BD. E H1 L1A OFF +15 Va 118A(W) NOISE_GND M 205 112A(W) 321B ON 204 M P82 WF2 RECEPTACLE 1J61 117A(R) 5J61 L 2J62 111A(R) 462 32E W 10/2 42C I V D7-D14 IN PARALLEL 32D K 24VAC TO DISPLAY BD. WHEN TRIGGER CLOSE L A 42V CAP.VOLT. & OUTPUT DISABLE SIGNALS TO CONTROL BD. 32C RECTIFIED CT VOLT. TO CONTROL BD. 42B FET GATE SIGNALS TO SWITCH BOARDS #1 & #2 32B I U DC SUPPLIES TO SNUBBER BD. A K (N.E.) 115V .0047/400 31C FLYBACK 106A J (ON OUTPUT RECTIFIER ASBLY) 102D D 31B 12C C 105A 9D 102B D 9C C J H1B 221A 321A H RUN MODE 121A TO WF1 RECEPTACLE H TO WF2 RECEPTACLE 167A GROUND PLANE #2 N FET GATE SIGNALS TO SWITCH BOARDS #3 & #4 67 FEEDBACK VOLTAGES ARC & WORK VOLTAGES TO SNUBBER BD. N B Return to Section TOC G-3 ELECTRICAL DIAGRAMS FEEDBACK VOLTAGES FROM SNUBBER BD. Return to Master TOC Return to Section TOC G-3 R4 FEEDED 25/25 1B 1B 9B 9B THRU CT .047/1200 C2 3500uF CB 5A 450V .047/1200 12B 2B R3 DC SUPPLIES TO SHUNT BD. 12B 2B 25/25 SHUNT CURRENT FROM SHUNT BD. MAIN TRANSFORMER RIGHT SIDE 403 1R 1W E 102C 5J93 A 177A 2J93 3J93 B 176A C 175A (24V) 4 4J93 2 6 H5A 5 H4A (380-415) 3 N (24V) PROTECTION BOARD H3A 6 U (42V) R (115V) NOTES : 362 N.A. SINCE COMPONENTS OR CIRCUITRY OF A PRINTED CIRCUIT BOARD MAY CHANGE WITHOUT AFFECTING THE INTERCHANGEABILITY OF A COMPLETE BOARD, THIS DIAGRAM MAY NOT SHOW THE EXACT COMPONENTS OR CIRCUITRY HAVING A COMMON CODE NUMBER. N.B. D1 THRU D6 OUTPUT DIODES ARE A MATCHED SET. D7 THRU D14 OUTPUT DIODES ARE A MATCHED SET. D15 THRU D20 OUTPUT DIODES ARE A MATCHED SET. N.C. C1, C2, C3, C4 CAPACITORS ARE A MATCHED SET. 2 3 H2A 1 H1A N.D. NOT EXIST ON MACHINE WITHOUT WATER COOLER N.E. NOT EXIST ON PW350 & PW500 (200-208) H1 361 454 5J4 (220-230) H2 H3 5 WATER COOLER (N.D.) F (REMOTE) 456 (440-460) H4 W 3J3 H5 7J93 455 (N.D.) 1 105B 5J3 AUXILIARY TRANSFORMER #2 D 6J3 296 P1 FOOT AMPTROL RECEPTACLE 4J3 293 3J92 6J92 4 PRIMARY LEADS 1T,1B,4T,4B ARE FEEDED THRU CURRENT TRANSFORMER 453 291 292 1J92 2J92 294 4J92 Return to Master TOC Return to Section TOC CURRENT TRANSFORMER ELECTRICAL SYMBOLS PER E1537 POWER WAVE 2J4 P5 MACHINE SCHEMATIC G 2990 7-21-95E NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. POWER WAVE 450 SCHEMATIC - CONTROL PC BOARD #1 2241-1 Return to Master TOC G-4 ELECTRICAL DIAGRAMS G Return to Section TOC G-4 +5V +15V +15V J22 10 1 C13 DZ4 4.7 32 18V 35V 1W C21 J22 12 4.7 35V 0.1 X20 50V 50V 34 74HC573 GND 10 24 C18 X5 0.1 74HC573 50V 14 C28 X16 C29 0.1 PSD301 GND 12 20 C27 X13 0.1 1 20 50V 10 50V 50V 12 DZ2 6.2V 1W 54HC08 7 12 C10 C11 4.7 0.1 35V 50V C19 C45 0.1 0.1 X26 50V 50V LM224 7 11 D DA-AD[0:7] (DSP1 DATA BUS) +5V 6A: PARALLEL COMMUNICATION +5V (DSP1) DIRECTION DA-AD[0] 47p DA-AD[2] 4.75K R5 R35 R34 R40 MODE_SLAVE 475 1.00K DZ8 10M 5.1V 1W R6 +5V 1/2W +6 1.00K C5 1.00K 0.1 C4 130 22p 22p R39 R38 1.00K +5V 5.1V I_CK C7 1.0 INPUT COMMAND Vdd X2 35V +6 RES RES S-8054HN 0.1 DZ5 50V R2 6.2V 50V 10K R10 0.1 10K 1W R25 A1/D1 10 DA-AD[1] A2/D2 11 DA-AD[2] MODA A3/D3 12 DA-AD[3] /XIRQ 100 A5/D5 14 XTAL A6/D6 15 DA-AD[6] VRH A7/D7 16 DA-AD[7] 20 RxD 31 OC5 A/D2 47 28 OC2 A/D3 49 30 OC4 A/D4 44 32 IC1 A/D5 46 33 IC2 A/D6 48 34 IC3 A/D7 50 TxD I_AD A9 41 AD[9] PAI A10 40 AD[10] A/D0 A11 39 AD[11] A12 38 22 MISO A13 37 AD[13] 23 MOSI A14 36 AD[14] AD[0] 21 24 SCK A15 35 AD[15] AD[1] 20 25 /SS E 5 E AD[2] 51 VRL R/W 6 R/W AS 4 R11 5 X26 0.1 DZ6 J25 Q2 10K 475 475 R30 R31 R24 R21 R23 J25 BE J25 50V 1.00K D 9 +15V 10 +15V 10K 3Ee: 12 VOLT PROGRAMMING SUPPLY 10K R12 R14 OPTIONAL OUTPUT SLAVE CONTROL /RES PC2 42 PA0 PB5 6 PA1 PB6 5 19 PA2 PB0 11 AD[3] 18 PA3 PB1 10 AD[4] 17 PA4 PB2 9 AD[5] 16 PA5 PB3 8 AD[6] 15 PA6 PB4 7 AD[7] 14 PA7 GND GND PC1 41 PC0 40 X13 10K R13 X26 AS 31 A8 32 A9 A0/D0 23 AD[10] 33 A10 A1/D1 AD[11] 35 A11 A2/D2 AD[12] 36 A12 A3/D3 AD[13] 37 A13 AD[14] 38 A14 AD[15] 39 A15 E 22 E DATA[4] 15 DATA[5] B6 14 DATA[6] B7 13 DATA[7] GND 24 BtoA SRC AtoB SRC BtoA CLK 23 3 DIR AtoB CLK 1 4 A0 5 A1 6 7 8 Vcc WRITE_1 (DSP1 PORT1) RD_HIGH (SHEET 2, X44) OE 21 B0 20 A2 B1 19 DATA[9] A3 B2 18 DATA[10] A4 B3 17 DATA[11] B4 16 DATA[12] B5 15 DATA[13] B6 14 DATA[14] B7 13 DATA[15] X12 A5 10 A6 11 A7 GND 74AC646 OE_HIGH DATA[8] D 2 3 DATA[0:15] X1 RD_FLASH 9 X1 10 BE 8 RD_HIGH (3) RD_LOW (3) 12 4 5 4 6 X1 X1 13 11 DA-AD[0] DA-AD[0] 2 24 DA-AD[1] DA-AD[1] 3 D1 25 DA-AD[2] DA-AD[2] 4 D2 26 DA-AD[3] DA-AD[3] 5 D3 A4/D4 27 DA-AD[4] DA-AD[4] 6 D4 Q4 15 A5/D5 28 DA-AD[5] DA-AD[5] 7 D5 Q5 14 A6/D6 29 DA-AD[6] DA-AD[6] 8 D6 Q6 13 A7/D7 30 DA-AD[7] DA-AD[7] 9 D7 Q7 12 11 LE 1 OE BE X5 3 D0 74HC573 X20 Q0 19 Q1 18 Q2 17 Q3 16 SWDK CONTROL PORT SWWF SERIAL LOOP SWITCHES SWOP N.C. 4 5 X3 6 D 32 AD[0] 12 A0 Vcc AD[1] 11 A1 /WE 31 AD[2] 10 A2 NC 30 AD[3] 9 A3 AD[4] 8 A4 AD[5] 7 AD[6] 6 AD[7] 5 AD[8] A17 /OE 24 DQ0 13 DA-AD[0] DA-AD[0] 2 A5 DQ1 14 DA-AD[1] DA-AD[1] 3 D1 A6 DQ2 15 DA-AD[2] DA-AD[2] 4 D2 A7 DQ3 17 DA-AD[3] DA-AD[3] 5 27 A8 DQ4 18 DA-AD[4] DA-AD[4] AD[9] 26 A9 DQ5 19 DA-AD[5] AD[10] 23 A10 DQ6 20 AD[11] 25 A11 DQ7 21 AD[12] 4 A12 NC 2 28 A13 29 A14 16 X15 Vpp A15 Vss /CE RD_FLASH Q0 19 AS1 Q1 18 AS2 Q2 17 AS3 D3 Q3 16 AS4 6 D4 Q4 15 AS5 DA-AD[5] 7 D5 Q5 14 AS6 DA-AD[6] DA-AD[6] 8 D6 Q6 13 AS7 DA-AD[7] DA-AD[7] 9 D7 Q7 12 AS8 11 LE 1 OE BE A16 1 3 22 Vpp A15 5 X5 6 74HC573 X16 CONTROL VOLTAGE SENSE MATRIX 9 4 DA-AD[0:7] D0 10 X3 8 CE_FLASH D Q3 12 X26 10K AD[9] BE 600mA 14 40V 12 9 13 R16 R15 16 B5 74AC646 1 2 A14 8 9 1.00K B4 A5 D46 10 10K DATA[3] A15 A17 34 13 28F512 Vpp_CTRL DATA[2] 17 C25 A16 AD[9] R18 OPTIONAL INPUT SLAVE CONTROL DATA[1] 18 B3 DATA[0] 100V A14 AD[8] AD[13] +15V 19 B2 A4 OE_LOW 47p CE_FLASH AS-LE PB7 B1 A3 2 43 R/W 0.1 A J25 3 A19 (SHEET 2, X44) A2 22 12 AD[8] 8 26.7 8 (DSP1 PORT1) RD_LOW 21 20 D 1 C24 1W 26.7 Vpp 11 7 WRITE_1 OE B0 X11 100V 44 R/W 12 4.75K 12 6 Vcc 47p +5V PSD301 5.1V 15.0K 26.7 C51 22p A1 C26 I_CK DZ7 1W D 7 R109 A 15V 600mA 40V AS-LE Vcc /BHE 2 RES 6 50V 7 267 R108 R20 R/W AD[12] 100V A0 5 9 1 A/D1 22p 4 A6 +5V 45 C50 1 A7 AD[0] 100V 23 AtoB CLK 12 AD[8] 22p BtoA CLK DIR 11 SWITCH2 100K C8 R22 SLAVE SWITCH1 100V AtoB SRC 3 10 MODE_SLAVE 42 /RES X5 R335 (SHEET 4) 43 MC68HC11 221 BtoA SRC 2 9 R333 R334 DA-AD[7] DIRECTION THERMAL 27 Vdd 221 221 R331 R332 DA-AD[5] DA-AD[6] R329 R330 221 221 (DSP1) E 6 221 AD[0:15] A8 13 5 267 221 24 22 (3) 17 R336 J25 OUTPUT_ON D +15V R29 29 OC3 3E: HC11 +5V J25 DA-AD[5] EXTAL 8 D +5V 3Ea: UNDER VOLTAGE LOCKOUT SLAVE REFERENCE VOLTAGE DA-AD[4] C49 D D 13 7 D R28 X10 A4/D4 52 10K 10K DA-AD[0] MODB 26 C2 Vss C23 D2 R7 R27 R26 4.75K 475 J25 100 LATCH_READ (DSP 1) 1W 9 /IRQ 21 TXD D J25 Vpp_CTRL D 100V DZ9 R37 2.21K +15V 4 RESET D J25 1.00K 475 SLAVE 50V A0/D0 R8 2 8.0MHz 100V R36 MACHINE CONNECTED IN PARALLEL RXD C6 Y2 D 3 R110 Vss 3 18 /XIRQ DA-AD[4] 2 19 2.21K D R9 Return to Master TOC 1 J25 R328 DA-AD[3] 10K R4 R3 100V 10K 221 DA-AD[1] C3 +5V 1 DATA[0:15] NOISE_GROUND J22 9 Return to Master TOC X3 NAND 50V 3 X3 2 4 D J22 3 Return to Section TOC X1 0.1 74AC646 14 A +5V J22 11 Return to Section TOC C1 X11 0.1 0.1 74AC646 7 C16 C17 X12 0.1 50V 54HC08 14 24 -15V J22 6 Vss C22 0.1 50V MC68HC11 16 1W C20 50V 28F512 18V 44 Vcc X10 0.1 X15 NOISE_GROUND DZ3 C15 26 Vdd Vpp AD[10] 10 X5 8 13 X3 11 WR_REF 10K R32 3Ec: HC11 SUPPORT R17 15.0K A AD[0:15] (HC11 ADDR/DATA BUS) HC11 CONTROL - SHEET 1 R19 Return to Master TOC Return to Section TOC D 15.0K GENERAL INFORMATION R- MFD ( .022/50V CAPACITORS = C9,12,14,58,71,72,74-76,78,82,89,92-94,99,131 A LAST NO. USED ELECTRICAL SYMBOLS PER E1537 NUMBERS NOT USED: RESISTORS = Ohms ( D1,3,6-9,44,45,48,49 DIODES = DZ1,23-26,28,29 1A, 400V 1/4W C- UNLESS OTHERWISE SPECIFIED) LABELS UNLESS OTHERWISE SPECIFIED) (UNLESS OTHERWISE SPECIFIED) SUPPLY OSI1 R1,75-83,85,100-107,111-117,123-125,131-133,137, SINCE COMPONENTS OR CIRCUITRY ON A PRINTED CIRCUIT BOARD MAY CHANGE WITHOUT AFFECTING THE INTERCHANGEABILITY OF A COMPLETE BOARD, THIS DIAGRAM MAY NOT SHOW THE EXACT COMPONENTS OR CIRCUITRY OF CONTROLS HAVING A COMMON CODE NUMBER. UNLESS OTHERWISE SPECIFIED TOLERANCE ON HOLES SIZES PER E-2056 ON 2 PLACE DECIMALS IS + .O2 ON 3 PLACE DECIMALS IS + .OO2 ON ALL ANGLES IS + .5 OF A DEGREE MATERIAL TOLERANCE ("t") TO AGREE WITH PUBLISHED STANDARDS Y1 Ch’ge.Sht.No. EQUIP. OSI- 8 93 Y- 2 SCALE DR. JRF DATE POWER WAVE TYPE CLEVELAND, OHIO U.S.A. 8-11-95C 8-13-99B 34 X- EARTH GROUND CONNECTION FILE: G2241_2A1 THE LINCOLN ELECTRIC CO. 1-6-95B 1-30-98B TP- 5 Q- 52 FRAME CONNECTION X4,6-9,17-19,22,23,31-36,40,47-49,51-53,57, N.A. DZ- 35 156 VOLTAGE NET COMMON CONNECTION 139,140,172,176,190,265,267-269,272,320-326 TP1 NOTES : 345 POWER SUPPLY SOURCE POINT Q1,11 58-60,62,65-67,69,70,72-89 D- SUBJECT CONTROL SCHEMATIC NONE 11-25-92 CHK. SUP’S’D’G. SHT. NO. G 2241-1 NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. POWER WAVE 450 SCHEMATIC - CONTROL PC BOARD #2 R339 R338 4.75K 4.75K R337 R345 4.75K 4.75K 2241-2 Return to Master TOC G-5 ELECTRICAL DIAGRAMS G Return to Section TOC G-5 +5V D (DSP1 ADDRESS BUS) 8 ADDR[0:11] A12 7 A11 ADDR[10] 6 A10 ADDR[9] 5 28 VCC X46 A9 (DSP1 DATA BUS) 16 A13 9 A14 10 /WE 27 DATA[0:15] 35V /WE 4 A8 /OE 22 ADDR[7] 3 A7 /CE 20 ADDR[6] 2 A6 I/O 0 11 ADDR[5] 1 A5 I/O 1 12 DATA[1] ADDR[4] 26 A4 I/O 2 13 DATA[2] ADDR[3] 25 A3 I/O 3 15 DATA[3] ADDR[2] 24 A2 I/O 4 16 DATA[4] ADDR[1] 23 A1 I/O 5 17 DATA[5] ADDR[0] 21 A0 I/O 6 18 DATA[6] I/O 7 19 DATA[7] GND C68 1.0 ADDR[8] 14 C70 0.1 50V /REN RAM_SEL C69 X38 0.1 TMS320E14 34 DATA[0] 50V X44 50V 74AC139 3 C60 C67 0.1 8 X21 0.1 C61 X41 0.1 50V 74AC04 50V 74AC153 20 14 14 16 C66 X43 0.1 SCHMITT NAND 0.1 50V 50V 35V C62 X25 C130 1.0 20 34 X27 0.1 50V TMS320E14 50V PAL16R4 3 20 20 50V 10 74AC573 10 10 50V 10 0.1 CY7C199 50V 14 8 C156 X46 0.1 CY7C199 50V 74AC139 C155 X45 0.1 74AC573 10 C43 X42 0.1 X30 50V 74AC573 28 C44 0.1 X29 50V 28 16 C42 0.1 X28 0.1 74AC573 20 C63 C65 C64 X39 0.1 7 7 8 C59 50V 14 D 3D: ANALOG/DIGITAL CONVERTERS CY7C199 +5V 3C: STATIC RAM ADDR[6] 2 A6 I/O 0 11 ADDR[5] 1 A5 I/O 1 12 DATA[9] ADDR[4] 26 A4 I/O 2 13 DATA[10] ADDR[3] 25 A3 I/O 3 15 DATA[11] ADDR[2] 24 A2 I/O 4 16 DATA[12] ADDR[1] 23 A1 I/O 5 17 DATA[13] ADDR[0] 21 A0 I/O 6 18 DATA[14] GND I/O 7 19 DATA[15] RAM_SEL +Vref_V VOLTAGE ADDR[2] C37 C38 ADDR[3] 0.1 18 50V 15V R51 C41 0.1 ADDR[6] 50V R46 R56 RD_HIGH J24 475 R42 R43 5.1V 1W 14 NOISE_GROUND A1a S/H Vin DB4 16 AD_DATA[4] 6 AVcc DB5 15 AD_DATA[5] AD_DATA[6] 9 Vref+ DB6 14 5 CS DB7 13 AD_DATA[7] 7 Vref- DB8 12 AD_DATA[8] DB9 11 ADDR[0:11] /REN /WE ADDR[0] 1 select a 15 select b 2 DSP_A11 AD_DATA[9] Y1a 5 A0b Y2a 6 Y0b 12 13 A1b Y1b 11 Y2b 10 Y3b 9 A0a AD_DATA[3] DATA[4] 6 D4 O4 15 O/D(4) O/D(4) 60 D4 IOP4 52 AD_DATA[4] 7 D5 IOP5 51 AD_DATA[5] IOP6 45 AD_DATA[6] IOP7 44 AD_DATA[7] AD_DATA[8] AD_DATA[9] 15 /WE (3) 17 /RS 23 /WTD 22 NMI/MC/MP 66 CMP4/CAP2/FSX 67 CAP1 34 Vss1 C56 7 2 68 11 10 48 65 50 DATA[8] 49 DATA[9] D10 46 D11 43 D12 40 D13 39 D14 D15 32 31 D 10K LE GND WRITE_0 /OE D0 D1 DATA[10] DATA[10] 4 DATA[11] DATA[11] 5 DATA[12] DATA[12] 6 DATA[13] DATA[13] 7 36 DATA[14] DATA[14] 35 DATA[15] DATA[15] R263 D 20 CLK CLKOUT IOP8 42 11 TCLK2/CLKX IOP9 41 10 TCLK1/CLKR 24 CLKIN O0 19 O/D(8) O/D(8) 50 D8 18 O/D(9) O/D(9) 49 D9 D2 O2 17 O/D(10) O/D(10) 46 D10 D3 O3 16 O/D(11) O/D(11) 43 D11 D4 O4 15 O/D(12) O/D(12) 40 D12 D5 O5 14 O/D(13) O/D(13) 39 D13 8 D6 O6 13 O/D(14) O/D(14) 36 D14 9 D7 O7 12 O/D(15) O/D(15) 35 