Instruction/ maintenance manual of the product SVM159-A Lincoln Electric
Go to page of 134
SVM159-A December , 2003 Safety Depends on Y ou Lincoln arc welding and cutting equipment is designed and built with safety in mind. However , your overall safety can be increased by pr oper installation .
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC i SAFETY i FOR ENGINE powered equipment. 1.a. T urn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running. ____________________________________________________ 1.
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.
SAFETY iii iii POWER W A VE 355/405 Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC FOR ELECTRICALL Y powered equipment. 8.a. T urn off input power using the disconnect switch at the fuse box before working on the equipment.
SAFETY iv iv POWER W A VE 355/405 Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC PRÉCAUTIONS DE SÛRETÉ Pour votre propre protection lire et observer toutes les .
INST ALLA TION v v POWER W A VE 355 Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC L10093 3-1-96H Conf or mance standard: EN 50 199 Electromagnetic Compatibility (EMC) Product Standard for Arc Welding Equipment. It All electrical equipment generates small amounts of electromagnetic emission.
INST ALLA TION vi vi POWER W A VE 355 Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC L10093 3-1-96H The size of the surrounding area to be considered will depend o.
MASTER T ABLE OF CONTENTS FOR ALL SECTIONS v v POWER W A VE 355/405 Page Safety .................................................................................................................................................i-iv Installation ........
SectionA-1 Section A-1 POWER W A VE 355/405 Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC T ABLE OF CONTENTS - INST ALLA TION SECTION - Installation T echnical Specifications 355 ..................................
POWER W A VE 355/405 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC A-2 INS.
INST ALLA TION A-3 A-3 POWER W A VE 355/405 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Retur.
A-4 A-4 POWER W A VE 355/405 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC INST ALLA TION ELECTRIC SHOCK can kill .
INST ALLA TION A-5 A-5 POWER W A VE 355/405 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC 5.50 10.0 0 MOUNTING HOLE LOCATIONS M19527 1/4-20 NUT (4 PLAC ES) NOTE: MOUNTING SCREWS CA 4/01 N NOT PROTR UDE MORE THAN 0.
INST ALLA TION A-6 A-6 POWER W A VE 355/405 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Enable the voltage sense leads as follows: T ABLE A.
INST ALLA TION A-7 A-7 POWER W A VE 355/405 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Retur.
INST ALLA TION A-8 A-8 POWER W A VE 355/405 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC SYSTEM SET -UP Basic Rules • Each group is required to have one user interface.
INST ALLA TION A-9 A-9 POWER W A VE 355/405 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC FIGURE A.3 Multiple Group System No “FH0 Allowed! FIGURE A.
INST ALLA TION A-10 A-10 POWER W A VE 355/405 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC FIGURE A.
INST ALLA TION A-11 A-11 POWER W A VE 355/405 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Ret.
INST ALLA TION A-12 A-12 POWER W A VE 355/405 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC I / O RECEPT ACLE SPECIFICA TIONS T ABLE A.
Section B-1 Section B-1 POWER W A VE 355/405 T ABLE OF CONTENTS - OPERA TION SECTION - Operation ............................................................................................................................... Section B Safety Precautions .
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC B-2 B-2 POWER W A VE 355/405 OPERA TION GENERAL DESCRIPTION The Power W ave semi-automatic power source is designed to be a part of a modular , multi-process weld- ing system.
OPERA TION B-3 B-3 POWER W A VE 355/405 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to.
OPERA TION B-4 B-4 POWER W A VE 355/405 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC FIGURE B.1 10 4 6 1 3 2 5 7 8 9 CASE FRONT LA YOUT POWER W A VE 355/405 5.
OPERA TION B-5 B-5 POWER W A VE 355/405 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC In non-synergic modes, the WFS control behaves more like a conventional CV power source where WFS and voltage are independent adjustments.
