Instruction/ maintenance manual of the product INVERTEC POWER WAVE 450 SVM112-B Lincoln Electric
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SERVICE MANUAL • World's Leader in W elding and Cutting Products • • Sales and Service through Subsidiaries and Distributors Worldwide • Cleveland, Ohio 441 17-1 199 U.S.A. TEL: 216.481.8100 F AX: 216.486.1751 WEB SITE: www .lincolnelectric.
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC FOR ENGINE powered equipment. 1.a. T urn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running. ____________________________________________________ 1.
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ii SAFETY ii ARC RA YS can burn. 4.a. Use a shield with the proper filter and cover plates to protect your eyes from sparks and the rays of the arc when welding or observing open arc welding.
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC FOR ELECTRICALL Y powered equipment. 8.a. T urn of f input power using the disconnect switch at the fuse box before working on the equipment. 8.b. Install equipment in accordance with the U.
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC iv SAFETY iv PRÉCAUTIONS DE SÛRETÉ Pour votre propre protection lire et observer toutes les instructions et les p.
MASTER T ABLE OF CONTENTS FOR ALL SECTIONS v v POWER W A VE 450 Page Safety .................................................................................................................................................i-iv Installation ............
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC T ABLE OF CONTENTS - INST ALLA TION SECTION - Section A-1 Section A-1 POWER W A VE 450 Installation T echnical Specifications .........................................
Input V oltages: 200 230 400 460 575 Input Currents @ 500A/40 VDC 87 76 44 38 32 @ 450A/38 VDC 75 65 38 32 28 Duty Cycle Amps V olts at Rated Amperes 60% Duty Cycle 500 40 VDC 100% Duty Cycle 450 38 V.
Read this entire installation section before you start installation. SAFETY PRECAUTIONS ELECTRIC SHOCK can kill. • Only qualified personnel should perform this installation. • T ur n the input power OFF at the disconnect switch or fuse box before working on this equipment.
Failure to follow these instructions can cause immedi- ate 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.
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC INST ALLA TION A-5 A-5 POWER W A VE 450 2 3 1 FIGURE A.
NOTES POWER W A VE 450 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC.
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC T ABLE OF CONTENTS - OPERA TION SECTION - Operation ...................................................................................................................
OPERA TION B-2 B-2 POWER W A VE 450 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC OPERA TING INSTRUCTIONS Read and understand this entire section of operating instructions before operating the machine.
QUICK ST ART REFERENCE FOR USING THE PROCESS SELECTION OVERLA Y Read and understand the “Controls and Settings” and “Operating Overlays” sections of this manual before using the following Quick Start Reference pr ocedure to operate the Power W ave.
GENERAL DESCRIPTION The INVERTEC Power W ave power source is a high performance, digitally controlled inverter welding power source capable of complex, high-speed wave- form control. It uses thr ee-phase input power only . The Power W ave is designed to be used as a syner gic welding system in conjunction with a wire feeder .
CONTROLS AND SETTINGS All operator controls and adjustments ar e located on the case front of the Power W ave. Refer to Figure B.1 and corresponding explanations. FIGURE B.1 – CASE FRONT CONTROLS CASE FRONT CONTROLS Refer to Figure B.1 for the location of the following controls: 1.
OPERA TING OVERLA YS OVERVIEW The Power W ave is controlled by a panel of keys (key- pad) located on the front of the machine. The opera- tor can access controls by placing an overlay over the keys. An OVERLA Y is a special plastic sheet with a number of keys and symbols printed on one side and a bar code printed on the other .
OVERLA Y TYPES Four types of overlays can be used with the Power W ave. 1. Process Overlays. These overlays are used to create, save and r ecall specific welding proce- dures by selecting and adjusting the various weld- ing settings that have been programmed into the Power W ave at the factory .
1. LCD DISPLA Y WINDOW : Power up the machine with this overlay in place. When the Power W ave is turned on, the following message appears on the display for a few seconds: LINCOLN ELECTRIC VERSION X.
3. ELECTRODE CLASS UP/DOWN: Use the ELEC- TRODE CLASS UP or DOWN keys to select from the material types available for the selected process. Pr ess the ELECTRODE CLASS UP or DOWN key until the desired material type is dis- played.
10. RECALL FROM MEMOR Y KEY : This key is used to recall an existing pr ocedure fr om memory . Y ou can recall and use any of the pr eviously created welding procedur es that are stor ed in one of the eight memory locations. Simply press the RECALL FROM MEMOR Y key and then the appropriate MEMOR Y LOCA TION NUMBER key .
1. LCD DISPLA Y WINDOW: Power up the machine with this overlay in place. When the Power W ave is turned on, the following message appears in the display window for a few seconds: LINCOLN ELECTRIC V ersion X.X This display is followed by: OVERLA Y ID NUMBER = 2 This message is then replaced by the following message: SELECT A MEMOR Y LOCA TION 2.
1. LCD DISPLA Y WINDOW: Power up the machine with this overlay in place. When the Power W ave is turned on, the following message appears in the display window for a few seconds: LINCOLN ELECTRIC V ersion X.X This display is followed by: OVERLA Y ID NUMBER = 3 This message is then replaced by the following message: SELECT A MEMOR Y LOCA TION 2.
When a pair of welding procedur es are r ecalled from memory , the display window will show the procedur e description, wire feed speed, and the preset voltage or ar c length trim of the LAST pro- cedure welded with. With this overlay in place, the wire feed speed and the preset voltage or ar c length trim can be changed from the wir e feeder .
1. LCD DISPLA Y WINDOW: Power up the machine with this overlay in place. When the Power W ave is turned on, the following message appears in the display window for a few seconds: LINCOLN ELECTRIC VERSION X.X This display is followed by: OVERLA Y ID NUMBER = 9 2.
1. LCD DISPLA Y WINDOW: Power up the machine with this overlay in place. When the Power W ave is turned on, the following message appears in the display window for a few seconds: LINCOLN ELECTRIC V ersion X.X This display is followed by: OVERLA Y ID NUMBER = 4 This message is then replaced by the following message: SELECT A MEMOR Y LOCA TION 2.
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 dis- played. Use the LIMIT UP and LIMIT DOWN keys to change the minimum wire feed speed to the desired value.
1. LCD DISPLA Y WINDOW: Power up the machine with this overlay in place. When the Power W ave is turned on, the following message appears in the display window for a few seconds: LINCOLN ELECTRIC V ersion X.X This display is followed by: OVERLA Y ID NUMBER = 0 This message is then replaced by the following message: POWER WA VE SETUP 2.
When the “WA TER COOLER PRESSURE” light turns on, release the key . If this key has been pressed for 30 seconds and the ‘W A TER 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 polari- ty of wire feeder 1.
Use the ELECTRODE SENSE LEAD KEY to select either the - output terminal or the electrode sense (67) lead for the positive voltage refer ence. The work sense (21) lead is used only in rare cir cum- stances. For most installations, use the WORK SENSE LEAD KEY to select the - output terminal for negative voltage refer ence.
OVERVIEW OF WELDING PROCEDURES FLUX CORED ARC WELDING (FCA W) AND GMA W PROCEDURES For each wire feed speed, a corr esponding voltage has been prepr ogrammed into the machine by welding experts. This prepr ogrammed voltage is the best average voltage for the procedur e at the given wire feed speed.
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC OPERA TION B-21 B-21 POWER W.
In Pulse processes: The wave control adjustment allows the fr equency set- ting to vary . Increasing the wave contr ol allows the fre- quency setting to increase, and decr easing the wave control allows the fr equency setting to decrease.