D15 GND LE 11 34 Vss1 X27 74AC573 WRITE_0 (3) 10K Vcc /OE 1 READ_0 19 DATA[1] 18 O1 D1 3 O/D(1) DATA[2] 17 O2 D2 4 O/D(2) DATA[3] 16 O3 D3 5 O/D(3) DATA[4] 15 O4 D4 6 O/D(4) DATA[5] 14 O5 D5 7 O/D(5) DATA[6] 13 O6 D6 8 O/D(6) DATA[7] 12 O7 D7 9 11 LE X29 3A: DSP 2 D0 100V 17 2 D RESET 67 47 48 68 65 66 38 IOP11 37 IOP12 32 IOP13 31 IOP15 29 /REN 16 IOP14 30 /WE 15 /INT NMI/MC/MP Vss2 1 2 O/D(7) 7 2 3 Vcc /OE 1 READ_0 DATA[8] 19 DATA[9] 18 O1 D1 3 O/D(9) DATA[10] 17 O2 D2 4 O/D(10) DATA[11] 16 O3 D3 5 O/D(11) DATA[12] 15 O4 D4 6 O/D(12) DATA[13] 14 O5 D5 7 O/D(13) DATA[14] 13 O6 D6 8 O/D(14) DATA[15] 12 O7 D7 9 11 LE +15V DSP2_W2 O0 X30 D0 GND O/D(8) 2 9 (PSD301) (DSP1, PORT1) RD_HIGH (PSD301) OE_HIGH 6A: CONTROL DATA FLOW (DSP 1 <> HC11) 5 6 X21 WRITE_0 DIRECTION HIGH.....HC11 -> DSP 1 DIRECTION LOW......DSP 1 -> HC11 74AC139 WRITE_1 +15V C31 0.1 50V Q6 C52 2N4401 J22 RD_CUR R264 50V 10K D50 D 1.00K DSP_REN 1N4936 Q7 R69 OUTPUT_ON RD_VOL 1 820p STROBE_AD 2N4401 * +5V 10K FET BANK A DSP_WE J22 2 22 A AD_DATA[0:15] CLK 8 (2) OVR_CUR 6 FAULT /XIRQ 10 1 CLK 2 I0 3 4 5 Vcc 20 O3 19 CHA I1 O2 18 CHB I2 D3 17 I3 D2 16 6 I4 D1 15 7 I5 D0 14 8 16 O1 13 9 17 O0 12 OE 11 GND X39 PAL16R4 +15V 11 STROBE_AD (4) CLR_CAP OUTPUT_ON X21 10 C32 0.1 12 50V (FROM HC11) Q5 11 X41 13 13 2N4401 C53 X21 12 J22 D 20 Zb CLR_CAP 18 X41 5 10 AD_DATA[0] 4 X41 I0b 3 CLR_SHUNT 1 /WTD 74AC573 CAP1 D 10 GND 23 IOP10 S1 RD_LATCH D O/D(0) DATA[0] O0 TMS320E14 C30 330p 20 X25 19 O1 10 3 Vcc 100K 2 (DSP1, PORT1) RD_LOW D READ_0 1.00K D7 3 R61 R63 R62 R58 R60 R59 D6 57 2 RD_DSP2 D 3B: DSP 1 FUNCTION GENERATOR 58 O/D(7) DATA[9] OUTPUT_ON 10K O/D(6) O/D(7) 11 DATA[8] RAM_SEL 10K O/D(6) 12 1 D 10K O/D(5) 13 O7 CLK 29 30 O/D(5) O6 D7 74AC573 D9 Vss2 8 O5 D6 9 47 D8 DSP 1 D5 8 10 CLKOUT TMS320E14 R266 53 IOP10 (3) A1 IOP3 38 /REN A0 D3 TXD /INT A3 61 IOP9 IOP11 A2 O/D(3) 41 16 A5 O/D(3) IOP8 18 A4 16 DATA[7] 19 A6 O3 DATA[6] 37 A9 D3 DATA[5] 24 A8 AD_DATA[2] 5 DATA[6] CLKIN A7 AD_DATA[1] IOP2 DATA[7] 11 RD_LATCH D2 DATA[5] 6 I1b 3B: BUS DECODE DSP 1 O/D(2) 1 Y3a GND I0a I3b 74AC153 100K O/D(2) 57 X42 DIRECTION RD_LATCH I2b GND 10K OE_LOW 12 8 A1a X44 13 4 (DSP1 ADDRESS BUS) O2 58 Y0a 16 3 ADDR[0:11] D2 D7 VCC 14 8 DSP_A2 54 D6 7 AD_DATA[3] 55 D5 Za AD_DATA[2] 56 CMP3 Vcc /Eb 18 8 28 /Ea DB2 DB3 27 16 1 15 5 RD ADC1061 +5V DSP2_W2 14 17 GND 4 X21 I1a IOP1 IOP7 3 S0 IOP0 59 10 DSP2_W0 I2a Vcc2 14 9 Y2b 2 X21 I3a D1 42 X38 Y3a GND 1 4 D0 DATA[4] Y1b Y3b A1b 7 D 11 3 Vcc1 59 12 AD_DATA[1] 62 Vcc X28 Y0b RD_DSP2 AD_DATA[0] 4 26 25 4 19 63 60 IOP6 21 5 Y0a 20 64 D4 IOP5 20 6 Y1a DB1 O/D(1) IOP4 DZ10 J24 3 Y2a X43 (3) DB0 O/D(0) DSP2_W2 475 3 X37 O/D(1) NOISE_GROUND J24 INT O/D(0) 52 10K 8 DVcc 2 17 DATA[3] R54 1W 1 18 DATA[3] DZ16 5.1V A0b 3A: BUS DECODE DSP 2 19 61 475 R47 A0a 14 CLK GND 74AC139 O1 D3 100V select b 2 13 AD_DATA[9] O0 IOP3 STROBE_AD 475 D1 53 NOISE_GROUND 7 D0 3 D2 44 A10 A11 A1 A0 A3 A2 A4 A5 A6 A9 DATA[2] /OE 2 RD_DSP2 IOP2 5.1V 1W 11 15 VCC R72 +5V DATA[2] 4 DATA[0] DATA[1] 62 330p DZ13 DB9 ADC1061 GND DSP_A2 select a 16 5: PAL 3Eb: WATCH DOG 7 820p 1.00K D D D51 50V Q4 R64 1N4936 2N4401 * R65 475 12 CMP0 J24 6 /WTD RD_LOW 475 DB8 CMP1 1W NOISE_GROUND DB7 CS CMP3 5.1V AD_DATA[8] Vref- 5 CMP2 DZ15 /WE RESET DATA[1] 14 13 CMP5/CAP3/FSX R53 DATA[0] 63 Vcc2 12 9 CMP4/CAP2/FSR 475 R48 64 D1 45 6 CAP0 475 DSP_A0 R41 +5V /REN J24 5 DSP_WE AD_DATA[6] AD_DATA[7] 13 10K 1W D0 IOP1 33 RXD LATCH_READ 5.1V NOISE_GROUND AD_DATA[5] 14 4 54 51 5 20 TXD DZ14 R262 DIRECTION IOP0 55 1 4 CAP1 R57 15 DB6 D /RS R45 (3) Vcc1 56 IOP14 4 475 O/D(0:15) 28 IOP15 10K 475 27 IOP13 J24 26 25 IOP12 1W NOISE_GROUND 21 CMP0 5.1V A8 A11 DZ12 20 CMP5/CAP3/FSX R55 14 13 RXD R44 12 9 33 CMP1 NOISE_GROUND 3 6 A7 5 ADDR[0:11] 1W 475 DB5 INT 7 DSP_A0 5.1V 475 DVcc 2 DSP_A11 DZ17 J24 1 1 7 A TCLK1/CLKR R49 DSP_REN ADDR[9] A10 R52 AD_DATA[4] 10 TCLK2/CLKX 475 16 ADDR[8] ADDR[10] 475 10.0K C39 18 15V ADDR[7] CAP0 2 V_AD ADDR[5] CMP2 J24 RD_VOL R268 475 R50 DB4 A/D CONVERSION STROBE_AD /WTD 475 AVcc D +5V ADDR[4] J24 6 8 A ADDR[1] 1 AD_DATA[3] 10 DATA[8] ADDR[0] 13 1W Return to Master TOC 50V CY7C199 NOISE_GROUND Return to Section TOC 15V /REN 10.0K 17 OUT 25mhz R74 A7 20 0.1 DB3 R179 22 18 Vref+ 50V 1.00K /OE /CE C33 50V 9 X24 0.1 35V 10K FET BANK B 1.00K A8 3 C34 0.1 15V AD_DATA[2] R71 4 ADDR[7] C40 18 AD_DATA[1] 18 1.00K ADDR[8] C35 /WE 19 DB2 R180 27 DB1 S/H R173 10 /WE Vin 3 1.00K 9 A14 A9 8 X14 C48 1.0 R70 A13 A10 5 Vcc C47 AD_DATA[0] 4.75K A11 6 ADDR[9] J24 5.1V Return to Master TOC X45 7 ADDR[10] 14 DZ11 Return to Section TOC VCC R267 Return to Master TOC Return to Section TOC +5V A12 28 20 4.75K I_AD STROBE_AD DB0 R73 +5V RD R68 4 R67 +Vref_I D 8 AD_DATA[0:15] A/D CONVERSION RD_CUR 1.00K R341 CURRENT 4.75K 4.75K R342 R343 4.75K 4.75K R344 (DSP2 MISC. I/O BUS) J22 8 A O/D(15) * INDICATES CHANGE FROM "XRF" VERSION 10 2O: MAIN FET DRIVE 74AC573 GENERAL INFORMATION LAST NO. USED R- ELECTRICAL SYMBOLS PER E1537 J24 DATA[0:15] 9 O/D(0:15) RESISTORS = Ohms ( DSP / FUNCTION GENERATOR - SHEET 2 (DSP2 DATA BUS) J24 MFD ( .022/50V CAPACITORS = DIODES = 1A, 400V 1/4W C- UNLESS OTHERWISE SPECIFIED) LABELS UNLESS OTHERWISE SPECIFIED) (UNLESS OTHERWISE SPECIFIED) D- SUPPLY 10 345 DZ- 156 Q- 34 52 X- 93 35 VOLTAGE NET POWER SUPPLY SOURCE POINT J24 6B: PARALLEL COMMUNICATION 11 COMMON CONNECTION FRAME CONNECTION J24 12 NOTES : N.A. NOISE_GROUND EARTH GROUND CONNECTION FILE: G2241_2A1 SINCE COMPONENTS OR CIRCUITRY ON A PRINTED CIRCUIT BOARD MAY CHANGE WITHOUT AFFECTING THE INTERCHANGEABILITY OF A COMPLETE BOARD, THIS DIAGRAM MAY NOT SHOW THE EXACT COMPONENTS OR CIRCUITRY OF CONTROLS HAVING A COMMON CODE NUMBER. UNLESS OTHERWISE SPECIFIED TOLERANCE ON HOLES SIZES PER E-2056 ON 2 PLACE DECIMALS IS + .O2 ON 3 PLACE DECIMALS IS + .OO2 ON ALL ANGLES IS + .5 OF A DEGREE MATERIAL TOLERANCE ("t") TO AGREE WITH PUBLISHED STANDARDS Ch’ge.Sht.No. THE LINCOLN ELECTRIC CO. 1-6-98B 8-13-99B SCALE DR. JRF DATE POWER WAVE TYPE CLEVELAND, OHIO U.S.A. 8-11-95C 1-30-98B EQUIP. SUBJECT CONTROL SCHEMATIC NONE 11-25-92 CHK. SUP’S’D’G. SHT. NO. G 2241-2 NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. POWER WAVE 450 +15V +5V +5V 2E: CURRENT MODE CONTROL R274 267 C132 20 14 0.1 0.1 50V 50V X63 C98 54HC4066 50V O7 12 /OE O6 13 O/D(10) 4 D2 O2 17 O/D(11) 5 D3 O3 16 6 D4 O4 15 7 D5 O5 14 8 D6 01 18 D7 00 19 LE 11 Vcc X90 GND C152 4 4 X71 C153 DGND 50V A A A 20 X61 0.1 20 20 C83 C148 0.1 C87 0.1 X68 50V 74AC573 74HC573 10 10 -5V -15V D 100K -15V 12 R278 DSP2_W0 13 (DSP2, PORT2) 20 R288 /OE 2 AGND D0 LE 11 3 DGND 3 D1 O0 19 15 O/D(2) 4 D2 O1 18 14 O/D(3) 5 D3 O2 17 13 O/D(4) 6 D4 O3 16 12 O/D(5) 7 D5 O4 15 11 O/D(6) 8 D6 O5 14 10 O/D(7) 9 O6 13 9 O7 12 14 221K X61 825 R282 R283 C137 OUT1 2 200 RFB VREF /CS 16 DB2 DB8 7 DB9 6 DB10 DB5 DB11 DB6 50V 2 +IN 3 -IN 4 V- 8 /Q OUT Q OUT 7 GND 6 LE 5 X93 2H: REFERENCE VOLTAGES OVR_CUR 10.0 R316 LT1016 A C95 0.1 50V A CLR_SHUNT +2.5V CURRENT MODE CONTROL, DISABLE THE (DSP2) R170 R172 10K 10K FETS AS SOON AS SECONDARY CURRENT 10K 4 9 1.00K IS GREATER THAN A REFERENCE LEVEL 10 R284 5 8 X61 200 825 R169 R286 R287 10K C139 8 DB7 V+ 6.81K 18 17 DB4 50V 1 R281 19 /WR DB3 DB1 820p 20 Vdd X54 DB0 C138 820p AD7545 X71 820p 820p 50V 50V 475 A 8 R280 X21 6 9 7 X71 SECONDARY CURRENT CLEARING NETWORK 33.2K SECONDARY CURRENT REGULATION R302 4.75K R156 R299 10.0 R130 X61 R155 150 (SHEET 2, X39) R154 600mA D52 R152 1.00K 1W R300 1.00K 15V C54 820p 750 1N914 Q10 CW 600mA 500 2C: SECONDARY CURRENT SENSE C85 (HC11 ADDR/DATA BUS) CURRENT FEEDBACK 50V 40V A A 22p 100V DA-AD[0:7] AMPLIFIER GAIN = 5.0 to 6.9 I_AD = 5.0V @ 800A OUTPUT 2D: CURRENT FEEDBACK DA-AD[0] 2 DA-AD[1] 3 D6 DA-AD[2] 4 D5 DA-AD[3] 5 D4 DA-AD[4] 6 D3 DA-AD[5] 7 D2 DA-AD[6] 8 D1 DA-AD[7] 7 J20 J20 J20 J20 J20 D7 9 D0 11 LE 1 OE 74HC573 X55 12 A8 A7 COMP Q7 19 11 Q6 18 3 Q5 17 10 A6 Q4 16 9 A5 Vref- Q3 15 8 A4 R CON Q2 14 7 A3 GND Q1 13 6 A2 A1 Q0 Io Vref+ Vee X56 Vcc 16 R310 681 4.75K 10 9 8 X71 Q8 R122 WR_REF -_OUTPUT DA-AD[0:7] R97 14 13 15 R171 R94 1.00K R98 1.00K R96 REFERENCE TRIM_DAC REFERENCE 1.50K VOLTAGE FEEDBACK 2 1.50K 1.00K C73 X26 0.1 1 1.00K 1 33.2K * R120 3 50V 10.0 A 67B 1.00K 1.00K C77 0.1 50V 2G: PROGRAMMABLE VREF 67A 1.00K R189 +Vref_V R121 2 5 10.0 A (SHEET 1, X5) R187 VOLTAGE A/D 2N4401 475 1.00K 4 MC1408 12 R126 A +_OUTPUT 1.00K R191 +Vref_I -5V 1.00K R188 R186 +15V 47.5K 4.75K D11 DZ27 50V +Vref_I R118 1N4936 R153 50V R149 40V 10.0 100V 0.27 0.1 A V_LIMIT R150 1A 1.00K C79 (2) TO CURRENT A/D R66 R142 Q12 +Vref_I 33.2K I_AD D10 1N914 4.75K Q13 C88 INTERGATOR 2 CLR_CAP CLEARING NETWORK 1.00K R33 CURRENT FEEDBACK 26.7K 1 10.0 R129 A 150 6 REFERENCE 10K +15V J21 1 CURRENT A/D 1.00K 3 2 2N4401 475 CURRENT SIGNAL IN 10mA = 800A OUTPUT Q9 R128 CLR_SHUNT (DSP2) A +15V 4.75K 1.00K Q33 2N4401 FILTER INCOMING R309 50V R279 150p 100V R312 C136 330p R308 C135 50V R311 R276 C134 820p +15V -15V 5 R314 R307 R275 +2.5V 22p 100V R313 C57 6.81K R127 GENERATE A REFERENCE LEVEL 1.00K 3 10.0 A (DSP2 DATA BUS) CURRENT FEEDBACK -5V 2N4403 R167 1 3 R285 A 1.00K Q14 2 C140 O/D(0:15) 8 3 D 6.81K SHUNT CONNECTION 50V MC1408 74AC573 10 A 0.1 X55 50V 50V 11 C81 X56 C84 0.1 X90 50V 0.1 33074A 11 A 50V 50V 33074A 50V 11 3 0.1 50V 0.1 33074A C101 0.1 A -5V 1 GND AGND 2 50V C100 33.2K O/D(1) D7 7 0.1 0.1 50V AD7545 C96 0.1 50V X92 A O/D(0) Vcc X54 54HC4066 C133 +5V TL431 6 1 X68 + 1 X91 8 REF 0.1 C151 C150 R315 D1 1 74AC573 D 21A 1.00K 21B CLAMP CIRCUIT FOR TRANSIENTS ABOVE 5.0V X63 3 POLE FILTER 1 2 SECOND STAGE CUTOFF FREQ = 3.3 KHZ 13 AS1 J21 THIRD STAGE CUTOFF FREQ = 3.4 KHZ R270 3 PRECISION R289 10 2 AS3 X64 4 3 3.32K 12 3 X92 1 R291 332 R293 C142 C143 0.1 .022 .0047 50V 50V 50V 13 X92 V_LIMIT 1N914 1N914 D14 D13 UNITY GAIN DIFFERENTIAL AMPLIFIER 33.2K 100K * 3 6 1.00K R89 1.00K 1.00K 1.00K R90 R93 R91 R92 1.00K 1.00K R135 5.1V 5.1V 5.1V 5.1V 5.1V 1W 1W 1W 1W 1W 1W 100K * 7 R292 332 R294 R296 5.11K 33.2K R298 R181 C144 C145 C146 0.1 .022 .0047 50V 50V 50V 100K * CONNECTED IN X92 R141 10 100K 475 475 R185 4 7 X71 V_AD 14 A NOISE_GROUND 0.1 50V 2N4403 R184 475 12 D C105 Q15 13 D15 1N914 475 I_AD R99 * 10K 1.00K 6 NOISE_GROUND 8 10.0 10.0 NOISE_GROUND V_AD R178 (TO VOLTAGE A/D) 150 -15V 2I: V LIMIT * D16 1N914 A 12 AS7 UNITY GAIN AMPLIFIER 2 CONTROLED BY SHEET 1, X16 NOTES : A 13 ( X92 6.81K X64 1 DZ22 10K 2.21K R304 10 J20 DZ21 26.7 15V D12 1N914 9 5 AS6 X63 11 DZ20 * R175 R146 R290 3.32K DZ19 J21 J21 R147 AS5 5 DZ18 DZ35 GRAPHICS ONLY 14 6.81K AS4 X63 4 NOISE_GROUND 15V 12 R297 C141 J21 R174 -15V 1W 9 6 5 R295 A 8 J20 DZ34 HERE AND ONLY HERE GAIN = 2 10K 22.1K X64 8 10K 2.21K R303 5 J20 ALL GROUNDS MEET RECTIFIER 11 4 1.00K R305 AS2 V_LIMIT +15V R301 9 6 X64 +15V +15V R306 8 80V=3.81V +5V 100 R148 VOLTAGE IDEALLY -15V 100 X63 EQUAL TO 10/210, SUPPLY RAIL R271 2 R183 MATRIX J21 FIRST STAGE CUTOFF FREQ = 4.8 KHZ R182 FEEDBACK SWITCH R177 KELVIN VOLTAGE R273 Return to Master TOC 13 4 Vdd R166 D0 3 10 Return to Master TOC 18 X64 7 R277 2 O/D(9) D Return to Master TOC C97 +2.5V O/D(8) +5V +5V 0.1 74AC573 Return to Section TOC +15V +5V 14 O/D(0:15) 10 Return to Section TOC +5V R168 2241-3 Return to Master TOC SCHEMATIC - CONTROL PC BOARD #3 9 Return to Section TOC G-6 ELECTRICAL DIAGRAMS G Return to Section TOC G-6 AS8 ) N.A. 2F: VOLTAGE FEEDBACK SINCE COMPONENTS