SVM112-B
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February, 2001
TM
INVERTEC POWER WAVE 450
For use with machines having Code Numbers: 10105 thru 10610
Safety Depends on You
Lincoln arc welding and cutting
equipment is designed and
built with safety in mind.
However, your overall safety
can be increased by proper
installation . . . and thoughtful
operation on your part. DO
NOT INSTALL, OPERATE OR
REPAIR THIS EQUIPMENT
WITHOUT READING THIS
MANUAL AND THE SAFETY
PRECAUTIONS CONTAINED
THROUGHOUT. And, most
importantly, think before you
act and be careful.
SERVICE MANUAL
Copyright © 2001 Lincoln Global Inc.
• World's Leader in Welding and Cutting Products •
• Sales and Service through Subsidiaries and Distributors Worldwide •
Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com
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ii
ii
SAFETY
ARC RAYS can burn.
ELECTRIC SHOCK can kill.
3.a. The electrode and work (or ground) circuits
are electrically “hot” when the welder is on.
Do not touch these “hot” parts with your bare
skin or wet clothing. Wear dry, hole-free
gloves to insulate hands.
4.a. Use a shield with the proper filter and cover
plates to protect your eyes from sparks and
the rays of the arc when welding or observing
open arc welding. Headshield and filter lens
should conform to ANSI Z87. I standards.
4.b. Use suitable clothing made from durable flame-resistant
material to protect your skin and that of your helpers from
the arc rays.
3.b. Insulate yourself from work and ground using dry insulation.
Make certain the insulation is large enough to cover your full
area of physical contact with work and ground.
4.c. Protect other nearby personnel with suitable, non-flammable
screening and/or warn them not to watch the arc nor expose
themselves to the arc rays or to hot spatter or metal.
In addition to the normal safety precautions, if welding
must be performed under electrically hazardous
conditions (in damp locations or while wearing wet
clothing; on metal structures such as floors, gratings or
scaffolds; when in cramped positions such as sitting,
kneeling or lying, if there is a high risk of unavoidable or
accidental contact with the workpiece or ground) use
the following equipment:
FUMES AND GASES
can be dangerous.
5.a. Welding may produce fumes and gases
hazardous to health. Avoid breathing these
• Semiautomatic DC Constant Voltage (Wire) Welder.
• DC Manual (Stick) Welder.
• AC Welder with Reduced Voltage Control.
fumes and gases.When welding, keep
your head out of the fume. Use enough
ventilation and/or exhaust at the arc to keep
3.c. In semiautomatic or automatic wire welding, the electrode,
electrode reel, welding head, nozzle or semiautomatic
welding gun are also electrically “hot”.
fumes and gases away from the breathing zone. When
welding with electrodes which require special
ventilation such as stainless or hard facing (see
instructions on container or MSDS) or on lead or
cadmium plated steel and other metals or coatings
which produce highly toxic fumes, keep exposure as
low as possible and below Threshold Limit Values (TLV)
using local exhaust or mechanical ventilation. In
confined spaces or in some circumstances, outdoors, a
respirator may be required. Additional precautions are
also required when welding on galvanized steel.
3.d. Always be sure the work cable makes a good electrical
connection with the metal being welded. The connection
should be as close as possible to the area being welded.
3.e. Ground the work or metal to be welded to a good electrical
(earth) ground.
3.f. Maintain the electrode holder, work clamp, welding cable and
welding machine in good, safe operating condition. Replace
damaged insulation.
5.b. Do not weld in locations near chlorinated hydrocarbon vapors
coming from degreasing, cleaning or spraying operations.
The heat and rays of the arc can react with solvent vapors to
form phosgene, a highly toxic gas, and other irritating prod-
ucts.
3.g. Never dip the electrode in water for cooling.
3.h. Never simultaneously touch electrically “hot” parts of
electrode holders connected to two welders because voltage
between the two can be the total of the open circuit voltage
of both welders.
5.c. Shielding gases used for arc welding can displace air and
cause injury or death. Always use enough ventilation,
especially in confined areas, to insure breathing air is safe.
3.i. When working above floor level, use a safety belt to protect
yourself from a fall should you get a shock.
5.d. Read and understand the manufacturer’s instructions for this
equipment and the consumables to be used, including the
material safety data sheet (MSDS) and follow your
employer’s safety practices. MSDS forms are available from
your welding distributor or from the manufacturer.
3.j. Also see Items 6.c. and 8.
5.e. Also see item 1.b.
Mar ‘95
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iii
iii
SAFETY
WELDING SPARKS can
cause fire or explosion.
CYLINDER may explode
if damaged.
6.a. Remove fire hazards from the welding area.
If this is not possible, cover them to prevent
7.a. Use only compressed gas cylinders
containing the correct shielding gas for the
the welding sparks from starting a fire.
Remember that welding sparks and hot
materials from welding can easily go through small cracks
and openings to adjacent areas. Avoid welding near
hydraulic lines. Have a fire extinguisher readily available.
process used and properly operating
regulators designed for the gas and
pressure used. All hoses, fittings, etc. should be suitable for
the application and maintained in good condition.
7.b. Always keep cylinders in an upright position securely
chained to an undercarriage or fixed support.
6.b. Where compressed gases are to be used at the job site,
special precautions should be used to prevent hazardous
situations. Refer to “Safety in Welding and Cutting” (ANSI
Standard Z49.1) and the operating information for the
equipment being used.
7.c. Cylinders should be located:
•Away from areas where they may be struck or subjected to
physical damage.
6.c. When not welding, make certain no part of the electrode
circuit is touching the work or ground. Accidental contact can
cause overheating and create a fire hazard.
•A safe distance from arc welding or cutting operations and
any other source of heat, sparks, or flame.
7.d. Never allow the electrode, electrode holder or any other
electrically “hot” parts to touch a cylinder.
6.d. Do not heat, cut or weld tanks, drums or containers until the
proper steps have been taken to insure that such procedures
will not cause flammable or toxic vapors from substances
inside. They can cause an explosion even though they have
been “cleaned”. For information, purchase “Recommended
Safe Practices for the Preparation for Welding and Cutting of
Containers and Piping That Have Held Hazardous
Substances”, AWS F4.1 from the American Welding Society
(see address above).
7.e. Keep your head and face away from the cylinder valve outlet
when opening the cylinder valve.
7.f. Valve protection caps should always be in place and hand
tight except when the cylinder is in use or connected for
use.
7.g. Read and follow the instructions on compressed gas
cylinders, associated equipment, and CGA publication P-l,
“Precautions for Safe Handling of Compressed Gases in
Cylinders,” available from the Compressed Gas Association
1235 Jefferson Davis Highway, Arlington, VA 22202.
6.e. Vent hollow castings or containers before heating, cutting or
welding. They may explode.
6.f. Sparks and spatter are thrown from the welding arc. Wear oil
free protective garments such as leather gloves, heavy shirt,
cuffless trousers, high shoes and a cap over your hair. Wear
ear plugs when welding out of position or in confined places.
Always wear safety glasses with side shields when in a
welding area.
FOR ELECTRICALLY
powered equipment.
6.g. Connect the work cable to the work as close to the welding
area as practical. Work cables connected to the building
framework or other locations away from the welding area
increase the possibility of the welding current passing
through lifting chains, crane cables or other alternate circuits.
This can create fire hazards or overheat lifting chains or
cables until they fail.
8.a. Turn off input power using the disconnect
switch at the fuse box before working on
the equipment.
8.b. Install equipment in accordance with the U.S. National
Electrical Code, all local codes and the manufacturer’s
recommendations.
6.h. Also see item 1.c.
8.c. Ground the equipment in accordance with the U.S. National
Electrical Code and the manufacturer’s recommendations.
Mar ‘95
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iv
iv
SAFETY
6. Eloigner les matériaux inflammables ou les recouvrir afin de
PRÉCAUTIONS DE SÛRETÉ
prévenir tout risque d’incendie dû aux étincelles.
Pour votre propre protection lire et observer toutes les instructions
et les précautions de sûreté specifiques qui parraissent dans ce
manuel aussi bien que les précautions de sûreté générales suiv-
antes:
7. Quand on ne soude pas, poser la pince à une endroit isolé de
la masse. Un court-circuit accidental peut provoquer un
échauffement et un risque d’incendie.
8. S’assurer que la masse est connectée le plus prés possible de
la zone de travail qu’il est pratique de le faire. Si on place la
masse sur la charpente de la construction ou d’autres endroits
éloignés de la zone de travail, on augmente le risque de voir
passer le courant de soudage par les chaines de levage,
câbles de grue, ou autres circuits. Cela peut provoquer des
risques d’incendie ou d’echauffement des chaines et des
câbles jusqu’à ce qu’ils se rompent.
Sûreté Pour Soudage A L’Arc
1. Protegez-vous contre la secousse électrique:
a. Les circuits à l’électrode et à la piéce sont sous tension
quand la machine à souder est en marche. Eviter toujours
tout contact entre les parties sous tension et la peau nue
ou les vétements mouillés. Porter des gants secs et sans
trous pour isoler les mains.
b. Faire trés attention de bien s’isoler de la masse quand on
soude dans des endroits humides, ou sur un plancher met-
allique ou des grilles metalliques, principalement dans
les positions assis ou couché pour lesquelles une grande
partie du corps peut être en contact avec la masse.
c. Maintenir le porte-électrode, la pince de masse, le câble de
soudage et la machine à souder en bon et sûr état defonc-
tionnement.
9. Assurer une ventilation suffisante dans la zone de soudage.
Ceci est particuliérement important pour le soudage de tôles
galvanisées plombées, ou cadmiées ou tout autre métal qui
produit des fumeés toxiques.
10. Ne pas souder en présence de vapeurs de chlore provenant
d’opérations de dégraissage, nettoyage ou pistolage. La
chaleur ou les rayons de l’arc peuvent réagir avec les vapeurs
du solvant pour produire du phosgéne (gas fortement toxique)
ou autres produits irritants.
d.Ne jamais plonger le porte-électrode dans l’eau pour le
refroidir.
e. Ne jamais toucher simultanément les parties sous tension
des porte-électrodes connectés à deux machines à souder
parce que la tension entre les deux pinces peut être le total
de la tension à vide des deux machines.
11. Pour obtenir de plus amples renseignements sur la sûreté, voir
le code “Code for safety in welding and cutting” CSA Standard
W 117.2-1974.
f. Si on utilise la machine à souder comme une source de
courant pour soudage semi-automatique, ces precautions
pour le porte-électrode s’applicuent aussi au pistolet de
soudage.
PRÉCAUTIONS DE SÛRETÉ POUR
LES MACHINES À SOUDER À
TRANSFORMATEUR ET À
REDRESSEUR
2. Dans le cas de travail au dessus du niveau du sol, se protéger
contre les chutes dans le cas ou on recoit un choc. Ne jamais
enrouler le câble-électrode autour de n’importe quelle partie du
corps.
3. Un coup d’arc peut être plus sévère qu’un coup de soliel, donc:
a. Utiliser un bon masque avec un verre filtrant approprié ainsi
qu’un verre blanc afin de se protéger les yeux du rayon-
nement de l’arc et des projections quand on soude ou
quand on regarde l’arc.
1. Relier à la terre le chassis du poste conformement au code de
l’électricité et aux recommendations du fabricant. Le dispositif
de montage ou la piece à souder doit être branché à une
bonne mise à la terre.
b. Porter des vêtements convenables afin de protéger la peau
de soudeur et des aides contre le rayonnement de l‘arc.
c. Protéger l’autre personnel travaillant à proximité au
soudage à l’aide d’écrans appropriés et non-inflammables.
2. Autant que possible, I’installation et l’entretien du poste seront
effectués par un électricien qualifié.
3. Avant de faires des travaux à l’interieur de poste, la debranch-
er à l’interrupteur à la boite de fusibles.
4. Des gouttes de laitier en fusion sont émises de l’arc de
soudage. Se protéger avec des vêtements de protection libres
de l’huile, tels que les gants en cuir, chemise épaisse, pan-
talons sans revers, et chaussures montantes.
4. Garder tous les couvercles et dispositifs de sûreté à leur place.
5. Toujours porter des lunettes de sécurité dans la zone de
soudage. Utiliser des lunettes avec écrans lateraux dans les
zones où l’on pique le laitier.
Mar. ‘93
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v
v
RETURN TO MAIN INDEX
MASTER TABLE OF CONTENTS FOR ALL SECTIONS
Page
Safety.................................................................................................................................................i-iv
Installation.............................................................................................................................Section A
Operation...............................................................................................................................Section B
Accessories...........................................................................................................................Section C
Maintenance .........................................................................................................................Section D
Theory of Operation .............................................................................................................Section E
Troubleshooting and Repair.................................................................................................Section F
How To Use Troubleshooting Guide ...........................................................................................F-2
PC Board Troubleshooting Procedures and Replacement.........................................................F-3
Troubleshooting Guide................................................................................................................F-5
Test Procedures ........................................................................................................................F-27
Removal and Replacement Procedures .................................................................................F-155
Electrical Diagrams..............................................................................................................Section G
Parts Manual................................................................................................................................P-261
POWER WAVE 450
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Section A-1
Section A-1
TABLE OF CONTENTS
- INSTALLATION SECTION -
Installation
Technical Specifications .............................................................................................................A-2
Safety Precautions......................................................................................................................A-3
Select Suitable Location.............................................................................................................A-3
Stacking................................................................................................................................A-3
Tilting .................................................................................................................................A-3
Lifting .................................................................................................................................A-3
High Frequency Precautions.......................................................................................................A-3
Input Connections.......................................................................................................................A-3
Ground Connections...................................................................................................................A-4
Input Power Connections ...........................................................................................................A-4
Input Fuse and Supply Wire Considerations .......................................................................A-4
Input Voltage Reconnect Procedure ....................................................................................A-4
Output Connections....................................................................................................................A-5
Work and Electrode Cable Connections..............................................................................A-5
Size.................................................................................................................................A-5
Routing...........................................................................................................................A-5
Water Cooler Connections ...................................................................................................A-5
Wire Feeder Connections.....................................................................................................A-5
POWER WAVE 450
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A-2
A-2
INSTALLATION
TECHNICAL SPECIFICATIONS - POWER WAVE 450
INPUT -THREE PHASE ONLY
Input Voltages:
200
230
400
460
575
Input Currents
@ 500A/40 VDC
@ 450A/38 VDC
87
75
76
65
44
38
38
32
32
28
RATED OUTPUT
Duty Cycle
Amps
Volts at Rated Amperes
60% Duty Cycle
100% Duty Cycle
500
450
40 VDC
38 VDC
Constant Open
Circuit Voltage
Continuous
Current Range
Process
Current Ranges
75 Volts
5-540 Amps
GMAW 50-540 Amps
FCAW 40-540 Amps
STICK 30-540 Amps
Pulse
Current Range
Pulse
Voltage Range
Pulse and Background
Time Range
Pulse
Frequency
5-750 Amps
5-55 Volts
100 Microsec - 3.3 Sec
0.15 - 1000 Hz
RECOMMENDED INPUT WIRE AND FUSE SIZES
Type 75°C
Copper Wire in
Conduit
Type 75°C
Ground Wire in
Conduit
Type 75°C
Input
Voltage/
Freqency
Duty
Cycle
Input Ampere
Rating on
(Super Lag)
or Breaker
Size (Amps)
Nameplate
AWG[IEC]
AWG[IEC]
Sizes (MM2)
Sizes (MM2)
200/50-60
230/50-60
400/50-60
460/50-60
575/50-60
200/50-60
230/50-60
400/50-60
460/50-60
575/50-60
60%
60%
87
76
44
38
32
75
65
38
32
28
4 (25)
4 (25)
8 (10)
8 (10)
8 (10)
4 (25)
4 (25)
8 (10)
8 (10)
8 (10)
8 (10)
8 (10)
10 (6)
10 (6)
10 (6)
8 (10)
8 (10)
10 (6)
10 (6)
10 (6)
120
100
50
60%
60%
60%
100%
100%
100%
100%
100%
50
50
100
100
50
50
40
PHYSICAL DIMENSION
Height
Width
Depth
Weight
905 mm
35.6 in.
515 mm
20.3 in.
1010 mm
39.8 in.
137.9 kg
303.5 lbs.
OPERATING TEMPERATURE RANGE STORAGE TEMPERATURE RANGE
0° to 40°C
-50° to 85°C
POWER WAVE 450
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A-3
A-3
INSTALLATION
Read this entire installation section before you
start installation.
LIFTING
Lift the machine by the lift bail only. Do not attempt to
lift the machine by the push handle.
SAFETY PRECAUTIONS
HIGH FREQUENCY PRECAUTIONS
If possible, locate the Power Wave away from radio
controlled machinery. The normal operation of the
Power Wave may adversely affect the operation of RF
controlled equipment, which may result in bodily injury
or damage to the equipment.
WARNING
ELECTRIC SHOCK can kill.
• Only qualified personnel should
perform this installation.
INPUT CONNECTIONS
• Turn the input power OFF at the
disconnect switch or fuse box
before working on this equipment.
Be sure the voltage, phase, and frequency of the input
power is as specified on the rating plate, located on
the rear of the machine. See Figure A.1 for the loca-
tion of the rating plate.
• Do not touch electrically hot parts.
• Always connect the Power Wave grounding terminal
(located inside the reconnect input access doors).
FIGURE A.1 - RATING PLATE LOCATION
SELECT SUITABLE LOCATION
Place the welder where clean cooling air can circulate
in through the rear louvers and out through the side
and front louvers. Dirt, dust, or any foreign material
that can be drawn into the welder should be kept at a
minimum. Using filters on the air intake to prevent dirt
from building up restricts air flow. Do not use such fil-
ters. Failure to observe these precautions can result in
excessive operating temperatures and nuisance shut-
downs.
2
1
3
The Power Wave may be used outdoors. Power Wave
power sources carry an IP23 enclosure rating. They
are rated for use in damp, dirty environments subject
to occasional falling water such as rain. However, the
best practice is to keep the machine in a dry, sheltered
area, since a wet environment speeds corrosion of
parts. Do not place the machine in puddles or other-
wise submerge parts of the machine in water. This
may cause improper operation and is a possible safe-
ty hazard.
1. RATING PLATE
2. RECONNECT/INPUT ACCESS DOOR
3. INPUT CORD ACCESS HOLE
STACKING
Power Wave machines cannot be stacked.
WARNING
TILTING
Only a qualified electrician should connect the input
leads to the Power Wave. Connections should be
made in accordance with all local and national electri-
cal codes and the connection diagram located on the
inside of the reconnect/input access door of the
machine. Failure to do so may result in bodily injury
or death.
Each machine must be placed on a secure, level sur-
face. The machine may topple over if this procedure
is not followed.