OVERLOAD PROTECTION THERMAL PROTECTION The Power W ave has thermostatic protection fr om excessive duty cycles, overloads, loss of cooling, and high ambient temperatures. When the power sour ce is subjected to any of these conditions or any of the con- ditions mentioned above, a thermostat will open.
NOTES POWER W A VE 450 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC.
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC T ABLE OF CONTENTS - ACCESSORIES - Accessories ........................................................................................................................
OPTIONS/ACCESSORIES • Syner gic 7 wire feeder (K632-1) standar d speed,or (K632-2) high speed • MAGNUM 400 gun (K471-2) or 550 gun (K598) • Internal water cooler • Undercarriages (Single [K961.
ACCESSORIES C-3 C-3 POWER W A VE 450 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC There are two water connections on the rear of the Power W ave.
G3503-[ ] COOLER PERIODIC MAINTENANCE 1. Preparation: • Always switch off the Power W ave machine power . • Always disconnect the Power W ave 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.
C-5 C-5 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. • T ighten v-clamp with 15 to 30 in-lbs. of torque. h. Attach coolant lines to QD and reser- voir .
C-6 C-6 NOTES POWER W A VE 450 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master T.
D-1 D-1 T ABLE OF CONTENTS -MAINTENANCE- POWER W A VE 450 Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Maintenance .................................................................................................
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC MAINTENANCE D-2 D-2 POWER W A VE 450 W ARNING W ARNING CAUTION SAFETY PRECAUTIONS ELECTRIC SHOCK can kill.
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC MAINTENANCE D-3 D-3 POWER W A VE 450 FIGURE D.1 – RESISTOR LOCA TIONS W ARNING 5.
6. Locate the #9 and #12 terminals, identified by the “Dischar ge” labels, on each of the four Switch Boards. See Figur e D.2. 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.
PREVENTIVE MAINTENANCE Perform the following preventive maintenance pr oce- dures at least once every six months. It is good prac- tice to keep a preventive maintenance r ecord; a r ecor d tag attached to the machine works best. 1. Remove the hex head screws fr om the sides and top of the machine.
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC MAINTENANCE D-6 D-6 POWER W A VE 450 FIGURE D.
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC T ABLE OF CONTENTS -THEOR Y OF OPERA TION- Theory of Operation ........................................................................................................
CONTROL BOARD DISPLA Y BOARD PROTECTION BOARD AUX. TRANS POWER BOARD CT CONT ACTOR INPUT INPUT RECTIFIER AND RECONNECT SWITCH BOARD FET ASSEMBL Y SWITCH BOARD FET ASSEMBL Y MAIN TRAMSFORMER OUTPUT REC.
PRECHARGE (SOFT ST ART) The Protection Boar d contains a “soft Start” circuit, which is powered by the Auxiliary T ransformer . During prechar ge or “soft start” only two phases of the input power , with current limiting, are connected to the input rectifier .
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC THEOR Y OF OPERA TION E-4 E-4 POWER W A VE 450 SWITCH BOARDS There ar e four Switch Boards in the Power W ave, each containing an input capacitor .
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC THEOR Y OF OPERA TION E-5 E-5 POWER W A VE 450 MAIN TRANSFORMER Each Switch Board assembly works as a switch pair .
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC THEOR Y OF OPERA TION E-6 E-.
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC THEOR Y OF OPERA TION E-7 E-7 POWER W A VE 450 CONTROL BOARD The Control Boar d is at the heart of controlling the out- put of the machine.
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC THEOR Y OF OPERA TION E-8 E-8 POWER W A VE 450 POWER BOARD The Power Board pr ovides gate drives for the FET s on the Switch Boards.
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC THEOR Y OF OPERA TION E-9 E-.
THERMAL PROTECTION T wo normally closed (NC) thermostats protect the machine from excessive operating temperatur es. These thermostats are wir ed in series and are con- nected to the Control Boar d. One of the thermostats is located on the heat sink of a switch board, and the other is located on the main choke.
An FET is a type of transistor . FET s are semi- conductors well suited for high-frequency switching. Drawing A above shows an FET in a passive mode. There is no gate signal (zer o volts) from the source and, ther efore, no curr ent flow . The drain terminal of the FET may be connected to a voltage supply .
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC THEOR Y OF OPERA TION E-12 E.
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC T ABLE OF CONTENTS -TROUBLESHOOTING & REP AIR SECTION- T roubleshooting & Repair Section ......................................................................
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AI.
ELECTRIC SHOCK can kill. Have an electrician install and ser- vice this equipment. T ur n the machine OFF before working on equipment. Do not touch electrically hot parts. Sometimes machine failures appear to be due to PC board failur es. These problems can sometimes be traced to poor electrical connections.
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AI.
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-5 F-5 POWER W A VE 450 TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginning of this manual.
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-6 F-6 POWER W A VE 450 TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginning of this manual.
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-7 F-7 POWER W A VE 450 TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginning of this manual.
TROUBLESHOOTING & REP AIR F-8 F-8 POWER W A VE 450 TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginning of this manual. CAUTION If for any reason you do not understand the tes.
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-9 F-9 POWER W A VE 450 TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginning of this manual.
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-10 F-10 POWER W A VE 450 TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginning of this manual.
TROUBLESHOOTING & REP AIR F-11 F-11 POWER W A VE 450 TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginning of this manual. CAUTION If for any reason you do not understand the t.
TROUBLESHOOTING & REP AIR F-12 F-12 POWER W A VE 450 TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginning of this manual. CAUTION If for any reason you do not understand the t.
TROUBLESHOOTING & REP AIR F-13 F-13 POWER W A VE 450 TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginning of this manual. CAUTION If for any reason you do not understand the t.
TROUBLESHOOTING & REP AIR F-14 F-14 POWER W A VE 450 TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginning of this manual. CAUTION If for any reason you do not understand the t.
TROUBLESHOOTING & REP AIR F-15 F-15 POWER W A VE 450 TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginning of this manual. CAUTION If for any reason you do not understand the t.
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-16 F-16 POWER W A VE 450 TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginning of this manual.
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-17 F-17 POWER W A VE 450 TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginning of this manual.
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-18 F-18 POWER W A VE 450 TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginning of this manual.
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-19 F-19 POWER W A VE 450 TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginning of this manual.
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-20 F-20 POWER W A VE 450 TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginning of this manual.
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-21 F-21 POWER W A VE 450 TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginning of this manual.
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AI.
CAP ACITOR DISCHARGE PROCEDURE Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may r esult in danger to the technician or machine operator and will invalidate your factory warranty .
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC POWER W A VE 450 F-24 F-24 CAP ACITOR DISCHARGE PROCEDURE (continued) TROUBLESHOOTING & REP AIR TEST PROCEDURE 1.
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC POWER W A VE 450 F-25 F-25 CAP ACITOR DISCHARGE PROCEDURE (continued) FIGURE F .
F-26 F-26 CAP ACITOR DISCHARGE PROCEDURE (continued) FIGURE F .4 - RESISTOR WITH LEADS CONNECTED. TROUBLESHOOTING & REP AIR 11. Check the voltage across terminals #9 and #12 with the DC voltmeter . T erminal #9 has positive polarity and terminal #12 has negative polarity .
AUXILIAR Y TRANSFORMER TEST #1 Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may r esult in danger to the technician or machine operator and will invalidate your factory warranty .