OR CIRCUITRY ON A PRINTED CIRCUIT BOARD MAY CHANGE WITHOUT AFFECTING THE INTERCHANGEABILITY OF A COMPLETE BOARD, THIS DIAGRAM MAY NOT SHOW THE EXACT COMPONENTS OR CIRCUITRY OF CONTROLS HAVING A COMMON CODE NUMBER. GENERAL INFORMATION LAST NO. USED ELECTRICAL SYMBOLS PER E1537 MFD ( .022/50V CAPACITORS = A RESISTORS = Ohms ( DIODES = 3Ef: MULTIPLEXING THE V 1A, 400V 1/4W UNLESS OTHERWISE SPECIFIED) LABELS UNLESS OTHERWISE SPECIFIED) (UNLESS OTHERWISE SPECIFIED) SUPPLY ANALOG CIRCUITRY - SHEET 3 INPUTS ARC R- 345 DZ- 35 C- 156 Q- 34 D- 52 X- 93 VOLTAGE NET POWER SUPPLY SOURCE POINT COMMON CONNECTION FRAME CONNECTION EARTH GROUND CONNECTION FILE: G2241_2A1 UNLESS OTHERWISE SPECIFIED TOLERANCE ON HOLES SIZES PER E-2056 ON 2 PLACE DECIMALS IS + .O2 ON 3 PLACE DECIMALS IS + .OO2 ON ALL ANGLES IS + .5 OF A DEGREE MATERIAL TOLERANCE ("t") TO AGREE WITH PUBLISHED STANDARDS Ch’ge.Sht.No. 8-13-99B THE LINCOLN ELECTRIC CO. 1-6-95B 1-30-98B SCALE DR. JRF DATE POWER WAVE TYPE CLEVELAND, OHIO U.S.A. 4-21-95J 8-11-95C EQUIP. SUBJECT CONTROL SCHEMATIC NONE 11-25-92 CHK. SUP’S’D’G. SHT. NO. G 2241-3 NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. POWER WAVE 450 SCHEMATIC - CONTROL PC BOARD #4 50V SER_LOOP C121 +15V 2700p J26 681 820p 600mA ON / OFF 40V SWITCH +5V C120 300V +5V 50V TP3 +15V 1 SWITCH1 (TO HC11) 5 1 OCI4 D22 6 SWITCH2 (TO HC11) 5 2 6 R256 150 THERMAL (TO HC11) 0.1 Return to Master TOC D 6 R232 C122 4 .0047 D27 400V D26 56.2K HIGH = FAULT C123 150p D 50V D28 J26 681 MUST BE ISOLATED FROM DK- 4 D TURN ON/OFF DISPLAY/KEYPAD FROM SERIAL LOOP R225 ALL OTHER SIGNALS 2 D30 R226 150 MUST BE ISOLATED FROM CNY17-3 200 LOW = NORMAL 50V J23 5 10K 45J C119 5.1V HIGH = TRIGGER OPEN 221K J26 6 R254 R220 221K R219 J26 R221 1W 4 LOW = TRIGGER CLOSED LOW = TRIGGER CLOSED J23 Q27 1.3K 150V 26.7 OCI7 2N4403 R240 (SHEET 1, X20) D24 1N914 DZ31 CNY17-3 4 V_LIMIT 10K 1.00K HIGH = TRIGGER OPEN 2 6 OCI8 D42 CNY17-3 2 10K 10K 5 R234 DIS2 J26 5 R238 +5.5V R239 10K 1 SWDK R222 DIS1 J26 1 R255 R257 +5.5V D29 R237 2K Q25 500mA R235 10.0 D NOISE_GROUND 50V ALL OTHER SIGNALS C124 +15V 2700p 2N: THERMAL OVERLOAD INPUT 2M: ON/OFF SWITCHES J27 1 WF+ 4 WF- R194 820p 3J23 INPUT FROM PROTECTION J23 3 +5V FOR FAULT CONDITION DZ32 VB 7 CATH VC 6 GND 5 NC 50V 681 D21 10K 1 50V 2K 56.2K 150p 5.1V J23 J27 NOISE_GROUND 10K TURN ON/OFF WIRE FEEDER 1 FROM SERIAL LOOP 2K: PROTECTION BOARD INTERFACE J27 R318 TP2 150V 45J J28 HIGH = NORMAL 10K R196 750 681 R199 R327 400V 1.00K .0047 R197 3.32K C118 300V 26.7K NC 4 OCI6 150 D41 221K R217 D20 J21 C116 C126 150p 330p 50V .022 50V 6 * 10K * X61 TP4 1N914 7 R198 D5 1 SWOP 330p 100V PRIMARY OVER CURRENT 10K 2 6 C125 4 .0047 D32 D17 400V D31 NORMAL X61-7 @ MINUS RAIL FAULT X61-7 @ PLUS RAIL 56.2K A C107 100V D40 45J CNY17-3 200 SHUTDOWN @ 214 AMPS 5 150V 26.7 OCI3 Q32 1.3K 150K 10K 5 2N4403 R247 (SHEET 1, X20) C90 R244 * R200 GND 5 2.21K C91 40V 47.5K R252 5 4.75K D37 820p R84 R87 R158 3 R162 2 CATH 10.0 1 ANODE VC R163 NC VB 6 10.0 VCC 7 R164 8 10.0 50V R160 C117 150p 50V 10.0 4.75K C115 150p R214 R212 3.32K C108 300V 600mA D4 R246 10K * 1N914 R161 1 R165 2.67K J21 R253 40V = 1.257 Volts D19 R213 10.0 R215 R86 220 Primary Amps D18 Q23 500mA Q19 R159 4.75K R211 R206 R216 CT FEEDBACK RXD (TO HC11) 2K Q18 2L: GENERATE FAULT SIGNAL 3.32K * Q30 500mA D +Vref_I 600mA 150p D 50V D35 J28 D43 D OPT+ 1 LOW = FAULT +5V 5.11K 3 C109 2700p 2N4401 10K 50V +15V Q34 R317 0.1 +15V 2 50V C111 1W J27 FAULT D23 DZ30 50V D36 +5V D25 1N4936 R208 C112 D 10.0 820p OCI5 D 56.2K 150p D R260 400V D39 50V R259 C114 .0047 D33 R248 ANODE 150p C129 4 R245 4 C127 6 61.9K 200 3 R202 R210 10K 2 2 D34 R319 Q22 1.3K C128 150p 45J CNY17-3 200 C110 J23 2 R224 2N4403 R204 R205 TXD (FROM HC11) 1W 50V 300V VCC 5.1V 1W 300V 500mA 10K DZ33 5.1V Q24 500mA NC X41 10 Q31 1.3K 150V 26.7 OCI2 2N4403 R249 (SHEET 1, X20) CAP1 (TO DSP2) 40V 8 8 10K 5 R201 R209 1.00K R218 750 1 9 R258 1 SWWF 1N914 D47 1.00K J23 4 Q21 TP5 R228 0V FOR NORMAL CONDITION 600mA 50V R193 R250 100K 681 R203 R119 R207 3.32K 1.00K 2700p 100K 40V 26.7K R242 26.7 R251 C113 600mA 26.7K R229 R223 R227 50V R230 D38 C106 300V 5 R261 2K 500mA J22 R243 681 300V Q17 Q16 +15V * Q29 500mA +15V 61.9K R192 R138 1.00K R195 3.32K 750 Q20 Return to Master TOC R236 300V Q28 ON / OFF Return to Section TOC * Q26 500mA 61.9K R231 R134 1.00K R241 750 SWITCH Return to Section TOC DK+ 3 R233 3.32K 2241-4 Return to Master TOC G-7 ELECTRICAL DIAGRAMS G Return to Section TOC G-7 SER_LOOP 2J: PRIMARY CURRENT SENSE J22 TURN ON/OFF OPT FROM SERIAL LOOP SL WIRE FEEDER TRANSMIT/RECEIVE FOR SERIAL LOOP J28 2B: SERIAL LOOP PORT SWITCHES J28 OPT- 4 4 2 3 2A: SERIAL LOOP Return to Master TOC Return to Section TOC * INDICATES CHANGE FROM "XRF" VERSION NOTES : N.A. GENERAL INFORMATION SINCE COMPONENTS OR CIRCUITRY ON A PRINTED CIRCUIT BOARD MAY CHANGE LAST NO. USED WITHOUT AFFECTING THE INTERCHANGEABILITY OF A COMPLETE BOARD, THIS DIAGRAM MAY NOT SHOW THE EXACT COMPONENTS OR CIRCUITRY OF CONTROLS HAVING A COMMON CODE ELECTRICAL SYMBOLS PER E1537 NUMBER. CAPACITORS = RESISTORS = Ohms ( DIODES = R- MFD ( .022/50V 1A, 400V 1/4W C- UNLESS OTHERWISE SPECIFIED) LABELS UNLESS OTHERWISE SPECIFIED) (UNLESS OTHERWISE SPECIFIED) D- SUPPLY SERIAL LOOP / PROTECTION INTERFACE - SHEET 4 345 DZ- 35 156 Q- 34 52 X- 93 VOLTAGE NET POWER SUPPLY SOURCE POINT COMMON CONNECTION FRAME CONNECTION EARTH GROUND CONNECTION FILE: G2241_2A1 UNLESS OTHERWISE SPECIFIED TOLERANCE ON HOLES SIZES PER E-2056 ON 2 PLACE DECIMALS IS + .O2 ON 3 PLACE DECIMALS IS + .OO2 ON ALL ANGLES IS + .5 OF A DEGREE MATERIAL TOLERANCE ("t") TO AGREE WITH PUBLISHED STANDARDS Ch’ge.Sht.No. THE LINCOLN ELECTRIC CO. 1-6-95B 8-13-99B SCALE DR. JRF DATE POWER WAVE TYPE CLEVELAND, OHIO U.S.A. 8-11-95C 1-30-98B EQUIP. SUBJECT CONTROL SCHEMATIC NONE 11-25-92 CHK. SUP’S’D’G. SHT. NO. G 2241-4 NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. POWER WAVE 450 PC BOARD ASSEMBLY-CONTROL ±.04 11.25 C73 C34 C17 R92 R90 C126 R253 R214 D19 D18 R213 D43 D40 R217 C116 R216 D20 XXXXXXXXXX C29 C28 C38 C37 R268 R172 R168 R126 R120 Q14 R169 R170 R167 R129 R130 R310 R314 C79 R127 R313 R311 R312 R128 X71 C100 X64 X92 R307 R308 R309 R118 R122 R121 R177 D15 R185 R184 R183 R305 C142 C143 R297 R290 R295 R293 C141 R289 C77 C97 Q8 R301 R182 R306 R87 R166 D12 D16 R150 C145 C90 R146 R298 R316 R315 C105 R84 R159 D4 Q9 R155 R154 R66 R149 R296 R294 C87 C96 R158 R86 C101 D11 D10 R156 R302 X61 Q15 R303 0 ±.04 0 8.00 .20 4.00 1 16 PART NO. S24073-2 S19400-10R0 7.80 DESCRIPTION 5 0 0 , 1 / 2 W, T R I M M E R 10 1/4W 6 S19400-1500 150 1/4W 1 8 S19400-1503 S19400-3321 150K 1/4W 3.32K 1/4W 4 4 6 S19400-5622 S19400-1301 S19400-2000 56.2K 1/4W 1.3K 1/4W 200 1/4W 2 1 4 4 3 1 5 2 2 8 S19400-5111 S19400-2671 S19400-2213 S19400-2001 S19400-6192 S19400-2212 S19400-6811 S19400-8250 S19400-3320 S19400-2210 5.11K 1/4W 2.67K 1/4W 221K 1/4W 2.0K 1/4W 61.9K 22.1K 1/4W 6.81K 1/4W 825 1/4W 332 1/4W 221 1/4W 4 1 1 2 1 2 1 2 1 3 1 1 1 1 6 1 1 1 2 1 2 1 1 3 2 1 1 1 T13640-11 S17900-1 M15102-3 S17900-13 M15101-6 S19650-7 s21291-5 M15105-4 M15104-6 S17900-25 S19650-1 M14428-2 S21292-5 S15128-4 S19650-5 S21293-3 S21294-1 S17900-24 S19650-3 S19650-6 M15104-11 M15105-11 M14513-4 S15128-18 S17900-22 S15128-10 S15128-21 S16665-5 CAPACITORS = MFD/VOLTS INDUCTANCE = HENRIES RESISTANCE = OHMS R32 R96 R97 Q3 R16 R18 R94 C81 C39 X37 R13 R108 R109 R15 R12 R14 R17 R19 C139 R286 R285 D5 D46 R274 X26 R304 C151 C152 C153 R93 R98 R171 C33 C24 R31 DZ7 R11 R30 C8 R267 C19 C35 XXXX C150 XXX X56 C41 C137 R282 R281 R278 C140 R284 R287 C133 R288 X14 R174 R181 R148 R141 R175 R99 R178 C146 R292 C144 DZ22 DZ21 DZ20 XXXXXXXXX X X55 C85 X91 R273 R147 D13 D14 R187 R89 C84 C16 X11 C95 Q10 D52 X93 R283 C132 R142 R277 R279 R280 C57 C54 C138 R317 X54 XXXXXXXXXXXX R291 R91 R336 C43 X16 C26 C25 R74 C63 C65 R331 R330 R329 R328 C83 C148 XXX C62 X90 XXXXXXXXXXXX XXXXXXXX R264 R266 R319 R318 X63 R186 R188 R211 C117 C114 XXXXXX C2 C49 C1 C21 R2 D2 X20 R135 DZ19 D41 R206 R212 C115 R215 D21 Q23 XXX C7 XX R8 R9 R10 C4 R7 XXX X C5 C155 R207 R203 R119 Q20 Q22 D17 R204 R210 R205 XXXXXXXXX R4 R3 R110 XXX C56 C51 C50 XXXXXXX R197 R199 R327 Q19 R247 R246 R252 D34 R195 Q31 C59 X X X5 C67 X12 X XXXXX X25 Q13 Q33 R153 R300 R152 C18 X44 R332 R333 R334 R335 C40 C31 R72 R73 R263 Q34 DZ4 DZ2 C10 DZ27 XXXXXXXX XXXXXXXXXXX R69 C30 X D50 C52 R179 R71 R70 Q32 Q16 XXXXXXXXXXXXXX C44 C64 X27 D47 C88 X15 R41 X68 R299 R275 C134 R276 C136 C135 C13 DZ3 C11 DZ34 D30 R240 R239 R238 R341 R344 X39 C47 X XXXXXXXXX XXXXXXXX X3 C60 X28 X24 C91 R33 R271 C15 R270 X1 X21 X29 C66 X43 C130 X2 D24 C48 Q7 Q12 X30 C42 C128 C127 XXXX DZ33 R180 DZ32 R173 R68 R260 R225 R65 R67 C32 C119 Q4 Q6 DZ35 Y2 X42 R338 R339 R345 R337 DZ11 R64 C53 R189 R5 C3 X46 C156 J24 J23 G2861-2 POWER WAVE CONTROL X45 C61 D51 J22 J21 J20 Q27 Q2 DZ17 R229 R226 R228 R259 R258 R230 R191 R6 C27 XXX X13 C45 X41 DZ10 DZ31 Return to Master TOC R342 C23 R26 R27 J25 Return to Master TOC DZ12 R221 R161 R163 R164 R160 R165 R162 XXXXXXX DZ14 R44 R52 R42 R50 R222 Q5 X10 XXXXXXXXXXXXX R55 R49 R51 R343 DZ15 X38 C22 C20 XXX X DZ13 R45 XXXXXXXXXXXX C6 XX OCI6 X R46 R48 C69 OCI5 X DZ16 R262 OCI3 X DZ8 R47 R59 R60 R56 R53 R57 R35 C112 R208 X R38 R40 DZ18 Return to Master TOC R61 R63 R62 R58 R43 R54 D23 D31 X Return to Section TOC C70 C68 X DZ6 DZ9 .20 R231 R134 X R23 R21 R36 R24 R22 R37 R39 R29 R34 OCI2 X R28 R25 Return to Section TOC R254 R255 R20 D22 5.63 OCI8 R219 R257 DZ5 J26 OCI4 D42 OCI7 Q28 D25 R220 D33 R150 R153,R160,R162,R163,R164 R165,R166,R225,R260,R305 R306,R307,R309,R312,R313 R316 R155,R178,R220,R253,R256 R299 R159 R195,R197,R207,R211,R212 R241,R289,R290 R200,R201,R208,R234 R204,R240,R247,R249 R205,R238,R250,R252,R282 R286 R206,R298 R215 R217,R219,R254,R288 R224,R237,R248,R261 R236,R243,R245 R273 R276,R281,R285,R303,R304 R283,R287 R291,R292 R328,R329,R330,R331,R332 R333,R334,R335 TP2,TP3,TP4,TP5 X1 X2 X3,X5 X10 X11,X12 X13 X14,X37 X15 X16,X20,X55 X21 X24 X25 X26 X27,X28,X29,X30,X68,X90 X38 X39 X41 X42,X43 X44 X45,X46 X54 X56 X61,X71,X92 X63,X64 X91 X93 Y2 Q24 DZ30 D32 C108 R198 C107 R200 C106 R193 C110 R201 C111 R202 REQ’D ITEM C113 R218 D36 D28 D29 Q18 D39 D26 R196 R245 R244 Q21 D27 R237 R256 C120 R235 C123 R234 C109 Q17 C124 R243 R242 R241 R138 R192 TP2 Q25 R233 R236 R232 C121 C122 TP3 C118 TP4 R194 Q29 Q26 TP5 J28 R248 R223 R227 R209 Q30 D35 D37 C125 R261 R249 R251 R250 C129 D38 C98 11.05 R224 Return to Section TOC G-8 ELECTRICAL DIAGRAMS J27 Return to Master TOC Return to Section TOC G-8 45J Q UA D 2 - I N P U T N A N D ( S S ) UNDERVOLT. SENSING CIR. (SS) QUAD TWO INPUT AND GATE (SS) MPU (SS) IC,CMOS,TRNSCVR,BUS (SS) R O M A S S E M B LY ( S S ) IC,CMOS,CONVERTER,A/D (SS) MPU (SS) I C , C M O S , L AT C H , 3 - S TAT E ( S S ) HEX INVERTER (SS) C RY S TA L , ( M O D U L E ) , 2 5 . 