Use a three-phase supply line. The Power Wave has
a 1.375” (35mm) access hole for the input cord, but
the input cord is not supplied.
POWER WAVE 450
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A-4
A-4
INSTALLATION
wire sizes. Fuse the input circuit with the recom-
mended super lag fuses or delay type circuit breakers.
Choose an input and grounding wire size according to
local or national electrical codes. Using fuses or cir-
cuit breakers smaller than recommended may result in
“nuisance” shut-offs from welder inrush currents, even
if the machine is not being used at high currents.
CAUTION
Failure to follow these instructions can cause immedi-
ate failure of components within the welder.
GROUND CONNECTIONS
INPUT VOLTAGE RECONNECT
PROCEDURE
The frame of the welder must be grounded.
A ground terminal marked with the symbol
is located inside the reconnect/input
access door for this purpose. See your
local and national electrical codes for proper ground-
ing methods. See Figure A.2 for the location of the
reconnect/input access door and related connection
diagram.
Welders are shipped connected for the highest input
voltage listed on the rating plate. To change this con-
nection for a different input voltage, refer to reconnect
instructions in Figure A.2 and proceed according to
the steps that follow for the appropriate voltage.
INPUT POWER CONNECTIONS
Connect L1, L2, L3 according to the Input Supply
Connection Diagram decal located on the reconnect/-
input access door. See Figure A.2.
INPUT FUSE AND SUPPLY WIRE
CONSIDERATIONS
Refer to the Technical Specifications at the beginning
of this Installation section for recommended fuse and
FIGURE A.2 - CONNECTION DIAGRAM ON RECONNECT/INPUT ACCESS DOOR
Also called “inverse time” or “thermal/magnetic” circuit breakers. These breakers have a delay in tripping action that decreases as the mag-
nitude of the current increases.
POWER WAVE 450
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A-5
A-5
INSTALLATION
FIGURE A.3 – FRONTPANEL/BACK PANEL
6
5
(IN)
4
(OUT)
2
1
3
1 WORK TERMINAL
2 ELECTRODE TERMINAL
3 REMOTE CONTROL AMPHENOL RECEPTACLE
4 WATER COOLING FITTINGS (ON BACK PANEL)
5 WIRE FEEDER CONNECTIONS (ON BACK PANEL)
6 ELECTRODE TERMINAL
To operate at 200-208 VAC:
OUTPUT CONNECTIONS
See Figure A.3 for the location of the work terminal,
electrode terminal, remote control amphenol recepta-
cle, water cooler fittings and wire feeder connections.
1. Open the reconnect/input access door.
2. Move the input voltage switch to Voltage = 200-
208V position.
WORK AND ELECTRODE CABLE
CONNECTIONS
3. Move “A” lead to the 200-208V terminal.
To operate at 220-230 VAC:
SIZE
1. Open the reconnect/input access door.
Use the largest welding (electrode and ground) cables
possible — at least 70mm2 (#2/0) copper wire — even
if the output current does not require it. When pulsing,
the pulse current often exceeds 650 amps with the
Power Wave 450. Voltage drops can become exces-
sive if undersized welding cables are used.
2. Move the input voltage switch to voltage = 220-
230V position.
3. Move “A” lead to the 220-230V terminal.
To operate at 380-415 VAC:
ROUTING
1. Open the reconnect/input access door.
To avoid interference problems with other equipment
and to achieve the best possible operation, route all
cables directly. Avoid excessive lengths, bundle the
electrode and ground cables together where practical,
and do not coil excess cable.
2. Move the input voltage switch to Voltage = 380-
415V position.
3. Move “A” lead to the 380-415 VAC terminal.
To operate at 440-460 VAC: No setup required. The
machine is factory-connected to operate at 440 volts.
To verify, do the following:
WATER COOLER CONNECTIONS
The water cooler fittings are a quick-connect type.
Refer to the Accessories section of this manual for
water cooler operation and antifreeze mixtures.
1. Open the reconnect/input access door.
2. Check that the input voltage switch is set to
Voltage = 440-460V position.
WIRE FEEDER CONNECTIONS
Refer to the Accessories section for Wire Feeder Con-
nections.
3. Check that the “A” lead is at the 440-460V.
Refer to Setup overlay in Operation section for Wire
Feeder Configuration.
POWER WAVE 450
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NOTES
POWER WAVE 450
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Section B-1
Section B-1
TABLE OF CONTENTS
- OPERATION SECTION -
Operation...............................................................................................................................Section B
Safety Instructions......................................................................................................................B-2
Quick Start Reference for Process Selection Overlay................................................................B-3
General Description....................................................................................................................B-4
Synergic Welding..................................................................................................................B-4
Recommended Processes...................................................................................................B-4
Operational Features and Controls......................................................................................B-4
Design Features and Advantages........................................................................................B-4
Welding Capability................................................................................................................B-4
Limitations............................................................................................................................B-4
Controls and Settings.................................................................................................................B-5
Case Front Controls .............................................................................................................B-5
Operating Overlays.....................................................................................................................B-6
Overview...............................................................................................................................B-6
Installing an Overlay.............................................................................................................B-6
Overlay Types.......................................................................................................................B-7
Pulse, GMAW, FCAW, Stick Overlay ..........................................................................................B-8
Weld from Memory Overlay......................................................................................................B-11
Weld from Memory, Dual Procedure Overlay ...........................................................................B-12
Dual Wire Feeders, Dual Procedure Overlay............................................................................B-14
Limits Overlay ...........................................................................................................................B-15
Setup Overlay ...........................................................................................................................B-17
Wire Feeder Setup Description ................................................................................................B-18
Overview of Welding Procedures .............................................................................................B-20
FCAW and GMAW..............................................................................................................B-20
Pulse Procedures ...............................................................................................................B-20
Stick/TIG Procedures.........................................................................................................B-20
Wave Control......................................................................................................................B-20
Tables B.3, B.4, B.5, B.6....................................................................................................B-21
Pulse Welding.....................................................................................................................B-22
Overload Protection..................................................................................................................B-23
Thermal Protection.............................................................................................................B-23
Over Current Protection .....................................................................................................B-23
POWER WAVE 450
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B-2
B-2
OPERATION
OPERATING INSTRUCTIONS
Read and understand this entire section of operating
instructions before operating the machine.
SAFETY INSTRUCTIONS
WARNING
ELECTRIC SHOCK can kill.
• Do not touch electrically live parts or
electrodes with your skin or wet cloth-
ing.
• Insulate yourself from the work and ground.
• Always wear dry insulating gloves.
FUMES AND GASES can be
dangerous.
• Keep your head out of fumes.
• Use ventilation or exhaust to remove
fumes from breathing zone.
WELDING SPARKS can cause
fire or explosion.
• Keep flammable material away.
• Do not weld on containers that have held com-
bustibles.
ARC RAYS can burn.
• Wear eye, ear, and body protection.
Observe additional Safety Guidelines
detailed in the beginning of this manual.
HOT COOLANT can burn skin.
• Always be sure coolant is not hot before
doing any work on cooler parts.
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B-3
B-3
OPERATION
Step 2: Adjust the wire feed to speed “WFS” and
voltage “V” or arc length “T” (if necessary).
QUICK START REFERENCE FOR
USING THE PROCESS SELECTION
OVERLAY
a. Press the DISPLAY RECALL key
view additional procedure information.
to
Read and understand the “Controls and Settings” and
“Operating Overlays” sections of this manual before
using the following Quick Start Reference procedure
to operate the Power Wave.
b. Adjust wire feed speed and voltage or arc
length trim through the controls on your wire
feeder. The new values appear on both the
wire feeder and the Power Wave display.
NOTE: Selection of certain options may limit the
selection of subsequent options.
Step 3: Save process information (if desired).
SAVE
Step 1: Select your process information:
a. Install the desired PROCESS OVERLAY.
b. Turn the machine ON.
a. Press the SAVE TO MEMORY key
.
b. Press one of the MEMORY LOCATION keys
(1-8).
c. Select the desired welding
PROCESS1.
You can recall your procedure later by pressing the
RECALL
RECALL FROM MEMORY key
priate MEMORY LOCATION key.
and the appro-
1 The electrode class, electrode size, and electrode/
gas type you can select for your process will be
limited to the machine’s programmed recommenda-
tions. Therefore, selecting certain options may limit
other option selections.
d. Select ELECTRODE CLASS.
2 The wave control scale displayed shows the default
setting. (The higher the setting, the softer the arc.) If
you change the setting, your new setting will be dis-
played.
e. Select ELECTRODE SIZE.
f. Select ELECTRODE/GAS TYPE.
g. Press the WAVE CONTROL
UP or DOWN keys to see
the present setting. Press
the WAVE CONTROL UP or
WAVE CONTROL DOWN
keys to adjust2.
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B-4
B-4
OPERATION
DESIGN FEATURES AND ADVANTAGES
GENERAL DESCRIPTION
• Designed to NEMA Standards.
• Multiple process output ranges 5 - 540 amps.
• 2-line LCD display.
The INVERTEC Power Wave power source is a high
performance, digitally controlled inverter welding
power source capable of complex, high-speed wave-
form control. It uses three-phase input power only.
The Power Wave is designed to be used as a synergic
welding system in conjunction with a wire feeder.
• Easy access for input connections. Connections
are simple strip and clamp (no lugs required).
SYNERGIC WELDING
• Modular construction for easy servicing.
• Thermostatically protected.
The Power Wave system is designed primarily as a
synergic welding system. The word “synergic” comes
from the word “synergism,” which means “two or more
things working together to achieve an effect which nei-
ther can achieve individually.”
• Electronic overcurrent protection.
• Overvoltage protection.
• Digital signal processor and microprocessor control.
The Power Wave and wire feeder operate as a team.
Each “knows” what the other is doing at all times.
They each also know what process, wire type, wire
size, and gas combination are being used. In a syner-
gic system, the wire feeder and power source must
“talk” together. This means that only certain wire feed-
ers can work in a synergic setup. A synergic feeder
has special circuitry to “talk” with and “listen” to the
Power Wave power source.
• RS232 interface for future welding application
updates.
• Simple, reliable reconnection for various input volt-
ages.
• New accessories and wire feeders communicate
using a digital current loop to transfer information.
• Auto device recognition simplifies accessory cable
connections.
Welding experts have preprogrammed the system for
the best range of process settings according to wire
type, wire size, and gas combination. When the wire
feed speed is changed, the system automatically
adjusts the current and voltage waveforms to give the
best weld characteristics. This improves the sound-
ness, appearance, and repeatability of welds.
• Direct support of two wire feeders.
• Auto-configurable for either metric or English mode.
• Multi-process control: Stick, short arc, GMAW
spray, GMAW pulse, and flux cored arc welding
(FCAW).
Refer to the Accessories section of this manual for
available wire feeders.
• Simple control through use of overlays that limit
access to only those keys required for a given appli-
cation.
RECOMMENDED PROCESSES
WELDING CAPABILITY
The Power Wave is designed to be used as a multiple
process machine. It comes preprogrammed with
GMAW pulse, GMAW (short arc and spray) FCAW
(Innershield™ and Outershield™), and stick proce-
dures.
The Power Wave 450 is rated at 500 amps, 40 volts at
60% duty cycle based on a ten minute time period. It
is capable of higher duty cycles at lower output cur-
rents. If the duty cycles are exceeded, a thermostat
will shut off the output until the machine cools to a rea-
sonable operating temperature.
OPERATIONAL FEATURES AND
CONTROLS
LIMITATIONS
The Power Wave, through use of a keypad overlay
system, provides various options and controls such as
Multiple Process/Procedure Selection; Memory
Storage of Procedures; Weld from Memory Only oper-
ation; Dual Process/Dual Feeder capability.
• The Power Wave is not recommended for process-
es other than those specified by available overlays.
• The Power Wave is not recommended for pipe
thawing.
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B-5
B-5
OPERATION
CASE FRONT CONTROLS
CONTROLS AND SETTINGS
Refer to Figure B.1 for the location of the following
controls:
All operator controls and adjustments are located on
the case front of the Power Wave. Refer to Figure B.1
and corresponding explanations.
1. LCD DISPLAY: Provides welding procedure infor-
mation and parameters such as wire type, gas
type, WFS, trim, etc.
FIGURE B.1 – CASE FRONT CONTROLS
6
2. POWER SWITCH: Controls input power to the
Power Wave. When the switch is turned to the ON
position, the connected wire feeder meters light
up and the LCD display on the Power Wave shows
the following:
3
1
LINCOLN ELECTRIC
Version X.X
2
This display is shown for a few seconds followed
by another display that depends on the overlay
placed on the machine. At this point, the machine
is ready for operation.
3. HIGH TEMPERATURE LIGHT (thermal overload): A
yellow light that comes on when an over tempera-
ture situation occurs. Output is disabled until the
machine cools down. At that point the light goes
out and output is enabled again.
5
4
1 LCD DISPLAY
2 POWER SWITCH
3 HIGH TEMPERATURE LIGHT
4 REMOTE CONTROL AMPHENOL RECEPTACLE
5 5 AMP CIRCUIT BREAKER
6 LCD DISPLAY ADJUSTMENT
4. REMOTE CONTROL AMPHENOL RECEPTACLE:
Allows remote current control during stick welding
via a hand or foot Amptrol accessory.
5. 5 AMP CIRCUIT BREAKER: Protects two auxiliary
power circuits: the 24V supply used by the trigger
circuits and the 42V supply used by the internal
machine circuits and the wire feeders.
6. LCD DISPLAY ADJUSTMENT: Use a small flat
blade screw driver to adjust the viewing angle of
the LCD display.
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B-6
B-6
OPERATION
INSTALLING AN OVERLAY
OPERATING OVERLAYS
1. Open the ACCESS DOOR by grasping the provid-
ed indent on the door and pulling the door for-
ward. See Figure B.3 for door location.
OVERVIEW
The Power Wave 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.
FIGURE B.3 – OVERLAY ACCESS DOOR
An OVERLAY is a special plastic sheet with a number
of keys and symbols printed on one side and a bar
code printed on the other. See Figure B.2. The print-
ed keys allow the operator to communicate with the
machine for a specific set of functions. The bar code
allows the machine to identify the overlay.
5
3
1
2
4
FIGURE B.2 – TYPICAL POWER WAVE OVERLAY
C
COPYRIGHT 1994
THE LINCOLN ELECTRIC COMPANY CLEVELAND, OHIO USA
L9361-2 WELD FROM MEMORY
™
R
INVERTEC POWER WAVE 350
HIGH TEMP.
WARNING
MEMORY RECALL
PROGRAM LIST
M
M
M
M
M
1
3
5
7
2
4
6
8
1
2
4
6
8
M
M
M
3
5
7
DISPLAY
RECALL
1 OVERLAY ACCESS DOOR
2 OVERLAY FRAME
3 ACCESS DOOR INDENT
4 TRACKS
Before the Power Wave is turned ON, the operator
selects the desired overlay and mounts it in the over-
lay frame on the front of the machine. Then, when the
machine is turned ON, it reads the overlay bar code
and configures the machine accordingly, allowing the
operator to access only certain keys. The machine
must be powered up each time an overlay is
changed.
5 LOCATING PINS
2. Select the desired overlay from the storage com-
partment located behind the access door.
3. Remove any overlay already in the overlay frame
and place it in the storage compartment.
4. Slide the new overlay into the overlay frame. Align
the overlay with the two tracks on the sides of the
frame. Be sure the overlay is seated in the bottom
lip of the frame and on the top two locating pins.
Close the access door securely.
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B-7
B-7
OPERATION
Overlay Overlay
Figure
No.
OVERLAY TYPES
Type
Name
Four types of overlays can be used with the Power
Wave.
1
GMAW PULSE, GMAW
FCAW, STICK PROCESS
SELECTION OVERLAY
1. Process Overlays. These overlays are used to
create, save and recall specific welding proce-
dures by selecting and adjusting the various weld-
ing settings that have been programmed into the
Power Wave at the factory.
B.4
B.5
B.6
2
2
2
WELD FROM MEMORY
OVERLAY
WELD FROM MEMORY, DUAL
PROCEDURE OVERLAY
2. Weld From Memory Overlays. These overlays
(also called Shop Overlays) provide a simple way
for operators to recall and use any of the welding
procedures that have been stored in the memory
of the Power Wave.
*DUAL WIRE FEEDERS, DUAL
PROCEDURES OVERLAY
B.7
B.8
B.9
3
3
*LIMITS OVERLAY
SETUP OVERLAY
3. Setup Overlays. These overlays provide specific
machine setup information, such as operating lim-
its for the welding procedures stored in memory.
*These overlays are optional. See Accessories
Section for Order Numbers.
4. Special Purpose Overlays. These are custom
overlays for specific customer applications.
Detailed information on how to use currently available
Power Wave overlays follows.
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B-8
B-8
OPERATION
PULSE, GMAW, FCAW, AND STICK/TIG
PROCESS SELECTION OVERLAY
An operator can use this overlay to create a new welding procedure, save a newly created welding procedure,
view an existing welding procedure, recall an existing welding procedure, and clear a memory location. See
Figure B.4. The steps for performing each of these functions are given below.
FIGURE B.4 – PULSE, GMAW, FCAW, STICK/TIG PROCESS SELECTION OVERLAY
1
11
10
8
2
6
9
3
4
5
7
1 LCD DISPLAY WINDOW
2 PROCESS SELECT KEY
7 DISPLAY RECALL KEY
8 SAVE TO MEMORY KEY
3 ELECTRODE CLASS UP/DOWN KEYS
4 ELECTRODE SIZE UP/DOWN KEYS
5 ELECTRODE/GAS TYPE UP/DOWN KEYS
6 WAVE CONTROL UP/DOWN KEYS
9 MEMORY LOCATION NUMBER KEYS
10 RECALL FROM MEMORY KEY
11 HIGH TEMPERATURE LIGHT
1. LCD DISPLAY WINDOW: Power up the machine
with this overlay in place. When the Power Wave
is turned on, the following message appears on
the display for a few seconds:
NOTE: The following four selections should
always be performed in this order: process, elec-
trode class, electrode size, electrode/gas type.
Selecting a setting for one component narrows
your choice of available settings in remaining com-
ponents. This is why the order of performing the
steps is important. However, if you make compo-
nent selections out of order, the machine will
prompt you to make a new selection for any set-
tings that do not apply.
LINCOLN ELECTRIC
VERSION X.X
This display is followed by:
OVERLAY ID
NUMBER = 1
2. PROCESS SELECT KEY: Use the PROCESS
SELECT key to select from the processes avail-
able in the machine. Press the PROCESS
SELECT key until the light by the desired process
is lit.