F-28 F-28 AUXILIAR Y TRANSFORMER TEST #1 (continued) FIGURE F .5 - TRANSFORMER T1 AND T2 LOCA TION 3 2 4 1 TROUBLESHOOTING & REP AIR 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.
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC POWER W A VE 450 F-29 F-29 AUXILIAR Y TRANSFORMER TEST #1 (continued) TROUBLESHOOTING & REP AIR 11.
POWER W A VE 450 FIGURE F .6 – INPUT AND AUXILIAR Y CIRCUIT WIRING DIAGRAM TROUBLESHOOTING & REP AIR F-30 F-30 (L1A) (L3A) 4 2 3 1 F1 FUSE P OWER SWITCH SWI (321B) (HIB) 321A MAIN CON T ACT OR (.
AUXILIAR Y TRANSFORMER TEST #2 Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may r esult in danger to the technician or machine operator and will invalidate your factory warranty .
F-32 F-32 AUXILIAR Y TRANSFORMER TEST #2 (continued) FIGURE F .7 - TRANSFORMER T1 AND T2 LOCA TION 3 1 2 TROUBLESHOOTING & REP AIR 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.
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC POWER W A VE 450 F-33 F-33 TROUBLESHOOTING & REP AIR 11. T o conduct this test, you will be measuring the voltage between pin 2 and pin 5 of plug J4.
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC POWER W A VE 450 F-34 F-34 TROUBLESHOOTING & REP AIR FIGURE F .
AUXILIAR Y TRANSFORMER PRIMAR Y WIRING HARNESS TEST Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may r esult in danger to the technician or machine operator and will invalidate your factory warranty .
F-36 F-36 AUXILIAR Y TRANSFORMER PRIMAR Y WIRING HARNESS TEST (continued) FIGURE F .9 - RECONNECT P ANEL/TERMINAL STRIP LOCA TION 1 3 2 4 TROUBLESHOOTING & REP AIR 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.
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC POWER W A VE 450 F-37 F-37 AUXILIAR Y TRANSFORMER PRIMAR Y WIRING HARNESS TEST (continued) TROUBLESHOOTING & REP AIR 10.
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC POWER W A VE 450 F-38 F-38 TROUBLESHOOTING & REP AIR FIGURE F .
POWER W A VE 450 AUXILIAR Y TRANSFORMER #1 SECONDAR Y AND WIRING HARNESS TEST Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may r esult in danger to the technician or machine operator and will invalidate your factory warranty .
F-40 F-40 AUXILIAR Y TRANSFORMER #1 SECONDAR Y AND WIRING HARNESS TEST (continued) FIGURE F .11 - PLUG AND RECEPT ACLE INSPECTION POINTS 2 3 4 5 6 1 TROUBLESHOOTING & REP AIR 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.
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC POWER W A VE 450 F-41 F-41 TROUBLESHOOTING & REP AIR 10. Check for shorts at plugs J33, J34, J35, J37, and J38 on the protection boar d.
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC POWER W A VE 450 F-42 F-42 2 5 3 6 W U N R 5A C.
INPUT POWER AND WIRING HARNESS TEST Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may r esult in danger to the technician or machine operator and will invalidate your factory warranty .
F-44 F-44 INPUT POWER AND WIRING HARNESS TEST FIGURE F .13 - INPUT POWER INSPECTION POINTS 1 2 3 TROUBLESHOOTING & REP AIR 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.
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC POWER W A VE 450 F-45 F-45 INPUT POWER AND WIRING HARNESS TEST (continued) TROUBLESHOOTING & REP AIR 9.
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC F-46 F-46 FIGURE F .
INPUT RECTIFIER RESIST ANCE TEST Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may r esult in danger to the technician or machine operator and will invalidate your factory warranty .
F-48 F-48 INPUT RECTIFIER RESIST ANCE TEST (continued) FIGURE F .15 - RECONNECT SWITCH LOCA TION 1 2 3 TROUBLESHOOTING & REP AIR 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.
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC POWER W A VE 450 F-49 F-49 INPUT RECTIFIER RESIST ANCE TEST (continued) TROUBLESHOOTING & REP AIR 9.
F-50 F-50 NOTES POWER W A VE 450 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master.
OUTPUT SHUNT/WELDING FEEDBACK TEST Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may r esult in danger to the technician or machine operator and will invalidate your factory warranty .
TEST PROCEDURE 1. Remove main input supply power to the Power W ave 450. 2. Disconnect the Output leads from the machine. 3. If a wire feeder is connected to the Power W ave 450, release the drive r oll tension so the unit will not feed wire when the trigger is activated.
F-53 F-53 OUTPUT SHUNT/WELDING FEEDBACK TEST (continued) FIGURE F .16 - SHUNT AMPLIFIER BOARD LOCA TION 1 TROUBLESHOOTING & REP AIR 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.
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC F-54 F-54 OUTPUT SHUNT/WELDING FEEDBACK TEST (continued) TROUBLESHOOTING & REP AIR ELECTRIC SHOCK can kill.
PIEZO-ELECTRIC ALARM BUZZER TEST Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may r esult in danger to the technician or machine operator and will invalidate your factory warranty .
F-56 F-56 PIEZO-ELECTRIC ALARM BUZZER TEST FIGURE F .17 - ALARM BUZZER LOCA TION 1 2 TROUBLESHOOTING & REP AIR 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.
OUTPUT RECTIFIER DIODES TEST Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may r esult in danger to the technician or machine operator and will invalidate your factory warranty .
F-58 F-58 OUTPUT RECTIFIER DIODES TEST FIGURE F .18 - SNUBBER BOARD, OUTPUT TERMINAL LOCA TION 3 4 1 2 TROUBLESHOOTING & REP AIR 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.
FIELD EFFECT TRANSISTOR/SWITCH BOARD TEST OR IGBT/SWITCH BOARD TEST Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may r esult in danger to the technician or machine operator and will invalidate your factory warranty .
F-60 F-60 FIELD EFFECT TRANSISTOR/SWITCH BOARD TEST FIGURE F .19 – F .E.T . SWITCH BOARD LOCA TION 1 TROUBLESHOOTING & REP AIR TEST PROCEDURE 1. Remove main input supply power to the machine. 2. With the 3/8" nut driver , r emove the screws that hold the handle to the machine.
F-61 F-61 FIELD EFFECT TRANSISTOR/SWITCH BOARD TEST (continued) FIGURE F .20 - RESISTOR LOCA TIONS TROUBLESHOOTING & REP AIR 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.
F-62 F-62 FIELD EFFECT TRANSISTOR/SWITCH BOARD TEST (continued) 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 TROUBLESHOOTING & REP AIR 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.
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC POWER W A VE 450 F-63 F-63 FIELD EFFECT TRANSISTOR/SWITCH BOARD TEST (continued) FIGURE F .
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC POWER W A VE 450 F-64 F-64 F.
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC POWER W A VE 450 F-65 F-65 FIELD EFFECT TRANSISTOR/SWITCH BOARD TEST (continued) T ABLE F .
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC POWER W A VE 450 F-66 F-66 TROUBLESHOOTING & REP AIR FIELD EFFECT TRANSISTOR/SWITCH BOARD TEST (continued) T ABLE F .
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC POWER W A VE 450 F-67 F-67 TROUBLESHOOTING & REP AIR FIELD EFFECT TRANSISTOR/SWITCH BOARD TEST (continued) T ABLE F .
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC POWER W A VE 450 F-68 F-68 TROUBLESHOOTING & REP AIR FIELD EFFECT TRANSISTOR/SWITCH BOARD TEST (continued) T ABLE F .