0 M H Z I C , C M O S , M C U, D S P ( S S ) LM224 OP-AMP I C , C M O S , L AT C H , 3 - S TAT E ( S S ) D S P A S S E M B LY ( S S ) I C , C M O S , P L D, G E N E R I C ( S S ) Q UA D S C H M I T T N A N D ( S S ) 1-OF-4 DECO/DEMUX (SS) IC,CMOS,MUX,4-INPUT (SS) I C,CMOS,EEPROM,FLASH (SS) CONVERTER,D/A (SS) IC,CONVERTER,D/A (SS) Q UA D - O P A M P Q UA D A N A L O G S W I T C H ( S S ) VO LTA G E R E F. I C , C O M PA R ATO R , H I - S P D, 5 - V 8.0 MHZ ITEM C1,C2,C6,C8,C11,C16,C17 C18,C19,C20,C21,C22,C23 C24,C27,C28,C29,C31,C32 C34,C37,C40,C41,C42,C43 C44,C45,C48,C59,C60,C61 C62,C63,C64,C65,C66,C67 C68,C69,C73,C77,C79,C81 C83,C84,C95,C97,C98,C100 C105,C111,C119,C155,C156 C3,C25,C26 C4,C5,C49,C50,C51,C57,C85 C7,C47,C70,C130 C10,C13,C15 C30,C56,C90,C126,C135 C33,C35,C38,C39 C52,C53,C54,C106,C108,C114 C120,C134,C137,C138,C139 C140 C87,C91,C96,C101,C132,C133 C141,C142,C144,C145,C148 C150,C151,C152,C153 C88 C107,C110,C112,C115,C116 C117,C123,C127,C128,C136 C109,C113,C121,C124 C118,C122,C125,C129 C143,C146 D2,D17,D18,D19,D20,D21,D22 D25,D26,D27,D28,D29,D30 D31,D32,D33,D34,D35,D36 D37,D38,D39,D40,D41,D42 D43,D46 D4,D5,D10,D11,D12,D13,D14 D15,D16,D24,D47 D23,D50,D51,D52 DZ2,DZ5 DZ3,DZ4 DZ6,DZ27,DZ34,DZ35 DZ7,DZ8,DZ9,DZ10,DZ11,DZ12 DZ13,DZ14,DZ15,DZ16,DZ17 DZ18,DZ19,DZ20,DZ21,DZ22 DZ30,DZ31,DZ32,DZ33 J20,J21 J22 J23,J26 J24 J25 J27,J28 OCI2,OCI3,OCI4,OCI7,OCI8 OCI5,OCI6 Q2,Q3,Q4,Q5,Q6,Q7,Q8,Q9 Q10,Q13,Q16,Q19,Q20,Q23 Q28,Q33,Q34 Q12 Q14,Q15,Q22,Q27,Q31,Q32 Q17,Q18,Q21,Q25 Q24,Q26,Q29,Q30 R2,R4,R8,R9,R10,R12,R13 R14,R16,R18,R20,R32,R35 R41,R58,R59,R60,R61,R62 R63,R65,R72,R74,R158,R169 R170,R172,R185,R193,R198 R202,R210,R213,R222,R235 R239,R246,R251,R255,R257 R262,R264,R267,R268,R279 R284,R295,R296,R297,R317 R318,R319 R3,R7,R68,R70,R142,R154 R161,R214,R216,R302,R310 R314,R336,R337,R338,R339 R341,R342,R343,R344,R345 R5,R37,R87,R293,R294 R6 R11,R99,R141,R148,R175 R209,R223,R263,R266,R277 R15,R36,R38,R39,R40,R64 R67,R69,R71,R73,R89,R90 R91,R92,R93,R94,R97,R108 R110,R118,R120,R127,R135 R152,R156,R168,R171,R173 R179,R180,R183,R186,R187 R188,R189,R191,R192,R199 R203,R221,R228,R231,R258 R275,R280,R300,R301,R308 R311,R315 R17,R19,R109 R21,R23,R24,R182,R227,R232 R242,R244 R22,R29,R274 R25,R28,R270,R271 R26,R27,R30,R31,R34,R42 R43,R44,R45,R46,R47,R48 R49,R50,R51,R52,R53,R54 R55,R56,R57,R122,R128,R146 R147,R167,R177,R184 R33,R86,R229,R230 R66,R84 R96,R98 R119,R126,R134,R138,R226 R259,R327 R121,R129,R130,R174,R181 R278 R149,R194,R196,R218,R233 REQ’D PART NO. DESCRIPTION 54 S16668-11 .1/50 3 7 4 3 5 4 12 S16668-2 S16668-1 S13490-42 S13490-25 S16668-8 S13490-39 S16668-7 47pF/100 22pF/100 1.0/35 4.7/35 330pF/100 18/15 820pF/50 15 S16668-5 .022/50 1 10 S13490-85 S16668-9 .27/50 150pF/100 4 4 2 27 S16668-4 S13490-3 S16668-6 T12199-1 2700pF/50 .0047/400 4700pF/50 1N4004 11 T12705-22 1N914 4 2 2 4 20 T12705-34 T12702-40 T12702-45 T12702-29 T12702-52 1N4936 1N4735 1N4746A 1N4744A 1N4733A 2 1 2 1 1 2 5 2 17 S20351-8 S20351-12 S20351-6 S20351-14 S20351-10 S20351-4 S15000-10 S15000-23 T12704-68 HEADER HEADER HEADER HEADER R T. A N G L E H E A D E R HEADER O P TO I S O L ATO R 6N136 OPTOCOUPLER 2N4401 1 6 4 4 52 T12704-73 T12704-69 T12704-35 T12704-47 S19400-1002 IC PKG MOSFET (SS) 2N4403 N P N T R A N S I S TO R .5AMP / 300 VOLT PNP 10K 1/4W 21 S19400-4751 4.75K 5 1 10 S19400-2211 T14231-2 S19400-1003 2.21K 1/4W 10M 1/2W 100K 1/4W 50 S19400-1001 1K 1/4W 3 8 S19400-1502 S19400-26R7 15K 1/4W 26.7 1/4W 3 4 28 S19400-2670 S19400-1000 S19400-4750 267 1/4W 100 1/4W 475 1/4W 4 2 2 7 S19400-2672 S19400-4752 S19400-1501 S19400-6810 26.7K 1/4W 47.5K 1/4W 1.5K 1/4W 681 1/4W 6 S19400-3322 33.2K 1/4W 5 S19400-7500 750 1/4W G 2861-2 11-12-99C 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 provided 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 450 SCHEMATIC - DISPLAY PC BOARD (SHEET 1) +5V +15V 9 Vdd C57 0.1 50V X7 MC68HC11 Vss 44 Vcc 26 20 C48 0.1 50V X8 DZ5 5.1V 1W PSD301 GND 1 12 DZ4 5.1V 1W C50 X4 20 C49 X9 0.1 50V 74HC573 GND 34 20 10 C56 X3 0.1 50V 74HC573 14 0.1 50V 74HC573 10 14 C20 X11 10 C12 X5 0.1 50V 74HC04 12 7 C52 X16 0.1 50V 54HC08 16 0.1 50V MC6850CS 7 X12 74HC4040 1 Vdd 16 C55 X14 C54 0.1 50V 74HC151 0.1 50V 8 3 C25 X10 4 Vss 8 Vss 14 0.1 50V C39 LM224 14 C40 X2 0.1 50V 11 11 X5 13 13 GD 11 3 5 14 X1 LED15 LED34 LED13 LED30 C16 18 15V Vss Vcc 1 -10RS232 +5RS232 10K C14 330p 50V 3 C15 18 15V 2 5 R41 R42 Q3 40V 600mA X15 10 R58 J17 10 13 13 D6 Q9 12 12 D7 C46 330p 50V 10K Q5 40V 600mA /DCD GRS232 4 d 5 c LED25 LED9 LED20 BANK5 17 4 d BANK4 16 5 c 6 b Vdd 7 a BANK3 10 BANK2 /ENABLE 14 BANK1 e Rx 15 13 BANK5 17 BANK4 16 b Vdd a BANK3 10 /ENABLE OC5 9 19 14 g 20 20 DATA OUT 18 12 CLOCK 11 11 R4 18 Q1 75.0 17 Q2 16 Q3 75.0 75.0 h BANK2 BANK1 Vss 2 f 1 D1 21 BI-DL[1] 5 /RTS D2 20 BI-DL[2] 6 TxData D3 19 BI-DL[3] 2 RxData D4 18 BI-DL[4] D5 17 BI-DL[5] D6 16 D7 15 CS1 RS TRIM4 GD X9 g DATA IN DATA OUT CLOCK Rx VCC 9 /CS2 3 BI-DL[1] BI-DL[1] 3 D1 4 BI-DL[2] BI-DL[2] 4 D2 D1 D2 2 D0 74HC573 X3 Q0 19 Q1 18 Q2 17 D3 5 BI-DL[3] BI-DL[3] 5 D3 Q3 16 6 BI-DL[4] BI-DL[4] 6 D4 Q4 15 D5 7 BI-DL[5] BI-DL[5] 7 D5 Q5 14 13 Q6 D6 8 BI-DL[6] BI-DL[6] 8 D6 Q6 13 12 Q7 D7 9 BI-DL[7] BI-DL[7] 9 D7 Q7 12 1 LE LE 10K 10K +5V 10K R30 R40 R39 +5V 1K R240 4.9152MHz INFRA2 INFRA3 SCK C36 0.1 50V INFRA1 10K Y1 C33 22p 100V INFRA4 INFRA5 GD C32 22p 100V INFRA6 MOSI R31 TRN REC RS_LCD BAUD0 INFRA7 BAUD1 GD INFRA8 BAUD2 CRYSTAL TRIG1 LE_INFRA TRIG2 1 SPTIG SPWF2 /PB4 1 X11 2 C34 0.1 50V 1 X5 3 LE_KEY C31 0.1 50V 4 +5V 9 X11 8 5 X5 6 25 2 3 BI-DL[6] BI-DL[7] U P1 P1 F P V 8 9 10 J18 J18 R13 /CS_RS232 X1 R71 R49 7 4.75K 4.75K 5 GD X1 R70 1 R7 10K 100K R5 R72 133K 4.75K 5 GD C60 0.1 50V LCD -5V 8 DISPLAY L1 10 GD -8V .39mH RS_LCD R68 J19 R61 100 DZ6 5.1V 1W RST J19 100 C35 0.1 50V OC5 (2) A0/D0 /SS A1/D1 10 BI-DL[1] R50 MODB A2/D2 11 BI-DL[2] R59 A3/D3 12 BI-DL[3] R60 A4/D4 13 BI-DL[4] R63 XTAL A5/D5 14 BI-DL[5] R64 7 EXTAL A6/D6 15 BI-DL[6] R65 52 VRH A7/D7 16 BI-DL[7] R67 24 SCK A8 42 BI-DL[8] A9 41 BI-DL[9] 40 BI-DL[10] 23 MOSI 22 MISO 21 TxD /IRQ 19 20 RxD A11 39 BI-DL[11] 27 PAI A12 38 BI-DL[12] 28 OC2 A13 37 BI-DL[13] 29 OC3 A14 36 BI-DL[14] 35 BI-DL[15] A10 30 OC4 A15 43 A/D1 E 45 A/D2 47 IRQ 5 E R/W 6 R/W A/D3 AS 4 AS 49 A/D4 /RES 17 RST 44 A/D5 A/D8 50 46 A/D6 IC1 32 48 A/D7 IC2 33 IC3 34 VRL 51 31 26 OC5 Vdd MC68HC11 LE_INFRA 44 .39mH 150 J19 150 24 A1/D1 PA0 21 J19 25 A2/D2 PA1 20 J19 BI-DL[3] 26 A3/D3 PA2 19 J19 BI-DL[4] 27 A4/D4 PA3 18 J19 BI-DL[5] 28 A5/D5 PA4 17 J19 BI-DL[6] 29 A6/D6 PA5 16 J19 BI-DL[7] 30 A7/D7 PA6 15 J19 BI-DL[8] 31 A8 PA7 14 J19 BI-DL[9] 32 A9 PB0 11 BI-DL[10] 33 A10 GND PB1 BI-DL[11] 35 A11 PB2 9 BI-DL[12] 36 A12 PB3 8 THERMAL BI-DL[13] 37 A13 PB4 7 PRESSURE BI-DL[14] 38 A14 PB5 6 FLAG BI-DL[15] 39 A15 PB7 4 E 22 E PC0 40 R/W 2 R/W 13 AS PB6 5 3 /RES PC1 41 1 /BHE PC2 42 AS RST /CSI PSD301 R/W /E_LCD J19 R36 J19 100 PIEZO /OE_KEY 100 DZ3 5.1V 1W WATER J19 /PB4 GD FAN 1 P1 +LEDB +5V GD BI-DL[2] GND P1 150 BI-DL[1] 10 7 -LEDB RS 150 Vcc 12 P1 150 A0/D0 34 P1 6 150 23 SENSE +5V 150 BI-DL[0] X8 2 L2 Vss X7 J19 4.75K BI-DL[0] 9 /XIRQ Vo DZ7 8.2V 1W 9 Vss MODA P1 1.00K 3 X1 X17 J19 2 +5V 4 P1 9 10 11 12 13 14 15 16 8 3 P1 P1 P1 P1 P1 P1 P1 P1 P1 P1 VDD D0 D1 D2 D3 D4 D5 D6 D7 E VSS GD /E_LCD /PB7 +5V /CS_RS232 43 R28 R29 R32 10.0K 10.0K 10.0K R25 R11 6 D2 GD GD 1.00K 1.00K R6 R12 1.00K R2 R16 1.00K 1.00K TEMPERATURE COMPENSATION R3 R21 R20 R18 R23 R19 2 D0 75.0 3 D1 75.0 4 D2 75.0 5 75.0 74HC573 Q0 19 BI-DL[0] GD Q1 18 BI-DL[1] Q2 17 BI-DL[2] D3 Q3 16 BI-DL[3] 6 D4 Q4 15 BI-DL[4] 75.0 7 D5 Q5 14 BI-DL[5] 75.0 8 D6 Q6 13 BI-DL[6] 9 D7 Q7 12 BI-DL[7] X4 1.00K 267 GD GD /OE_KEY 11 LE 1 OE LAST NO. USED GENERAL INFORMATION C1 0.1 50V CAPACITORS = MFD ( .022/50V RESISTORS = Ohms ( DIODES = GD 1A, 400V 1/4W D- 24 DZ- 28 C- 101 X- 17 TP- 1 LED- 34 Q- 29 OCI- 18 R- 240 ELECTRICAL SYMBOLS PER E1537 UNLESS OTHERWISE SPECIFIED) UNLESS OTHERWISE SPECIFIED) (UNLESS OTHERWISE SPECIFIED) LABELS SUPPLY VOLTAGE NET R99-R106 ARE NOT ASSIGNED POWER SUPPLY SOURCE POINT COMMON CONNECTION FILE NAME: G2239_1DA +5V KEYPAD INTERFACE XIRQ C24 0.1 50V DZ2 5.1V 1W 301 RESET R26 J18 J18 (POWER DOWN) R34 J16 2.67K 1.00K BI-DL[15] Vdd 6.81K C2 M 6 475 R27 R22 C3 E 4 J18 C4 P1 J18 C7 P1 P1 2 C6 P1 1.00K T R24 O C11 Return to Master TOC Return to Section TOC J 475 R33 -5V +5V D 8 GD 8 18 SPWF1 /PB7 S J16 445 R62 GD 2 L J15 GD E I J15 MAIN PROCESSOR 1.50K GD C C41 0.1 50V IRQ GD GD R 4 8 1 11 OE OE Q -8V 6 C44 1.0 35V CW S-8054HN 18 R35 BI-DL[0] 2 D4 11 LE_KEY 74HC573 BI-DL[0] D0 GRS232 J16 444 PIEZO BUZZER R/W 8 CS0 C59 0.1 50V 10M 1/2W Q4 14 TRIM2 TRIM3 N 23 /DCD 11 9 e DRIVE Q5 15 TRIM1 C5 J18 7 Q0 75.0 C9 R10 C10 R8 J18 C8 P1 J18 5 BI-DL[0] RES R38 3 22 7 /IRQ 15 XIRQ P1 13 D0 10 13 BI-DL[0:15] P1 R/W TxCLK 3 LED 19 3 MC14489 GD R9 RxCLK 1.00K R17 Return to Master TOC X13 SCK 1.50K J16 442 C70 BI-DL[14] 7 MC14489 J18 VSS MC6850CS 6 19 f 2 8 3 h Vss 1 1 1 4 LED23 LED26 12 DATA IN _ J15 C38 0.1 50V C37 1.0 35V 11 3 24 /CTS LED3 X10 + +5RS232 2 4.75K 5 GRS232 P1 3 3.32K +5V 2 40V R115 E 4 J15 C19 1.0 35V J16 443 600mA PIEZO BI-DL[11] MOSI H STROBE 10K R55 6 OCI5 H11L2 2 Q15 A2 7 R73 J17 7 R52 8 Rx LED21 LED2 OC5 B 1 BI-DL[0:15] 12 750 6.81K +15V D21 9 X16 14 E 1 K 6 X14 22.1K Tx LED6 GD G /Y PIEZO BUZZER CIRCUITRY GD LED22 LED5 GD A 5 A1 10 BAUD1 Y A0 11 BAUD0 GD 12 X15 DATA CARRIER DETECT Return to Section TOC Q8 GND LED24 LED8 R54 9 9 C45 330p 50V TRANSMIT R /DCD 22.1K 10K 11 4 8 +15V 10 +5V LED7 R53 R51 R57 J17 5 D5 +5RS232 2 6 J17 J17 2 D4 14 LED27 +5V X15 D3 15 4 LED4 +5RS232 13 1 2 Q7 LED11 GRS232 +5RS232 4 3 Q6 /C 74HC151 LED31 +5V 6 Q5 Q1 BAUD2 ISOLATED POWER & SIGNALS 1 Q10 10 LED29 LED12 GRS232 OCI8 H11L2 14 LED10 J17 5 J17 GRS232 Q6 600mA 40V D2 LED17 Rx 3 J17 11 267 D1 2 74HC4040 LED33 GD RECEIVE 4.75K 3 5 LED28 J17 Tx 6 Q4 9 LED16 4 Q3 R48 GRS232 19 C2- 6 X12 R66 4 1 10K Q11 8 LED32 R47 X15 LED14 OCI7 H11L2 17 Vdd GND C2+ R56 Return to Master TOC Return to Section TOC C1- C1+ 2 +10RS232 18 20 C17 18 15V 750 6.81K R43 C18 18 15V -5V C21 0.1 50V R37 +5V Q12 D0 R14 +5RS232 16 X15 1 15 4 R114 LED18 16 Vcc GA GD J16 447 -5V LED19 5 J16 GD Q2 C28 1.0 35V 9 6 X11 13 1 W1 C26 0.1 50V 446 GA 7 C29 0.1 50V C23 1.0 35V 7 4 X11 C22 0.1 50V 12 GD J17 C27 0.1 50V J16 449 12 X11 0.1 50V LM224 -5V FULL DUPLEX RS232 COMMUNICATION LINK +5V 1 10 X11 12 C30 X13 MC14489 11 4 X1 0.1 50V MC14489 J16 448 8 X5 10 3 Vdd FROM POWER BOARD Return to Master TOC G-9 ELECTRICAL DIAGRAMS G 2239-1 Return to Section TOC G-9 FRAME CONNECTION SHEET 1 OF 2 Ch’ge.Sht.No. NOTES : N.A. SINCE COMPONENTS OR CIRCUITRY ON A PRINTED CIRCUIT BOARD MAY CHANGE WITHOUT AFFECTING THE INTERCHANGEABILITY OF A COMPLETE BOARD, THIS DIAGRAM MAY THE LINCOLN ELECTRIC CO. 1-6-95B CLEVELAND, OHIO U.S.A. 12-8-95E SCALE NOT SHOW THE EXACT COMPONENTS OR CIRCUITRY OF CONTROLS HAVING A COMMON CODE NUMBER. DR. DB DATE EARTH GROUND CONNECTION EQUIP. TYPE SUBJECT INVERTEC V400 DISPLAY/KEYPAD PCB SCHEMATIC NONE 1-26-94 CHK. SUP’S’D’G. SHT. NO. G 2239-1 NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. POWER WAVE 450 SCHEMATIC - DISPLAY PC BOARD (SHEET 2) R194 +15V 100 R195 4 R199 C98 330p 100V GA R200 681 3 1 INFRA4 6.81K GA 75.0 2 4 Q22 600mA 40V R176 22.1K 3 1 4 2 2 Q23 600mA 40V R182 6.81K 22.1K C88 3 1 4 2 OCI10 OPTEK OPB706 Q24 600mA 40V R177 INFRA6 6.81K 22.1K C89 150 3 1 4 2 OCI12 OPTEK OPB706 SENSE SENSE INFRA5 150 R110 150 OCI18 OPTEK OPB706 SENSE DZ25 15V 1W R175 R198 GD 22.1K 10.0 1 OCI17 OPTEK OPB706 Q29 600mA 40V FAN +5V OCI11 OPTEK OPB706 SENSE 6.81K 22.1K C90 SENSE Q13 600mA 40V R179 INFRA7 INFRA8 Q9 600mA 40V R103 6.81K R102 3 75.0 R204 6 150 R104 R196 100 150 R105 J11 R180 10K 4 R178 R206 C99 0.1 50V 681 R205 DZ26 5.1V 1W J11 THERMAL R203 5 +5V THERMAL FAN R197 GA +5V +5V R154 1.00K +5V J11 200 R174 R201 10K J11 2 C97 0.1 50V DZ24 15V 1W R152 100 +15V R202 Return to Master TOC G-10 ELECTRICAL DIAGRAMS G 2239-2 Return to Section TOC G-10 22.1K C91 C68 GD GD GD GD GD +15V GD NOTE: 8 MULTIPLEXED SIGNALS (UNDER SOFTWARE CONTROL) ARE SAMPLED AT THIS NODE SENSE +15V R191 R192 22.1K R121 6.81K GA 75.0 22.1K 4 2 INFRA2 R183 6.81K 22.1K C94 SENSE INFRA3 6.81K 22.1K C93 C77 Q27 600mA 40V R185 2N4401 C75 22.1K GD GD GD +15V 1.00K J14 R101 2700p 1.00K R132 1.00K R123 50V C69 +15V REFERENCE CIRCUIT R108 750 Q11 R160 TRN R129 R227 DZ10 20V 5W D7 4 R143 C80 0.1 50V R230 R147 3 R113 C74 .0047 400V Q7 600mA 40V 24VAC ISOLATED TRIGGER CIRCUIT 10K 5.11K 3.32K REC D11 Q16 600mA 40V R120 14 - PIN REMOTE 2 C67 0.1 50V J12 R215 +t 56 D19 D17 GD R172 X2 100K DZ18 10V 1W GA 1 L4 .39mH 7 1 3.32K 7 6 R162 R171 475 R164 14 - PIN REMOTE SPWF1 4 DZ21 5.1V 1W C87 0.1 50V 10K C66 20 50V 3 J12 J12 221 J14 1 ANODE 2 VC CATH 3 5 GND NC 4 2 C64 150p 50V 6 150 C63 330p 100V D9 2 J14 WIRE FEEDER COMM. 4 3 GD Q8 600mA 40V 24VAC ISOLATED TRIGGER CIRCUIT GENERAL INFORMATION 10K LAST NO. USED ELECTRICAL SYMBOLS PER E1537 CAPACITORS = MFD ( .022/50V RESISTORS = Ohms ( GD N.A. DIODES = 1A, 400V 1/4W UNLESS OTHERWISE SPECIFIED) UNLESS OTHERWISE SPECIFIED) (UNLESS OTHERWISE SPECIFIED) LABELS R- _ D- _ R- _ C- _ C- _ C- _ D- _ D- _ D- _ SUPPLY VOLTAGE NET POWER SUPPLY SOURCE POINT SINCE COMPONENTS OR CIRCUITRY ON A PRINTED CIRCUIT BOARD MAY CHANGE WITHOUT AFFECTING THE INTERCHANGEABILITY OF A COMPLETE BOARD, THIS DIAGRAM MAY COMMON CONNECTION FILE NAME: G2239_1DA NUMBER. 