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC OPERA TION B-6 B-6 POWER W A VE 355/405 TIG GT A W The TIG mode features continuous control from 5 to 425 amps.
INST ALLA TION B-7 B-7 POWER W A VE 355 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to.
INST ALLA TION B-8 B-8 POWER W A VE 355 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to.
C-1 C-1 POWER W A VE 355/405 Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC T ABLE OF CONTENTS - ACCESSORIES SECTION - Accessories ...................................................................................
ACCESSORIES C-2 C-2 POWER W A VE 355/405 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC OPTIONAL EQUIPMENT F ACTOR Y INST ALLED None Available.
Section D-1 Section D-1 POWER W A VE 355/405 T ABLE OF CONTENTS -MAINTENANCE- Maintenance ......................................................................................................................... Section D Capacitor Dischar ge Procedur e .
MAINTENANCE D-2 D-2 POWER W A VE 355/405 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Have qualified personnel do the maintenance work.
W ARNING W ARNING AVI SO DE PRECAUCION A TTENTION ! ! ! ! Lor em i psum dol or si t a me t cons ecte t ue r a di pi sci ng Lorem ipsum dolor sit amet consectetuer ad ipiscing e lit, ed d i am nonummy .
NOTES D-4 D-4 POWER W A VE 355/405 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Mast.
Section E-1 Section E-1 POWER W A VE 355/405 Theory of Operation ............................................................................................................. Section E General Description ..............................................
FIGURE E.2 – INPUT VOL T AGE AND PRECHARGE Control Board Choke Positive Output T erminal Negative Output T erminal Board C urrent Feedback Reconnect Switch Output V oltage Sense Input switch Input R.
SWITCH BOARD & MAIN TRANSFORMER There is one switch boar d in the POWER WA VE 355/405. This board incorporates two pairs of input capacitors, two insulated gate bipolar transistor (IGBT) switching circuits, a fan motor drive cir cuit, and a volt- age/frequency capacitor feedback cir cuit.
THEOR Y OF OPERA TION E-4 E-4 POWER W A VE 355/405 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC FIGURE E.
OUTPUT RECTIFIER AND CHOKE The output rectifier r eceives the AC output from the main transformer secondary and rectifies it to a DC voltage level. Since the output choke is in series with the negative leg of the output rectifier and also in series with the welding load, a filtered DC output is applied to the machine’ s output terminals.
THERMAL PROTECTION Three normally closed (NC) thermostats pr otect the machine from excessive operating temperatur es. These thermostats are wir ed in series and are con- nected to the control boar d.
INSULA TED GA TE BIPOLAR TRANSIST OR (IGBT) OPERA TION An IGBT is a type of transistor . IGBT are semiconduc- tors well suited for high frequency switching and high current applications. Example A in Figure E.6 shows an IGBT in passive mode. There is no gate signal, zer o volts relative to the source, and ther efore, no curr ent flow .
PULSE WIDTH MODULA TION The term Pulse Width Modulation is used to describe how much time is devoted to conduction in the posi- tive and negative portions of the cycle.
POWER W A VE 355/405 Section F-1 Section F-1 Tr oubleshooting & Repair Section ................................................................................. Section F How to Use T roubleshooting Guide ..........................................
HOW TO USE TROUBLESHOOTING GUIDE Service and repair should be performed by only Lincoln Electric Factory T rained Personnel. Unauthorized repairs performed on this equipment may r esult in danger to the technician and machine operator and will invalidate your factory warranty .
POWER W A VE 355/405 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-3 F-3 Sometimes machine failures appear to be due to PC board failures.
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC POWER W A VE 355/405 TROUBLESHOOTING & REP AIR F-4 F-4 Observe Safety Guidelines TROUBLESHOOTING GUIDE detailed in the beginning of this manual.
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC POWER W A VE 355/405 TROUBLESHOOTING & REP AIR F-5 F-5 TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginning of this manual.