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC POWER W A VE 450 F-69 F-69 TROUBLESHOOTING & REP AIR FIELD EFFECT TRANSISTOR/SWITCH BOARD TEST (continued) T ABLE F .
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC POWER W A VE 450 F-70 F-70 TROUBLESHOOTING & REP AIR FIELD EFFECT TRANSISTOR/SWITCH BOARD TEST (continued) T ABLE F .
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC POWER W A VE 450 F-71 F-71 TROUBLESHOOTING & REP AIR FIELD EFFECT TRANSISTOR/SWITCH BOARD TEST (continued) T ABLE F .
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC POWER W A VE 450 F-72 F-72 TROUBLESHOOTING & REP AIR FIELD EFFECT TRANSISTOR/SWITCH BOARD TEST (continued) T ABLE F .
F-73 F-73 IGBT/SWITCH BOARD TEST (G3165-1) T ABLE F .6 – NOTE: This test will NOT determine if an individual IGBT device is open. TROUBLESHOOTING & REP AIR POWER W A VE 450 Return to Section TOC.
F-74 F-74 IGBT/SWITCH BOARD TEST (Continued) T ABLE F .6 (Continued) TROUBLESHOOTING & REP AIR POWER W A VE 450 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section .
SNUBBER AND BLEEDER RESISTOR TEST Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may r esult in danger to the technician or machine operator and will invalidate your factory warranty .
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC POWER W A VE 450 F-76 F-76 SNUBBER AND BLEEDER RESIST OR TEST FIGURE F .
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC F-77 F-77 SNUBBER AND BLEEDER RESIST OR TEST (continued) TROUBLESHOOTING & REP AIR TEST PROCEDURE 1.
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC F-78 F-78 SNUBBER AND BLEEDER RESIST OR TEST (continued) TROUBLESHOOTING & REP AIR C.
F-79 F-79 FIGURE F .25 – SNUBBER AND BLEEDER RESISTOR WIRING DIAGRAM ( ) ( ) SWITCH BOARD #3 405 12C 406 9C C 3 (405) (12G) (12C) (406) (9G) (9C) R5 ( ) 25 Ω 25W ( ) 25 Ω 25W R6 T O R ECONNECT SWITCH 7.
F-80 F-80 NOTES POWER W A VE 450 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master.
RECONNECT SWITCH TEST 1 Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may r esult in danger to the technician or machine operator and will invalidate your factory warranty .
F-82 F-82 RECONNECT SWITCH TEST 1 FIGURE F .26 - RECONNECT SWITCH 1 2 3 TROUBLESHOOTING & REP AIR 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.
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC F-83 F-83 RECONNECT SWITCH TEST 1 (continued) TROUBLESHOOTING & REP AIR For 380 or 460 V AC: A.
F-84 F-84 FIGURE F .27 – INPUT AND RECONNECT WIRING DIAGRAM 6 R9 U V W G L1 L2 L3 CR1 T1 T2 T3 (326) (324) AC 1 AC 2 AC 3 - + POS NEG 12A 9A C1 C2 C3 C4 SWITCH BOARD # 1 SWITCH BOARD # 2 SWITCH BO A.
RECONNECT SWITCH TEST 2 Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may r esult in danger to the technician or machine operator and will invalidate your factory warranty .
F-86 F-86 RECONNECT SWITCH TEST 2 (continued) FIGURE F .28 - RECONNECT SWITCH 1 2 3 TROUBLESHOOTING & REP AIR 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.
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC F-87 F-87 RECONNECT SWITCH TEST 2 (continued) TROUBLESHOOTING & REP AIR • Lead #9A between the reconnect switch and switch board #1.
F-88 F-88 FIGURE F .29 – INPUT AND RECONNECT WIRING DIAGRAM 6 R9 U V W G L1 L2 L3 CR1 T1 T2 T3 (326) (324) AC 1 AC 2 AC 3 - + POS NEG 12A 9A C1 C2 C3 C4 SWITCH BO AR D #1 SWITCH BO AR D #2 SWITCH BO.
ST A TIC CAP ACITOR BALANCE TEST Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may r esult in danger to the technician or machine operator and will invalidate your factory warranty .
F-90 F-90 ST A TIC CAP ACIT OR BALANCE TEST (continued) FIGURE F .30 - BLEEDER RESISTORS R9 AND R10 LOCA TION 1 TROUBLESHOOTING & REP AIR 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.
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC F-91 F-91 ST A TIC CAP ACIT OR BALANCE TEST (continued) TROUBLESHOOTING & REP AIR ELECTRIC SHOCK can kill.
F-92 F-92 Figure F .31 – SNUBBER AND BLEEDER RESISTOR WIRING DIAGRAM ( ) ( ) SWITCH BOARD #3 405 12C 406 9C C 3 (405) (12G) (12C) (406) (9G) (9C) R5 ( ) 25 Ω 25W ( ) 25 Ω 25W R6 T O R ECONNECT SWITCH 7.
DYNAMIC CAP ACITOR BALANCE TEST Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may r esult in danger to the technician or machine operator and will invalidate your factory warranty .
F-94 F-94 DYNAMIC CAP ACITOR BALANCE TEST (continued) FIGURE F .32- CONTROL BOARD PLUG LOCA TIONS PRO TECTION B D G RO UND PL ANE CONTROL BD J20 J21 J22 J23 J24 J25 J26 J27 J28 J30 J31 J32 J33 J34 J35.
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC F-95 F-95 DYNAMIC CAP ACITOR BALANCE TEST (continued) TROUBLESHOOTING & REP AIR ELECTRIC SHOCK can kill.
F-96 F-96 FIGURE F .33 – INPUT AND RECONNECT WIRING DIAGRAM 6 R9 U V W G L1 L2 L3 CR1 T1 T2 T3 (326) (324) AC 1 AC 2 AC 3 - + POS NEG 12A 9A C1 C2 C3 C4 SWITCH BOARD # 1 SWITCH BO AR D #2 SWITCH BO .
INTERNAL AND AUXILIAR Y SUPPL Y VOL T AGE TEST Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may r esult in danger to the technician or machine operator and will invalidate your factory warranty .
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC F-98 F-98 INTERNAL AND AUXILIAR Y SUPPL Y VOL T AGE TEST (continued) TROUBLESHOOTING & REP AIR TEST PROCEDURE 1.
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC F-99 F-99 INTERNAL AND AUXILIAR Y SUPPL Y VOL T AGE TEST (continued) TROUBLESHOOTING & REP AIR C.
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC F-100 F-100 INTERNAL AND AUXILIAR Y SUPPL Y VOL T AGE TEST (continued) TROUBLESHOOTING & REP AIR 13.
F-101 F-101 FIGURE F .34 – INTERNAL AUXILIAR Y SUPPL Y WIRING DIAGRAM P82 WF2 R ECEPT ACLE 2 5 3 6 P83 WF1 R ECEPT ACLE SQU ARE W A VE TIG PRO TECTI ON BD 24V TRIG 1 J92 J92 6 3 P83 A I K C J D COMM.
F-102 F-102 NOTES POWER W A VE 450 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Mast.
MAIN CONT ACTOR TEST Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may r esult in danger to the technician or machine operator and will invalidate your factory warranty .
F-104 F-104 MAIN CONT ACTOR TEST (continued) FIGURE F .35 - MAIN CONT ACTOR CR1 L 1 A L1 L2 L3 T1 T2 T3 L 3 A TROUBLESHOOTING & REP AIR 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.