13 +t D8 1 NOT SHOW THE EXACT COMPONENTS OR CIRCUITRY OF CONTROLS HAVING A COMMON CODE R170 NC VB 6 D13 J14 OCI4 CNY17 NOTES : GD VCC 7 5 D15 D16 1 8 D14 R219 J12 475 C84 0.1 50V 4.75K 3.32K R220 5 C73 150p 50V OCI3 TRIG1 3.32K R218 DZ12 20V 5W 4.75K R216 R217 100K C71 150p 50V D12 221K 475 3.3V 1W 3.32K 3.32K D18 R93 D24 DZ13 20V 5W 10K DZ14 1.00K R94 R116 2.67K R90 DZ19 5.1V 1W R214 R95 C83 0.1 50V R169 R166 3.32K R117 +5V 681 SPWF2 2 9 +5V R100 475 TP1 150V 45J +15V R97 R173 475 D22 4 R98 R225 R226 R44 R163 2K C65 0.1 50V 4 +5V 13 1.00K J10 6 3.32K R99 R168 100K DZ20 10V 1W 100K C86 0.1 50V J10 R232 1N4936 D10 DZ11 5.1V 1W 5 GD 14 X2 C85 0.1 50V 100K J10 2 12 R165 GA 5 J14 CNY17-3 D3 J13 J13 C72 150p 50V GD 1.00K J10 OCI2 C61 20 50V 100K 100K +10V J10 10K 3.32K 6 - PIN REMOTE 8 50V 5 11 R45 TO REMOTE 10K POTENTIOMETERS GA 100K 100K J10 1 D5 1 1.00K J10 3.32K J13 SPTIG C82 0.1 50V DZ16 5.1V 1W J14 TRIG2 R80 475 R149 9 820p 10K R119 R146 +10V DZ17 10V 1W 475 8 X2 100K 221 GD R234 C81 0.1 50V 4.75K R229 3.32K DZ9 20V 5W 475 3.3V 1W 3.32K R231 100K 100K J10 R74 D23 D6 R148 C62 GND 5 OCI13 R88 D4 12 6 NC R85 56 100K 10 6 4 221K R239 J10 7 VC DZ8 R228 +t GA J10 8 VB CATH 1.00K R83 47.5K VCC ANODE 3 R84 100K 200 NC 2 Q10 500mA 300V 500mA 300V 4.75K 10.0 J13 R118 2 10K 1 D20 R79 1.00K 33.2K DZ15 15V 1W +5V R78 +10V C76 0.1 50V R81 .39mH +5V 221K 56 R167 +t 1.3K 681 R125 10 Q14 1.00K R77 L3 R145 R238 R130 10.0 4 R124 3 2N4403 R111 R86 X2 1 R87 3 1 R112 R155 2 R131 J10 2 2N4401 14 R128 J10 J10 475 Q21 +10V J10 100K R107 Q12 600mA 40V +5V 6 R89 16 26.7 R106 C101 0.1 50V DZ28 5.1V 1W R109 FLAG R213 15 4.75K Return to Master TOC C79 22.1K GD 100K Return to Master TOC 22.1K 2N4401 C78 22.1K C92 3.32K J10 R212 10K J10 Return to Section TOC 6.81K Q19 GD GD Return to Section TOC R139 2N4401 R157 R137 R127 2N4401 6.81K Q18 2 SENSE Q25 600mA 40V 6.81K Q20 R141 4 6.81K Q17 R138 R158 R161 R156 OCI16 OPTEK OPB706 R135 2 Q26 600mA 40V 1 OCI15 OPTEK OPB706 SENSE INFRA1 C96 330p 100V 3 1 6.81K TRIM4 33.2K R136 3 10.0K TRIM3 33.2K R134 4 DZ23 15V 1W R122 475 3.32K R133 1 TRIM2 R126 Q28 600mA 40V R190 1.50K R142 3 OCI14 OPTEK OPB706 WATER 33.2K 150 R159 R153 150 J11 J16 GD GA 133K R140 3 12 150 R181 R210 10.0 WATER COOLER R151 10K 47.5K TRIM1 C95 0.1 50V R184 R211 681 8 56 +5V +5V J11 R150 R207 C100 0.1 50V 1 +t J16 PRESSURE R209 Return to Master TOC Return to Section TOC DZ27 5.1V 1W R46 5 R208 7 J11 +5V J16 1.00K J11 (9) +15V 4 1.50K FRAME CONNECTION SHEET 2 OF 2 56 Ch’ge.Sht.No. 1-6-95B CLEVELAND, OHIO U.S.A. 12-8-95E SCALE DR. DB DATE EARTH GROUND CONNECTION EQUIP. TYPE THE LINCOLN ELECTRIC CO. SUBJECT INVERTEC V400 DISPLAY/KEYPAD PCB SCHEMATIC NONE 1-17-94 CHK. SUP’S’D’G. SHT. NO. G 2239-2 NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. POWER WAVE 450 Return to Master TOC G-11 ELECTRICAL DIAGRAMS PC BOARD ASSEMBLY-DISPLAY G 2862-1 Return to Section TOC G-11 ITEM R50,R59,R60,R63,R64,R65 REQ’D PART NO. S19400-1500 150 1/4W 16 S19400-2212 22.1K 1/4W R67,R88,R104,R105,R110 DESCRIPTION .1/50 C56,C57,C59,C60,C65,C67 C76,C80,C81,C82,C83,C84 R184,R191,R199 11.75 PART NO. S16668-11 C48,C49,C50,C52,C54,C55 R175,R178,R180,R181 12.00 45 C35,C36,C38,C39,C40,C41 R134,R135,R140,R174 ±.04 REQ’D C26,C27,C29,C30,C31,C34 R150,R151,R152,R153,R154 R51,R102,R114,R122,R126 ITEM C1,C12,C20,C21,C22,C24,C25 DESCRIPTION 16 C85,C86,C87,C95,C97,C99 R73 1 T10812-41 10K 1/2W TRIMMER C100,C101 R79,R95 2 S19400-2210 221 1/4W C2,C3,C4,C5,C6,C7,C8,C9 R80,R90,R97 3 S19400-2213 221K 1/4W C10,C11,C68,C70,C75,C77 R85,R115,R120,R123,R127,R216 15 S19400-3321 3.32K 1/4W C78,C79,C88,C89,C90,C91 R89 1 S19400-2001 2.0K 1/4W R109 1 S19400-26R7 26.7 1/4W C100,C101 R111 1 S19400-1301 1.3K 1/4W R112,R196 2 S19400-2000 R118 1 S19400-5111 23 S16668-5 .022/50 C14,C45,C46,C63,C96,C98 6 S16668-8 330pF/100 C15,C16,C17,C18 4 S13490-39 18/15 C32,C33 2 S16668-1 22pF/100 200 1/4W C61,C66 2 S13490-73 20/50 5.11K 1/4W C62 1 S16668-7 820pF/50 C64,C71,C72,C73 4 S16668-9 150pF/100 R217,R218,R219,R220,R229 C92,C93,C94 R230,R231,R232,R234 R128,R130,R202,R209 4 S19400-10R0 10 1/4W C69 1 S16668-4 2700pF/50 R129,R137,R139,R158 4 S19400-3322 33.2K 1/4W C74 1 S13490-3 .0047/400 D2,D3,D4,D5,D6,D7,D8,D9 22 T12199-1 1N4004 D11,D12,D13,D14,D15,D16 R156,R167 2 S19400-4752 47.5K 1/4W D23,D24 R198,R204,R210,R214,R227 5 S19400-6810 681 1/4W D10 TP1 1 T13640-11 45J DZ2,DZ3,DZ4,DZ5,DZ6,DZ11 W1 1 CJ000001 E2387-#20-2.00 DZ7 1 T12702-55 1N4738A X1,X2 2 S15128-4 LM224 OP-AMP DZ8,DZ14 2 T12702-53 1N4728A X3,X4,X9 3 S17900-25 IC,CMOS,LATCH,3-STATE (SS) DZ9,DZ10,DZ12,DZ13 4 T12702-25 T12705-34 1N4936 T12702-52 1N4733 XXXXXXXX S17900-13 QUAD TWO INPUT AND GATE (SS) DZ15,DZ23,DZ24,DZ25 4 T12702-29 1N4744A 1 S23996 HC11 MICROPROCESSOR(SS) DZ17,DZ18,DZ20 3 T12702-27 1N4740 X8 1 S21290-4 ROM ASSEMBLY(SS) X10,X13 1 S18248-16 HEADER 2 S20496-1 LED DRIVER (SS) J10 X11 1 S17900-2 HEX INVERTER (SS) J11 1 S18248-8 CONNECTOR X12 1 S17900-6 12 STAGE BINARY COUNTER (SS) J12,J13,J15 3 S18248-4 HEADER X14 1 S17900-26 SELECT/MULTIPLX(SS) J14 1 S18248-6 HEADER X15 1 IC,CMOS,DRVR/RCVR,EIA232 J16 1 S18248-12 HEADER X16 1 S20603-1 IC,CMOS,ACIA,2.0MHZ,68B50P J17 1 S18248-10 HEADER X17 1 M15102-3 RESET I.C. UNDERVOLT. SENSING CIR. (SS) J18 1 S19365-10 RT. ANGLE HEADER J19 1 S18899-16 ST. HEADER L1,L2,L3,L4 4 T12218-9 .39mH LED2,LED3,LED4,LED5,LED6 32 T13657-3 GREEN LED 1 S20353-1 S16665-6 CRYSTAL,QUARTZ,4.9152MHZ 1 XXXXXXXXXX XXXXXXXXXX X 4.73 XX XXXXXXXXXXXXXXX X XXXX X XXXXXXX LED24 1 T13657-4 YELLOW LED OCI2,OCI4 2 S15000-10 OPTO ISOLATOR X X XX X XXXXXXXXXXX LED25,LED26,LED27,LED28 LED33,LED34 X V400 DISPLAY KEYPAD LED20,LED21,LED22,LED23 LED29,LED30,LED31,LED32 X Return to Master TOC LED16,LED17,LED18,LED19 X XXXXXXXXX XX LED12,LED13,LED14,LED15 CAPACITORS = MFD/VOLTS INDUCTANCE = HENRIES RESISTANCE = OHMS X XX 1N5357B 1 X7 X XXXXXXXXXXXXXXXXX XXXXXXXX DZ28 X5 Y1 XXXXXXXXXX XXXXXXXXXX XXXXXXXX XXXXXXXX XXXXXXXX 16 8.27 (JUMPER) LED7,LED8,LED9,LED10,LED11 XXXXX XXXXXXXXXXXXXX XXXXXXXX 6.00 Return to Section TOC 1 12 DZ16,DZ19,DZ21,DZ26,DZ27 Return to Master TOC Return to Section TOC D17,D18,D19,D20,D21,D22 OCI3,OCI13 2 OCI5,OCI7,OCI8 3 S15000-19 IC,OPTOISOLATER OCI10,OCI11,OCI12,OCI14 8 S15000-24 S15000-23 OPTOSENSOR,REFLECTIVE 6N136 OPTOCOUPLER 23 T12704-68 2N4401 Q10 1 T12704-47 .5AMP/300V PNP Q11 1 T12704-35 NPN TRANSISTOR Q14 1 T12704-69 2N4403 R2,R6,R11,R12,R14,R16,R24 23 S19400-1001 1K 1/4W OCI15,OCI16,OCI17,OCI18 Q3,Q5,Q6,Q7,Q8,Q9,Q12,Q13 Q15,Q16,Q17,Q18,Q19,Q20 Q21,Q22,Q23,Q24,Q25,Q26 Q27,Q28,Q29 R27,R66,R70,R101,R124,R131 R132,R147,R164,R169,R203 R208,R213,R215,R228,R240 R3,R117 2 S19400-2671 2.67K 1/4W R4,R8,R9,R10,R18,R19,R20 13 S19400-75R0 75 1/4W R197 R5,R161 2 S19400-1333 133K 1/4W R7,R44,R45,R87,R106,R108 17 S19400-1003 100K 1/4W R125,R146,R148,R165,R166 R168,R172,R225,R226,R238 R239 G2862-1 .95 R13 1.23 1 S19400-3010 301 1/4W R17,R35,R159,R207 4 S19400-1501 1.5K 1/4W R25,R42,R53,R103,R121,R133 16 S19400-6811 6.81K 1/4W R136,R138,R141,R142,R176 R177,R179,R182,R183,R185 R26,R57 2 S19400-2670 267 1/4W R28,R29,R30,R31,R32,R39 24 S19400-1002 10K 1/4W 12 S19400-4750 475 1/4W 100 1/4W R40,R41,R47,R52,R55,R58,R77 .25 R78,R86,R98,R99,R113,R116 R157,R201,R205,R211,R212 0 R33,R34,R74,R93,R143,R149 R190 Return to Master TOC Return to Section TOC R155,R162,R163,R171,R173 R36,R37,R61,R68,R194,R195 0 7 S19400-1000 R38 1 T14231-2 10M 1/2W R43,R54,R107 3 S19400-7500 750 1/4W R46,R83,R94,R145,R170 5 S18380-1 PTC THERMISTOR R48,R49,R56,R62,R71,R72 11 S19400-4751 4.75K R197 .25 ±.04 4.50 9.00 R81,R84,R100,R119,R160 9-27-96K 1-6-95B 3-21-97D 2-10-95F 1-7-2000E EQUIP. THE LINCOLN ELECTRIC CO. TYPE CLEVELAND, OHIO U.S.A. 8-11-95C 12-8-95E 1-26-96 NOTE: SCALE DR MP FULL DATE 9-22-94 SUBJECT CHK DRS REF. INVERTER WELDERS DISPLAY/KEYPAD P.C. BOARD ASSEMBLY G2407-1 G 2862-1 SHT. SUP’S’D’G NO. 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 provided 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 450 2240 INVERTER POWER SUPPLIES PRIMARY SWITCHING CIRCUIT +5Vref 10K 14 R6 R2 R57 C2 3 COMP IN E1 16 GND X1 TL494 12 100 X2 R26 13 200 200 200 RES 7 1 D11 CR1 CR2 12Vdc 12Vdc R25 R70 R69 R68 R67 D29 1N4936 +5Vref 10K C12 .022 50V .5 5W R33 100K 100K SWITCH_GND C32 0.1 50V GND 1mH 35V 1000 8 D35 9t DZ17 6.2V 1W R190 C178 1N4936 D34 L11 C37 0.1 50V D60 GND CR2 4 IN 8 1mH b OUT X9 -5Vb 15mA N.D. J42 IN +5Va OUT X5 C140 0.1 50V 2.21K 2.21K 2.21K X6 IN R193 e 5 J42 -15Va 350mA C23 0.1 50V 243 N.B. N.C. J44 301 J44 40mAe J44 -8Vb 6 R150 R83 50mA J42 Used on -1A 8 Used on -1B N.C. J44 -5Vb J44 +15Vb J44 +5Vb 11 J42 J44 J44 PWR_DN 10 J42 +5Va 7 9 J42 +15Va a OUT J42 J42 1.50K -15Va 1mH 301 4 3 4 D39 R110 gate 2 1.50K GND J44 +5Vc 5 1N4936 D37 6 J44 12 a Used on -1B 7 1N4936 J41 T5 1N5402 1.3K gate 1 R36 3.32K C17 2.7 50V Q9 500mA 300V DZ8 15V 1W C26 0.1 50V C27 4.7 35V GATE 2 GATE J41 6 J41 4 DRIVE Q10 4A 100V DZ9 15V 1W 4.75K J41 1 5 2.21K 10K R40 R80 DZ16 27V 5W C19 4.7 35V R197 15V 4.75K 1.50K DZ7 1W R39 2.67K R88 G R37 C18 2 150V R93 D59 3 J41 J41 J41 DZ10 27V 5W DZ11 27V 5W J41 J41 J41 J41 J41 J41 d d J41 J41 a (cosmetic trace connecting ground planes) 1 FET DRIVE 2 J40 T6 2 1.50K 10 7 15 8 gate 2 C28 0.1 50V C29 4.7 35V 4 10K 5 6 GATE J40 6 J40 4 J40 J40 J40 DZ13 27V 5W DZ14 27V 5W J40 J40 J40 J40 J40 12 14 2 DRIVE J40 11 13 GATE Q11 4A 100V DZ12 15V 1W J40 1 5 16 3 3 d IN OUT J40 J40 30mA C39 0.1 50V GND C159 0.1 50V RS232 c 10 10 100 15t 11 T4 SEC. C189 9 1N4936 D40 7 12 L119 R194 301 9 R107 .39mH 30t L116 150 CR2 13 C102 2 150V 150 C190 .1 100V 1W D43 11 C191 0.1 50V L120 3 301 40mA @ 27V 60mA limit 5.1V D42 9 40mAe R109 CURRENT SOURCE DZ115 1N4936 1 R192 1mH Q111 100V 1A R156 6 J40 18Vd 9 R92 S D .22mH J41 18Vd FET DRIVE 