A welding procedure is made up of seven compo-
nents: process, material type, wire diameter, program,
wire feed speed, voltage or arc length trim, and wave
control. A new welding procedure is created by
selecting a combination of these components from the
ones that have been programmed into the Power
Wave. See Figure B.4 for key locations.
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B-9
B-9
OPERATION
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. Press the ELECTRODE CLASS UP or
DOWN key until the desired material type is dis-
played.
7. DISPLAY RECALL KEY: Since not all the informa-
tion about the procedure can be seen on the 2-line
LCD display window at the same time, use the
DISPLAY RECALL key to display and verify all of
the selected procedure information. The normal
default display window shows the Procedure
Description, WFS, and preset voltage or arc length
trim values. Press and hold the DISPLAY RECALL
key, and the window shows the procedure de-
scription and gas type for as long as the key is
held depressed. Release the DISPLAY RECALL
key, and the window shows wire size, material
type, and process description. After a few sec-
onds, the window changes back to the default dis-
play.
4. ELECTRODE SIZE UP/DOWN: Use the ELEC-
TRODE SIZE UP or DOWN keys to select from the
wire diameters available for the selected process
and material type. Press the ELECTRODE SIZE
UP or DOWN key until the desired wire diameter is
displayed.
5. ELECTRODE/GAS TYPE UP/DOWN KEYS: Use
the ELECTRODE/GAS TYPE UP or DOWN keys to
select from the programs available for the select-
ed process, material type, and wire diameter.
Press the ELECTRODE/GAS TYPE UP or DOWN
Key until the desired program is displayed.
8. SAVE TO MEMORY KEY: This key is used to save
a newly created welding procedure. The Power
Wave has eight memory locations which can be
used to store all the settings of up to eight welding
procedures. Once stored in a memory location, a
procedure can be recalled for later use with the
RECALL FROM MEMORY key. To save a newly
created welding procedure:
6. WAVE CONTROL UP/DOWN KEYS: Press one of
the two WAVE CONTROL keys to display the pre-
sent wave control. This is shown on a scale from
LO to HI. Use the WAVE CONTROL UP or WAVE
CONTROL DOWN key to change the wave control
to the desired level. When this scale is shown, the
WAVE CONTROL setting can also be changed
while welding (on the fly). Press the DISPLAY
RECALL key to exit the wave control function. For
a description of how the wave control setting
affects the welding procedure, refer to the
Overview of Welding Procedures sub-section of
the Operation section of this manual.
SAVE
Press the SAVE TO MEMORY key
and then
one of the MEMORY LOCATION NUMBER keys.
Keep a record of this number for future reference.
Any previously created welding procedure stored
in that location will be erased.
If you press the SAVE TO MEMORY key but
decide not to save the procedure, you can exit this
function by pressing the DISPLAY RECALL key.
The wire feed speed and voltage or arc length
trim desired for the new procedure can be
changed from the wire feeder.
9. MEMORY LOCATION NUMBER KEYS: To view
information about any stored welding procedure,
simply press its MEMORY LOCATION NUMBER
key.
As you hold down the selected key, the procedure
description and gas type of the procedure appear
in the display window. The process type is shown
by the indicating light opposite the appropriate
process symbol.
When you release the selected key, the wire size,
material type and process description appear for a
few seconds.
This function does not display the wire feed speed
and voltage or arc length trim settings. To view
these, you must recall the procedure from memo-
ry with the RECALL FROM MEMORY key.
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B-10
B-10
OPERATION
10. RECALL FROM MEMORY KEY: This key is used
to recall an existing procedure from memory. You
can recall and use any of the previously created
welding procedures that are stored in one of the
eight memory locations.
RECALL FROM MEMORY key
Simply press the
RECALL
and then the
appropriate MEMORY LOCATION NUMBER key.
If you press the RECALL FROM MEMORY key and
then change your mind, you can exit this function
by pressing the DISPLAY RECALL key. If the
memory location you select does not contain a
stored welding procedure, this will be indicated in
the display window. Select another memory loca-
tion. It is not necessary to save a procedure back
to memory after it is recalled from memory. When
a procedure is saved into a memory location, it
can be recalled from there until another procedure
is stored in that location or the location is cleared.
The RECALL FROM MEMORY and SAVE TO
MEMORY keys can be used to clear a memory
location.
SAVE
Press the SAVE TO MEMORY key
the RECALL FROM MEMORY key
and then
. (Do not
RECALL
press both keys at the same time.) A message in
the display window will ask you to press the MEM-
ORY LOCATION NUMBER key of the memory
location you want to clear.
If you press the SAVE TO MEMORY and RECALL
FROM MEMORY keys and then change your
mind, you can exit this function by pressing the
DISPLAY RECALL key.
11. HIGH TEMPERATURE LIGHT: The high tempera-
ture light comes on when the internal machine
temperature exceeds the allowed limit. Output is
disabled until the machine cools down and the
high temperature light goes out.
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B-11
B-11
OPERATION
WELD FROM MEMORY OVERLAY
The Weld From Memory Overlay lets an operator recall and use any welding procedure stored in one of eight mem-
ory locations. See Figure B.5.
FIGURE B.5 – WELD FROM MEMORY OVERLAY
1
1 LCD DISPLAY WINDOW
2 MEMORY RECALL KEYS
3 PROGRAM LIST
5
6
4 DISPLAY RECALL KEY
5 HIGH TEMPERATURE LIGHT
6 MEMORY LIGHTS
2
3
4
1. LCD DISPLAY WINDOW: Power up the machine
with this overlay in place. When the Power Wave
is turned on, the following message appears in the
display window for a few seconds:
With this overlay in place, the wire feed speed and
the preset voltage or arc length trim can be
changed from the wire feeder. The new values will
replace the previous values and become a perma-
nent part of the procedure.
LINCOLN ELECTRIC
Version X.X
If limits have been set on the wire feed speed, volt-
age or arc length trim of the selected procedure,
these limits will be active when this overlay is in
place. They cannot be overridden from this over-
lay.
This display is followed by:
OVERLAY ID
NUMBER = 2
This message is then replaced by the following
message:
3. PROGRAM LIST: The PROGRAM LIST block in
the center of this overlay provides a convenient
place to record a brief description of each welding
procedure stored in memory. A “Dry Erase” mark-
er should be used for this purpose.
SELECT A MEMORY
LOCATION
2. MEMORY RECALL NUMBERS: Select the mem-
ory location of the desired welding procedure by
pressing the appropriate MEMORY RECALL
NUMBER key.
4. DISPLAY RECALL KEY: To view other information
about the selected procedure, press the DISPLAY
RECALL key. The display window will show the
procedure description and gas type of the se-
lected procedure for as long as the key is held
depressed. When the key is released, material
type, wire size, and process descriptions will be
displayed for a few seconds.
If no procedure was saved in the selected memo-
ry location, the following message appears:
MEMORY LOCATION
# IS EMPTY
5. HIGH TEMPERATURE LIGHT: The high tempera-
ture light comes on when the internal machine
temperature exceeds the allowed limit. Output is
disabled until the machine cools down and the
high temperature light goes out.
Select another memory location.
When a welding procedure is recalled from mem-
ory, the display window will show the procedure
description, wire feed speed, and arc length trim
or preset voltage.
6. MEMORY LIGHTS: A memory light is on when its
corresponding memory is selected. This tells you
what memory is active at any given time.
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B-12
B-12
OPERATION
WELD FROM MEMORY, DUAL PROCEDURE OVERLAY
The Weld From Memory, Dual Procedure Overlay lets an operator recall and use dual welding procedures stored
in memory. The overlay must be used with a separate dual procedure switch or a gun that has a two position
trigger. The switch or trigger selects which procedure will be active. See Figure B.6
FIGURE B.6 – WELD FROM MEMORY, DUAL PROCEDURE OVERLAY
1
5
6
2
3
4
1 LCD DISPLAY WINDOW
2 MEMORY RECALL KEYS
3 PROGRAM LIST
4 DISPLAY RECALL KEY
5 HIGH TEMPERATURE LIGHT
6 MEMORY LIGHTS
1. LCD DISPLAY WINDOW: Power up the machine
with this overlay in place. When the Power Wave is
turned on, the following message appears in the
display window for a few seconds:
Select a memory location PAIR for the two desired
welding procedures by pressing either of the two cor-
responding MEMORY RECALL NUMBER keys.
If no procedure was saved to one of the memory pair
locations, the following message appears:
LINCOLN ELECTRIC
Version X.X
MEMORY LOCATION
# IS EMPTY
This display is followed by:
OVERLAY ID
NUMBER = 3
In this case select another memory pair.
Set the dual procedure switch or gun trigger to the
position for PROCEDURE A or PROCEDURE B.
Position A activates the welding procedure from the
odd numbered memory locations (1, 3, 5 or 7).
Position B activates the welding procedure from the
corresponding even numbered memory locations (2, 4,
6 or 8). For example, if memory location 3 was
selected, Position A activates the procedure from
memory location 3; Position B activates the proce-
dure from memory location 4.
This message is then replaced by the following
message:
SELECT A MEMORY
LOCATION
2. MEMORY RECALL KEYS: The following four
memory pairs are available on this overlay:
Memory 1 and Memory 2
Memory 3 and Memory 4
Memory 5 and Memory 6
Memory 7 and Memory 8
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B-13
B-13
OPERATION
When a pair of welding procedures are recalled
from memory, the display window will show the
procedure description, wire feed speed, and the
preset voltage or arc length trim of the LAST pro-
cedure welded with.
With this overlay in place, the wire feed speed and
the preset voltage or arc length trim can be
changed from the wire feeder. The new values will
replace the previous values and become a perma-
nent part of the procedure.
If limits have been set on the wire feed speed, volt-
age or arc length trim of the selected procedures,
these limits will be active when this overlay is in
place. They cannot be overridden from this over-
lay.
3. THE PROGRAM LIST: The PROGRAM LIST block
in the center of this overlay provides a convenient
place to record a brief description of each welding
procedure stored in memory. A “Dry Erase” mark-
er should be used for this purpose.
4. DISPLAY RECALL KEY: To view other information
about the active procedure, press the DISPLAY
RECALL key. The display window will show the
procedure description and gas type of the active
procedure for as long as the key is held
depressed. When the key is released, the wire
size, material type, and process descriptions dis-
play for a few seconds.
5. HIGH TEMPERATURE LIGHT: The high tempera-
ture light comes on when the internal machine
temperature exceeds the allowed limit. Output is
disabled until the machine cools down and the
high temperature light goes out.
6. MEMORY LIGHTS: A memory light is on when its
corresponding memory is selected. This tells you
what memory location is active at any given time.
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B-14
B-14
OPERATION
DUAL WIRE FEEDERS, DUAL PROCEDURE OVERLAY (OPTIONAL)
The Dual Wire Feeders, Dual Procedures Overlay is used when the Power Wave is equipped with two wire feed-
ers and two guns with two position switches. Any welding procedure stored in memory locations 1, 2, 3, or 4
can be automatically recalled and used. See Figure B.7.
FIGURE B.7 – DUAL WIRE FEEDERS, DUAL PROCEDURE OVERLAY
1 LCD DISPLAY WINDOW
1
2 WIRE FEEDERS MEMORY CHART
3 DISPLAY RECALL KEY
4 HIGH TEMPERATURE LIGHT
5 MEMORY LIGHTS
5
4
2
3
1. LCD DISPLAY WINDOW: Power up the machine
with this overlay in place. When the Power Wave is
turned on, the following message appears in the
display window for a few seconds:
With this overlay in place, the wire feed speed and
the preset voltage or arc length trim can be
changed from the wire feeder. The new values
replace the previous values and become a perma-
nent part of the procedure.
LINCOLN ELECTRIC
VERSION X.X
If limits have been set on the wire feed speed, volt-
age or arc length trim of the selected procedures,
these limits will be active when this overlay is in
place. They cannot be overridden from this over-
lay.
This display is followed by:
OVERLAY ID
NUMBER = 9
2. WIRE FEEDERS MEMORY CHART: The active
welding procedure is determined by the active
wire feeder and its gun switch position. The weld-
ing procedure recall from memory is as follows:
3. DISPLAY RECALL KEY:To view other information
about the active welding procedure, press the
DISPLAY RECALL key. The display window will
show the procedure description and gas type of
the last active procedure for as long as the key is
held depressed. When the key is released, the wire
size, material type, and process descriptions will
be displayed for a few seconds.
Active
Gun Trigger Memory Location
Wire Feeder
Position
of Procedure
#1
#1
#2
#2
A
B
A
B
1
2
3
4
4. HIGH TEMPERATURE LIGHT: The high tempera-
ture light comes on when the internal machine
temperature exceeds the allowed limit. Output is
disabled until the machine cools down and the
high temperature light goes out.
Pull the trigger on either wire feeder.
Depending on the gun switch position, the corre-
sponding memory location is automatically
recalled. The wire feeders memory chart has no
keys; it is simply a chart.
5. MEMORY LIGHTS: A memory light is on when its
corresponding memory is selected. This tells you
what memory location is active at any given time.
The display window will show the procedure
description, wire feed speed, and the preset volt-
age or arc length trim of the last active welding
procedure.
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B-15
B-15
OPERATION
LIMITS OVERLAY (OPTIONAL)
The Limits Overlay is used to set the maximum and minimum limits of the wire feed speed and voltage or arc length
trim for any welding procedure stored in memory. See Figure B.8.
FIGURE B.8 – LIMITS OVERLAY
1
8
2
6
3
4
5
7
1 LCD DISPLAY WINDOW
5 LIMIT UP/DOWN KEYS
2 RECALL FROM MEMORY KEY
3 MEMORY LOCATION NUMBER KEYS
4 SET LIMIT KEY
6 SAVE TO MEMORY KEY
7 DISPLAY RECALL KEY
8 MEMORY LIGHTS
1. LCD DISPLAY WINDOW: Power up the machine
with this overlay in place. When the Power Wave is
turned on, the following message appears in the
display window for a few seconds:
Determine the memory location number of the
welding procedure for which you want to set lim-
its.Then press the RECALL FROM MEMORY key
RECALL
followed by the MEMORY LOCATION NUM-
BER key for the selected procedure.
LINCOLN ELECTRIC
Version X.X
If no procedure was saved in the selected memo-
ry location, the following message appears:
This display is followed by:
MEMORY LOCATION
# IS EMPTY
OVERLAY ID
NUMBER = 4
Select another memory location.
4. SET LIMIT KEY:
This message is then replaced by the following
message:
SELECT A MEMORY
LOCATION
AND
5. LIMIT UP / DOWN KEYS:
2. RECALL FROM MEMORY KEY:
The SET LIMIT key and LIMIT UP / LIMIT DOWN
keys are used to set the maximum and minimum
allowed wire feed speed, and voltage trim or arc
length trim values of the procedure that was
recalled from memory.
AND
3. MEMORY LOCATION NUMBERS:
RECALL
The RECALL FROM MEMORY key
is used
to recall a welding procedure from memory.
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B-16
B-16
OPERATION
Use the LIMIT UP and LIMIT DOWN keys to
change the maximum wire feed speed to the
desired value.
7. DISPLAY RECALL KEY: To view other information
about the active welding procedure, press the
DISPLAY RECALL key. The display window will
show the procedure description and gas type of
the last active procedure for as long as the key is
held depressed. When the key is released, the wire
size, material type, and process descriptions will
be displayed for a few seconds.
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.
6. MEMORY LIGHTS: A memory light is on when its
corresponding memory is selected. This tells you
what memory is active at any given time.
Press the SET LIMIT key. The present maximum
and minimum voltage trim or arc length trim will be
displayed. (Refer to Table B.3 to see how voltage
trim affects preset voltage. Refer to Table B.6 to
see how arc length trim affects preset arc length.)
Use the LIMIT UP and LIMIT DOWN keys to
change the maximum value. The maximum for
either type is 1.5.
Press the SET LIMIT key. The new maximum and
old minimum voltage trim or arc length trim will be
displayed.
Use the LIMIT UP and LIMIT DOWN keys to
change the minimum value. The minimum for
either type is 0.5.
6. SAVE TO MEMORY KEY: The SAVE TO MEMO-
RY KEY is used to save the procedure with the
newly set limits to memory. Press the SAVE TO
SAVE
MEMORY key
followed by the MEMORY
LOCATION NUMBER key of the desired memory
location. This does not have to be the original
location from which the procedure was recalled.
Step 6 can be performed any time during the limit-
setting process. You do not have to set all the
available limits. When you have set all the desired
limits, save the procedure to memory.
To clear any previously set limits, recall the proce-
dure from memory and change the limits to the
maximum range available. Then save the proce-
dure to memory.
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B-17
B-17
OPERATION
SETUP OVERLAY
The Setup Overlay is used to control the water cooler operation (on/off and prime the water cooler), and to set
up the voltage sensing configuration of the machine and wire feeder(s) connected to the Power Wave. See Figure
B.9.
FIGURE B.9 – SETUP OVERLAY
C
COPYRIGHT 1994
THE LINCOLN ELECTRIC COMPANY CLEVELAND, OHIO USA
L9660 SETUP OVERLAY
R
WARNING
+POLARITY
+POLARITY
1
3
ELECTRODE
SENSE LEAD
ENABLED
ELECTRODE
SENSE LEAD
ENABLED
WORK SENSE
LEAD ENABLED
WORK SENSE
LEAD ENABLED
WATER COOLER ENABLED
WATER COOLER PRESSURE
5
6
7
WATER
COOLER
ENABLE
+/
-
+/
-
POLARITY
POLARITY
2
ELECTRODE
SENSE
LEAD
ELECTRODE
SENSE
LEAD
PRIME
WATER
COOLER
WATER COOLER CAN ONLY BE
PRIMED WHEN IT IS ENABLED.
4
WORK
SENSE
LEAD
WORK
SENSE
LEAD
PRIME THE WATER COOLER
UNTIL WATER COOLER PRESSURE
LIGHT TURNS ON.
WATER COOLER SETUP
WIRE
FEEDER 1
WIRE
FEEDER 2
1 LCD DISPLAY WINDOW
5 WIRE FEEDER 1+/- POLARITY KEY
2 WATER COOLER ON/OFF KEY
3 WATER COOLER PRESSURE LIGHT
4 PRIME WATER COOLER KEY
6 WIRE FEEDER 1 ELECTRODE SENSE LEAD KEY
7 WIRE FEEDER 1 WORK SENSE LEAD KEY
1. LCD DISPLAY WINDOW: Power up the machine
with this overlay in place. When the Power Wave
is turned on, the following message appears in the
display window for a few seconds:
3. WATER COOLER PRESSURE LIGHT: This light
indicates whether or not the coolant flow rate is
high enough for normal water cooler operation. If
the water cooler loses the required flow rate it will
shut down within a couple of seconds, the water
cooler pressure light will turn off,and the machine
sounds a buzzer.