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC F-105 F-105 MAIN CONT ACTOR TEST (continued) TROUBLESHOOTING & REP AIR A. With the power switch SW1 OFF , check to see if leads L1A and L3A are shorted together .
F-106 F-106 FIGURE F .36 – INPUT AND RECONNECT WIRING DIAGRAM 6 R9 U V W G L1 L2 L3 CR1 T1 T2 T3 (326) (324) AC 1 AC 2 AC 3 - + POS NEG 12A 9A C1 C2 C3 C4 SWITCH BO AR D #1 SWITCH BO AR D #2 SWITCH .
SERIAL LOOP WIRING HARNESS TEST Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may r esult in danger to the technician or machine operator and will invalidate your factory warranty .
F-108 F-108 SERIAL LOOP WIRING HARNESS TEST (continued) FIGURE F .37 - WIRE FEEDER AMPHENOL LOCA TIONS 1 TROUBLESHOOTING & REP AIR 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.
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC F-109 F-109 SERIAL LOOP WIRING HARNESS TEST (continued) TROUBLESHOOTING & REP AIR B.
F-110 F-110 FIGURE F .38 – SERIAL LOOP WIRING DIAGRAM 40mA cu rrent supply J22 J26 J26 J27 J27 J28 J28 J22 5 3 4 1 4 1 4 4 (263) (264) (111A) (112A) (117A) (118A) (5R) (5W) 5 J44 40mA cu rrent path 4 J44 P OWER BOARD Seria l Loop M aster T ra nsm it & Re ceiv e Lines TxD RxD Displa y Boa rd Por t S wi tch Open: DK Boa r d S.
WIRE FEEDER 1 TRIGGER CIRCUIT TEST Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may r esult in danger to the technician or machine operator and will invalidate your factory warranty .
F-112 F-112 WIRE FEEDER 1 TRIGGER CIRCUIT TEST (continued) FIGURE F .39 - DISPLA Y BOARD PLUG LOCA TIONS J17 J16 J15 J14 J13 J12 J11 J10 TROUBLESHOOTING & REP AIR 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.
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC F-113 F-113 WIRE FEEDER 1 TRIGGER CIRCUIT TEST (continued) TROUBLESHOOTING & REP AIR 11.
F-114 F-114 FIGURE F .40 – TRIGGER CIRCUIT WIRING DIAGRAM (2) (4) 8-pin Amphenols 14 -pin Amphenols (2) (4) C D C D C D C D F E D C B A R (2) (4) (75) (76) (77) A Remo te Co ntrol Kit K941 - 1 6- pi.
WIRE FEEDER 2 TRIGGER CIRCUIT TEST Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may r esult in danger to the technician or machine operator and will invalidate your factory warranty .
F-116 F-116 WIRE FEEDER 2 TRIGGER CIRCUIT TEST (continued) FIGURE F .41 - DISPLA Y BOARD PLUG LOCA TIONS J17 J16 J15 J14 J13 J12 J11 J10 TROUBLESHOOTING & REP AIR 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.
F-117 F-117 WIRE FEEDER 2 TRIGGER CIRCUIT TEST (continued) TROUBLESHOOTING & REP AIR 11. Remove plug J30 fr om the protection board. See Figure F .1 for location of the board and plug J30. ELECTRIC SHOCK can kill. With the input power ON, there ar e high voltages inside the machine.
F-118 F-118 FIGURE F .42 – TRIGGER CIRCUIT WIRING DIAGRAM (2) (4) 8-pin Amphenols 14 -pin Amphenols (2) (4) C D C D C D C D F E D C B A R (2) (4) (75) (76) (77) A Remo te Co ntrol Kit K941 - 1 6- pi.
TRIGGER CIRCUIT AND WIRING HARNESS TEST Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may r esult in danger to the technician or machine operator and will invalidate your factory warranty .
F-120 F-120 TRIGGER CIRCUIT AND WIRING HARNESS TEST (continued) FIGURE F .43 - PROTECTION BOARD PLUG/HEADER LOCA TIONS 3 1 16 1 14 1 6 1 6 1 14 1 6 1 1 1 1 4 4 4 4 11 4 7 2 PRO TECTION B D J30 J31 J32 J33 J34 J35 J36 J37 J38 J39 TROUBLESHOOTING & REP AIR TEST PROCEDURE 1.
F-121 F-121 FIGURE F .44 AUXILIAR Y TRANSFORMER #1 SECONDAR Y CIRCUIT WIRING DIAGRAM 2 5 3 6 W U N R 5A C.B. 33 32A 333 334 *336 42V 24V 115V COMMON A UXILIA R Y TRANSF ORM ER 1 PRO TECTION B OA RD A .
F-122 F-122 NOTES POWER W A VE 450 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Mast.
INTERNAL REMOTE CONTROL TEST Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may r esult in danger to the technician or machine operator and will invalidate your factory warranty .
F-124 F-124 INTERNAL REMOTE CONTROL TEST (continued) FIGURE F .45 - DISPLA Y BOARD PLUG LOCA TIONS J17 J16 J15 J14 J13 J12 J11 J10 TROUBLESHOOTING & REP AIR 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.
F-125 F-125 INTERNAL REMOTE CONTROL TEST (continued) TROUBLESHOOTING & REP AIR ELECTRIC SHOCK can kill. With input power ON, there are high voltages inside the machine, including the pro- tection board. Do not r each into the machine or touch any internal part.
F-126 F-126 FIGURE F .46 – TRIGGER CIRCUIT WIRING DIAGRAM (2) (4) 8-pin Amphenols 14 -pin Amphenols (2) (4) C D C D C D C D F E D C B A R (2) (4) (75) (76) (77) A Remo te Co ntrol Kit K941 - 1 6- pi.
K941-1 REMOTE CONTROL KIT TEST Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may r esult in danger to the technician or machine operator and will invalidate your factory warranty .
F-128 F-128 K941-1 REMOTE CONTROL KIT TEST (continued) FIGURE F .47 - 6-PIN AMPHENOL LOCA TION 1 2 TROUBLESHOOTING & REP AIR TEST PROCEDURE 1. Remove the Remote Control Kit fr om the power source. 2. Perform the following tests. If any test fails, the Remote Control Kit is faulty and should be replaced.
F-129 F-129 FIGURE F .48 – TRIGGER CIRCUIT WIRING DIAGRAM (2) (4) 8-pin Amphenols 14 -pin Amphenols (2) (4) C D C D C D C D F E D C B A R (2) (4) (75) (76) (77) A Remo te Co ntrol Kit K941 - 1 6- pi.
F-130 F-130 NOTES POWER W A VE 450 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Mast.
K941-1 REMOTE CONTROL KIT TRIGGER CIRCUIT TEST Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may r esult in danger to the technician or machine operator and will invalidate your factory warranty .
F-132 F-132 K941-1 REMOTE CONTROL KIT TRIGGER CIRCUIT TEST (continued) FIGURE F .49 - DISPLA Y BOARD PLUG LOCA TIONS J17 J16 J15 J14 J13 J12 J11 J10 TROUBLESHOOTING & REP AIR TEST PROCEDURE NOTE: Before tr oubleshooting the remote con- trol trigger cir cuit, troubleshoot the remote contr ol kit itself.
F-133 F-133 K941-1 REMOTE CONTROL KIT TRIGGER CIRCUIT TEST (continued) TROUBLESHOOTING & REP AIR 11. Remove plug J30 fr om the protection board. See Figure F .1 for location of the board and plug J30. ELECTRIC SHOCK can kill. With the input power ON, there ar e high volt- ages inside the machine.