1 18Vd 1.00K 9 b R89 FET DRIVER SUPPLY 1.00K 8 1A/20.4usec max Q8 100V D14 3A 600V +5Vc X10 1.00K C38 4.7 35V D38 D41 1N4936 4A L4 L12 1mH ADJ C25 0.1 50V C141 0.1 50V R188 R187 R145 2.21K R144 R142 2.21K R143 2.21K 2 c OPTIONAL 13VDC FAN 3 J42 gate 1 9 J44 2 18.2K 18.2K 18.2K 18.2K 18.2K R157 J42 R108 TESTVa N.D. 250mA 1 R106 +5Vb 1 J42 TESTVa WELD & CURRENT CONTROL J44 R105 380mA C21 0.1 50V J42 R104 OUT GND C139 0.1 50V N.D. R86 D17 1N4936 200mA 100 1N4936 6 C36 0.1 50V R103 X4 IN 4.75K 8 D13 3A 600V C34 0.1 50V b C35 4.7 35V R163 R137 4.75K C22 4.7 35V L8 +5Vb OUT GND 8t D23 .22mH C24 4.7 35V X8 C165 0.1 50V C33 7 Vcc(+15) CR1 13 60mA IN D32 1N4936 8t D26 Return to Master TOC +15Vb OUT C166 0.1 50V L10 9 13.7K T3 D25 1N4936 Return to Section TOC 2.43K SEC. R191 D22 3A 600V D15 3A 600V 2.43K D33 D31 1N4936 9t 2N4401 R32 2.43K 10 1.00M 10K X7 IN 2.43K C30 4.7 35V D36 100 D16 3A 600V L9 10K DZ6 6.2V 1W -8Vb 6 12 D30 1mH R24 X2 PWR_DN D12 D28 1N4936 R162 4.75K R138 4.75K R136 8 L7 C15 0.1 50V LM2901 -8Vb C20 4.7 35V 19t TL494 X2 200 10K 1.00K R28 R76 R55 X3 +15Va R135 4 D19 1N4936 SEC. PRI. D20 CR1 10 PRI. C14 1.0 35V C10 .001 400V 6 C11 1.0 35V 10 11 S-8054HN D/K 3 C13 0.1 50V X1 R170 1N4936 D27 8 100 4 10K T4 12 T4 R169 D47 R29 6 D/K Vcc(+15) 5 T3 R164 L6 T1 PRI. RS 232 CURRENT SOURCE Vcc(+15) R168 10K X2 4.75K R4 2 100 9t 5 T2 40mAe 20t 20t 5 +5Vc e R186 C176 6 4t c T3 3 R167 14 10K 2N4401 D24 1N4936 DISPLAY KEYPAD S R19 R22 5 R180 R184 OCI1 Q15 2N4403 R3 1 4 C175 0.1 50V Q7 8t D 26.7 40V 600mA DZ4 Q4 1W 15V 100 Q12 7 DISPLAY KEYPAD -8Vb G R18 9 R35 CNY17-3 R21 8t 100 R15 100K T2 1.00K Q6 18A 200V OVERCURRENT PROTECTION b SEC. 1.00K 1.00K Vss 9t R10 C8 .0047 50V Vdd 9 DISPLAY KEYPAD -5Vb 20t 3 4 20t Q3 600mA 40V R14 R11 R7 R34 2 +5Vref D21 3A 600V DISPLAY KEYPAD +15Vb CTRL 7 5 +5Vb X2 68.1K C177 3 3 PRI. +15Vb 47.5K 10 WELD & CURRENT CONTROL +5Vb FET T2 Vcc(+15) 5 R185 1mH -15Va DISPLAY KEYPAD R177 D18 1N4936 WELD & CURRENT CONTROL BRD T1 1 20t 12.1K 1.00M DZ5 12V 1W C9 .001 400V 1 20t Vcc(+15) R61 100 2 1 T1 C16 0.1 50V Vcc(+15) PWR DN R195 R31 R30 12.1K WELD & CURRENT CONTROL +15Va 10 Ct R8 CW 200 20t DZ3 15V 1W 6 Rt 1.00K 200 5 9 E2 2+IN 200 11 Vcc 1-IN 2-IN 7 200 20t 8 2.21K 221K Return to Master TOC C1 1+IN 100 13 Ot C DT CON 15 D58 1N4936 Vref 1 2 22.1K 500 40V 600mA Q2 R13 D46 Return to Master TOC Return to Section TOC C5 4.7 35V 18.2K S 26.7 4.75K Q5 18A 200V G R17 4 100 100 D R66 100 R12 R65 475 267 Q1 600mA 40V R64 SWITCH_GND C4 4.7 35V 1 C7 0.1 50V C6 0.1 50V 1N4007 10K +5Va a Vcc(+15) 26.7 D9 1N4007 18Vd b R63 400V D8 1N4936 R23 D10 400V D7 1N4936 R16 320V 160J D4 8A D6 1N4936 R27 320V 160J D3 8A R196 .0047 3000V J43 TP3 C3 4.7 35V DZ2 15V 1W D5 1N4936 R9 4 L3 1mH TRANS USE FET DRIVER d Vcc(+15) Q13 1A 100V TP2 VOLTAGE FEEDBACK 5W C2 3900 80V 320V 160J C41 VOLTAGE 1K 5W R5 .0047 3000V J43 C1 3900 80V TP1 1K 5W R59 C42 1K N.B. R56 N.C. D2 8A 400V J43 42VAC 1 D1 8A 400V R198 3 GND J43 R139 2 R130 N.B. N.C. R1 Return to Master TOC SCHEMATIC - POWER PRINTED CIRCUIT BOARD C40 .0047 3000V Return to Section TOC G-12 ELECTRICAL DIAGRAMS G Return to Section TOC G-12 18.2K .39mH e 1N4936 6 14 8 16 NOTES : N.A. SINCE COMPONENTS OR CIRCUITRY ON A PRINTED CIRCUIT BOARD MAY CHANGE WITHOUT AFFECTING THE INTERCHANGEABILITY OF A COMPLETE BOARD, THIS DIAGRAM MAY GENERAL INFORMATION LAST NO. USED NOT SHOW THE EXACT COMPONENTS OR CIRCUITRY OF CONTROLS HAVING A COMMON CODE R-198 ELECTRICAL SYMBOLS PER E1537 NUMBER. CAPACITORS = 2 MFD ( .022/50V RESISTORS = Ohms ( DIODES = 4 1A, 400V 1/4W UNLESS OTHERWISE SPECIFIED) UNLESS OTHERWISE SPECIFIED) (UNLESS OTHERWISE SPECIFIED) POWER SUPPLY SOURCE POINT COMMON CONNECTION 7 FRAME CONNECTION 10 FILE: G2240_1D2 EARTH GROUND CONNECTION 12 Ch’ge.Sht.No. 15 D-60 SUPPLY VOLTAGE NET 5 13 C-191 LABELS THE LINCOLN ELECTRIC CO. 1-6-95B CLEVELAND, OHIO U.S.A. 3-29-96L 7-9-99F EQUIP. TYPE SCALE DR. DB DATE SUBJECT NONE 6-26-94 CHK. RM INVERTER WELDERS SCHEMATIC, POWER P.C. BOARD SUP’S’D’G. SHT. NO. G 2240 NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. POWER WAVE 450 ITEM 8.00 7.80 G2163-1 J44 J42 D9 TP1 R35 TP2 C39 R55 C42 OCI1 R180 C41 J43 R76 R130 23 S16668-11 C8 1 S16668-6 C9,C10 2 S13490-76 C11,C14 2 S13490-42 1.0/35 C12,C176,C177,C178,C189 5 S16668-5 .022/50 C17 1 S13490-40 2.7/50 C18,C102 2 S13490-68 2/150 C33 1 S13490-121 C40,C41,C42 3 T11577-58 .0047/3000V C190 1 T11577-26 .1/100 CR1,CR2 2 S13929-8 D1,D2,D3,D4 4 S18395-22 DIODE HS ASBLY 23 T12705-34 1N4936 D5,D6,D7,D8,D17,D18,D19 . 1/50 TP3 T5 C27 C36 R88 DZ9 DZ16 R197 C23 C24 C21 R8 R143 R142 R136 C4 R144 R137 R145 R138 C176 D46 R15 R86 R83 R150 1 T12702-19 1N4742A DZ6,DZ17 2 DZ10,DZ11,DZ13,DZ14,DZ16 5 T12702-17 1N5361B ZENER DIODE DZ115 1 T12702-52 D17 1N4733A J40,J41 2 S20351-16 HEADER J42,J44 2 S20351-12 J43 1 S20351-4 HEADER L3,L6,L8,L9,L10,L11,L12,L116 8 T12218-12 CHOKE 2 D16 D13 D21 D19 D22 D15 R191 CR1 R186 D18 D24 D25 HEADER INDUCTOR L119,L120 2 T12218-9 .39mH OCI1 1 S15000-10 OPTO ISOLATOR Q1,Q3,Q7,Q12 4 T12704-68 2N4401 Q2,Q4,Q15 3 T12704-69 2N4403 Q5,Q6 2 T12704-61 TRANSISTOR Q9 1 T12704-35 NPN TRANSISTOR 3 T12704-80 (SS) TRANSISTOR-NMF Q13 1 S18395-19 PNP TRANSISTOR H.S. ASBLY Q111 1 T12704-37 TRANSISTOR-P R1,R130,R139 3 T14648-19 1K 5W 7 S19400-1822 13 S19400-1000 100 1/4W 8 S19400-4751 4.75K R6 1 S19400-2212 22.1K 1/4W R7,R11,R16,R26,R34,R162 8 S19400-1001 1 8.2K 1/4W 1K 1/4W R8 1 T10812-62 500 1/2W TRIMMER R9,R22,R23,R24,R25,R29,R31 11 S19400-1002 10K 1/4W 8 S19400-2211 R17,R18,R196 3 S19400-26R7 26.7 1/4W R19 1 T12300-80 5 WATT 0.5 OHM RESISTOR R21,R32,R33 3 S19400-1003 R27,R177 2 S19400-1004 1M 1/4W R28 1 S19400-1372 13.7K 1/4W R30,R195 2 S19400-1212 12.1K 1/4W R37 1 S19400-2671 2.67K 1/4W R39 1 S19400-1301 1.3K 1/4W R55 2.21K 1/4W 100K 1/4W 1 S19400-2213 221K 1/4W R59 1 S19400-2670 267 1/4W R63,R64,R65,R66,R67,R68 8 S19400-2000 200 1/4W R80 1 S19400-3321 3.32K 1/4W R83,R92,R93,R150 4 S19400-1501 1.5K 1/4W R86 1 S19400-2430 243 1/4W R107,R156 2 S19400-1500 150 1/4W R109,R110,R192,R193 4 S19400-3010 301 1/4W R167,R168,R169,R170 4 S19400-2431 R184 1 S19400-6812 68.1K 1/4W R185 1 S19400-4752 47.5K 1/4W R69,R70 T1 T2 D5 D6 D8 D7 R66 1 1 0 1 S19400-4750 475 1/4W T1 1 M16744-1 TRANSFORMER T2 1 M16744-4 TRANSFORMER T3 1 M16744-3 TRANSFORMER T4 1 M16744-2 TRANSFORMER 2 T12737-7 3 T13640-18 160J 1 M15458-3 PWM CONTROLLER,IC X2 1 S15128-11 14 PIN QUAD COMPARATOR X3 1 X4 1 S18395-8 REGULATOR ASSEMBLY X5 1 S18395-7 S15128-15 ON S18104-5 X6 1 S15128-12 IC - VOLT REG X7 1 S15128-6 IC - VOLT REG X8 1 S18395-13 5V REG. ASBLY X9 1 S15128-7 IC - VOLT REG X10 1 S15128-5 IC - VOLT REG TP1,TP2,TP3 X1 5.63 11.05 11.25±.04 2.43K 1/4W R198 T5,T6 .20 T12218-11 1N4735 R76,R88,R89,R180 .20 0 T12702-40 R163,R164 C177 L3 R18 DZ4 R17 1N4744A DZ5 R187,R188,R197 C10 Q2 DIODE T12702-29 R10,R142,R143,R144,R145 Q3 Q1 600V/3A T12705-14 7 R137,R138 DZ8 Q9 D11 T12705-59 1 DZ2,DZ3,DZ4,DZ7,DZ8,DZ9 DZ12 R5,R35,R36,R40,R135,R136 R40 L6 R14 R12 C22 C20 R11 6 D59 R57,R61,R186,R190,R191,R194 R39 C17 R16 C14 1N4004 R2,R103,R104,R105,R106, R108,R157 C140 R36 R10 C13 1N4007 T12199-1 R3,R4,R12,R13,R14,R15,R56 C18 R80 C8 C139 C7 R37 D23 R135 R188 C19 L4 X1 R2 D20 R187 DZ7 L7 R6 C141 R198 R7 T12199-2 12 Q8,Q10,Q11 Q5 R70 R69 R68 R67 R9 D58 R65 D28 D29 Q8 X5 D26 R196 R56 C16 T3 T4 1 R57 Q4 C9 D37 1 R5 R64 XXX XXXXX XX XXX XX XX X X L9 L11 D35 D32 D34 D41 D43 D42 D40 D31 L10 L120 L119 L12 D38 XX XXX XXX XX XXXX XXXXXX XX XX XX C102 Q7 XXXX XXX XX X4 C5 C6 2 D11,D12,D20,D23,D26,D30 L4,L7 R61 R59 Q6 D12 D47 R22 R63 C178 Q12 X6 L8 C3 R32 C191 R164 D27 R19 R33 C2 R163 C189 C33 R103 DZ115 CR2 R104 R162 DZ17 R27 R26 DZ3 R105 XX XXXX XXXXXX XX XX XX R190 R194 R3 DZ6 C1 X8 R106 XXXX XXX XX C190 R21 R4 R108 X2 D36 X9 L116 R107 R89 R28 XX XXXXXX XX XXX XX XX XX R167 DZ12 C11 R24 XXXX XXX XX R168 DZ13 DZ11 C25 R29 R25 XXXXXXXXXX XX XXX XX R169 Q11 C12 DZ2 R23 R170 R157 C175 R13 R193 R110 R192 R109 C38 D3 C29 DZ14 R184 D2 Q10 DZ10 DZ5 C165 D9,D10 D13,D14,D15,D16,D21,D22 C28 R185 Q13 D33 D41,D42,D43,D58 R92 C26 Q15 C15 R34 D1 R177 D4 C35 R156 RELAY, 12V DC D33,D36,D39,D46,D47,D60 R93 C30 C34 .001/400 D32,D34,D35,D37,D38,D40 T6 D59 R195 R139 R30 D14 C40 R31 Q111 4700pF/50 D24,D25,D27,D28,D29,D31 D30 C37 J40 D10 C166 4.00 J41 X7 D39 Return to Master TOC 4.7/35 C159,C165,C166,C175,C191 POWER WAVE POWER C159 Return to Master TOC 3900/80V S13490-25 C37,C39,C139,C140,C141 R1 Return to Master TOC DESCRIPTION S13490-141 12 C25,C26,C28,C32,C34,C36 D60 Return to Section TOC PART NO. 2 C3,C4,C5,C19,C20,C22,C24 C6,C7,C13,C15,C16,C21,C23 ±.04 C32 Return to Section TOC REQ’D C1,C2 C27,C29,C30,C35,C38 X3 Return to Master TOC PC BOARD ASSEMBLY-POWER X10 Return to Section TOC G-13 ELECTRICAL DIAGRAMS G 2163-1 Return to Section TOC G-13 M15102-3 PULSE TRANSFORMER RESET I.C. UNDERVOLT. SENSING CIR. (SS) CAPACITORS = MFD/VOLTS RESISTORS = OHMS Ch’ge. Sht. No. 1-6-95B 3-29-96K EQUIP. THE LINCOLN ELECTRIC CO. TYPE CLEVELAND, OHIO U.S.A. 3-29-96L 7-25-97K 7-9-99F NOTE: SCALE FULL DR FM DATE 3-9-94 SUBJECT INVERTER WELDERS POWER P.C. BOARD ASSEMBLY G 2163-1 SHT. CHK DB/FV REF. SUP’S’D’G NO. 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 provided 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 450 SCHEMATIC - PROTECTION PRINTED CIRCUIT BOARD D15 DISPLAY BD AMPTROL 2 3 4 5 6 1 2 3 4 5 6 8 9 10 11 12 13 1 14 2 3 4 5 6 1 2 3 4 1 2 3 24VAC +24V 150 R2 J38 J38 J38 J38 J37 J37 J37 J37 J35 J35 J35 J35 J35 J35 J34 J34 J34 J34 J34 J34 7 J34 J34 J34 J34 J34 J34 J34 J34 J33 J33 J33 J33 J33 J33 R1 1 L1 R3 150 R4 D1 C1 D3 24V 42V 150 J36 D11 D13 J32 J32 C12 6.81K .39mH +t 4.7 35V C11 .25 START 221 C10 3300 50V TP2 50V 15J L2 R162 OUT ADJ .39mH J32 TO CONTROL BD 50V 4 2 3 1 J36 24VAC FROM AUXILIARY TRANSFORMER 1N4936 150 R5 TRANSFORMER 1 J36 3 1N4936 115V FROM CURRENT X4 IN 150 4 R134 POWER BD R135 WIRE FEEDER 2 WIRE FEEDER 1 D12 R136 AUXILIARY START Return to Master TOC G-14 ELECTRICAL DIAGRAMS G 2451 10K D14 D4 D2 105 1N4936 2 1N4936 Return to Section TOC G-14 POWER SUPPLY 106 J36 4 SECONDARY - 4000V ISOLATION FROM PRIMARY CIRCUITS +24V 16 11 2 3 4 5 J30 J30 J30 J30 J30 J30 J30 J30 TO LOAD SIDE OF CONTACTOR 7 8 2 R60 1 R161 R132 R129 R150 R151 J30 15 J30 J30 14 .0027 50V X7 C D21 9 LOWER CAP D22 FAULT C27 VOLTAGE MONITOR J31 Q11 600mA 40V 133K C16 100 20V R154 R155 5 3.32K J32 R13 J39 4 100 R157 R141 J32 4 1.00K Q12 R85 8 2N4401 22.1K 9 10K 6 +24V RUN MODE 1 C34 0.1 50V 5 CNY17-3 2 6 TO CONTROL BD DZ15 6.2V 1W OCI4 R11 R80 8 R81 150K C15 R78 J31 475 X6 C OUTPUT DISABLE J32 C25 .1 400V MT1 DISABLE RUN MODE 10 10 Vlowcap 150K TRI1 G 4 +24V TO CONTACTOR COIL 26.7 R139 R82 14 X5 D 12 R77 MT2 1.00K RUN MODE DISABLE OCI5 3043 2 R86 150K 15.0K 150K 4.75K CAP2 FAULT R79 13 R76 R130 START 200 6 15.0K VOLTAGE J31 ENABLE RUN MODE D35 133K C36 0.1 50V 1.00K Vupcap or 0V GAIN = .016 V/V 10K 1 R83 5 2K R73 R70 13 3.32K R140 +24V 7 R84 CW R72 R71 267K 4 R92 NO FAULT J31 33.2K ENABLE OUTPUT R104 9 R103 33.2K 8 68.1K Vupcap + Vlowcap 10 2K OR Vlowcap X7 B 475 R95 12 R111 R159 R117 681 2.43K DZ13 10V 1W +10Vp R120 100K R115 R105 1K 1.0 1W CAP DELTA + R8 6 4 X5 LM224 11 4 C21 X6 LM224 11 4 C22 X7 LM224 11 C23 X8 33074A 11 R125 J39 DZ12 15V 1W FREQ RANGE 0-2.5KHz CAP1=CAP2 Fc=1.25KHz CAP1>CAP2 F<1.25KHz DEADBAND GAIN F>1.25KHz +/- 375 Hz .25 KHz/V 3 GND R152 R93 12 X7 D R10 2.21K CAP1<CAP2 1 CNY17-3 4 GND 14 13 GENERAL INFORMATION 56.2K LAST NO. USED ELECTRICAL SYMBOLS PER E1537 MFD ( .022/50V C33 CAPACITORS = 150p RESISTORS = Ohms ( 50V C20 2 TO CONTROL BD 1A 100V R123 4 2N4401 R153 DZ14 6.2V 1W 5 Q16 15V 1W Q17 OCI3 2 Q15 1A 100V CAP DELTA MONITOR X9 TL431 Q14 600mA 40V 10 1 DZ11 J39 SECONDARY - 4000V ISOLATION FROM PRIMARY 8 2.21K +24V 100 D28 C18 0.27 50V (ADDS GAIN + SHIFTS Fc) C30 4.7 35V R106 X8 C 1N4936 R158 R107 5 J39 R9 C32 100K CW 6 9 1.50K +10Vp 1 7 1.00K 100K R124 X8 B R126 100K 6 33.2K 2.21K R110 +10Vp C17 18 15V +24V 22.1K R122 R109 1 R114 R7 3.32K 3.32K R108 +10Vp X8 A 3 2.21K +10V PREC. 2.43K 14 X6 D 10K 2 1.82K 13 R112 V/F CONVERTER 1.50K R116 10K X8 D C31 100K +24V 13 R143 R144 R119 22.1K R113 22.1K 14 R127 +10Vp 15.0K 12 R96 C28 REF C35 150p 15.0K Vfault R90 MONITOR 3 GAIN = .016 V/V 15.0K 8 7 6 50V R142 2.67K 56.2K VOLTAGE 10K GND R12 DISABLE OUTPUT 5 56.2K R101 R102 R100 R99 R97 R98 267K 267K X5 C CW R89 D24 R91 10K 1 22.1K J31 15.0K 267K R68 R69 12 3.32K R138 3.32K 33.2K 6 MONITOR 2 267K 10 24VAC V > 170V ENABLE RM R128 50V X5 B 267K 9 J30 R58 47.5K J30 R48 8.25K R75 10K R74 267K 1 J30 R61 SOFT START J31 267K FROM ALL CIRCUITS 2N4401 5.11K D17 V < 170V DISABLE RM R49 C14 .0027 J31 10 Return to Master TOC CR2 3 6 7 6 J31 Return to Master TOC 20W TO LOAD SIDE OF INPUT SWITCH J31 1.00K 200 +24V X6 B J31 7 20W PRIMARY - 2500V ISOLATION 5 J31 6 13 22.1K 200 Q9 Vfault Vupcap > 170 VDC 1.00K 2 11 C29 20W J30 15.0K C24 18 15V 200 4 CR1 3 2 Q6 600mA 40V 20W 1 R6 14 9 X7 A 200 4 3 10K 20W UNDER VOLTAGE & VERIFY CHARGE 4 Return to Section TOC D18 200 J30 +10Vp 10K 22.1K 3 Return to Section TOC D16 C26 J31 8 R137 R52 1 2 20W DISABLE SOFT START 475 R50 R43 R44 X6 A VOLTAGE MONITOR 1 GAIN = .016 V/V 33.2K 3 Vupcap 3 2K R45 R40 267K 267K R42 267K R41 NO FAULT 1 X5 A CW SOFT START DISABLE 68.1K 2 R46 10K R53 12 VOLTAGE MONITOR 33.2K FAULT 200 2 ENABLE SOFT START CAP1 FAULT 15.0K 10K R51 UPPER CAP R47 J31 24 VDC 15.0K +10Vp J31 5 CR2 D19 R59 HIGH VOLTAGE DIVIDERS 50V R54 .0027 +24V R55 C13 R160 +24V 267K Return to Master TOC Return to Section TOC 1 CR1 24 VDC DIODES = SECONDARY - 4000V ISOLATION FROM PRIMARY 1A, 400V 1/4W UNLESS OTHERWISE SPECIFIED) UNLESS OTHERWISE SPECIFIED) (UNLESS OTHERWISE SPECIFIED) LABELS R- 162 Q- 17 C- 36 DZ- 15 D- 35 SUPPLY VOLTAGE NET POWER SUPPLY SOURCE POINT COMMON CONNECTION FRAME CONNECTION FILENAME: G2451_2DA NOTES : N.A. SINCE COMPONENTS OR CIRCUITRY ON A PRINTED CIRCUIT BOARD MAY CHANGE WITHOUT AFFECTING THE INTERCHANGEABILITY OF A COMPLETE BOARD, THIS DIAGRAM MAY NOT SHOW THE EXACT COMPONENTS OR CIRCUITRY OF CONTROLS HAVING A COMMON CODE NUMBER. Ch’ge.Sht.No. THE LINCOLN ELECTRIC CO. 1-6-95B CLEVELAND, OHIO U.S.A. 10-27-95G 1-10-97D EARTH GROUND CONNECTION EQUIP. TYPE SCALE DR. TEL DATE SUBJECT NONE 12-26-91 CHK. TEL INVERTEC PROTECTION PC BOARD SCHEMATIC SUP’S’D’G. SHT. NO. G 2451 NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. POWER WAVE 450 Return to Master TOC G-15 ELECTRICAL DIAGRAMS PC BOARD ASSEMBLY-PROTECTION G 3196-1 Return to Section TOC G-15 ITEM .20 11.05 5.63 ±.04 7.80 PROTECTION Q9 R60 R72 R61 G3196-1 R44 R73 C22 R84 R79 R152 R153 C15 R81 C28 C27 R96 R90 C17 R91 C21 3300 / 50 1 S13490-92 11 S16668-5 C12,C30 2 S13490-25 .022/50 R159 R50 DZ13 R51 R49 R48 X6 R7 R119 R144 D17 R120 C31 D16 T12705-34 D11,D12,D13,D14,D15,D16 13 T12199-1 2 T12702-29 D35 1 T12702-27 1N4740 DZ14,DZ15 2 T12702-40 1N4735 1 S20351-16 HEADER J31,J34 2 S20351-14 HEADER J32,J33,J35 3 S20351-6 HEADER J36,J37,J38,J39 4 S20351-4 HEADER L1,L2 2 T12218-9 OCI3,OCI4 2 S15000-10 . 39mH OCI5 1 S15000-11 3043 Q6,Q9,Q11,Q12,Q14,Q17 6 T12704-68 2N4401 Q15,Q16 2 T12704-73 IC PKG MOSFET (SS) R1,R2,R3,R4,R5 5 S19400-1500 150 1/4W R6,R8,R11,R107,R139,R157 6 S19400-1001 1K 1/4W R7,R108,R128,R138,R154 6 S19400-3321 3.32K 1/4W 2 S19400-1000 100 1/4W R10,R12,R90 3 S19400-5622 56.2K 1/4W R40,R41,R42,R43,R68,R69 12 S19400-2673 267K 1/4W 3 T10812-73 O P T O I S O L AT O R S19400-3322 33.2K 1/4W S19400-2212 22.1K 1/4W R49 1 S19400-8251 8.25K 1/4W R50,R53,R61,R81,R86,R93 9 S19400-1502 15K 1/4W R157 4.00 CR1 TP2 D19 2K 1/2W TRIMMER R141 R95,R96,R153 R54 1 S19400-4752 47.5K 1/4W R55,R89 2 S19400-6812 68.1K 1/4W R60 1 S19400-5111 5.11K 1/4W R76,R77,R78,R79 4 S19400-1503 150K 1/4W R82,R91,R137 3 S19400-4750 475 1/4W R83,R84 2 S19400-1333 133K 1/4W R105 1 T10812-68 1K 1/2W TRIMMER R106 1 S19400-2671 2.67K 1/4W R109,R110,R113,R114,R115 5 S19400-1003 100K 1/4W R116,R117 2 S19400-2431 2.43K 1/4W 1.5K 1/4W S19400-2211 2.21K 1/4W 1 S19400-1821 1.82K 1/4W R129,R132,R150,R151,R160 6 T14900-1 200 20W R130 1 S19400-4751 4.75K R134 1 S19400-2210 221 1/4W R135 1 S19400-6811 6.81K 1/4W R4 R140 1 S19400-2000 R3 R141 1 S19400-26R7 R158 1 T12300-79 1 W AT T 1 O H M 1 % R E S I S T O R R159 1 S19400-6810 681 1/4W R99 S19400-1501 4 R127 R70 2 R122,R123,R125,R126 R42 R119,R120 CR2 D3 R161 R98 R41 R5 R69 D2 D1 C25 R2 R97 R68 R40 R1 J33 J32 J31 XXXXXXXXXXXXXXXXXXXXXXXXXXXX XXXXX XXXXXXXXXXXXXXXXXXXXXXXXXXXX XXXXX XXXXXXXXXXX XXXXXXXXXXX XXXXXXXXXXXXXXXXXXXXXXXX J36 J34 200 1/4W 26.7 1/4W R162 1 S18380-4 TP2 1 T13640-15 PTC THERMISTOR TRI1 1 S18395-9 S15161-27 ON S18104-5 X4 1 S18395-7 S15128-15 ON S18104-5 X5,X6,X7 3 S15128-4 X8 1 S15128-18 QUAD-OP AMP X9 1 S15128-10 V O LTA G E R E F. XXXXXXXXXXXXXXXXXXXXXXXX J30 .20 0 15J LM224 OP-AMP CAPACITORS = MFD/VOLTS INDUCTANCE = HENRIES RESISTORS = OHMS ±.04 11.25 Ch’ge. Sht. No. XA THE LINCOLN ELECTRIC CO. CLEVELAND, OHIO U. S. A. 1-9-98D 8-27-99B SCALE DR. NOTE: 1N4744A DZ13 7 D4 J37 1N4004 D17,D18,D19,D21,D22,D24 6 R139 C1 R E L AY 1N4936 R48,R59,R85,R142,R143,R144 C30 C33 R10 R9 R12 DZ14 C35 R13 DZ15 5 R47,R58,R75,R92,R104,R124 OCI5 J35 0 D1,D2,D3,D4,D28 .1/50 R152 TRI1 J38 S15122-4 R111,R112,R136 R162 J39 2 R110 R6 OCI3 CR1,CR2 150pF/100 5.62K 1/4W R105 XXXXXX XXXXXX OCI4 S16668-11 10K 1/4W C36 XXXXXXXXXXXXXXXXXXXXXXXXXXXX XXXXXXXXXXXXXXXXXXXXXXXXXXXX S16668-9 2 S19400-5621 R140 R8 2 C34,C36 S19400-1002 L2 C32 C34 C33,C35 18 / 15 3 L1 R11 0.1/400 S13490-39 9 Q16 R127 .27/50 T11577-57 R46,R51,R52,R74,R80,R103 DZ12 R154 S13490-85 1 R45,R73,R102 R126 R155 1 C25 R111 X9 DZ11 R125 C18 2 C18 R114 R43 R158 C17,C24 R44,R72,R101 R106 R122 Q15 100 / 20 R115 R107 R109 R123 R142 Return to Master TOC D21 R143 D28 2700pF/50 S13490-97 R70,R71,R97,R98,R99,R100 R71 X8 R124 S16668-4 1 R113 D12 R108 R117 3 R9,R13 R100 R116 C23 C10 R138 R86 R80 D22 R112 R128 R89 R85 D24 4.7/35 C13,C14,C15 C16 R155 D13 Q14 R52 D18 C11 D14 R95 R104 D11 R53 C26 R103 C14 Q12 Q6 R75 R150 Q11 Q17 R78 R129 R93 R137 X4 R77 X5 R160 R74 R132 R130 R151 R46 D15 R92 R76 R47 D35 R135 R82 X7 R161 C13 R55 C24 Return to Master TOC R102 R134 R54 Return to Master TOC 4 . 0 M F D , 5 0 V C A PA C I T O R C10 J30 C20 C16 R136 R58 C12 C29 R59 Return to Section TOC IDENTIFICATION PART NO. T11577-50 C11,C20,C21,C22,C23,C26 DZ11,DZ12 R101 R45 R83 Return to Section TOC 1 C27,C28,C29,C31,C32 8.00 Return to Section TOC REQ’D C1 DRS FULL DATE 2-27-97 CHK. EQUIP. TYPE SUBJECT DRS INVERTER WELDERS PROTECTION P.C. BOARD ASSEMBLY REF. G2453-2 SHT. NO. G 3196-1 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 provided 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 450 Return to Master TOC G-16 ELECTRICAL DIAGRAMS SCHEMATIC -SQUARE WAVE PROTECTION PRINTED CIRCUIT BOARD M 16115 Return to Section TOC G-16 L4 1 J23 J22 .39mH 5 C4 .0047 3000V L5 J23 J22 .39mH 4 C5 Return to Master TOC .0047 3000V L1 3 J23 J22 .39mH 1 C1 .0047 3000V L2 4 J23 J22 .39mH FRANCE Return to Section TOC 2 2 C2 .0047 3000V L6 J23 J22 .39mH 6 C6 .0047 3000V L3 7 AUSTRALIA Return to Master TOC Return to Section TOC CANADA 5 8 J23 J22 .39mH 3 C3 J23 .0047 3000V GENERAL INFORMATION LAST NO. USED R- _ ELECTRICAL SYMBOLS PER E1537 CAPACITORS = MFD ( .022/50V RESISTORS = Ohms ( DIODES = 1A, 400V UNLESS OTHERWISE SPECIFIED) 1/4W UNLESS OTHERWISE SPECIFIED) (UNLESS OTHERWISE SPECIFIED) Return to Master TOC Return to Section TOC D- _ SUPPLY VOLTAGE NET POWER SUPPLY SOURCE POINT NOTES : N.A. C- _ LABELS COMMON CONNECTION SINCE COMPONENTS OR CIRCUITRY ON A PRINTED CIRCUIT BOARD MAY CHANGE WITHOUT AFFECTING THE INTERCHANGEABILITY OF A COMPLETE BOARD, THIS DIAGRAM MAY FRAME CONNECTION NOT SHOW THE EXACT COMPONENTS OR CIRCUITRY OF CONTROLS HAVING A COMMON CODE EARTH GROUND CONNECTION NUMBER. Ch’ge. Sht. No. 5-29-90SPA EQUIP. THE LINCOLN ELECTRIC CO. TYPE CLEVELAND, OHIO U.S.A. SCALE DR MK/DRS SUBJECT NONE DATE 1-12-90 SQUARE WAVE TIG 350 PROTECTION P.C. BOARD SCHEMATIC SHT. CHK GM/BS REF. SUP’S’D’G NO. M 16115 NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. POWER WAVE 450 Return to Master TOC G-17 ELECTRICAL DIAGRAMS PC BOARD ASSEMBLY-SQUARE WAVE PROTECTION M 16062-1 Return to Section TOC G-17 AICF Return to Master TOC IDENTIFICATION C1, C2, C3, C4, C5, C6 6 T11577-58 .0047/3000 V L1, L2, L3, L4, L5, L6 6 T12218-9F .39 mH J22 1 S18248-6 HEADER J23 1 S18248-8 HEADER -.02 SQUARE WAVE PROTECTION 3.40 Return to Section TOC PART NO. CAPACITORS = MFD/VOLTS +.05 3.60 REQ’D ITEM 3.10 ±.12 B L6 M16062-1 L4 L5 J23 C4 Return to Master TOC Return to Section TOC C5 C1 L1 C2 .60 J22 ±.12 L3 L2 C3 C6 .20 Return to Master TOC Return to Section TOC 0 .20 .50 ±.12 3.40 0 Ch’ge. Sht. No. 12-8-89B 3.60 +.05 -.02 EQUIP. THE LINCOLN ELECTRIC CO. TYPE CLEVELAND, OHIO U.S.A. 11-30-90B SCALE DR NOTE: FV DOUBLE DATE 9-8-89 SUBJECT CHK DEC REF. SQUAREWAVE TIG 300 & 350 PROTECTION P.C. BOARD ASSEMBLY L8088-1 SHT. SUP’S’D’G NO. M 16062-1 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 provided 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 450 R10 7 VOLTAGE TO CURRENT 4 R11 J50 R2 511 4.75K 2 INPUT - V CC 3 INPUT + OUT 6 VEE NC 5 C1 4 2 R3 R4 511 4.75K NULL X1 NULL 100 8 562 500 Return to Master TOC G Iout = -Vin * 74.51 (R7 + 392) MAY CHANGE THIS DIAGRAM MAY NOT OR CIRCUITRY OF A PRINTED WITHOUT AFFECTING OF A COMPLETE BOARD. SHOW THE EXACT COMPONENTS CONTROLS HAVING A COMMON CODE NUMBER. Ch’ge.Sht.No. 1-6-95 11-21-97G MFD ( .022/50V RESISTORS = Ohms ( DIODES = 1A, 400V 1/4W SUPPLY UNLESS OTHERWISE SPECIFIED) FRAME CONNECTION EARTH GROUND CONNECTION (UNLESS OTHERWISE SPECIFIED) COMMON CONNECTION THE LINCOLN ELECTRIC CO. CLEVELAND, OHIO U.S.A. SCALE DB VOLTAGE NET POWER SUPPLY SOURCE POINT UNLESS OTHERWISE SPECIFIED) DR. 4 FILE: S21151_2BA LABELS ELECTRICAL SYMBOLS PER E1537 CAPACITORS = A J50 GENERAL INFORMATION SINCE COMPONENTS OR CIRCUITRY ON THE INTERCHANGEABILITY J50 -15V 6 1.30K 392K CIRCUIT BOARD 1 OP27 R8 N.A. J50 7 R9 Vin R1 1 R6 5 R7 J50 G DZ2 15V 1W J50 +15V 3 R5 NOTES : Return to Master TOC C3 0.1 50V 392K Return to Master TOC Return to Section TOC OP27 PADS IN GRAPHICS ONLY TO NEGATIVE OUTPUT STUD Return to Section TOC X1 50mV = 5mA SHUNT 100 DZ1 15V 1W C2 0.1 50V CW Return to Master TOC SCHEMATIC - SHUNT PRINTED CIRCUIT BOARD TO DIODE BRIDGE Return to Section TOC G-18 ELECTRICAL DIAGRAMS S 21151 Return to Section TOC G-18 DATE NONE 2-7-94 CHK. EQUIP. TYPE SUBJECT INVERTEC V400 SHUNT AMPLIFIER PCB SCHEM. SUP’S’D’G. SHT. NO. S 21151 NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. POWER WAVE 450 Return to Master TOC G-19 ELECTRICAL DIAGRAMS PC BOARD ASSEMBLY- SHUNT M 17150-2 Return to Section TOC G-19 .13 AMPLIFIER