LINCOLN ELECTRIC
Version X.X
This display is followed by:
OVERLAY ID
NUMBER = 0
4. PRIME WATER COOLER KEY: The water cooler
may have to be primed if there is not enough
coolant in the system for proper operation. Make
sure that the water cooler has been turned on
before it is primed. (The “WATER COOLER ON”
light should be turned on.) Check reservoir for
proper coolant level - See Water Cooler informa-
tion in ACCESSORIES section. To prime the water
cooler, hold the PRIME WATER COOLER key
down. While this key is pressed, the display will
show:
This message is then replaced by the following
message:
POWER WAVE
SETUP
2. WATER COOLER ON/OFF KEY: Press this key to
toggle the water cooler between being enabled
and disabled. The present status of the water
cooler is indicated by the “WATER COOLER ON”
light.
PRIME WATER
COOLER
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B-18
B-18
OPERATION
When the “WATER COOLER PRESSURE” light
+/- POLARITY KEY
turns on, release the key. If this key has been
pressed for 30 seconds and the ‘WATER COOLER
PRESSURE’ light still did not turn on, check the
water cooler for adequate fluid level.
A. Positive Voltage Sensing Polarity:
In most welding applications the electrode cable is
connected to the + output terminal and the work
cable is connected to the - output terminal of the
power source. This is the positive voltage sensing
polarity, illustrated by Figure B.10. When the
Power Wave and the wire feeder(s) are connected
in this manner, the arc voltage can be measured in
one of four ways. These four ways are shown in
Table B.1.
5. WIRE FEEDER 1 +/- POLARITY KEY: Press this
key to change the present voltage sensing polari-
ty of wire feeder 1. The present polarity of wire
feeder 1 is indicated by the “WIRE FEEDER 1+
POLARITY” light. If wire feeder 1 is set for positive
voltage sensing polarity, this light is turned on.
6. WIRE FEEDER 1 ELECTRODE SENSE LEAD
KEY: Press this key to enable or disable the elec-
trode sense lead (lead #67) of wire feeder 1. When
enabled, voltage sensing is done by the electrode
sense lead. When disabled, voltage sensing is
done at the Power Wave output terminal. When
enabled, the “WIRE FEEDER 1 ELECTRODE
SENSE LEAD ENABLED” light will be illuminated.
Table B.1: Positive Voltage Sensing Options
Positive Voltage Reference
+ Output Terminal
Negative Voltage Reference
- Output Terminal
+ Output Terminal
Work Sense (21) Lead*
- Output Terminal
Electrode Sense (67) Lead
Electrode Sense (67) Lead
Work Sense (21) Lead*
* Consult the factory before using this option.
7. WIRE FEEDER 1 WORK SENSE LEAD KEY:
Press this key to enable or disable the work sense
lead (lead #21) of wire feeder 1. When enabled,
voltage sensing is done by the work sense lead.
When disabled, voltage sensing is done at the
Power Wave output terminal. When enabled, the
Use the ELECTRODE SENSE LEAD KEY to
select either the + output terminal or the electrode
sense (67) lead for the positive voltage reference.
The work sense (21) lead is used only in rare cir-
cumstances. For most installations, use the
WORK SENSE LEAD KEY to select the - output
terminal for negative voltage reference. Consult
the factory if use of the work sense (21) lead is
desired.
“WIRE FEEDER
1
WORK SENSE LEAD
ENABLED” light will be illuminated.
WIRE FEEDER SETUP DESCRIPTION
The Power Wave may be set up for either positive
or negative arc voltage sensing using any two of
the following places:
B. Negative Voltage Sensing Polarity:
1. the positive output terminal of the Power Wave
2. the negative output terminal of the Power Wave
In some welding applications (such as Inner-
shield®) the electrode cable is connected to the -
output terminal and the work cable is connected
to the + output terminal of the power source. This
is the negative voltage sensing polarity, illustrated
by Figure B.11. When the Power Wave and the
wire feeder(s) are connected in this manner, the
arc voltage can be measured in one of four ways.
These four ways are shown in Table B.2.
3. the electrode sense lead (67 lead) of the wire
feeder
4. the work sense lead (21 lead) of the wire feeder
The SETUP Overlay allows you to select between
which two places arc voltage will be sensed.
Once the selection is made it is not necessary to
reconfirm the selection every time a new overlay is
used or a wire feeder is replaced with another one.
The selection will remain until it is changed with
the SETUP Overlay.
Table B.2: Negative Voltage Sensing Options
Positive Voltage Reference
– Output Terminal
Negative Voltage Reference
+ Output Terminal
When welding with a stick procedure, the arc volt-
age is automatically measured between the Power
Wave’s output studs.
– Output Terminal
Work Sense (21) Lead*
+ Output Terminal
Electrode Sense (67) Lead
Electrode Sense (67) Lead
I. Select arc voltage sensing polarity first.
Work Sense (21) Lead*
* Consult the factory before using this option.
11/96
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B-19
B-19
OPERATION
Use the ELECTRODE SENSE LEAD KEY to select
either the - output terminal or the electrode sense (67)
lead for the positive voltage reference.
The two wire feeders can only be connected in the
same manner, either by the Positive Polarity or the
Negative Polarity setup.
The work sense (21) lead is used only in rare circum-
stances. For most installations, use the WORK
SENSE LEAD KEY to select the - output terminal for
negative voltage reference. Consult the factory if use
of the work sense (21) lead is desired.
FIGURE B.10
POSITIVE VOLTAGE SENSING POLARITY
Power
Wave
Control Cable (includes 67 lead)
Electrode Sense Lead
67
Wire Feeder
Block
+
-
Electrode
Cable
Work Cable
FIGURE B.11
NEGATIVE VOLTAGE SENSING POLARITY
Power
Wave
Control Cable (includes 67 lead)
Electrode Sense Lead
67
Wire Feeder
Block
+
-
Electrode
Cable
Work Cable
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B-20
B-20
OPERATION
Increasing the arc length by 10 percent at a given wire
feed speed also increases all the other arc length set-
tings of the procedure by 10 percent. In the GMAW
Pulse process, the display shows the Procedure
Description, WFS and Arc Length Trim. Arc length trim
is programmed to a default at the factory and may be
adjusted on the wire feeder. When the trigger is
pulled, the WFS, Actual Arc Voltage and Actual Arc
Current are displayed.
OVERVIEW OF WELDING
PROCEDURES
FLUX CORED ARC WELDING (FCAW)
AND GMAW PROCEDURES
For each wire feed speed, a corresponding voltage
has been preprogrammed into the machine by welding
experts. This preprogrammed voltage is the best
average voltage for the procedure at the given wire
feed speed. If the wire feed speed is changed on the
wire feeder, the voltage automatically changes with it.
STICK/TIG
PROCEDURES
Stick welding can be performed with the Power Wave
by attaching a remote control kit to the 6-pin amphe-
nol on the front of the machine. The K941-1 remote
control kit is recommended. Select the stick process
from either the GMAW Pulse, GMAW FCAW, stick
process selection overlay, or recall it from a previously
stored memory location with a Weld From Memory
overlay. When this process is selected, the Power
Wave reads the current (amps) setting from the remote
control kit. It also controls the output of the machine
based on the position of the Output Terminals switch,
which is also located on the remote control kit. When
this switch is in the ON position, the output terminals
of the Power Wave are electrically hot. When the
switch is in the OFF position, the output terminals of
the Power Wave are electrically cold and the machine
cannot produce an output. In the stick process, the
LCD display shows Procedure Description, and Preset
Current (SET=). The Current Trim is always equal to 1
(T=1.00). When the trigger is pulled the Preset Current,
Actual Arc Voltage and Actual Arc Current are dis-
played.
In some cases, the operator may want to change the
preprogrammed voltages; for example, to compensate
for cable and fixture voltage drops. The preset volt-
ages can be adjusted on the wire feeder’s Voltage dis-
play. When a change is made to the voltage at one
wire-feed speed, this change is applied to all other
wire feed speed settings. For example, if the operator
turns up the voltage by 10 percent, the machine auto-
matically increases the preset voltages at all the other
wire feed speeds by 10 percent. In the GMAW FCAW
process, the display shows the Procedure Description,
WFS and Preset Voltage. The preset voltage which
was programmed at the factory, may be changed on
the wire feeder voltage display. Note that, if you
change the default preset voltage up or down, a
V
respective “ ” or “V” sign will be displayed after the
preset value. When the gun trigger is pulled, note that
the display changes to show WFS, Actual Arc Voltage
and Actual Arc Current. See Table B.5 for display
summary.
PULSE PROCEDURES
In these procedures, the actual voltage greatly
depends on the waveform used. The peak currents,
background currents, rise times, fall times, and pulse
times all affect the actual voltage. The actual voltage
for a given wire feed speed is not directly predictable
unless the waveform is known. In this case, it is not
practical to preset an actual voltage for the procedure.
Instead, an arc length adjustment is provided. The
machine “knows” what the best arc length is at the
given wire feed speed but allows the operator to
change it.
See Tables B.3 through B.6 for a summary of the
information discussed above.
WAVE CONTROL
The wave control settings of all procedures can be
changed on the Power Wave GMAW Pulse, GMAW
FCAW, Stick Process Selection Overlay. The wave
control is a setup parameter that may be adjusted
when the welding procedures are set. This feature
provides an easy way to change the arc behavior with-
out creating a new procedure. The wave control set-
ting of a procedure limits the speed at which the cur-
rent waveform of that procedure can change. Typically,
each procedure is programmed to have average wave
control (at the center of the scale).
The arc length can be adjusted between 0.5 and 1.5
on the wire feeder’s Voltage display. An arc length trim
of 1.0 means that no adjustments will be made to the
preset arc lengths. An arc length trim greater than 1.0
increases the preset arc lengths. An arc length trim
less than 1.0 decreases the preset arc lengths. The
arc length adjustment is factored in at all wire feed
speed settings. Refer to Table B.6 for summary of arc
length trim.
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B-21
B-21
OPERATION
TABLE B.6 – RELATIONSHIP BETWEEN
SELECTED ARC LENGTH TRIM AND PRESET
ARC LENGTH AS INDICATED BY ARC LENGTH
TABLE B.3 – RELATIONSHIP BETWEEN
VOLTAGE TRIM AND PRESET VOLTAGE
Voltage Trim
Relationship to Preset Voltage
60% of preset voltage
0.6
0.8
1.0
1.2
1.4
Arc Length Trim
Preset Arc Length
60% of preset length
80% of preset length
no change to preset length
120% of preset length
140% of preset length
80% of preset voltage
0.6
0.8
1.0
1.2
1.4
no change to preset voltage
120% of preset voltage
140% of preset voltage
Explanation of Table B.3:
If, for example, the minimum voltage trim is set to 0.8
and the maximum voltage trim is set to 1.4, this
means that the voltage for a given wire feed speed
can be adjusted to be anywhere between 80% and
140% of the preset voltage of that wire feed speed.
TABLE B.4 – ADJUSTABLE PARAMETERS
Adjustable
Parameters
GMAW
Pulse
GMAW
FCAW
Stick
Wire Feeder
WFS Display
Wire Feed
Speed
Wire Feed
Speed
—
Wire Feeder
Voltage Display
Arc Length
Trim
Preset
Voltage
—
Power Wave 450 Display
(with GMAW Pulse,
Wave
Control
Wave
Control
Wave
Control
GMAW FCAW, Stick
Process Selection Overlay)
(Frequency)
(Inductance)
(Arc Force)
TABLE B.5 – DISPLAYS OF THE POWER WAVE AND WIRE FEEDERS
FOR DIFFERENT PROCESSES IN BOTH TRIGGER POSITIONS
Wire Feeder
Power Wave 450
Trigger
Position
1
1
GMAW
Pulse
GMAW
FCAW
STICK
GMAW
Pulse
GMAW
FCAW
WFS DISPLAY:
Wire Feed Speed
VOLTAGE
WFS DISPLAY:
Wire Feed Speed
VOLTAGE
WFS and
WFS and
Preset
Open
Arc Length Trim
Preset Voltage
Current
DISPLAY:
DISPLAY:
Arc Length Trim
Preset Voltage
WFS,
WFS,
WFS DISPLAY:
Wire Feed Speed
VOLTAGE
DISPLAY:
Actual Arc Voltage
WFS DISPLAY:
Wire Feed Speed2
VOLTAGE
DISPLAY:
Actual Arc Voltage
Actual Arc
Voltage,
Actual Arc
Current
Actual Arc
Voltage,
Actual Arc
Current
Preset Current,
Actual Arc
Voltage, Actual
Arc Current
Closed
1In Stick, trigger is on Remote Control Kit K941-1.
2Arc Current, not wire feed speed, is displayed if a Remote Control Kit is attached to the wire feeder.
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B-22
B-22
OPERATION
The pulsing process greatly affects the heat input
to the workpiece. This can be a valuable tool for
either increasing or decreasing the heat input with a
given process. For instance, it is possible to greatly
increase the heat input when welding steel at high
deposition rates. On the other hand, it is possible to
reduce the heat input using the pulsing process. For
example, heat input is reduced greatly with some of
the low current stainless steel procedures using the
processes programmed into the Power Wave. In all
cases, the Power Wave procedures have been
checked for their ability to deliver a sound weld.
However, the fusion of the weld metal into the work-
piece may be affected. It is the responsibility of the
user to determine if the welds produced are suitable
and sound.
In Pulse processes:
The wave control adjustment allows the frequency set-
ting to vary. Increasing the wave control allows the fre-
quency setting to increase, and decreasing the wave
control allows the frequency setting to decrease.
Varying the wave control setting affects the droplet
transfer and allows fine-tuning for different welding
positions.
In GMAW and FCAW processes:
The wave control adjusts the inductance. (Inductance
is inversely proportional to pinch.) Increasing the wave
control setting decreases the inductance, which
results in the arc getting colder and pinched tighter.
Decreasing the wave control setting increases the
inductance, which results in the arc getting wider.
The Power Wave 450 is optimized for use with a
0.75” (1.9 cm) stickout. The adaptive behavior is pro-
grammed to support a stickout range from 0.5” to
1.25” (1.3 to 3.2 cm). In the low and high end of the
wire feed speed ranges of most processes, the adap-
tive behavior may be restricted. This is a physical
restriction due to reaching the edge of the operating
range for the process. It is possible to achieve adap-
tive behavior for longer stickout lengths. However,
shielding gas is often lost when the stickout is too
long.
In Stick processes:
The wave control adjusts the arc force. Increasing the
wave control setting increases the arc force, making
the arc more harsh but less likely to stick. Decreasing
the wave control setting decreases the arc force, mak-
ing the arc softer and smoother.
PULSE WELDING
Some people have trouble getting used to the behav-
ior of the pulsing arc. The parameters programmed
into the Power Wave have been thoroughly tested for
their ability to deliver a sound weld with good appear-
ance. There are, however, a few things to keep in mind
when pulse welding.
A longer electrical stickout is often used with the
pulsing process at higher deposition rates. A long
stickout will increase the melt-off rate of the wire. In
pulse welding, like other wire welding processes, the
arc length is determined by the voltage setting. This
voltage is programmed at the factory for each process
and wire feed speed. It may be changed using the
Voltage setting on the wire feeder.
Spatter levels are often very low with the pulse
welding process. Pulsing is often used to eliminate
cleaning operations necessary when using other weld-
ing processes.
When adaptive processes are used, the voltage will
vary with stickout. The machine must change the
voltage to keep a stable arc. It is very important to
recognize this. “Actual” arc voltage when welding will
vary because the stickout will seldom be held at the
nominal 1.9 cm value.
Fume levels are sometimes lower with the pulsing
process. Whether or not you will get lower fume lev-
els depends on the pulsing programs used. Certain
waveform characteristics are necessary to get low
fume levels. Unfortunately, low fume procedures are
harder to weld with than procedures designed to opti-
mize the welding process.
The pulsing process is not slower than other
processes. The process is sometimes less forgiving
when the arc gets on or ahead of the puddle. More
attention must be paid to the weld to avoid losing the
puddle. Speed is a matter of deposition rate. All
things being equal regarding the joint being welded,
the speed will depend on the wire feed speed. The
travel speed is maximized by maintaining a very short
arc. Often the process is “trimmed” down until the arc
“crackles.” The spatter increases slightly, but many of
the advantages of pulsing are retained. When welding
steel, the Power Wave is designed to run well in this
region between pulse and short arc.
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B-23
B-23
OPERATION
OVERLOAD PROTECTION
OVER CURRENT PROTECTION
THERMAL PROTECTION
The Power Wave 450 is limited to producing 750 amps
peak current. If the average current exceeds 540
amps, then the peak current will be limited to 100
amps until the average current decreases to under 50
amps.
The Power Wave has thermostatic protection from
excessive duty cycles, overloads, loss of cooling, and
high ambient temperatures. When the power source is
subjected to any of these conditions or any of the con-
ditions mentioned above, a thermostat will open. The
yellow high temperature light on the case front comes
on. See Figure B.1 for location. Machine output is
disabled, and welding is not possible until the machine
is allowed to cool and the High Temperature Light
goes out.
POWER WAVE 450
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NOTES
POWER WAVE 450
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Section C-1
Section C-1
TABLE OF CONTENTS
- ACCESSORIES -
Accessories...........................................................................................................................Section C
Options/Accessories...................................................................................................................C-2
Wire Feeder Setup ...............................................................................................................C-2
Guns and Cables .................................................................................................................C-2
Water Cooler Usage ...................................................................................................................C-2
Recommended Coolants............................................................................................................C-3
Priming the Cooler......................................................................................................................C-3
Cooler Periodic Maintenance .....................................................................................................C-4
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C-2
C-2
ACCESSORIES
GUNS AND CABLES
OPTIONS/ACCESSORIES
Several MAGNUM guns are recommended for use
with the Power Wave as shown in Table C.1.
•
•
•
•
•
•
•
•
•
•
Synergic 7 wire feeder (K632-1) standard speed,or (K632-2) high speed
MAGNUM 400 gun (K471-2) or 550 gun (K598)
Internal water cooler
Place the proper liner in the gun and connect the gun
to the feeder. Consult the specific instructions sup-
plied with the gun for detailed operating instructions.
Undercarriages (Single [K961-1]or Dual [K962-1]Gas Cylinders)
Remote control (stick welding) K941-1
Amptrols (Hand K963-1 or -2, Foot K870)
Limits Overlay K946-4
FIGURE C.1 – WIRE FEEDER AND
WATER COOLER CONNECTIONS
Dual Wire Feeders, Dual Procedures Overlay K946-9
Dual Feeder, Dual Procedure, Memory Selection Overlay K946-12
Test and Calibration Overlay
1
2
3
WIRE FEEDER SETUP
5
4
The Power Wave must be used with wire feeders list-
ed above. Mount the feeder in a location suitable to
your needs.