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC F-134 F-134 FIGURE F .
LCD DISPLA Y TEST Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may r esult in danger to the technician or machine operator and will invalidate your factory warranty .
F-136 F-136 LCD DISPLA Y TEST (continued) FIGURE F .51 - DISPLA Y BOARD PLUG LOCA TIONS J17 J16 J15 J14 J13 J12 J11 J10 TROUBLESHOOTING & REP AIR 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.
F-137 F-137 LCD DISPLA Y TEST (continued) TROUBLESHOOTING & REP AIR ELECTRIC SHOCK can kill. With input power ON, there are high voltages inside the machine.
F-138 F-138 FIGURE F .52 – INTERNAL AUXILIAR Y SUPPL Y WIRING DIAGRAM P82 WF2 R ECEPT ACLE 2 5 3 6 P83 WF1 R ECEPT ACLE SQU ARE W A VE TIG PRO TECTI ON BD 24V TRIG 1 J92 J92 6 3 P83 A I K C J D COMM.
CALIBRA TION PROCEDURES POWER W A VE PC BOARD REPLACEMENT CALIBRA TION PROCEDURES If the display board is r eplaced, the display sensor cal- ibration 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.
F-140 F-140 NOTES POWER W A VE 450 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Mast.
SENSOR CALIBRA TION TEST (FOR DISPLA Y BOARD) Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may r esult in danger to the technician or machine operator and will invalidate your factory warranty .
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC F-142 F-142 SENSOR CALIBRA TION TEST (FOR DISPLA Y BOARD) (continued) FIGURE F .
QUICK VOL T AGE CALIBRA TION Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may r esult in danger to the technician or machine operator and will invalidate your factory warranty .
F-144 F-144 QUICK VOL T AGE CALIBRA TION (continued) FIGURE F .54 - TEST AND CALIBRA TION OVERLA Y TROUBLESHOOTING & REP AIR PROCEDURE 1. Before changing or disturbing the display board, power up the machine with the L9660-255 T est and Calibration overlay in place.
FULL VOL T AGE CALIBRA TION Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may r esult in danger to the technician or machine operator and will invalidate your factory warranty .
F-146 F-146 FULL VOL T AGE CALIBRA TION (continued) FIGURE F .55 - TEST AND CALIBRA TION OVERLA Y TROUBLESHOOTING & REP AIR PROCEDURE 1. The voltage calibration numbers are stored in the display board. They ar e program- mable from the fr ont panel using the T est and Calibration Overlay .
FULL VOL T AGE CALIBRA TION USING A WELDING ARC Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may r esult in danger to the technician or machine operator and will invalidate your factory warranty .
F-148 F-148 FULL VOL T AGE CALIBRA TION (continued) FIGURE F .55a - TEST AND CALIBRA TION OVERLA Y TROUBLESHOOTING & REP AIR PROCEDURE 1. The voltage calibration numbers are stored in the display board. They ar e programma- ble from the fr ont panel using the T est and Calibration Overlay .
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC F-149 F-149 FULL VOL T AGE CALIBRA TION (continued) TROUBLESHOOTING & REP AIR – POLARITY (+21A) + POLARITY – POLARITY NOTE: Do not attempt to weld for –Polarity (+21A).
F-150 F-150 NOTES POWER W A VE 450 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Mast.
CURRENT CALIBRA TION Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may r esult in danger to the technician or machine operator and will invalidate your factory warranty .
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC F-152 F-152 CURRENT CALIBRA TION (continued) TROUBLESHOOTING & REP AIR 2. Locate the 10 tur n trimmer potentiometer located on the control boar d.
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC F-153 F-153 CURRENT CALIBRA TION (continued) TROUBLESHOOTING & REP AIR PROCEDURE 1.
F-154 F-154 NOTES POWER W A VE 450 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Mast.
T1 AUXILIAR Y TRANSFORMER REMOV AL AND REPLACEMENT Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may r esult in danger to the technician or machine operator and will invalidate your factory warranty .
F-156 F-156 T1 AUXILIAR Y TRANSFORMER REMOV AL AND REPLACEMENT (continued) FIGURE F .59 - T1 AUXILIARY TRANSFORMER LOCA TION 1 2 TROUBLESHOOTING & REP AIR 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.
W A TER COOLER REMOV AL AND REPLACEMENT For later model coolers (Inlet & Outlet on lower left of machine back) Refer to IM645-A Service and repair should be performed by only Lincoln Electric factory trained personnel.
F-158 F-158 W A TER COOLER REMOV AL AND REPLACEMENT (continued) FIGURE F .60 - WA TER COOLER LOCA TION 1 3 2 TROUBLESHOOTING & REP AIR PROCEDURE NOTE: These instructions may vary slightly with later model coolers. See instruc- tions included with cooler kit.
F-159 F-159 W A TER COOLER REMOV AL AND REPLACEMENT (continued) TROUBLESHOOTING & REP AIR 10. With the 9/16" open end wrench, r emove the circuit br eaker . 11. Locate and disconnect plug J4, behind the water cooler . Plug J 4, a large molex plug, has two leads (H1A and H3A).
F-160 F-160 NOTES POWER W A VE 450 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Mast.
W A TER COOLER DISASSEMBL Y Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may r esult in danger to the technician or machine operator and will invalidate your factory warranty .
F-162 F-162 W A TER COOLER DISASSEMBL Y (continued) FIGURE F .61 - WA TER COOLER DISASSEMBL Y (EARL Y MODEL) 1 2 3 TROUBLESHOOTING & REP AIR 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.
F-163 F-163 W A TER COOLER DISASSEMBL Y (continued) TROUBLESHOOTING & REP AIR Reservoir Removal A. After you have completed the capacitor dischar ge procedur e for all four switch boards, r emove the water cooler assembly . Refer to the W ater Cooler Removal and Replacement Procedure in this section of the manual.
F-164 F-164 NOTES POWER W A VE 450 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Mast.
T2 AUXILIAR Y TRANSFORMER REMOV AL AND REPLACEMENT Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may r esult in danger to the technician or machine operator and will invalidate your factory warranty .
F-166 F-166 T2 AUXILIAR Y TRANSFORMER REMOV AL AND REPLACEMENT (continued) FIGURE F .62 - T2 AUXILIARY TRANSFORMER LOCA TION 1 2 3 TROUBLESHOOTING & REP AIR 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.
F AN MOTOR REMOV AL AND REPLACEMENT Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may r esult in danger to the technician or machine operator and will invalidate your factory warranty .
F-168 F-168 F AN MOTOR REMOV AL AND REPLACEMENT (continued) FIGURE F .63 - F AN MOTOR LOCA TION 1 2 3 TROUBLESHOOTING & REP AIR 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.
F-169 F-169 F AN MOTOR REMOV AL AND REPLACEMENT (continued) FIGURE F .64 - MACHINE BACK SECURED TO LIFT BAIL. 1 2 TROUBLESHOOTING & REP AIR 11. With the 3/4" wrench, r emove the lead connected to the rear positive (+) output terminal. 12. Swing the back panel up and secur e it to the lift bail.
F-170 F-170 NOTES POWER W A VE 450 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Mast.
INPUT RECTIFIER REMOV AL AND REPLACEMENT Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may r esult in danger to the technician or machine operator and will invalidate your factory warranty .