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC POWER W A VE 355/405 TROUBLESHOOTING & REP AIR F-6 F-6 Observe Safety Guidelines TROUBLESHOOTING GUIDE detailed in the beginning of this manual.
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC POWER W A VE 355/405 TROUBLESHOOTING & REP AIR F-7 F-7 Observe Safety Guidelines TROUBLESHOOTING GUIDE detailed in the beginning of this manual.
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC POWER W A VE 355/405 TROUBLESHOOTING & REP AIR F-8 F-8 Observe Safety Guidelines TROUBLESHOOTING GUIDE detailed in the beginning of this manual.
F-9 F-9 POWER W A VE 355/405 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR USING THE ST A TUS LED TO TROUBLESHOOT SYSTEM PROBLEMS The Power W ave / Power Feed are best diagnosed as a system.
POWER W A VE 355/405 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-10 F-10 ST A TUS LED ERROR CODE T ABLE NOTE: The error code signal sequence is always pr eceded by a 2 second green light.
POWER W A VE 355/405 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-11 F-11 43 Capacitor delta error .
NOTES F-12 F-12 POWER W A VE 355/405 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Ma.
W ARNING Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING &am.
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-14 F-14 POWER W A VE 355/405 ELECTRIC SHOCK can kill.
MAIN SWITCH BOARD TEST Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may r esult in danger to the technician or machine operator and will invalidate your factory warranty .
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-16 F-16 POWER W A VE 355/405 MAIN SWITCH BOARD TEST (continued) FIGURE F .
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-17 F-17 POWER W A VE 355/405 MAIN SWITCH BOARD TEST (continued) T ABLE F .
NOTES F-18 F-18 POWER W A VE 355/405 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Ma.
TROUBLESHOOTING & REP AIR F-19 F-19 POWER W A VE 355/405 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC INPUT RECTIFIER TEST Service and repair should be performed by only Lincoln Electric factory trained personnel.
TEST PROCEDURE 1. Remove input power to the POWER WA VE 355/405 machine. 2. Using a 5/16” nut driver , remove the case wraparound cover . 3. Perform the Capacitor Discharge Procedur e detailed earlier in this section. 4. Locate the input r ectifier and associated leads.
TROUBLESHOOTING & REP AIR F-21 F-21 POWER W A VE 355/405 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC 9. If the input r ectifier does not meet the acceptable readings outlined in T able F .
NOTES F-22 F-22 POWER W A VE 355/405 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Ma.
F-23 F-23 POWER W A VE 355/405 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR POWER BOARD TEST Service and repair should be performed by only Lincoln Electric factory trained personnel.
TROUBLESHOOTING & REP AIR F-24 F-24 POWER W A VE 355/405 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC POWER BOARD TEST (CONTINUED) J42 J41 J43 FIGURE F .
POWER BOARD CONNECTOR PLUG J41 POWER BOARD CONNECTOR PLUG J42 POWER BOARD CONNECTOR PLUG J42 POWER BOARD CONNECTOR PLUG J42 POWER BOARD CONNECTOR PLUG J43 POWER BOARD CONNECTOR PLUG J43 POWER BOARD CO.
NOTES F-26 F-26 POWER W A VE 355/405 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Ma.
TROUBLESHOOTING & REP AIR F-27 F-27 POWER W A VE 355/405 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC DC BUS BOARD TEST W ARNING Service and repair should be performed by only Lincoln Electric factory trained personnel.
TROUBLESHOOTING & REP AIR F-28 F-28 POWER W A VE 355/405 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC DC BUS BOARD W A R N IN G R E M O T E P O W E R O F F O N STATUS THERMAL LINCOLN ELECTRIC FIGURE F .
TROUBLESHOOTING & REP AIR F-29 F-29 POWER W A VE 355/405 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC DC BUS BOARD TEST (CONTINUED) 6.
NOTES F-30 F-30 POWER W A VE 355/405 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Ma.