For most applications, connect the electrode cable
between the feeder and the positive (+) connection of
the power source. When negative electrode polarity is
required, such as in some Innershield™ applications,
connect the electrode cable between the feeder and
the negative (-) connection of the power source. See
Figure C.1.
1 WIRE FEEDER CONNECTIONS (LOCATION)
2 WATER COOLER LINE (IN)
3 WATER COOLER LINE (OUT)
4 CIRCUIT BREAKER (WATER COOLER)
5 FILL SPOUT (WATER COOLER)
Connect the control cable between the feeder and
power source. The cable has different connectors on
each end and will fit in only one way. If only one feed-
er is used, it must be connected to the Feeder 1
Amphenol located on the back panel in the upper left-
hand corner (as you view the machine from the back).
If a second feeder is used, it must be plugged into the
Feeder 2 Amphenol receptacle located just to the right
of the Feeder 1 Amphenol receptacle.
Using a water-cooled gun is recommended to reduce
the size of the gun and improve parts life. The Power
Wave comes with a standard internal water cooler.
However, an external cooler may also be used.
TABLE C.1 – RECOMMENDED GUNS FOR USE
WITH POWER WAVE 450
Gun
Application
GMAW
Cooling
Gas
Product No.
K471-2
Connect the work cable between the work and the
negative (-) connection of the power source. When
negative electrode polarity is required, such as in
some Innershield™ applications, connect the work
cable between the work and the positive (+) connec-
tion of the power source. See Figure C.1.
MAGNUM 400
MAGNUM 550
GMAW
Gas
K598
WATER COOLER USAGE
The Power Wave is equipped with an optional internal
water cooler. We recommend using the water cooler
when welding above 300 amps with argon blends on
a regular basis. The gun heating from pulsing above
300 amps average current is often excessive and
leads to reduced consumable life, reduced gun life,
and operator discomfort. Water cooling greatly
increases the durability of the gun and parts at high
current.
•
•
•
Connect the feeder to a welding gas supply.
Load the wire into the feeder and gun.
Configure wire feeders (Refer to Setup overlay in
operation section.
1Use of the Synergic 7 wire feeder requires appropriate input cable assembly, wire stand, and drive roll kit. Refer to Synergic 7 Operators
Manual for available options.
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C-3
C-3
ACCESSORIES
a. Install the Set-up overlay.
There are two water connections on the rear of the
Power Wave. See Figure C.1. Connect the water lines
between these connectors and those on the wire feed-
er. The water is fed through the feeder into the gun.
When a water cooler is used, the water cooler must be
enabled by using the Setup Overlay.
b. Keep accessories’ hose lengths horizontal, either
coiled or straight, and no higher than 4 feet of the
specified coolant level.
c. Switch on the Power Wave machine.
The water cooler contains a flow switch, which is
closed when there is adequate coolant circulating in
the system. If this flow rate drops below the switch
manufacturer’s set point, the flow switch opens. A cou-
ple of seconds after the flow switch opens the water
cooler shuts down. If the water cooler is enabled and
the flow switch opens, the machine beeps loudly indi-
cating that there is a problem with the water cooler
operation.
d. Press the "WATER COOLER ENABLE" button so
that the "WATER COOLER ENABLED" light is
illuminated.
e. Press the "PRIME WATER COOLER" button until
the "WATER COOLER PRESSURE" light is
steadily illuminated.
4. Check coolant level. Add more if required.
Figure C.2
RECOMMENDED COOLANTS
Rear Panel of
Power Wave
1. The following coolants have been determined to be
compatible with the wetted materials used in the
G3503-[ ] cooler assembly:
Reservoir Screen
• Distilled or deionized water
• Potable tap water
Visible Coolant Level
• Sediment-free mixtures containing a maxi-
mum of 50% ethylene glycol or automotive-
grade antifreeze and the balance of distilled
or deionized water.
0.25 to 0.50
inches
2. Ethylene glycol mixtures should be selected if the
cooler may be exposed to a temperature below the
freezing point of water.
Do Not Use: Any prepacked welding industry coolant
mixture, such as those offered by Miller, OKI,
Bernhard, or Dynaflux. These coolants contain sub-
stances which attack plastic components and may
shorten the life of the system. Once added, these
substances are virtually impossible to purge from the
system. DO NOT USE OIL-BASED COOLANTS OF
ANY TYPE.
3. Consult gun, torch, and wire feeder manuals for
coolant recommendations and select one from the
above list.
4. Pure solutions and mixtures of, or materials (i.e.
towels) wetted with ethylene glycol are toxic to
humans and animals. They must not be haphaz-
ardly discarded, especially by pouring liquids down
the drain. Contact the local EPA office for responsi-
ble disposal methods or for recycling information.
K961-1 Single Cylinder Undercarriage -
Designed for quick installation in the field. Consists of
a front caster assembly, a rear platform assembly, a
handle, and an upper cylinder support.
5. The cooler’s reservoir has a nominal liquid capaci-
ty of 1.6 gallons.
PRIMING THE COOLER
K962-1 Dual Cylinder Undercarriage -
Designed for quick installation in the field. Consists of
a front caster assembly, a dual bottle rear platform
assembly, a handle, and a dual bottle upper cylinder
support.
1. Select a recommended coolant and fill cooler to
specified level (see Fig. C.2).
2. Attach desired water-cooled accessory (gun and
wire feeder or TIG torch) to cooler’s QDs.
3. Prime the cooler:
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C-4
C-4
ACCESSORIES
G3503-[ ] COOLER PERIODIC MAINTENANCE
8. Flush coolant from the system and replace with
fresh, recommended coolant at least once a year.
More frequent flushing may be necessary, depend-
ing upon a user’s particular system or its usage.
1. Preparation:
• Always switch off the Power Wave machine
power.
• Always disconnect the Power Wave machine
from service input power.
• Do not remove the pump relief valves' 3/4 in.
acorn hex nut or attempt to adjust the relief
valve setting.
NOTE: Never run the pump dry. Always use a recom-
mended coolant, otherwise pump damage may
result.
9. Reinstall the G3503-[ ] cooler into the Power Wave
machine.
2. Remove the G3503-[ ] cooler from the Power Wave
machine.
G3503-[ ] COOLER SERVICE
3. Clean the pump’s inlet strainer:
• Drain the reservoir of coolant and dispose of it
in an environmentally responsible manner (see
Recommended Coolants).
• Place absorbent towels underneath pump
head.
1. Preparation:
• Always switch off the Power Wave machine
power.
• Always disconnect the Power Wave machine
from service input power.
• Hold pump head to apply countertorque when
loosening strainer’s 7/8 acorn nut. Do not con-
fuse with 3/4 acorn nut. Remove nut and slide
inlet strainer down and out from pump head.
• Gently rinse strainer under running water to
thoroughly clean it.
• Do not remove the pump relief valves' 3/4 in.
acorn hex nut or attempt to adjust the relief
valve setting.
2. Remove the G3503-[ ] cooler from the Power Wave
machine whenever:
• Use the mirror to inspect inside of pump for
contamination. Carefully remove hardened
debris with dental pick if necessary, without
scratching inside of the pump.
• Reinstall strainer and acorn nut, tightening with
75±15 in.-lbs. of torque. Wipe dry all areas wet-
ted by coolant. Dispose of towels in an envi-
• replacing major cooler components (i.e. pump,
motor, heat exchanger, etc.).
• replacing hoses and electrical harnesses that
are kinked or damaged (cut, abraded, deterio-
rated or swollen, etc.).
• investigating suspect coolant leakage.
ronmentally
Recommended Coolants).
responsible
manner
(see
3. Pump replacement:
a. Drain the reservoir of coolant and dispose of it
in an environmentally responsible manner (see
Recommended Coolants).
4. Gently rinse the reservoir’s strainer under running
water to thoroughly clean it.
b. Remove fan shroud.
c. Place absorbent towels underneath pump head
and wherever coolant system is opened.
d. Carefully pull pump inlet hose and its elbow
from reservoir (bottom).
5. Remove fan shroud and inspect hoses and electrical
harnesses for kinking or damage (cut, abrasion,
swelling, etc.). Replace if necessary.
e. Loosen pump outlet hose clamp at QD then
carefully remove from fitting.
f. Disconnect v-band clamp from motor and
remove pump:
6. Remove accumulated dust from cooler, especially
from the motor and heat exchanger, by blowing it off
with shop air or vacuuming it out.
• The heat exchanger fins are sharp but can be
easily bent. Treat them with care to avoid per-
sonal injury and damaging them.
• Remove the cooler from the machine for a
more thorough cleaning job.
• Do not drop or lose drive coupling between
pump and motor.
• Do not discard old pump. Remove both fit-
tings, Keep v-clamp, Seal old pump in a
waterproof bag, Package into protective con-
tainer, and Return to nearest Lincoln Electric
FSS center.
7. Motor lubrication is recommended once a year:
• Remove plug over lube port at top of motor
near fan end.
• Add 20 drops of electric motor or SAE 10 oil
then reinstall plug.
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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.
• Tighten v-clamp with 15 to 30 in-lbs. of
torque.
h. Attach coolant lines to QD and reser-
voir.
i. Wipe dry all areas wetted by coolant.
Dispose of towels in an environmentally
responsible manner (see Recommended
Coolants).
j. Reinstall cooler into machine.
4. Motor removal or replacement:
• Do not reuse the 4 internal-tooth star
washers. Replace with new parts.
5. Installing the fan:
• Slide onto motor shaft until the fan is
located between 0.25 to 0.50 inches
from the heat exchanger.
• Tighten set screw with 65 to 75 in-lbs
of torque against motor shaft’s flat.
• Fan rotation is counterclockwise, as
viewed from fan-end of motor’s shaft.
• Fan pulls air through the heat
exchanger, blows it over the motor,
then exhausts it through the reservoir.
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C-6
C-6
NOTES
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D-1
D-1
TABLE OF CONTENTS
-MAINTENANCE-
Maintenance .........................................................................................................................Section D
Safety Precautions......................................................................................................................D-2
Routine and Periodic Maintenance ............................................................................................D-2
Input Filter Capacitor Discharge.................................................................................................D-2
Preventive Maintenance .............................................................................................................D-5
General Component Locations...................................................................................................D-6
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D-2
D-2
MAINTENANCE
SAFETY PRECAUTIONS
WARNING
ELECTRIC SHOCK can kill.
• Only Qualified personnel should
perform this maintenance.
• Turn the input power OFF at the
disconnect switch or fuse box
before working on this equipment.
•
Do not touch electrically hot parts.
ROUTINE AND PERIODIC
MAINTENANCE
Perform the following preventive maintenance at least
once every six months.
WARNING
Prior to performing preventive maintenance it is impor-
tant to perform the following capacitor discharge pro-
cedure to avoid electric shock.
INPUT FILTER CAPACITOR DIS-
CHARGE PROCEDURE
1. Turn off input power and disconnect input power
lines.
2. Remove the hex head screws from the top and the
sides of the machine. Remove the handle bar and
the wrap-around machine cover.
3. Remove the two case sides. There are hex head
screws on each side.
CAUTION
TO PREVENT DAMAGE TO MACHINE, AVOID
UNNECESSARY MOVEMENT OF FRONT PANEL.
4. Obtain a high resistance and high wattage resistor
(25-1000 ohms and 25 watts minimum). This
resistor is not supplied with the machine. Secure
this resistor to a piece of insulating material such
as a glastic board. See Figure D.3. NEVER USE A
SHORTING STRAP FOR THIS PROCEDURE.
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D-3
D-3
MAINTENANCE
FIGURE D.1 – RESISTOR LOCATIONS
5 PAIRS OF RESISTORS
CHECK VOLTAGES BETWEEN EACH
TERMINAL AND FROM EACH RESISTOR
TO CASE GROUND
5. Locate two sets of two resistors on the left side of
the machine and three sets of two resistors on the
right side of the machine. See Figure D.1. Do not
touch the resistors or any other internal machine
component. Using a DC voltmeter, check for any
DC voltage that may be present across the termi-
nals of each resistor and from each resistor to
case ground (20 measurements in all). If a voltage
is present, be careful not to touch these resistors.
WARNING
ELECTRIC SHOCK can kill.
• Proceed with caution being care-
ful not to touch any internal
machine components during the
discharge procedure.
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D-4
D-4
MAINTENANCE
6. Locate the #9 and #12 terminals, identified by the
“Discharge” labels, on each of the four Switch
Boards. See Figure D.2.
FIGURE D.3 – RESISTORS WITH LEADS
CONNECTED
7. Using insulated, needle nose-type jumper leads
and insulated gloves, connect one jumper lead to
one end of the resistor obtained in step 4.
Connect the other jumper lead to the other end of
the resistor.
8. Carefully connect the needle nose end of one of
the jumper leads to terminal #9. See Figure D.3.
Connect the needle nose end of the other jumper
lead to terminal #12. Terminals #9 and #12 are
indicated by the “Discharge” label. Leave resistor
connected for 10 seconds. DO NOT TOUCH TER-
MINALS, RESISTORS, OR ANY INTERNAL
MACHINE COMPONENT DURING THIS PROCE-
DURE!
FIGURE D.2 – DISCHARGE LABEL
D
I
D
I
D
I
S
C
H
A
R
G
E
S
C
H
A
R
G
E
S
C
H
A
R
G
E
9. Check voltage across terminals (9 and 12) with a
DC voltmeter. Terminal 9 has positive polarity and
terminal 12 has negative polarity. Voltage should
be zero. If any voltage remains, repeat this capac-
itor discharge procedure.
D
I
D
I
S
C
H
A
R
G
E
S
C
H
A
R
G
E
10. Repeat discharge procedure (steps 7, 8 and 9) for
each of the other three Switch Boards.
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D-5
D-5
MAINTENANCE
8. Reconnect the shunt and wire #467 to the nega-
tive (-) output terminal. Make sure the connection
is tight.
PREVENTIVE MAINTENANCE
Perform the following preventive maintenance proce-
dures at least once every six months. It is good prac-
tice to keep a preventive maintenance record; a record
tag attached to the machine works best.
9. Replace and secure the machine covers and han-
dle bar.
10. Remove the overlay from the front panel of the
machine. Clean the plastic case with a low pres-
sure airstream. Wipe the sensors (Fig D.4 Item 8)
with a clean, soft cloth. Make sure the sensors are
not scratched in the process.
1. Remove the hex head screws from the sides and
top of the machine. Remove the handle bar and
the machine wrap-around cover. Remove the two
case sides. There are hex head screws on each
side.
11. Check the back of the overlays. If the bar code
(black square(s)) on the back of the overlay is
scratched, apply a dull black spray finish to the
scratched-off areas only. If a large area of the bar
code is scratched off, the machine either will not
recognize the overlay or will mistake the overlay
for another one.
2. Perform the input filter capacitor discharge proce-
dure described at the beginning of the
Maintenance Section.
3. Disconnect the shunt from the negative (-) output
terminal. Failure to do this could cause damage to
the shunt circuitry.
4. Clean the inside of the machine with a low pres-
sure airstream. Be sure to clean the following
components thoroughly (Refer to Figure D.4):
12. Inspect gun and cables for good condition.
•
Display, Snubber, and Shunt printed circuit
boards
•
•
•
•
•
•
•
•
Power Switch
Main Transformer
Auxiliary Transformers
Input Rectifier
Heat Sink Fins
Input Filter Capacitors
Output Terminals
Terminal Strip
5. Examine the capacitors for leakage or oozing.
Replace if needed.
6. Examine the wrap-around and side covers for
dents and breakage. Repair them as needed. The
covers must be kept in good condition to assure
that high voltage parts are protected and that cor-
rect spacings are maintained.
7. Remove welding cables and check the electrical
ground continuity. Use an ohmmeter to measure
the resistance between each output terminal and
an unpainted surface of the machine case. The
meter reading should be 500,000 ohms or more. If
the meter reading is less than 500,000 ohms,
check for electrical components that are not prop-
erly insulated from the case. Correct component
insulation, if needed.
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D-6
D-6
MAINTENANCE
FIGURE D.4 – GENERAL COMPONENT LOCATIONS
1 DISPLAY BOA
2 POWER SWITC
3 MAIN TRANSF
4 AUXILIARY TR
5 INPUT RECTIF
6 HEAT SINK FIN
7 OUTPUT TERM
8 OVERLAY BAR
9 TERMINAL ST
5
9
4
1
8
6
2
7
3
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Section E-1
Section E-1
TABLE OF CONTENTS
-THEORY OF OPERATION-
Theory of Operation .............................................................................................................Section E
General Description ....................................................................................................................E-2
Input Voltage...............................................................................................................................E-2
Precharge (Soft Start)..................................................................................................................E-3
Switch Boards.............................................................................................................................E-4
Main Transformer ........................................................................................................................E-5
Output Rectifier and Choke........................................................................................................E-6
Control Board..............................................................................................................................E-7
Power Board ...............................................................................................................................E-8
Display Board..............................................................................................................................E-9
Thermal Protection....................................................................................................................E-10
Protective Circuits.....................................................................................................................E-10
Over Current Protection .....................................................................................................E-10
Over Voltage Protection......................................................................................................E-10
Field Effect Transistor (FET) Operation .....................................................................................E-11
Pulse Width Modulation............................................................................................................E-12
Minimum Output.................................................................................................................E-12
Maximum Output................................................................................................................E-12
FIGURE E.1 – POWER WAVE BLOCK LOGIC DIAGRAM
INPUT
MAIN
TRAMSFORMER
OUTPUT
RECTIFIER
RECTIFIER
AND
INPUT
CONTACTOR
RECONNECT
CHOKE
POSITIVE
LEFT
SWITCH
BOARD
THREE
PHASE
INPUT
FET
POWER
ASSEMBLY
CT
AUX.
TRANS
INPUT
LINE
SWITCH
RIGHT
SWITCH
BOARD
PROTECTION
BOARD
FAN
FET
NEGATIVE
ASSEMBLY
SHUNT
POWER
BOARD
SNUBBER AND
SENSE LEADS
CONTROL
BOARD
WATER
COOLER
LCD
DISPLAY
DISPLAY
BOARD
KEYPAD
PC
INTERFACE
OVERLAY
WF1
WF2
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E-2
E-2
THEORY OF OPERATION
FIGURE E.2 – INPUT VOLTAGE CIRCUIT
INPUT
MAIN
TRAMSFORMER
OUTPUT
RECTIFIER
RECTIFIER
INPUT
CONTACTOR
AND
RECONNECT
CHOKE
POSITIVE
LEFT
SWITCH
BOARD
THREE
PHASE
INPUT
FET
POWER
ASSEMBLY
CT
AUX.