F-172 F-172 INPUT RECTIFIER REMOV AL AND REPLACEMENT (continued) FIGURE F .65 - INPUT RECTIFIER LOCA TION CR1 1 2 3 4 5 6 TROUBLESHOOTING & REP AIR 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.
F-173 F-173 INPUT RECTIFIER REMOV AL AND REPLACEMENT (continued) TROUBLESHOOTING & REP AIR 10. With the 5 mm Allen wrench and the 10 mm open end wrench, r emove the two screws mounting the input r ectifier to the heat sink panel.
F-174 F-174 NOTES POWER W A VE 450 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Mast.
PRINTED CIRCUIT BOARD REMOV AL AND REPLACEMENT (CONTROL BOARD, POWER BOARD, AND PROTECTION BOARD) Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may r esult in danger to the technician or machine operator and will invalidate your factory warranty .
F-176 F-176 PRINTED CIRCUIT BOARD REMOV AL AND REPLACEMENT (CONTROL BOARD, POWER BOARD, AND PROTECTION BOARD) (continued) FIGURE F .66 - PC BOARD REMOV AL 1 3 2 TROUBLESHOOTING & REP AIR PROCEDURE 1. Remove main input supply power to the machine. 2.
F-177 F-177 PRINTED CIRCUIT BOARD REMOV AL AND REPLACEMENT (CONTROL BOARD, POWER BOARD, AND PROTECTION BOARD) (continued) TROUBLESHOOTING & REP AIR Be sure to follow the r ecommended static-free methods for handling printed circuit boar ds. Failure to do so can r esult in permanent dam- age to the equipment.
F-178 F-178 NOTES POWER W A VE 450 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Mast.
DISPLA Y BOARD REMOV AL AND REPLACEMENT Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may r esult in danger to the technician or machine operator and will invalidate your factory warranty .
F-180 F-180 DISPLA Y BOARD REMOV AL AND REPLACEMENT (continued) FIGURE F .68 - DISPLA Y BOARD REMOV AL 3 4 5 2 1 TROUBLESHOOTING & REP AIR NOTE: Before changing or disturbing the dis- play board follow the procedure outlined under QUICK VOL T AGE CALIBRA TION (Fig.
F-181 F-181 DISPLA Y BOARD REMOV AL AND REPLACEMENT (continued) TROUBLESHOOTING & REP AIR 8. Carefully remove the key pad ribbon con- nector from the right side of the display board.
F-182 F-182 NOTES POWER W A VE 450 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Mast.
MAIN INPUT CONT ACTOR (CR1) REMOV AL AND REPLACEMENT Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may r esult in danger to the technician or machine operator and will invalidate your factory warranty .
F-184 F-184 MAIN INPUT CONT ACTOR (CR1) REMOV AL AND REPLACEMENT (continued) FIGURE F .69 - MAIN CONT ACTOR CR1 L 1 A L1 L2 L3 T1 T2 T3 3 2 4 3 2 6 T1 T3 L 3 A TROUBLESHOOTING & REP AIR PROCEDURE 1. Remove main input supply power to the machine. 2.
F-185 F-185 MAIN INPUT CONT ACTOR (CR1) REMOV AL AND REPLACEMENT (continued) TROUBLESHOOTING & REP AIR 9. With the slot head screw driver , remove the two small leads (T1 and T3) from the output side of the contactor . 10. With the slot head screw driver , remove the two contactor coil leads (#324 and #326) from the contactor .
F-186 F-186 NOTES POWER W A VE 450 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Mast.
OUTPUT RECTIFIER BRIDGE REMOV AL AND REPLACEMENT Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may r esult in danger to the technician or machine operator and will invalidate your factory warranty .
F-188 F-188 OUTPUT RECTIFIER BRIDGE REMOV AL AND REPLACEMENT (continued) FIGURE F .70 - OUTPUT RECTIFIER BRIDGE LOCA TION 1 TROUBLESHOOTING & REP AIR 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.
F-189 F-189 OUTPUT RECTIFIER BRIDGE REMOV AL AND REPLACEMENT (continued) TROUBLESHOOTING & REP AIR 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.
F-190 F-190 OUTPUT RECTIFIER BRIDGE REMOV AL AND REPLACEMENT (continued) TROUBLESHOOTING & REP AIR 13. For r eassembly , attach the glastic insulat- ed angle mounting pieces to the heat sink first. Slide the bridge into position and then fasten the bottom tab to the sub- frame with the bolt, split-ring lock washer and nut.
FET MODULE REMOV AL AND REPLACEMENT Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may r esult in danger to the technician or machine operator and will invalidate your factory warranty .
F-192 F-192 FET MODULE REMOV AL AND REPLACEMENT (continued) FIGURE F .73 - FET MODULE LOCA TION 1 4 3 2 TROUBLESHOOTING & REP AIR 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.
F-193 F-193 FET MODULE REMOV AL AND REPLACEMENT (continued) FIGURE F .74 - LIFT BAFFLE/BAIL REMOV AL TROUBLESHOOTING & REP AIR 9. With the wire cutters, cut all necessary cable ties. 10. Disconnect the leads to the output rectifi- er bridge. Cut all necessary cable ties.
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC F-194 F-194 TROUBLESHOOTING & REP AIR 21. Remove the water cooler assembly in order to access the r etainer clips that hold the bottom of the FET module assembly in place.
F-195 F-195 FET MODULE REMOV AL AND REPLACEMENT (continued) TROUBLESHOOTING & REP AIR 30. Install the water cooler assembly . Refer to the W ater Cooler Removal and Replace- ment Procedure in this section of the module.
F-196 F-196 NOTES POWER W A VE 450 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Mast.
MAIN TRANSFORMER REMOV AL AND REPLACEMENT Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may r esult in danger to the technician or machine operator and will invalidate your factory warranty .
F-198 F-198 MAIN TRANSFORMER/CHOKE REMOV AL AND REPLACEMENT (continued) FIGURE F .75 - MAIN TRANSFORMER LOCA TION 1 TROUBLESHOOTING & REP AIR 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.
TROUBLESHOOTING & REP AIR F-199 F-199 POWER W A VE 450 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to M.
SETUP THE POWER W A VE FOR PRETEST 1. T urn the input power switch to the OFF position. 2. Unplug P73. See wiring diagram. 3. Install the L9660-255 Calibration & T est over- lay into the Power W ave. 4. Construct an isolated variable AC supply circuit as shown in Figure F .
MAKE SURE FIL TER CAP ACITORS ARE DISCHARGED 1. Construct a 1 15V AC pretest power supply as per Figure F .78 using the following: Switch (SPST) Fuse (5 amp max) P70 adapter ALL AC SUPPLIES MUST BE ELECTRICAL- L Y ISOLA TED (isolation transformers). THE PRINTED CIRCUIT BOARDS WILL BE DAMAGED IF THE AC SUPPLIES ARE NOT ISOLA TED.
Connect the pretest power supply to plug P70 as per Figure F .78. See wiring diagram. ARC ST ART PW450 WITH WIREFEEDER The arc start may be initiated by any of the follow- ing methods: 1. Release wire tension and pull gun trigger . 2. Jumper pins C and D on wire feeder input con- nector .
ARC ST ART FOR PW450 ROBOTIC 1. Construct and connect an arc start circuit as per Figure F .79. 2. Install leads and an arc start switch into plug J103 pin 10 to pin 1 1 on the interface PC board. Make sure the arc start switch leads are long enough to reach outside of the machine case.