OUTPUT DIODE MODULES TEST Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may r esult in danger to the technician or machine operator and will invalidate your factory warranty .
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-32 F-32 POWER W A VE 355/405 OUTPUT DIODE MODULES TEST (continued) TEST PROCEDURE 1.
TROUBLESHOOTING & REP AIR F-33 F-33 POWER W A VE 355/405 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC OUTPUT DIODE MODULES TEST (continued) 5.
TROUBLESHOOTING & REP AIR OUTPUT DIODE MODULES TEST (continued) F-34 F-34 POWER W A VE 355/405 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Figure F .
AUXILIAR Y TRANSFORMER TEST Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may r esult in danger to the technician or machine operator and will invalidate your factory warranty .
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-36 F-36 POWER W A VE 355/405 AUXILIAR Y TRANSFORMER TEST (continued) TEST PROCEDURE 1.
TROUBLESHOOTING & REP AIR AUXILIAR Y TRANSFORMER NO.1 TEST (continued) F-37 F-37 POWER W A VE 355/405 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC 7.
NOTES F-38 F-38 POWER W A VE 355/405 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Ma.
TROUBLESHOOTING AND REP AIR F-39 F-39 POWER W A VE 355/405 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC CURRENT TRANSDUCER TEST Service and repair should be performed by only Lincoln Electric factory trained personnel.
TROUBLESHOOTING AND REP AIR CURRENT TRANSDUCER TEST (continued) F-40 F-40 POWER W A VE 355/405 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TEST PROCEDURE 1.
TROUBLESHOOTING AND REP AIR CURRENT TRANSDUCER TEST (continued) F-41 F-41 POWER W A VE 355/405 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC 8.
NOTES F-42 F-42 POWER W A VE 355/405 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Ma.
TROUBLESHOOTING AND REP AIR F-43 F-43 POWER W A VE 355/405 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC F AN CONTROL AND MOTOR TEST Service and repair should be performed by only Lincoln Electric factory trained personnel.
TROUBLESHOOTING AND REP AIR F AN CONTROL AND MOTOR TEST (continued) F-44 F-44 POWER W A VE 355/405 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TEST PROCEDURE 1.
Plug J20 Lead 715+ 1 2 3 4 7 8 6 5 Lead 716- TROUBLESHOOTING AND REP AIR F AN CONTROL AND MOTOR TEST (continued) F-45 F-45 POWER W A VE 355/405 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC 7.
NOTES F-46 F-46 POWER W A VE 355/405 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Ma.
CONTROL BOARD REMOV AL AND REPLACEMENT Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty .
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC POWER W A VE 355/405 TROUBLESHOOTING & REP AIR F-48 F-48 PROCEDURE 1. Remove input power to the POWER WA VE 355/405.
Observe static precautions detailed in PC Board T roubleshooting Procedures at the beginning of this section. 6. Using a phillips head screwdriver r emove the two screws and their washers fr om above and below the input power switch. See Figure F .18.
POWER W A VE 355/405 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC 12. Using a 3/8” nut driver remove the two mounting nuts from the top two corners of the control board.
MAIN SWITCH BOARD REMOV AL AND REPLACEMENT Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may r esult in danger to the technician or machine operator and will invalidate your factory warranty .
PROCEDURE 1. Remove the input power to the POWER WA VE 355/405. 2. Using a 5/16” nut driver remove the case wrap- around cover . 3. Perform the Input Filter Capacitor Discharge Procedure detailed earlier in this section. Observe static precautions detailed in PC Board Tr oubleshooting Procedures at the beginning of this section.
POWER W A VE 355/405 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-53 F-53 FIGURE F.
NOTES F-54 F-54 POWER W A VE 355/405 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Ma.
SNUBBER BOARD REMOV AL AND REPLACEMENT Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may r esult in danger to the technician or machine operator and will invalidate your factory warranty .