TRANS
INPUT
LINE
SWITCH
RIGHT
SWITCH
BOARD
PROTECTION
BOARD
FAN
FET
NEGATIVE
ASSEMBLY
SHUNT
POWER
BOARD
SNUBBER AND
SENSE LEADS
CONTROL
BOARD
WATER
COOLER
LCD
DISPLAY
DISPLAY
BOARD
KEYPAD
PC
INTERFACE
OVERLAY
WF1
WF2
GENERAL DESCRIPTION
INPUT VOLTAGE
The Power Wave is an inverter type power source that
can support most welding procedures. It is modeled
after a P.C. (Personal Computer). There are no specif-
ic welding characteristics designed into the power
portion of the machine. All welding characteristics are
programmed into the software package.
The Power Wave can be connected for a variety of
three phase voltages. The initial input power is applied
to the Power Wave through a line switch located on
the front of the machine. The voltage is connected to
the Protection Board where it is current limited before
being passed on to the input rectifier and reconnect
switches. The reconnect panel allows the user to
switch to low or high voltage and connect the Auxiliary
Transformer to the appropriate input voltage. The
Auxiliary Transformer supplies power to the fan motors
and, through the Protection Board, to the printed cir-
cuit boards and wire feeder(s).
NOTE: Unshaded areas of Block Logic Diagram are the subject of discussion.
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E-3
E-3
THEORY OF OPERATION
FIGURE E.3 – PRECHARGE CIRCUIT
INPUT
MAIN
TRAMSFORMER
OUTPUT
RECTIFIER
RECTIFIER
INPUT
CONTACTOR
AND
RECONNECT
CHOKE
POSITIVE
LEFT
SWITCH
BOARD
THREE
PHASE
INPUT
FET
POWER
ASSEMBLY
CT
AUX.
TRANS
INPUT
LINE
SWITCH
RIGHT
SWITCH
BOARD
PROTECTION
BOARD
FAN
FET
NEGATIVE
ASSEMBLY
SHUNT
POWER
BOARD
SNUBBER AND
SENSE LEADS
CONTROL
BOARD
WATER
COOLER
LCD
DISPLAY
DISPLAY
BOARD
KEYPAD
PC
INTERFACE
OVERLAY
WF1
WF2
PRECHARGE (SOFT START)
The Protection Board contains a “soft Start” circuit,
which is powered by the Auxiliary Transformer. During
precharge or “soft start” only two phases of the input
power, with current limiting, are connected to the input
rectifier. This AC input voltage is rectified, and the DC
voltage is applied through the Reconnect Switches to
the input capacitors located on the Switch Boards.
The Protection Board monitors the voltage across the
capacitors. When the capacitors have charged to an
acceptable level, the Protection Board energizes the
Main Input Contactor, making all three phases of input
power available to the input capacitors. At this point
the Power Wave is in the “Run Mode” of operation. If
the capacitors become under- or overvoltaged, the
Protection Board will de-energize the Main Input
Contactor, and the machine output will be disabled.
NOTE: Unshaded areas of Block Logic Diagram are the subject of discussion.
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E-4
E-4
THEORY OF OPERATION
FIGURE E.4 – SWITCH BOARD CIRCUIT
INPUT
MAIN
TRAMSFORMER
OUTPUT
RECTIFIER
RECTIFIER
INPUT
CONTACTOR
AND
RECONNECT
CHOKE
POSITIVE
LEFT
SWITCH
BOARD
THREE
PHASE
INPUT
FET
POWER
ASSEMBLY
CT
AUX.
TRANS
INPUT
LINE
SWITCH
RIGHT
SWITCH
BOARD
PROTECTION
BOARD
FAN
FET
NEGATIVE
ASSEMBLY
SHUNT
POWER
BOARD
SNUBBER AND
SENSE LEADS
CONTROL
BOARD
WATER
COOLER
LCD
DISPLAY
DISPLAY
BOARD
KEYPAD
PC
INTERFACE
OVERLAY
WF1
WF2
SWITCH BOARDS
There are four Switch Boards in the Power Wave, each
containing an input capacitor. The capacitors on
Switch Boards #1 and #2 are always in parallel, and
the capacitors on Switch Boards #3 and #4 are always
in parallel. When the filter capacitors are fully charged,
they act as power supplies for the Switch Boards. The
Switch Boards contain the Field Effect Transistors
(FETs) which, when switched on, supply the Main
Transformer primary windings with DC current flow.
See FET operation discussion and diagrams (Figures
E.10 and E11).
NOTE: Unshaded areas of Block Logic Diagram are the subject of discussion.
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E-5
E-5
THEORY OF OPERATION
FIGURE E.5 – MAIN TRANSFORMER
INPUT
MAIN
TRAMSFORMER
OUTPUT
RECTIFIER
RECTIFIER
INPUT
CONTACTOR
AND
RECONNECT
CHOKE
POSITIVE
LEFT
SWITCH
BOARD
THREE
PHASE
INPUT
FET
POWER
ASSEMBLY
CT
AUX.
TRANS
INPUT
LINE
SWITCH
RIGHT
SWITCH
BOARD
PROTECTION
BOARD
FAN
FET
NEGATIVE
ASSEMBLY
SHUNT
POWER
BOARD
SNUBBER AND
SENSE LEADS
CONTROL
BOARD
WATER
COOLER
LCD
DISPLAY
DISPLAY
BOARD
KEYPAD
PC
INTERFACE
OVERLAY
WF1
WF2
MAIN TRANSFORMER
Each Switch Board assembly works as a switch pair.
Each board feeds current to a primary winding of the
Main Transformer. These primary currents are moni-
tored by the Current Transformer (CT). The CT sends
a signal through the Protection Board to the Control
Board. If the primary currents become abnormally
high, the Control Board will shut off the FETs, thus dis-
abling machine output. The right and left sides of the
transformer are isolated from each other. The right
side of the transformer is supplied from Switch Boards
#1 and #2, while the left side of the transformer is sup-
plied from Switch Boards #3 and #4. The DC current
flow through each primary winding is clamped back to
each respective input capacitor when the FETs are
turned off. The firing of the four Switch Board pairs
occurs during halves of a 50 microsecond interval,
creating two constant 20 kHz square waves on the pri-
mary side of the transformer. The current flow through
the Main Transformer primaries induces a 20 kHz AC
square wave output signal at the secondary of the
Main Transformer.
NOTE: Unshaded areas of Block Logic Diagram are the subject of discussion.
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E-6
E-6
THEORY OF OPERATION
FIGURE E.6 – OUTPUT RECTIFIER AND CHOKE
INPUT
MAIN
TRAMSFORMER
OUTPUT
RECTIFIER
RECTIFIER
AND
RECONNECT
INPUT
CONTACTOR
CHOKE
POSITIVE
LEFT
SWITCH
BOARD
THREE
PHASE
INPUT
FET
POWER
ASSEMBLY
CT
AUX.
TRANS
INPUT
LINE
SWITCH
RIGHT
SWITCH
BOARD
PROTECTION
BOARD
FAN
FET
NEGATIVE
ASSEMBLY
SHUNT
POWER
BOARD
SNUBBER AND
SENSE LEADS
CONTROL
BOARD
WATER
COOLER
LCD
DISPLAY
DISPLAY
BOARD
KEYPAD
PC
INTERFACE
OVERLAY
WF1
WF2
OUTPUT RECTIFIER AND CHOKE
The Output Rectifier receives the AC output from the
Main Transformer secondary and rectifies it to a DC
level with a 40 kHz ripple.
Since the Output Choke is in series with the positive
leg of the Output Rectifier and also in series with the
welding load, a filtered DC output is applied to the
machine output terminals.
NOTE: Unshaded areas of Block Logic Diagram are the subject of discussion.
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E-7
E-7
THEORY OF OPERATION
FIGURE E.7 – CONTROL BOARD
INPUT
MAIN
TRAMSFORMER
OUTPUT
RECTIFIER
RECTIFIER
INPUT
CONTACTOR
AND
RECONNECT
CHOKE
POSITIVE
LEFT
SWITCH
BOARD
THREE
PHASE
INPUT
FET
POWER
ASSEMBLY
CT
AUX.
TRANS
INPUT
LINE
SWITCH
RIGHT
SWITCH
BOARD
PROTECTION
BOARD
FAN
FET
NEGATIVE
ASSEMBLY
SHUNT
POWER
BOARD
SNUBBER AND
SENSE LEADS
CONTROL
BOARD
WATER
COOLER
LCD
DISPLAY
DISPLAY
BOARD
KEYPAD
PC
INTERFACE
OVERLAY
WF1
WF2
CONTROL BOARD
The Control Board is at the heart of controlling the out-
put of the machine. With the information it receives
from the Shunt (current feedback), the voltage sensing
leads, the wire feeder(s), and the other printed circuit
boards, the Control Board optimizes the welding
results by regulating the FETs’ switching times, which
in turn control the output of the machine. The Control
Board also monitors the thermal protection devices
and the regulation and fault signals produced on the
Protection Board.
NOTE: Unshaded areas of Block Logic Diagram are the subject of discussion.
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E-8
E-8
THEORY OF OPERATION
FIGURE E.8 – POWER BOARD
INPUT
MAIN
TRAMSFORMER
OUTPUT
RECTIFIER
RECTIFIER
INPUT
CONTACTOR
AND
RECONNECT
CHOKE
POSITIVE
LEFT
SWITCH
BOARD
THREE
PHASE
INPUT
FET
POWER
ASSEMBLY
CT
AUX.
TRANS
INPUT
LINE
SWITCH
RIGHT
SWITCH
BOARD
PROTECTION
BOARD
FAN
FET
NEGATIVE
ASSEMBLY
SHUNT
POWER
BOARD
SNUBBER AND
SENSE LEADS
CONTROL
BOARD
WATER
COOLER
LCD
DISPLAY
DISPLAY
BOARD
KEYPAD
PC
INTERFACE
OVERLAY
WF1
WF2
POWER BOARD
The Power Board provides gate drives for the FETs on
the Switch Boards. It does so based on the “turn-on”
signals it receives from the Control Board. One func-
tion of the Power Board is to isolate the Control Board
from the Switch Boards. The Power Board also pro-
vides the other printed circuit boards with the DC volt-
age supply they require.
NOTE: Unshaded areas of Block Logic Diagram are the subject of discussion.
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E-9
E-9
THEORY OF OPERATION
FIGURE E.9 – DISPLAY BOARD
INPUT
MAIN
TRAMSFORMER
OUTPUT
RECTIFIER
RECTIFIER
INPUT
CONTACTOR
AND
RECONNECT
CHOKE
POSITIVE
LEFT
SWITCH
BOARD
THREE
PHASE
INPUT
FET
POWER
ASSEMBLY
CT
AUX.
TRANS
INPUT
LINE
SWITCH
RIGHT
SWITCH
BOARD
PROTECTION
BOARD
FAN
FET
NEGATIVE
ASSEMBLY
SHUNT
POWER
BOARD
SNUBBER AND
SENSE LEADS
CONTROL
BOARD
WATER
COOLER
LCD
DISPLAY
DISPLAY
BOARD
KEYPAD
PC
INTERFACE
OVERLAY
WF1
WF2
DISPLAY BOARD
The Display Board allows the operator to select from
the procedures that are programmed into the
machine, and it lets the Control Board know which
procedure was selected. These procedures are pro-
grammed into the machine’s software package. The
Display Board is used to communicate with the oper-
ator. It determines what Overlay is installed in the
machine and which buttons are active on the keypad.
It also controls the LCD display, the lights on the front
of the machine, the Piezo Buzzer and the water cool-
er. Through the use of a current serial loop, the
Display Board and Control Board communicate (or
talk) to the wire feeder(s). The Display Board can also
communicate with a computer through the RS232
interface.
NOTE: Unshaded areas of Block Logic Diagram are the subject of discussion.
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E-10
E-10
THEORY OF OPERATION
THERMAL PROTECTION
PROTECTIVE CIRCUITS
Two normally closed (NC) thermostats protect the
machine from excessive operating temperatures.
These thermostats are wired in series and are con-
nected to the Control Board. One of the thermostats
is located on the heat sink of a switch board, and the
other is located on the main choke. Excessive tem-
peratures may be caused by a lack of cooling air or
operating the machine beyond the duty cycle or out-
put rating. If excessive operating temperatures should
occur, the thermostats will prevent output from the
machine. The displays will remain on during this time;
and the yellow Thermal light, located of the front of the
machine, will be illuminated. The thermostats are self-
resetting once the machine cools sufficiently. If the
thermostat shutdown was caused by excessive output
or duty cycle and the fans are operating normally, the
Power Switch (SW1) may be left on and the reset
should occur within a 15-minute period. If one or both
of the fans are not turning or the air intake louvers are
obstructed, then the power must be removed from the
machine, and the fan problem air obstruction must be
corrected.
Protective circuits are designed into the Power Wave
to sense trouble and shut down the machine before
damage occurs to the machine’s internal components.
OVER CURRENT PROTECTION
If the average current exceeds 520 amps, then the
peak current will be limited to 100 amps until the aver-
age current decreases to under 50 amps.
OVER VOLTAGE PROTECTION
A protective circuit is included on the Protection Board
to monitor the voltage across the input capacitors. In
the event that a capacitor voltage is too high, the pro-
tection circuit will prevent output. Also, in the event
that a capacitor voltage is too low, the machine output
is disabled and the “soft start” mode is repeated. The
protection circuit may prevent output if any of the fol-
lowing circumstances occur:
1. Capacitor condition is required. (Required if
machine has been off for a long period of time and
is connected for high input voltage operation.)
2. Voltage across a capacitor exceeds 370 volts.
(High line surges or improper input voltage connec-
tions.)
3. Voltage across a capacitor is under 170 volts. (Due
to improper input voltage connections.)
4. Internal component damage.
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E-11
E-11
THEORY OF OPERATION
FIELD EFFECT TRANSISTOR (FET) OPERATION
FIGURE E.10 – FIELD EFFECT TRANSISTOR OPERATION
GATE
DRAIN
TERMINAL
(0 VOLTS)
SOURCE
TERMINAL
TERMINAL
DRAIN (N)
SOURCE (N)
N CHANNEL
SUBSTRATE (P)
A. PASSIVE
GATE
TERMINAL
(+ 6 VOLTS)
SOURCE (N)
DRAIN (N)
ELECTRONS
B. ACTIVE
An FET is a type of transistor. FETs are semi-
conductors well suited for high-frequency
switching.
Drawing B above shows the FET in an active
mode. When the gate signal, a positive DC
voltage relative to the source, is applied to the
gate terminal of the FET, it can’t conduct cur-
rent. A voltage supply connected to the drain
terminal will allow the FET to conduct and
henceforth supply current to downstream
components. Current will flow through the
conducting FET to downstream components
as long as the gate signal is present. This is
similar to turning on a light switch.
Drawing A above shows an FET in a passive
mode. There is no gate signal (zero volts) from
the source and, therefore, no current flow. The
drain terminal of the FET may be connected to
a voltage supply. But since there is no con-
duction, the circuit will not supply current to
downstream components connected to the
source. The circuit is turned off like a light
switch in the OFF position.
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E-12
E-12
THEORY OF OPERATION
PULSE WIDTH MODULATION
FIGURE E.11 – TYPICAL FET OUTPUTS
(+)
(–)
48 µsec
50 µsec
1 µsec
1 µsec
MINIMUM OUTPUT
(+)
(–)
20 µsec
20 µsec
10 µsec
50 µsec
MAXIMUM OUTPUT
The term PULSE WIDTH MODULATION is
used to describe how much time is devoted to
conduction in the positive and negative por-
tions of the cycle. Changing the pulse width is
MAXIMUM OUTPUT
By holding the gate signals on for 20 micro-
seconds each and allowing only 10 microsec-
onds of dwell time (off time) during the 50-
microsecond cycle, the output is maximized.
The darkened area under the top curve can be
compared to the area under the bottom curve.
The more dark area under the curve, the more
power is present.
known as MODULATION.
Pulse Width
Modulation (PWM) is the varying of the pulse
width over the allowed range of a cycle to
affect the output of the machine.
MINIMUM OUTPUT
By controlling the duration of the gate signal,
the FET is turned on and off for different dura-
tions during a cycle. The top drawing above
shows the minimum output signal possible
over a 50-microsecond time period.
The positive portion of the signal represents
one FET group1 conducting for 1 microsec-
ond. The negative portion is the other FET
group1. The dwell time (off time) is 48 micro-
seconds (both FET groups off). Since only 2
microseconds of the 50-microsecond time
period is devoted to conducting, the output
power is minimized.
1A FET group consists of the sets of FET modules grouped onto one switch board.
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Section F-1
Section F-1
TABLE OF CONTENTS
-TROUBLESHOOTING & REPAIR SECTION-
Troubleshooting & Repair Section.......................................................................................Section F
How to Use Troubleshooting Guide............................................................................................F-2
PC Board Troubleshooting Procedures and Replacement.........................................................F-3
Troubleshooting Guide................................................................................................................F-5
Test Procedures ........................................................................................................................F-23
Capacitor Discharge Procedure .........................................................................................F-23
Auxiliary Transformer Test 1 ...............................................................................................F-27
Auxiliary Transformer Test 2 ...............................................................................................F-31
Auxiliary Transformer Primary Wiring Harness Test ...........................................................F-35
Auxiliary Transformer #1 Secondary and Wiring Harness Test ..........................................F-39
Input Power and Wiring Harness Test................................................................................F-43
Input Rectifier Resistance Test...........................................................................................F-47
Output Shunt/Welding Feedback Test................................................................................F-51
Piezo-Electric Alarm Buzzer Test........................................................................................F-55
Output Rectifier Diodes Test ..............................................................................................F-57
Field Effect Transistor/Switch Board Test...........................................................................F-59
Snubber and Bleeder Resistor Test....................................................................................F-75
Reconnect Switch Test 1....................................................................................................F-81
Reconnect Switch Test 2....................................................................................................F-85
Static Capacitor Balance Test ............................................................................................F-89
Dynamic Capacitor Balance Test .......................................................................................F-93
Internal and Auxiliary Supply Voltage Test .........................................................................F-97
Main Contactor Test .........................................................................................................F-103
Serial Loop Wiring Harness Test ......................................................................................F-107
Wire Feeder 1 Trigger Circuit Test ....................................................................................F-111
Wire Feeder 2 Trigger Circuit Test ....................................................................................F-115
Trigger Circuit and Wiring Harness Test...........................................................................F-119
Internal Remote Control Test............................................................................................F-123
K941-1 Remote Control Kit Test ......................................................................................F-127
K941-1 Remote Control Kit Trigger Circuit Test...............................................................F-131
LCD Display Test ..............................................................................................................F-135
Calibration Procedures............................................................................................................F-139
Sensor Calibration Test (For Display Board) ....................................................................F-141
Quick Voltage Calibration .................................................................................................F-143
Full Voltage Calibration.....................................................................................................F-145
Full Voltage Calibration Using A Welding Arc...................................................................F-147
Current Calibration ...........................................................................................................F-151
Replacement Procedures........................................................................................................F-155
T1 Auxiliary Transformer Removal and Replacement ......................................................F-155
Water Cooler Removal and Replacement ........................................................................F-157
Water Cooler Disassembly ...............................................................................................F-161
T2 Auxiliary Transformer Removal and Replacement ......................................................F-165
Fan Motor Removal and Replacement.............................................................................F-167
Input Rectifier Removal and Replacement.......................................................................F-171
Printed Circuit Board Removal and Replacement ...........................................................F-175
Display Board Removal and Replacement.......................................................................F-179
Main Input Contactor (CR1) Removal and Replacement.................................................F-183
Output Rectifier Bridge Removal and Replacement........................................................F-187
FET Module Removal and Replacement..........................................................................F-191
Main Transformer Removal and Replacement .................................................................F-197
Pre-Powerup Switch Board Test Procedure.....................................................................F-199
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F-2
F-2
TROUBLESHOOTING & REPAIR
HOW TO USE TROUBLESHOOTING GUIDE
WARNING
Service and repair should be performed by only Lincoln Electric Factory Trained Personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician and machine
operator and will invalidate your factory warranty. For your safety and to avoid Electrical Shock, please
observe all safety notes and precautions detailed throughout this manual.