TROUBLESHOOTING & REP AIR F-204 F-204 POWER W A VE 450 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC PRE-POWERUP SWITCH BOARD TEST PROCEDURE FOR REPLACEMENT OF SWITCH ASSEMBL Y G2402-2 (continued) 1.
TROUBLESHOOTING & REP AIR F-205 F-205 POWER W A VE 450 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC PRE-POWERUP SWITCH BOARD TEST PROCEDURE FOR REPLACEMENT OF SWITCH ASSEMBL Y G2402-2 (continued) SNUBBER SIGNAL TEST 1.
TROUBLESHOOTING & REP AIR F-206 F-206 POWER W A VE 450 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC PRE-POWERUP SWITCH BOARD TEST PROCEDURE FOR REPLACEMENT OF SWITCH ASSEMBL Y G2402-2 (continued) 460V AC RECONNECT 1.
TROUBLESHOOTING & REP AIR F-207 F-207 POWER W A VE 450 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC PRE-POWERUP SWITCH BOARD TEST PROCEDURE FOR REPLACEMENT OF SWITCH ASSEMBL Y G2402-2 (continued) 8.
TROUBLESHOOTING & REP AIR F-208 F-208 POWER W A VE 450 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC PRE-POWERUP SWITCH BOARD TEST PROCEDURE FOR REPLACEMENT OF SWITCH ASSEMBL Y G2402-2 (continued) 5.
Electrical Diagrams Section ................................................................................................ Section G Wiring Diagram .....................................................................................................
ELECTRICAL DIAGRAMS G-2 POWER W A VE 450 WIRING DIAGRAM - POWER W A VE 450 KEYPAD RS232 CONNECTOR 1 2 3 4 5 6 7 8 20 LCD DISPLAY RECEPTACLE 5A CIRCUIT BREAKER + - + - + - + - CURRENT TRANSFORMER B C D.
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ELECTRICAL DIAGRAMS G-3 POWE.
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ELECTRICAL DIAGRAMS G-4 POWER W A VE 450 SCHEMA TIC - CONTROL PC BOARD #1 1W 6.
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ELECTRICAL DIAGRAMS G-5 POWER W A VE 450 SCHEMA TIC - CONTROL PC BOARD #2 4 .7 5K R342 4 .
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ELECTRICAL DIAGRAMS G-6 POWER W A VE 450 SCHEMA TIC - CONTROL PC BOARD #3 1.
ELECTRICAL DIAGRAMS G-7 POWER W A VE 450 SCHEMA TIC - CONTROL PC BOARD #4 5.11K R2 06 10.0 R225 221K R219 CNY17-3 OCI4 4 2 1 6 5 10K R257 221K R254 CNY17-3 OCI8 4 2 1 6 5 D42 150 R256 J26 6 10K R255 D22 J26 2 150 R220 DIS2 SWITCH2 +5V DIS1 1N4936 D23 J26 1 +5V J23 6 J26 5 SWITCH1 +5V LOW = TRIGGER CLOSED (TO HC11) HIGH = TRIGGER OPEN +5.
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.
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ELECTRICAL DIAGRAMS G-9 POWER W A VE 450 SCHEMA TIC - DISPLA Y PC BOARD (SHEET 1) J17 7 Tx GRS232 GD +5V 22.
ELECTRICAL DIAGRAMS G-10 POWER W A VE 450 SCHEMA TIC - DISPLA Y PC BOARD (SHEET 2) PRESSURE 50V 150p C71 6.81K R103 TO REMOTE 10K POTENTIOMETE RS 22.1K R 102 40V 600mA Q9 +15V THERMAL +15V +15V GD TRIM1 TRIM3 TRIM2 TRIM4 GD +5V +5V SENSE +5V GD INFRA6 GD INFRA5 +5V SENSE J11 5 10.
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.
ELECTRICAL DIAGRAMS G-12 POWER W A VE 450 SCHEMA TIC - POWER PRINTED CIRCUIT BOARD GND IN OUT X9 301 R192 1mH L116 1A 100V Q111 GND IN OUT X10 -8Vb e 1W 5.1V DZ115 1N4936 D43 CURRENT SOURCE 18.2K R105 18.2K R108 18.2K R104 40mAe +5Vc c FILE: G2240_1D2 Ch’ge.
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.
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ELECTRICAL DIAGRAMS G-14 POWER W A VE 450 SCHEMA TIC - PROTECTION PRINTED CIRCUIT BOARD +10Vp 2.
NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your factory warranty . Individual Printed Circuit Board Components are not available from Lincoln Electric.
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ELECTRICAL DIAGRAMS G-16 POWER W A VE 450 SCHEMA TIC -SQUARE W A VE PROTECTION PRINTED CIRCUIT BOARD SUPPLY VOLTAGE NET FRAME CONNECTION COMMON CONNECTION 3000V .
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.
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ELECTRICAL DIAGRAMS G-18 POWER W A VE 450 SCHEMA TIC - SHUNT PRINTED CIRCUIT BOARD NEGATIVE OUTPUT STUD TO GENERAL INFORMATION A PRINTED Iout = A NOTES : N.
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.
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ELECTRICAL DIAGRAMS G-20 POWER W A VE 450 SCHEMA TIC - SNUBBER PRINTED CIRCUIT BOARD +15V .
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.
ELECTRICAL DIAGRAMS G-22 POWER W A VE 450 SCHEMA TIC-SWITCH PRINTED CIRCUIT BOARD 600mA 40V Q8 600mA 40V Q9 1/2W 1 R28 1W 10V DZ10 100V 1A Q10 1N4936 D10 50V 2700p C8 15.0K R32 1W 6.2V DZ9 47.5 R36 1W 10V DZ2 1N4936 D7 1/2W 1 R22 100V 1A Q1 1W 15V DZ7 C6 10.
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.
ELECTRICAL DIAGRAMS G-24 G-24 POWER W A VE 450 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Re.
SVM ERROR REPORTING FORM We need to know if there are errors in our manuals. W e also value any suggestions as to additional tests or procedures that would make this SVM a better tool for you.
An important point after buying a device Lincoln Electric INVERTEC POWER WAVE 450 SVM112-B (or even before the purchase) is to read its user manual. We should do this for several simple reasons:
If you have not bought Lincoln Electric INVERTEC POWER WAVE 450 SVM112-B yet, this is a good time to familiarize yourself with the basic data on the product. First of all view first pages of the manual, you can find above. You should find there the most important technical data Lincoln Electric INVERTEC POWER WAVE 450 SVM112-B - thus you can check whether the hardware meets your expectations. When delving into next pages of the user manual, Lincoln Electric INVERTEC POWER WAVE 450 SVM112-B you will learn all the available features of the product, as well as information on its operation. The information that you get Lincoln Electric INVERTEC POWER WAVE 450 SVM112-B will certainly help you make a decision on the purchase.
If you already are a holder of Lincoln Electric INVERTEC POWER WAVE 450 SVM112-B, but have not read the manual yet, you should do it for the reasons described above. You will learn then if you properly used the available features, and whether you have not made any mistakes, which can shorten the lifetime Lincoln Electric INVERTEC POWER WAVE 450 SVM112-B.
However, one of the most important roles played by the user manual is to help in solving problems with Lincoln Electric INVERTEC POWER WAVE 450 SVM112-B. Almost always you will find there Troubleshooting, which are the most frequently occurring failures and malfunctions of the device Lincoln Electric INVERTEC POWER WAVE 450 SVM112-B along with tips on how to solve them. Even if you fail to solve the problem, the manual will show you a further procedure – contact to the customer service center or the nearest service center