PROCEDURE 1. Remove input power to the POWER WA VE 355/405. 2. Using a 5/16” nut driver remove the case wrap- around cover . 3. Perform the Input Filter Capacitor Discharge Procedure detailed earlier in this section. 4. Locate the snubber board.. See Figur e F .
POWER BOARD REMOV AL AND REPLACEMENT Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may r esult in danger to the technician or machine operator and will invalidate your factory warranty .
PROCEDURE 1. Remove input power to the POWER WA VE 355/405. 2. Using a 5/16” nut driver remove the case wrap- around cover . 3. Perform the Input Filter Capacitor Discharge Procedure detailed earlier in this section. 4. Locate the power board. See Figur e F .
TROUBLESHOOTING & REP AIR POWER BOARD REMOV AL AND REPLACEMENT (continued) F-59 F-59 POWER W A VE 355/405 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Re.
NOTES F-60 F-60 POWER W A VE 355 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master.
F-61 F-61 POWER W A VE 355 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC DC BUS BOARD REMOV AL AND REPLACEMENT Service and repair should be performed by only Lincoln Electric factory trained personnel.
TROUBLESHOOTING & REP AIR F-62 F-62 POWER W A VE 355 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC PROCEDURE 1. Remove input power to the POWER WA VE 355/405.
TROUBLESHOOTING & REP AIR F-63 F-63 POWER W A VE 355 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC 9. Label and remove two thermostat leads and four leads from the bus r ectifier .
16. Replace the two 5/16” mounting scr ews to the bottom of the case front. 17. Replace the case wrapar ound cover . TROUBLESHOOTING & REP AIR DC BUS BOARD REMOV AL AND REPLACEMENT (Continued) F.
TROUBLESHOOTING & REP AIR F-65 F-65 POWER W A VE 355/405 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to.
PROCEDURE 1. Remove input power to the POWER WA VE 355/405. 2. Using a 5/16” nut driver remove the case wraparound cover . 3. Perform the Input Filter Capacitor Discharge Procedure detailed earlier in this section. 4. Locate the input rectifier . See figure F .
9. Apply a thin coat of Penetrox A-13 heatsink com- pound to the point of contact between the input r ectifier and the mounting surface. 10. Secure the new input bridge into its proper posi- tion with the two 3/16”in. allen mounting screws previously r emoved.
NOTES F-68 F-68 POWER W A VE 355/405 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Ma.
F-69 F-69 POWER W A VE 355/405 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master T.
PROCEDURE 1. Remove input power to the POWER WA VE 355/405. 2. Using a 5/16” nut driver remove the case wrap- around cover . 3. Perform the Input Filter Capacitor Discharge Procedure detailed earlier in this section. 4. Locate the output diode modules located behind the snubber board.
8. Under the copper plate pr eviously removed, ther e is an allen bolt. Remove it using a 9/64” allen wrench. See Figur e F .33. 9. Using a 7/16” socket remove the mounting bolts at the top and bottom of the modules. See Figure F .33. 10. The output rectifier modules are r eady for removal and/or replacement.
NOTES F-72 F-72 POWER W A VE 355/405 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Ma.
F-73 F-73 POWER W A VE 355/405 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master T.
PROCEDURE 1. Remove input power to the POWER WA VE 355/405. 2. Using a 5/16” nut driver remove the case wrap- around cover . 3. Perform the Input Filter Capacitor Discharge Procedure detailed earlier in this section. 4. Using a 5/16” nut driver remove the four scr ews from the bottom and right side of the r ear assem- bly .
5. Label and remove the four leads connected to the r econnect panel. Pliers may be necessary . 6. Label and remove the two leads connected to the CB2 circuit br eaker . 7. Using a crescent wr ench, remove the lar ge plastic nut from ar ound the input power line located at bot- tom of the rear assembly .
11. The back of the machine may now gently be pulled away to gain access to the current trans- ducer . Note: The rear of the machine cannot be r emoved completely . 12. Carefully swing the r ear of the machine open to the left while facing the rear of the machine.