This Troubleshooting Guide is provided to help
you locate and repair possible machine malfunc-
tions. Simply follow the three-step procedure
listed below.
Step 3. PERFORM COMPONENT TESTS. The
last column, labeled “Recommended Course of
Action,” lists the most likely components that
may have failed in your machine. It also specifies
the appropriate test procedure to verify that the
subject component is either good or bad. If there
are a number of possible components, check the
components in the order listed to eliminate one
possibility at a time until you locate the cause of
your problem.
Step 1. LOCATE PROBLEM (SYMPTOM). Look
under the column labeled “PROBLEM (SYMP-
TOMS). This column describes possible symp-
toms that the machine may exhibit. Find the list-
ing that best describes the symptom that the
machine is exhibiting. Symptoms are grouped
into three main categories: Output Problems,
Function Problems, and Welding Problems.
All of the referenced test procedures referred to in
the Troubleshooting Guide are described in detail
at the end of this chapter. Refer to the
Troubleshooting and Repair Table of Contents to
locate each specific Test Procedure. All of the
referred to test points, components, terminal
strips, etc., can be found on the referenced elec-
trical wiring diagrams and schematics. Refer to
the Electrical Diagrams Section Table of Contents
to locate the appropriate diagram.
Step 2. PERFORM EXTERNAL TESTS. The
second column, labeled “POSSIBLE AREAS OF
MISADJUSTMENT(S),” lists the obvious external
possibilities that may contribute to the machine
symptom. Perform these tests/checks in the
order listed. In general, these tests can be con-
ducted without removing the case wrap-around
cover.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the test/repairs
safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before
you proceed. Call 1-800-833-9353.
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F-3
F-3
TROUBLESHOOTING & REPAIR
PC BOARD TROUBLESHOOTING PROCEDURES AND REPLACEMENT
• Remove the PC Board from the static-shielding bag
and place it directly into the equipment. Don’t set
the PC Board on or near paper, plastic or cloth
which could have a static charge. If the PC Board
can’t be installed immediately, put it back in the sta-
tic-shielding bag.
WARNING
ELECTRIC SHOCK can kill.
Have an electrician install and ser-
vice this equipment.
machine OFF before working on
equipment. Do not touch electrically hot parts.
Turn the
• If the PC Board uses protective shorting jumpers,
don’t remove them until installation is complete.
• If you return a PC Board to The Lincoln Electric
Company for credit, it must be in the static-shield-
ing bag. This will prevent further damage and allow
proper failure analysis.
Sometimes machine failures appear to be due to PC
board failures. These problems can sometimes be
traced to poor electrical connections. To avoid prob-
lems when troubleshooting and replacing PC boards,
please use the following procedure:
4. Perform any necessary PC Board calibration pro-
cedures. See the flow chart on the next page.
5. Test the machine to determine if the failure symp-
tom has been corrected by the replacement PC
board.
1. Determine to the best of your technical ability that
the PC board is the most likely component causing
the failure symptom.
NOTE: Allow the machine to heat up so that all elec-
trical components can reach their operating
temperature.
2. Check for loose connections at the PC board to
assure that the PC board is properly connected.
6. Remove the replacement PC board and substitute
it with the original PC board to recreate the original
problem. Recalibrate if required.
3. If the problem persists, replace the suspect PC
board using standard practices to avoid static elec-
trical damage and electrical shock. Read the warn-
ing inside the static resistant bag and perform the
following procedures.
a. If the original problem does not reappear
by substituting the original board, then the
PC board was not the problem. Continue
to look for bad connections in the control
wiring harness, junction blocks, and termi-
nal strips.
PC Board can be damaged by
static electricity.
• Remove your body’s static
charge before opening the stat-
ic-shielding bag. Wear an anti-
b. If the original problem is recreated by the
substitution of the original board, then the
PC board was the problem. Reinstall the
replacement PC board, recalibrate if
required, and test the machine.
ATTENTION
Static-Sensitive
Devices
Handle only at
static wrist strap. For safety,
use a 1 Meg ohm resistive cord
connected to a grounded part of
the equipment frame.
Static-Safe
7. Always indicate that this procedure was followed
when warranty reports are to be submitted.
Workstations
• If you don’t have a wrist strap,
touch an unpainted, grounded,
part of the equipment frame.
Keep touching the frame to pre-
vent static build-up. Be sure not
to touch any electrically live
parts at the same time.
NOTE: Following this procedure and write on the war-
ranty report, “INSTALLED AND SWITCHED
PC BOARDS TO VERIFY PROBLEM,” will help
avoid denial of legitimate PC board warranty
claims.
Reusable
Container
Do Not Destroy
• Tools which come in contact with the PC Board
must be either conductive, anti-static or static-dis-
sipative.
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F-4
F-4
TROUBLESHOOTING & REPAIR
PC BOARD REPLACEMENT
CALIBRATION REQUIREMENTS
SHUNT
DISPLAY
BOARD
REPLACED
CONTROL
BOARD
REPLACED
SNUBBER
AMPLIFIER
BOARD
BOARD
REPLACED
REPLACED
IF POSSIBLE
QUICK
VOLTAGE
CURRENT
CALIBRATION
CALIBRATION
FULL
VOLTAGE
CALIBRATION
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F-5
F-5
TROUBLESHOOTING & REPAIR
TROUBLESHOOTING GUIDE
Observe Safety Guidelines
detailed in the beginning of this manual.
PROBLEMS
(SYMPTOMS)
POSSIBLE AREAS OF
MISADJUSTMENT(S)
RECOMMENDED
COURSE OF ACTION
OUTPUT PROBLEMS
Major physical or electrical dam-
age is evident when the sheet
metal cover(s) are removed.
1. Contact your local authorized
Lincoln Electric Field Service
Facility for technical assis-
tance.
Machine is dead – no output – no
fans – no displays.
1. Check the main input fuses. If
open, replace.
1. If fuse (F1) quickly fails, per-
form the Auxiliary
Transformer Primary Wiring
Harness Test.
2. Make certain that the input
power switch (S1) is in the
“ON” position.
2. If fuse (F1) does not fail, per-
form the Auxiliary
3. Check for proper input voltage
– must match the rating on the
machine nameplate.
Transformer Test #1.
4. Make certain the reconnect
panel is configured properly for
the applied voltage.
5. Check fuse (F1) in the recon-
nect panel. If faulty, replace
with 5-amp slow-blow fuse.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, con-
tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-
800-833-9353.
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F-6
F-6
TROUBLESHOOTING & REPAIR
TROUBLESHOOTING GUIDE
Observe Safety Guidelines
detailed in the beginning of this manual.
PROBLEMS
(SYMPTOMS)
POSSIBLE AREAS OF
MISADJUSTMENT(S)
RECOMMENDED
COURSE OF ACTION
OUTPUT PROBLEMS
Machine has no output – fans are
running – display is on – a “click-
ing” sound is heard coming from
the machine.
1. Turn power OFF immediately.
1. Perform the Auxiliary
Transformer Test #1
2. Check for proper input voltage
(per machine nameplate).
2. Perform the Main Contactor
Test.
3. Make certain the reconnect
panel is configured properly for 3. Perform the Reconnect
the applied voltage.
Switch Test #1.
4. Perform the Reconnect
Switch Test #2.
5. Perform the Input Rectifier
Test.
6. Perform the Switch Board
Test.
7. Perform the Snubber and
Bleeder Resistor Test.
8. The protection board may be
faulty. Replace.
9. The input filter capacitors may
be faulty. Replace.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, con-
tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-
800-833-9353.
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F-7
F-7
TROUBLESHOOTING & REPAIR
TROUBLESHOOTING GUIDE
Observe Safety Guidelines
detailed in the beginning of this manual.
PROBLEMS
(SYMPTOMS)
POSSIBLE AREAS OF
MISADJUSTMENT(S)
RECOMMENDED
COURSE OF ACTION
OUTPUT PROBLEMS
Fans run slow or intermittently –
display is very dim – no weld out-
put.
1. Make certain the reconnect
panel and fuse (F1) jumper “A”
is configured properly for the
input voltage being applied.
1. Perform the Auxiliary
Transformer Test #1.
Machine has no output – no dis-
play – fans run – circuit breaker (5
amp) repeatedly trips.
1. Make sure that not more than
5 amps of auxiliary power are
being drawn.
1. The circuit breaker (5 amp)
may be faulty. Test or replace.
2. Perform the Auxiliary
Transformer #1 Secondary
and Wiring Harness Test.
2. Remove the wire feeder control
cable from the Power Wave. If
the symptom disappears, the
wire feeder or control cable is
faulty.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, con-
tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-
800-833-9353.
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F-8
F-8
TROUBLESHOOTING & REPAIR
TROUBLESHOOTING GUIDE
Observe Safety Guidelines
detailed in the beginning of this manual.
PROBLEMS
(SYMPTOMS)
POSSIBLE AREAS OF
MISADJUSTMENT(S)
RECOMMENDED
COURSE OF ACTION
OUTPUT PROBLEMS
Machine has no output – no fans
– no display. Main input fuses are
open indicating excessive input
current draw.
1. Check for proper input voltage
connections.
1. Perform the Input Power and
Wiring Harness Test.
2. Make certain the reconnect
panel is configured properly for
the applied voltage.
2. Perform the Input Rectifier
Test.
3. Perform the Reconnect
3. Replace the input fuses with
proper size and ratings.
Switch Test #1.
4. Perform the Switch Board
Test.
5. Perform the Snubber and
Bleeder Resistor Test.
Machine has no output – no dis-
play – fans run.
1. Check circuit breaker (5 amp)
located on the front panel.
Reset if necessary.
1. Perform the Auxiliary
Transformer Test #1.
2. Perform the Internal and
Auxiliary Supply Voltage Test.
Machine has no output – fans run
- Display flashes On and Off
repeatedly.
1. Check for loose or faulty con-
nections at the Power P.C.
1. Replace the Power P.C. Board.
Board. See Wiring Diagram.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, con-
tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-
800-833-9353.
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F-9
F-9
TROUBLESHOOTING & REPAIR
TROUBLESHOOTING GUIDE
Observe Safety Guidelines
detailed in the beginning of this manual.
PROBLEMS
(SYMPTOMS)
POSSIBLE AREAS OF
MISADJUSTMENT(S)
RECOMMENDED
COURSE OF ACTION
OUTPUT PROBLEMS
Circuit breaker (5 amp) trips when
gun trigger is pulled – fans run.
1. Make sure that not more than
5 amps of auxiliary power are
being used.
1. The 5 amp circuit breaker may
be faulty. Test or replace.
2. Perform the Trigger Circuit
2. Remove the wire feeder’s con-
trol cable(s) from the Power
Wave. If the symptoms disap-
pear, replace the wire feeder
and cables with known good
equipment. If the problem is
solved, the wire feeder or con-
trol cable is faulty.
and Wiring Harness Test.
The machine intermittently loses
output. The wire feeder still feeds
wire.
1. If after a few seconds the con-
tactor “pulls” back in, then
check for high input line
voltage.
1. Perform the Static Capacitor
Balance Test.
2. Perform the Welding
Feedback Test.
3. The control board may be
faulty. Replace.
4. The shunt board assembly may
be faulty. Replace.
5. Perform the Switch Board
Test.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, con-
tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-
800-833-9353.
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F-10
F-10
TROUBLESHOOTING & REPAIR
TROUBLESHOOTING GUIDE
Observe Safety Guidelines
detailed in the beginning of this manual.
PROBLEMS
(SYMPTOMS)
POSSIBLE AREAS OF
MISADJUSTMENT(S)
RECOMMENDED
COURSE OF ACTION
OUTPUT PROBLEMS
Machine has no welding output –
fans run – display is on.
1. Make sure that the machine
was powered up with a proper-
ly installed overlay. Without an
overlay installed in the Power
Wave, or an invalid overlay
installed, the machine will not
have welding output.
1. Perform the Wire Feeder
Trigger Circuit Test (#1 or #2)
for the appropriate wire feeder
receptacle (amphenol).
2. If a K941-1 Remote Control Kit
is attached to the Power Wave,
then perform the K941-1
Remote Control Kit Trigger
Circuit Test.
2. Check to see if the Limits or
Setup overlay is installed on
the front panel. These two
overlays cannot be used for
welding.
3. Perform the Reconnect
Switch Test #1.
4. Perform the Output Rectifier
3. Check for proper input voltage
per machine nameplate.
Diodes Test.
5. Perform the Switch Board
4. Make certain the reconnect
panel is configured properly.
Test.
6. Perform the Snubber and
5. Check to see that when the
trigger is pulled on the wire
Bleeder Resistor Test.
feeder the wire feeder’s voltage 7. Perform the Static Capacitor
display changes to indicate arc
voltage. If this does not hap-
pen, the feeder or control
cable may be faulty.
Balance Test.
8. Perform the Dynamic
Capacitor Balance Test.
6. Check wire feeder control
cable for loose or faulty con-
nections.
7. If the machine is connected for
380VAC or higher and has not
been used for a long period of
time, the capacitors may
require “conditioning.” Let the
Power Wave run at an idle
state for 30 minutes.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, con-
tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-
800-833-9353.
POWER WAVE 450
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F-11
F-11
TROUBLESHOOTING & REPAIR
TROUBLESHOOTING GUIDE
Observe Safety Guidelines
detailed in the beginning of this manual.
PROBLEMS
(SYMPTOMS)
POSSIBLE AREAS OF
MISADJUSTMENT(S)
RECOMMENDED
COURSE OF ACTION
OUTPUT PROBLEMS
Machine regularly overheats-yel-
low light (LED) on the front panel
glows, indicating a thermal over-
load. The display is on.
1. Welding application may
exceed recommended duty
cycle.
1. One of the thermostats located
on the output rectifier or FET
heat sink may be faulty. Test
or replace.
2. Dirt and dust may have
clogged the cooling channels
inside the machine. Refer to
the Maintenance Section of
this manual.
3. Air intake and exhaust louvers
may be blocked due to inade-
quate clearance around
machine.
4. Make sure both fans are func-
tioning correctly.
Machine does not appear to over- NONE
heat, but yellow light turns on and
off intermittently. Output is dis-
1. Check thermostats on output
rectifier and switch board #1.
These thermostats are normal-
ly closed.
abled whenever yellow light is on.
2. Check leads from thermal
switches to molex plug J23 on
the control board for loose or
faulty connections.
3. The control board may be
faulty. Replace, and perform
voltage calibration and current
calibration procedures.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, con-
tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-
800-833-9353.
POWER WAVE 450
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F-12
F-12
TROUBLESHOOTING & REPAIR
TROUBLESHOOTING GUIDE
Observe Safety Guidelines
detailed in the beginning of this manual.
PROBLEMS
(SYMPTOMS)
POSSIBLE AREAS OF
MISADJUSTMENT(S)
RECOMMENDED
COURSE OF ACTION
FUNCTION PROBLEMS
The voltage and or wire feed
speed will not adjust to user satis-
faction.
1. Certain limits may have been
imposed on the welding para-
meters. Refer to the Limits
NONE
Overlay section of this manual.
The voltage and or wire feed
speed can be adjusted on the
wire feeder, but the changes are
not shown on the Power Wave
display.
1. When the Limits Overlay or the 1. Try the other wire feeder
Setup Overlay is installed in
the Power Wave, the machine
and wire feeder displays do
not match. These overlays
cannot be used for welding.
receptacle. If the problem is
solved, the initial receptacle or
associated wiring is faulty.
2. If the problem persists with
both wire feeder receptacles,
check or replace the wire feed-
er and control cable.
2. If two wire feeders are con-
nected to the Power Wave,
only one of the feeder’s set-
tings can be displayed on the
Power Wave at one tme. Pull
the trigger of the wire feeder
whose settings you want dis-
played on the Power Wave.
3. If the wire feeder and control
cable are OK, then perform the
Serial Loop Wiring Harness
Test.
4. The display board may be
faulty. Replace and perform
voltage calibration.
5. The control board may be
faulty. Replace and perform
voltage calibration and current
calibration.
The Dual Procedure overlay is
installed, and the user cannot
change from procedure “A” to
procedure “B” or vice versa.
1. Check for proper installation of 1. Perform the Serial Loop
the Dual Procedure overlay.
Wiring Harness Test.
2. Check the Dual Procedure Gun
Trigger or separate dual proce-
dure switch.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, con-
tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-
800-833-9353.
POWER WAVE 450
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F-13
F-13
TROUBLESHOOTING & REPAIR
TROUBLESHOOTING GUIDE
Observe Safety Guidelines
detailed in the beginning of this manual.
PROBLEMS
(SYMPTOMS)
POSSIBLE AREAS OF
MISADJUSTMENT(S)
RECOMMENDED
COURSE OF ACTION
FUNCTION PROBLEMS
The display cannot be seen clear-
ly or cannot be seen at all.
1. Adjust the viewing angle of the 1. Perform the LCD Display Test.
display. Follow the instructions
provided in the Operation
Section of this manual. (Look
under the “LCD DISPLAY
ADJUSTMENTS” in the “CON-
TROLS AND SETTINGS” sub-
section of the Operation
Section.)