Return to Master TOC PA R T N O DESCRIPTION C1 1 S16668-5 .022/50 C2,C3 2 S16668-11 .1/50 DZ1,DZ2 2 T12702-29 1N4744A J50 1 S18248-6 HEADER R1,R3 2 S19400-5110 511 1/4W R2,R4 2 S19400-4751 4.75K R5,R8 2 S19400-3923 392K 1/4W R6 1 S19400-5620 562 1/4W R7 1 S16296-3 500 1/2W TRIMMER R9 1 S19400-1301 1.3K 1/4W R10,R11 2 S19400-1000 100 1/4W X1 1 S15128-13 PRECISION OP AMP IC C3 DZ2 R3 R2 C2 DZ1 R10 X1 R9 R7 R6 J50 R5 CAPACITORS = MFD/VOLTS 0 +.04 - 2.25 0 Return to Section TOC R8 C1 R4 R1 R11 1.75 M17150-2 SHUNT Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC +.04 - 1.63 REQ’D ITEM Ch’ge. Sht. No. 11-21-97G EQUIP. THE LINCOLN ELECTRIC CO. TYPE CLEVELAND, OHIO U.S.A. 4-20-2000D SCALE DR NOTE: LJB SUBJECT FULL DATE 11-4-97 CHK J.J. REF. INVERTER WELDERS SHUNT AMPLIFIER P.C. BD. ASSEMBLY M17150-1 SHT. SUP’S’D’G NO. M 17150-2 Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your factory warranty. Individual Printed Circuit Board Components are not available from Lincoln Electric. This information is provided 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 450 11 +OUTPUT (499) J60 100K .5W +15V R11 R12 100K .5W 100K .5W 10.0K 10 R8 100K .5W 100K .5W R17 R9 100K .5W 100K .5W R6 R4 R21 5 +15V 6 X1 10.0K 3 +15V 2 D1 6 DZ3 5.1V 1W 10K R23 5 100K .5W DZ5 5.1V 1W 10K C6 820p 50V DZ4 5.1V 1W L3 (461) 5 6 7 10 12 14 16 1 C7 820p 50V DZ7 5.1V 1W 10K DZ6 5.1V 1W DZ9 5.1V 1W 10K C8 820p 50V 6 DZ8 5.1V 1W X2 TP1 320V 160J J60 J60 -OUTPUT (467) 7 J60 J60 BACKGND (468) 8 5 3 C3 .0047 400V TP2 320V 160J C2 .0047 400V 9 (203) J61 10.0K 10K COSMETIC TRACE (J62-4 TO J61-5) 2.7 10W C13 0.1 50V R18 J62 J62 X1 C12 0.1 50V X1 33074A C4 .047 1200V C1 .1 1000V 100 -15V (208) J61 4 1 J61 DZ11 15V 1W C10 0.1 50V DZ12 15V 1W C11 0.1 50V X2 3 8 GENERAL INFORMATION 12 13 X2 LAST NO. USED R- 24 ELECTRICAL SYMBOLS PER E1537 14 CAPACITORS = MFD ( .022/50V RESISTORS = Ohms ( DIODES = 1A, 400V 1/4W DZ- 12 C- 13 UNLESS OTHERWISE SPECIFIED) LABELS UNLESS OTHERWISE SPECIFIED) (UNLESS OTHERWISE SPECIFIED) D- 5 SUPPLY VOLTAGE NET POWER SUPPLY SOURCE POINT NOTES : N.A. 2 10 9 (464) +15V (204) J61 11 10W R11 40/100W 1 100 3 2 2.7 4 J62 (462) (205) J61 4 X2 2 5 +15V 4 J62 J62 J60 J60 (207) J61 10.0K 7 DZ10 5.1V 1W J62 J62 J60 J60 8 R24 C9 820p 50V J62 TP3 320V 160J CHASSIS J60 J60 (206) J61 1 X2 R19 4 10 R22 D2 11 3 (201) J61 10.0K 7 33074A 2 7 TO CONTROL BOARD R14 DZ1 5.1V 1W 1 (202) D3 100K .5W J60 6 J61 8 X1 9 R2 Return to Master TOC J61 14 +15V DZ2 5.1V 1W Return to Master TOC X1 R20 D4 C5 820p 50V Return to Section TOC 13 R13 21B (221A) J60 100K .5W 12 R5 Return to Master TOC Return to Section TOC 13 J60 R10 R16 9 21A (121A) J60 D5 R3 R1 15 J60 R7 8 67A (67) +15V R15 Return to Master TOC SCHEMATIC - SNUBBER PRINTED CIRCUIT BOARD 67B (167A) Return to Section TOC G-20 ELECTRICAL DIAGRAMS M 16761 Return to Section TOC G-20 COMMON CONNECTION SINCE COMPONENTS OR CIRCUITRY ON A PRINTED CIRCUIT BOARD MAY CHANGE WITHOUT AFFECTING THE INTERCHANGEABILITY OF A COMPLETE BOARD, THIS DIAGRAM MAY FRAME CONNECTION NOT SHOW THE EXACT COMPONENTS OR CIRCUITRY OF CONTROLS HAVING A COMMON CODE NUMBER. EARTH GROUND CONNECTION FILE: M16761_1BA Ch’ge.Sht.No. EQUIP. TYPE THE LINCOLN ELECTRIC CO. 1-6-95A CLEVELAND, OHIO U.S.A. DR. DB SCALE DATE SUBJECT NONE 1-31-93 CHK. DB INVERTER WELDERS SNUBBER P.C. BD. SCHEMATIC SUP’S’D’G. SHT. NO. M 16761 NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. POWER WAVE 450 PC BOARD ASSEMBLY- SNUBBER IDENTIFICATION 820pF/50 C10,C11,C12,C13 4 S16668-11 D1,D2,D3,D4,D5 5 T12199-1 1N4004 DZ1,DZ2,DZ3,DZ4,DZ5,DZ6 10 T12702-52 1N4733A 2 T12702-29 1N4744A . 1/50 HEADER S18248-10 HEADER J62 1 S18248-8 CONNECTOR R1,R7,R13,R15,R16,R20,R21 10 S19400-1002 10K 1/4W R2,R5 2 T14649-7 2.7 10W R3,R4,R6,R8,R9,R10,R11,R12 10 S20620-1003 R2 C4 R5 100K 1/2W R18,R19 2 S19400-1000 100 1/4W TP1,TP2,TP3 3 T13640-18 160J X1,X2 2 S15128-18 QUAD-OP AMP R14,R17 D5 D4 TYPE S18248-16 1 SUBJECT 1 J61 CLEVELAND, OHIO U.S.A. R23 DZ5 DZ2 DZ1 DZ4 DZ3 DZ7 DZ9 J60 R22,R23,R24 R24 R1 C7 C5 DZ6 R15 R7 C6 C8 R16 DZ8 R13 C9 X2 D1 Return to Master TOC DZ10 D2 3.85 C13 THE LINCOLN ELECTRIC CO. DZ11,DZ12 SNUBBER L9579-1 EQUIP. DZ7,DZ8,DZ9,DZ10 L 9579-1 S16668-7 SHT. 5 NO. .047/1200 C5,C6,C7,C8,C9 SUP’S’D’G .0047/400 S13490-112 REF. S13490-3 1 CHK DB 2 C4 FULL C2,C3 DATE 2-25-94 .1/1000 SCALE S20500-1 DR JLV ±.04 PART NO. 1 INVERTER WELDERS 3.08 REQ’D C1 SNUBBER P.C. BOARD ASSEMBLY ITEM 4.05 X1 5.00 0 4.80 CAD Return to Master TOC 3.05 L 9579-1 Return to Section TOC .20 THE LINCOLN ELECTRIC CO. ±.04 WITHOUT THE EXPRESS PERMISSION OF THIS SHEET CONTAINS PROPRIETARY INFORMATION OWNED BY THE LINCOLN ELECTRIC CO. AND IS J60 0 1-6-95A Ch’ge. Sht. No. UNLESS OTHERWISE SPECIFIED TOLERANCE ON HOLE SIZES PER E2056 ON 2 PLACE DECIMALS IS .02 ON 3 PLACE DECIMALS IS .002 ON ALL ANGLES IS .5 OF A DEGREE t AGREE MATERIAL TOLERANCE (" ") TO WITH PUBLISHED STANDARDS. TP2 xxxxxxxxxxxxxxxx TP3 J62 J61 NOT TO BE REPRODUCED, DISCLOSED OR USED .45 xxxxxxxxxxxxxxxx R18 TP1 C2 xxxxxxxxxxxxxxxx C10 C3 R19 DZ11 DZ12 R14 R6 R17 R11 C11 Return to Master TOC Return to Section TOC R3 C1 xxxxxxxxxxxxxxxx R22 R21 CAPACITORS = MFD/VOLTS R20 R8 R4 R9 R12 C12 R10 Return to Section TOC G-21 ELECTRICAL DIAGRAMS D3 Return to Master TOC Return to Section TOC G-21 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 provided 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 450 C1 10.0 402 --404 R9 10.0 R33 D1 1N4936 W R22 R41 R40 39.2K 39.2K A1 M16100-26 A2 D10 1N4936 2 4 1A 100V 10V 1W IRFD110 DZ10 10V 1W 10.0 R26 10.0 C8 2700p 50V R25 10.0 475 475 C1 C2 G2 G3 G4 C3 C4 C5 C4 .047 1200V A1 401 --403 M16100-26 E1 E2 E3 405 --407 10.0 L 10611 SHT. NO. SUP’S’D’G. DRS INVERTER WELDERS SWITCH P.C. BOARD SCHEMATIC NONE 10-28-96 A1 SNUBBER RESISTOR A1 10.0 R34 SUBJECT E4 E5 R27 100 R24 G1 G5 15.0K 20 R31 R19 DZ7 15V 1W R32 Q12 600mA 40V Q8 600mA 40V 2N4403 1 1/2W TRANSFORMER PRIMARY A Q9 600mA 40V 2N4403 DZ2 R29 Q10 INPUT FILTER CAPACITOR C2 R37 R20 1.00K DZ8 6.2V 1W R30 39.2K 47.5 1 1/2W 1W R28 R21 6.2V C5 R R39 39.2K 2N4403 1.00K 1.50K DZ9 R38 NOTES : R2 Q11 600mA 40V R23 D8 1N4936 M16100-26 C1 C6 12 NEGATIVE INPUT L 10611 Return to Master TOC D7 1N4936 1A 100V IRFD110 2N4401 Return to Section TOC Q1 R36 Return to Master TOC Return to Section TOC R1 221 22.1K EARTH GROUND CONNECTION CHK. A2 100 FRAME CONNECTION DR. A2 M16100-23 D6 1N4936 COMMON CONNECTION POWER SUPPLY SOURCE POINT TRANSFORMER PRIMARY XA C2 7-18-97 1 3 R Ch’ge.Sht.No. C7 R5 EQUIP. TYPE UNLESS OTHERWISE SPECIFIED) C3 .047 1200V 10.0 NUMBER. 100 406 --408 NOT SHOW THE EXACT COMPONENTS OR CIRCUITRY OF CONTROLS HAVING A COMMON CODE 475 SINCE COMPONENTS OR CIRCUITRY ON A PRINTED CIRCUIT BOARD MAY CHANGE WITHOUT AFFECTING THE INTERCHANGEABILITY OF A COMPLETE BOARD, THIS DIAGRAM MAY 475 N.A. C2 2700p 50V DATE E4 E5 SCALE E3 JP/FM M16100-23 E1 E2 THE LINCOLN ELECTRIC CO. SNUBBER RESISTOR A2 M16100-23 (UNLESS OTHERWISE SPECIFIED) A1 FILE: L10611_1AA G5 C5 1A, 400V G4 R6 C3 C4 A2 DIODES = G3 C1 C2 1/4W G2 10.0 R18 R13 D5 1N4936 G1 10.0 R17 15.0K 20 R8 MFD ( .022/50V R35 1 1/2W DZ4 15V 1W R10 R11 DZ3 10V 1W Q5 600mA 40V 2N4403 RESISTORS = Ohms ( R12 IRFD110 Q4 600mA 40V 2N4401 1.50K Q6 600mA 40V 2N4403 10V 1W POSITIVE INPUT 9 B DZ1 1A 100V DZ5 6.2V 1W R7 D9 1N4936 Q3 C1 Return to Master TOC 1W R42 R14 6.2V 1.00K CAPACITORS = DZ6 1.00K ELECTRICAL SYMBOLS PER E1537 Q7 600mA 40V 2N4403 R16 R15 22.1K 47.5 1 1/2W UNLESS OTHERWISE SPECIFIED) D3 1N4936 1A 100V GENERAL INFORMATION R4 Q2 CLEVELAND, OHIO U.S.A. 221 100 SUPPLY VOLTAGE NET Q- 12 W D2 1N4936 DZ- 10 A- 2 LABELS D4 1N4936 D- 10 R- 42 LAST NO. USED C- 8 SCHEMATIC-SWITCH PRINTED CIRCUIT BOARD IRFD110 Return to Section TOC G-22 ELECTRICAL DIAGRAMS R3 Return to Master TOC Return to Section TOC G-22 NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. POWER WAVE 450 Return to Master TOC G-23 ELECTRICAL DIAGRAMS PC BOARD ASSEMBLY-SWITCH G 2390-1 Return to Section TOC G-23 ITEM REQ’D A1 1 21B 11B 01B 9B 7B 3B 6B 5B 2B 1B 6.50 A2 1 M16100-7 ELECTRONIC MODULE (SS) B1,B2,B3,B5,B6,B7,B9,B10 10 T13157-6 TAB TERMINAL C1,C5,C6,C7 4 S16668-5 .022/50 C2,C8 2 S16668-4 2700pF/50 C3,C4 { 2 S13490-112 .047/1200 D1,D2,D3,D4,D5,D6,D7,D8,D9 10 T12705-34 1N4936 D10 3C C1 R3 R1 4C C5 D2 DZ1,DZ2,DZ3,DZ12 4 T12702-27 1N4740 DZ4,DZ7 2 T12702-29 1N4744A DZ5,DZ6,DZ8,DZ9 4 T12702-40 1N4735 D1 Q1,Q2,Q3,Q10 { Q4,Q12 4 2 T12704-68 2N4401 D6 Q5,Q6,Q7,Q8,Q9,Q11 6 T12704-69 2N4403 R1,R3,R5,R24 R14 R23 R16 Return to Master TOC R13 R5 D8 DZ8 DZ5 R7 R30 R12 R20 R2 R22 DZ9 Q1 S19400-2210 221 1/4W 10 S19400-10R0 10 1/4W R38,R39,R40,R41 4 S19400-3922 39.2K 1/4W R7,R30 2 S19400-1501 1.5K 1/4W R10,R32 2 S19400-1502 15K 1/4W R11,R15,R22,R28,R43,R44 8 S19400-2R00 2 1/4W R12,R14,R20,R21 4 S19400-1001 1K 1/4W R13,R31 2 S19400-20R0 20 1/4W R16,R23 2 S19400-2212 R18,R29,R37,R42 4 S19400-4750 475 1/4W R35,R36 2 S19400-47R5 47.5 1/4W 22.1K 1/4W R28 Q10 A1 A2 R46 B4 R33 R34 R9 R27 R6 R25 R17 R26 R8 R19 C6 C7 R18 R29 R42 R37 DZ4 DZ7 R36 R35 D3 Q8 R41 R40 R38 R39 D7 Q5 Q6 100 1/4W 2 R6,R8,R9,R17,R19,R25,R26 Q9 Return to Master TOC 2.41 R11 Q3 R44 DZ3 B8 S19400-1000 R2,R4 CAPACITORS = MFD/VOLTS INDUCTANCE = HENRIES RESISTANCE = OHMS DZ12 R45 DZ6 R15 Q2 R43 R4 4 IC PKG MOSFET (SS) R45,R46 R31 R24 D5 T12704-73 R27,R33,R34 Q12 Q7 Q11 R21 Q4 1 Return to Section TOC DESCRIPTION ELECTRONIC MODULE (SS) B11,B12 D4 Return to Section TOC PART NO. M16100-8 D9 D10 DZ1 DZ2 C8 C2 R32 R10 G2390-1 V400 SWITCH Return to Master TOC Return to Section TOC 0 0 4.13 8.25 Ch’ge. Sht. No. 1-6-95B 5-19-95F 9-22-2000 EQUIP. THE LINCOLN ELECTRIC CO. TYPE CLEVELAND, OHIO U.S.A. 8-25-95A 7-25-97F 7-25-97J NOTE: SCALE DR JLV FULL DATE 2-16-94 SUBJECT CHK R.M. REF. INVERTER WELDERS SWITCH P.C. BOARD ASSEMBLY L8982-1 G 2390-1 SHT. SUP’S’D’G NO. 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 provided 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 450 Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC G-24 G-24 ELECTRICAL DIAGRAMS POWER WAVE RS 232 CONNECTIONS 9 PIN FROM PC NULL MODEM CABLE RS 232 CONNECTOR DCD 1 RD 2 2 TD TD 3 3 RD POWER WAVE INTERNAL WIRING 1 #302 J17 MOLEX DISPLAY BOARD 1 2 3 #303 DTR 4 4 RTS GND 5 5 CTS 5 DSR 6 6 DSR 6 RTS 7 7 GND #306 7 CTS 8 8 DCD #307 8 RI 9 4 9 20DTR 22RI NOTE: Lincoln Electric assumes no responsibility for liabilities resulting from board level troubleshooting. PC Board repairs will invalidate your factory warranty. This Printed Circuit Board schematic is provided for reference only. It may not be totally applicable to your machine’s specific PC board version. This diagram is intended to provide general information regarding PC board function. 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 450 Return to Master TOC 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 column 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 Return to Master TOC Return to Section TOC Return to Section TOC SVM ERROR REPORTING FORM FAX 216-481-2309 SVM Number ___________________________ Page Number if necessary__________________ Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Your Company__________________________ Your Name_____________________________ Please give detailed description below: ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ SD287 01/99