21. Replace the current transducer . 22. Replace the two 3/8” mounting nuts previously re moved. 23. Reconnect plug #J90 to the current transducer . 24. Replace any necessary cable ties previously cut. 25. From the rear of the machine, r eplace the heavy flex lead to the bottom of the output diode heatsink assembly using a 1/2” wrench.
Retest a machine: If it is rejected under test for any reason that requires you to remove any part which could affect the machine’ s electrical characteristics.
G-1 ELECTRICAL DIAGRAMS G-1 T ABLE OF CONTENTS -ELECTRICAL DIAGRAMS SECTION- ELECTRICAL DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION G WIRING DIAGRAM (G4131) . . . . . .
ELECTRICAL DIAGRAMS G-2 POWERW A VE 355/405 WIRING DIAGRAM - POWERW A VE 355/405 - G4131 NOTES : N.A. 1. FO R MA CHI NE S WIT H RE D, BL ACK AN D W HITE POW ER C ORD S- FOR SINGL E P HAS E IN PUT: CON NE CT G RE EN L EAD T O G RO UND PER NATI ON AL EL ECT RIC AL CO DE.
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ELECTRICAL DIAGRAMS G-3 POWERW A VE 355/405 SCHEMA TIC - COMPLETE MACHINE EN-170 G4132 PO WE RW AV E 355/ 405 MACHINE SC HEM ATI C NON E G4093 F.
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ELECTRICAL DIAGRAMS G-4 POWERW A VE 355/405 SCHEMA TIC - DIGIT AL CONTROL PC BOARD #1 G-4 NOTE: This diagram is for reference only .
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ELECTRICAL DIAGRAMS G-5 POWERW A VE 355/405 SCHEMA TIC - DIGIT AL CONTROL PC BOARD #2 G-5 NOTE: This diagram is for reference only .
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ELECTRICAL DIAGRAMS G-6 POWERW A VE 355/405 SCHEMA TIC - DIGIT AL CONTROL PC BOARD #3 G-6 NOTE: This diagram is for reference only .
ELECTRICAL DIAGRAMS G-7 POWERW A VE 355/405 SCHEMA TIC - DIGIT AL CONTROL PC BOARD #4 G-7 NOTE: This diagram is for reference only . It may not be accurate for all machines covered by this manual.
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ELECTRICAL DIAGRAMS G-8 POWE.
ELECTRICAL DIAGRAMS G-9 POWERW A VE 355/405 SCHEMA TIC - SWITCH PC BOARD G-9 NOTE: This diagram is for reference only . It may not be accurate for all machines covered by this manual.
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-11 POWERW A VE 355/405 SCHEMA TIC - SNUBBER PC BOARD S24761 6-2-2000 G-11 NOTE: This diagram is for reference only .
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-13 POWERW A VE 355/405 SCHEMA TIC - 40 VDC BUSS PC BOARD G-13 NOTE: This diagram is for reference only . It may not be accurate for all machines covered by this manual.
SVM ERROR REPORTING FORM We need to know if there are errors in our manuals. We also value any suggestions as to additional tests or procedures that would make this SVM a better tool for you.
An important point after buying a device Lincoln Electric SVM159-A (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 SVM159-A 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 SVM159-A - thus you can check whether the hardware meets your expectations. When delving into next pages of the user manual, Lincoln Electric SVM159-A you will learn all the available features of the product, as well as information on its operation. The information that you get Lincoln Electric SVM159-A will certainly help you make a decision on the purchase.
If you already are a holder of Lincoln Electric SVM159-A, 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 SVM159-A.
However, one of the most important roles played by the user manual is to help in solving problems with Lincoln Electric SVM159-A. Almost always you will find there Troubleshooting, which are the most frequently occurring failures and malfunctions of the device Lincoln Electric SVM159-A 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