Machine does not respond to
keys being pressed, or the
machine has improper displays.
1. Each time an overlay is
changed, make certain that the
machine is powered-up with
the new overlay in place.
1. Using the test and calibration
overlay L9660-255, perform
the keyboard/LED test. See
overlay.
2. Make certain that the correct
overlay ID number is displayed
on power-up. Refer to the
Operation Section of this
manual for the overlay descrip-
tion.
2. Perform the Serial Loop
Wiring Harness Test.
3. Replace the control board and
perform voltage calibration and
current calibration.
4. Replace the display board and
perform voltage calibration.
3. In some cases, some of the
keys on the overlay may be
locked out. Refer to the
Operation Section of this
manual for the overlay descrip-
tions.
5. Replace the power board.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, con-
tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-
800-833-9353.
POWER WAVE 450
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F-14
F-14
TROUBLESHOOTING & REPAIR
TROUBLESHOOTING GUIDE
Observe Safety Guidelines
detailed in the beginning of this manual.
PROBLEMS
(SYMPTOMS)
POSSIBLE AREAS OF
MISADJUSTMENT(S)
RECOMMENDED
COURSE OF ACTION
FUNCTION PROBLEMS
Machine display reads “Error
Invalid Overlay,” or it displays an
invalid ID number on power-up.
1. Make certain the overlay is
installed properly.
1. Perform the Sensor
Calibration Test.
2. Inspect the infrared sensors on
the front panel. If they are
dirty, blow them out with low
pressure air and clean with a
soft cloth.
3. Inspect for damage to the Bar
Code(s) (black squares) on the
back of the overlay. Also
check for dirt build-up on back
of overlay. Wipe off with a soft
rag.
Machine displays “ERROR: S.L.
NOT INITIALIZED” on power-up.
1. Contact your local Lincoln
Authorized Field Service
Facility for technical assis-
tance.
1. Perform the Serial Loop
Wiring Harness Test.
2. The control board may be
faulty. Replace and perform
voltage calibration and current
calibration.
3. The display board may be
faulty. Replace and perform
voltage calibration.
4. The power board may be
faulty. Replace.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, con-
tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-
800-833-9353.
POWER WAVE 450
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F-15
F-15
TROUBLESHOOTING & REPAIR
TROUBLESHOOTING GUIDE
Observe Safety Guidelines
detailed in the beginning of this manual.
PROBLEMS
(SYMPTOMS)
POSSIBLE AREAS OF
MISADJUSTMENT(S)
RECOMMENDED
COURSE OF ACTION
FUNCTION PROBLEMS
The Beeper (Piezoelectric Buzzer)
cannot be heard – machine oper-
ating normally.
1. Background noise may be too
loud for user to hear beeper.
1. Perform the Piezoelectric
Buzzer Test.
2. The display board may be
faulty. Replace and perform
voltage calibration.
The welding parameters that were 1. Make certain that a remote
1. Check the continuity of wire
#445 (8J44 to 8J16).
saved in memory are different
when recalled.
control unit is NOT connected.
When a remote control unit is
used, the weld parameters are
set by the remote control
potentiometers.
2. The power board may be
faulty. Replace.
3. The display board may be
faulty. Replace.
The water cooler does not turn
on.
1. Make sure that the water cool-
er has been installed and also
enabled. Refer to the Setup
Overlay description in the
Operation Section of the
manual.
1. Perform the Auxiliary
Transformer #2 Test.
2. Check the continuity of leads
#453, 454, 455 & 456. From
plug J3 to J11. See wiring dia-
gram.
2. If the water cooler is enabled
but there is insufficient flow
rate in the water cooler hose,
the Power Wave will beep
loudly, and the water cooler
will shut down. Prime the
water cooler. Refer to the
Setup Overlay description in
the Operation Section of this
manual.
3. The display board may be
faulty. Replace.
4. The water cooler may be faulty.
3. The coolers circuit breaker
may have tripped. Reset if
necessary
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, con-
tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-
800-833-9353.
POWER WAVE 450
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F-16
F-16
TROUBLESHOOTING & REPAIR
TROUBLESHOOTING GUIDE
Observe Safety Guidelines
detailed in the beginning of this manual.
PROBLEMS
(SYMPTOMS)
POSSIBLE AREAS OF
MISADJUSTMENT(S)
RECOMMENDED
COURSE OF ACTION
FUNCTION PROBLEMS
The machine beeps without the
keys being pressed.
If the water cooler is enabled and
the flow switch inside the water
cooler opens (due to inadequate
coolant flow rate), the machine
indicates this by beeping. This
happens regardless of the overlay
placed on the machine. In this
case, do the following.
1. Perform the Auxiliary
Transformer #2 Test.
2. The water cooler may be
defective. Replace.
3. Check the continuity of lead
#453, 454, 455 & 456 from
plug J3 to J11. See wiring dia-
gram.
1. Turn the machine off and on a
couple of times and see if the
beeping continues. If the flow
rate dropped momentarily, then
turning the machine off and on
eliminates the beeping. A
momentary drop in flow rate
could be due to a temporary
restriction in the water cooler
hose.
4. The display board may be
faulty. Replace.
2. Check the water cooler and
accessory hoses for kinks,
internal obstructions or block-
age, or ruptures. If such prob-
lems were found then correct
them. Turn the machine Off
and On to check if the beeping
has been eliminated.
3. Check the water cooler fluid
level. Low coolant level could
cause the flow rate to drop.
4. Prime the water cooler. Refer
to the Setup Overlay section
of this manual for instructions.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, con-
tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-
800-833-9353.
POWER WAVE 450
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F-17
F-17
TROUBLESHOOTING & REPAIR
TROUBLESHOOTING GUIDE
Observe Safety Guidelines
detailed in the beginning of this manual.
PROBLEMS
(SYMPTOMS)
POSSIBLE AREAS OF
MISADJUSTMENT(S)
RECOMMENDED
COURSE OF ACTION
FUNCTION PROBLEMS
Foreign characters are shown on
the Power Wave display.
Contact your local Lincoln
Authorized Field Service Facility.
1. Make sure molex plug J19 is
plugged into the Display board
securely and the pins are
secure in the plug body.
2. The display board may be
faulty. Replace and perform
voltage calibration.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, con-
tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-
800-833-9353.
POWER WAVE 450
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F-18
F-18
TROUBLESHOOTING & REPAIR
TROUBLESHOOTING GUIDE
Observe Safety Guidelines
detailed in the beginning of this manual.
PROBLEMS
(SYMPTOMS)
POSSIBLE AREAS OF
MISADJUSTMENT(S)
RECOMMENDED
COURSE OF ACTION
FUNCTION PROBLEMS
The control knob on the Remote
Control Kit (K941-1) does not
change the preset current on the
Power Wave display.
1. Make sure that a stick welding
procedure is selected on the
Power Wave.
1. Perform the (K941-1) Remote
Control Kit Test or install a
new K941-1.
2. Make certain that the (K941-1)
remote control is securely
2. Perform the Internal Remote
Control Test.
plugged into the Power Wave 6
pin amphenol receptacle.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, con-
tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-
800-833-9353.
POWER WAVE 450
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F-19
F-19
TROUBLESHOOTING & REPAIR
TROUBLESHOOTING GUIDE
Observe Safety Guidelines
detailed in the beginning of this manual.
PROBLEMS
(SYMPTOMS)
POSSIBLE AREAS OF
MISADJUSTMENT(S)
RECOMMENDED
COURSE OF ACTION
WELDING PROBLEMS
Machine loses output while weld-
ing. Fans and display are func-
tioning properly.
1. Check the yellow High
Temperature light on the front-
panel. If the light is “ON,” then
refer to the Output Problems
section in this table relating to
this condition.
1. Perform the Welding
Feedback Test.
2. Perform the Switch Board
Test.
3. Perform the Snubber and
Bleeder Resistor Test.
2. Check for proper input volt-
ages (per machine nameplate).
4. Perform the Static Capacitor
Balance Test.
3. Check for balanced three-
phase input supply voltages.
5. Perform the Dynamic
Capacitor Test.
4. Check electrode and work
cables for loose or poor con-
nections.
6. Perform the appropriate Wire
Feeder Trigger Circuit Test.
If a K941-1 Remote Control Kit
is used, perform the K941-1
Remote Control Kit Trigger
Circuit Test.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, con-
tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-
800-833-9353.
POWER WAVE 450
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F-20
F-20
TROUBLESHOOTING & REPAIR
TROUBLESHOOTING GUIDE
Observe Safety Guidelines
detailed in the beginning of this manual.
PROBLEMS
(SYMPTOMS)
POSSIBLE AREAS OF
MISADJUSTMENT(S)
RECOMMENDED
COURSE OF ACTION
WELDING PROBLEMS
For no apparent reason the weld
characteristics have changed.
1. Check for proper wire feed
speed setting. In the
1. If zero arc voltage is displayed
while welding, the voltage
MIG/MAG and FCAW Modes,
check for proper voltage set-
tings. In the MIG/MAG Pulse
Modes, check the arc length
trim setting. These controls
are on the wire feeder. In the
Stick Mode, check for proper
preset current setting.
sense leads may be broken.
Check the following molex
plugs and associated wiring for
loose or faulty connections:
J60, J62 on the snubber board
J20 on the control board
2. Perform the Welding
Feedback Test.
2. Check for proper shielding gas
and gas flow.
3. The control board may be
faulty. Replace and perform
voltage calibration and current
calibration.
3. Check for loose or faulty weld-
ing cables.
The arc is “too hot,” and cannot
be adjusted.
1. Perform the full voltage cali-
bration.
1. Check plugs J60, J62 and J20
for loose or faulty connections.
See Wiring Diagram.
2. The snubber board may be
faulty. Replace and perform
full voltage calibration.
3. The control board may be
faulty. Replace and perform
voltage calibration and current
calibration.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, con-
tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-
800-833-9353.
POWER WAVE 450
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F-21
F-21
TROUBLESHOOTING & REPAIR
TROUBLESHOOTING GUIDE
Observe Safety Guidelines
detailed in the beginning of this manual.
PROBLEMS
(SYMPTOMS)
POSSIBLE AREAS OF
MISADJUSTMENT(S)
RECOMMENDED
COURSE OF ACTION
WELDING PROBLEMS
Machine often “noodle welds” with 1. The machine may be trying to
If problem occurs all the time -
change the control board.
a particular procedure.
deliver too much power. When
the average output current
exceeds a maximum limit, the
peak current is drastically cut
back. Lower the welding para-
meter settings and/or increase
the stickout length to eliminate
this problem.
Power Wave 450 – When the
average output current exceeds
540 amps, the peak output cur-
rent is folded back to 100 amps.
Erratic output or greater than 6
amps reading on display with no
output.
None
Replace shunt and lead assembly.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, con-
tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-
800-833-9353.
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F-22
F-22
TROUBLESHOOTING & REPAIR
PC BOARD CONNECTOR LOCATIONS
FIGURE F.1 – PC BOARD CONNECTOR LOCATIONS
POWER WAVE 450
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F-23
F-23
TROUBLESHOOTING & REPAIR
CAPACITOR DISCHARGE PROCEDURE
WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician or
machine operator and will invalidate your factory warranty. For your safety and to avoid elec-
trical shock, please observe all safety notes and precautions detailed throughout this manual.
If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou-
bleshooting assistance before you proceed. Call 1-800-833-9353 (WELD).
PURPOSE FOR THE PROCEDURE
This procedure will drain off any charge stored in the four large capacitors that are part of the
FET or IGBT switch board assembly. This procedure MUST be performed, as a safety pre-
caution, before conducting any test or repair procedure that requires you to touch internal
components of the machine.
MATERIALS NEEDED
Volt/Ohmmeter (Multimeter)
5/16" Nut driver
3/8" Nut driver
Insulated gloves
Jumper wire with insulated leads and needle-nose ends
High wattage resistor - 25 to 1000 ohms, 25 watts minimum
Piece of glastic board or similar insulating materials on which to secure the resistor
This procedure takes approximately 25 minutes to perform.
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F-24
F-24
TROUBLESHOOTING & REPAIR
CAPACITOR DISCHARGE PROCEDURE (continued)
TEST PROCEDURE
1. Remove main input supply power to the
machine.
7. Locate the two sets of two resistors on the
left side of the machine and three sets of
two resistors on the right side of the
machine. See Figure F.2. Do not touch the
resistors or any other internal machine
component. Using a DC voltmeter, check
for any DC voltage that may be present
across the terminals of each resistor and
from each resistor to case ground (20 mea-
surements in all). If a voltage is present, be
careful not to touch these resistors.
2. With the 3/8" nut driver, remove the screws
that hold the handle to the machine.
3. Remove the rubber gasket (cover seal)
from the lift bail.
4. With the 5/16" nut driver, remove the sheet
metal screws from the case top.
5. With the 5/16" nut driver, remove the
screws holding the right and left case
sides. Remove the case sides by lifting up
and out.
8. Locate terminals #9 and #12 on the switch
boards. They can be identified by the
“Discharge” labels, which are located on
each of the four switch boards. See Figure
F.3.
6. Obtain a high resistance and high wattage
resistor (25 - 1000 ohms, 25 watts mini-
mum). This resistor is not supplied with the
machine. Secure this resistor to a piece of
insulating material such as a glastic board.
See Figure F.4. NEVER USE A SHORTING
STRAP FOR THIS PROCEDURE.
FIGURE F.2 – RESISTOR LOCATIONS
5 PAIRS OF RESISTORS
CHECK VOLTAGES BETWEEN
EACH TERMINAL AND FROM
EACH RESISTOR TO CASE
GROUND
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F-25
F-25
TROUBLESHOOTING & REPAIR
CAPACITOR DISCHARGE PROCEDURE (continued)
FIGURE F.3 – DISCHARGE LABEL
D
I
D
I
D
I
S
C
H
A
R
G
E
S
C
H
A
R
G
E
S
C
H
A
R
G
E
D
I
D
I
S
C
H
A
R
G
E
S
C
H
A
R
G
E
WARNING
ELECTRIC SHOCK can kill.
Proceed with caution. Be careful not to touch any internal machine components
during the discharge procedure.
9. Using the insulated, needle nose type
10. Carefully connect the needle nose end of
one of the jumper leads to terminal #9.
See Figure F.5. Connect the needle nose
end of the other jumper lead to terminal
#12. Terminals #9 and #12 are indicated
by the "Discharge" label. Leave the resis-
tor connected for 10 seconds. DO NOT
TOUCH TERMINALS, RESISTORS, OR
ANY INTERNAL MACHINE COMPO-
NENTS DURING THIS PROCEDURE!
jumper leads and insulated gloves, con-
nect one jumper lead to one end of the
resistor obtained in step 6. Connect the
other jumper lead to the other end of the
resistor.
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F-26
F-26
TROUBLESHOOTING & REPAIR
CAPACITOR DISCHARGE PROCEDURE (continued)
FIGURE F.4 - RESISTOR WITH LEADS CONNECTED.
11. Check the voltage across terminals #9 and
12. Repeat discharge procedure steps 9, 10,
and 11 for each of the other three switch
boards of the FET or IGBT switch board
assembly.
#12 with the DC voltmeter. Terminal #9
has positive polarity and terminal #12 has
negative polarity. Voltage should be zero.
If any voltage remains, repeat this capaci-
tor discharge procedure.
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F-27
F-27
TROUBLESHOOTING & REPAIR
AUXILIARY TRANSFORMER TEST #1
WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician or
machine operator and will invalidate your factory warranty. For your safety and to avoid elec-
trical shock, please observe all safety notes and precautions detailed throughout this manual.
If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou-
bleshooting assistance before you proceed. Call 1-800-833-9353 (WELD).
TEST DESCRIPTION
This test will determine if the correct voltage is being applied to the primary of Auxiliary
Transformer #1 and also if the correct voltages are being induced on the secondary wind-
ings of the transformer.
MATERIALS NEEDED
Volt/Ohmmeter (Multimeter)
5/16" Nut driver
3/8" Nut driver
Input and Auxiliary Circuit Wiring Diagram – Figure F.6.
This procedure takes approximately 35 minutes to perform.
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F-28
F-28
TROUBLESHOOTING & REPAIR
AUXILIARY TRANSFORMER TEST #1 (continued)
FIGURE F.5 - TRANSFORMER T1 AND T2 LOCATION
3
2
4
1. AUXILIARY TRANSFORMER T1, PLUG
J5 LOCATED IN BASE
1
2. PROTECTION BOARD
3. PLUG J30
4. AUXILIARY TRANSFORMER T1
TEST PROCEDURE
1. Remove main input supply power to the
machine.
7. After you have completed the capacitor
discharge procedure for all four switch
boards, remove the PC board cover. Use
the 5/16" nut driver.
2. With the 3/8" nut driver, remove the 4
screws that hold the handle to the machine.
8. Remove plug J5 from the T2 transformer
located in the machine base assembly.
This is a 6-pin molex plug with 5 wires;
see Figure F. 5 for location. T2 is con-
nected in parallel with T1. Leaving the two
transformers connected in parallel for the
test might result in incorrect readings;
therefore plug J5 should be disconnected.
3. Remove the rubber gasket (cover seal) from
the lift bail.
4. With the 5/16" nut driver, remove the sheet
metal screws from the case top.
5. With the 5/16" nut driver, remove the
screws holding the right and left case sides.
Remove the case sides by lifting up and
out.
9. Remove plug J30 from the protection
board. See Figure F.1 for location of the
board and plug J30.
6. Perform the Capacitor Discharge Proce-
dure described earlier in this section of the
manual.
10. Remove the 5 leads ( 3 heavy and 2 small)
T1, T2, T3 from main input contactor CR1.
This is a safety precaution. It prevents
high voltage from being put on the
machine during the test. Wrap tape
around the lead ends to insulate them and
prevent them from touching.
WARNING
Before continuing with the
test procedure, perform the
capacitor discharge proce-
dure to avoid electric shock.
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F-29
F-29
TROUBLESHOOTING & REPAIR
AUXILIARY TRANSFORMER TEST #1 (continued)
11. Remove plugs J32 and J33 from the pro-
If these voltages are wrong or missing, check
the associated wiring to the transformer prima-
ry. Check the leads at power switch S1. See
the Input and Auxiliary Circuit Wiring Diagram,
Figure F.6.
tection board.
12. Turn the main input supply power to the
machine back ON.
If the correct voltages are applied to the pri-
mary and the secondary voltages are incorrect,
the transformer may be faulty. Replace the
WARNING
ELECTRIC SHOCK
can kill.
transformer.
Refer to the T1 Auxiliary
Transformer Removal and Replacement
procedure in this section of the manual.
Proceed with caution. Be
careful not to touch any
internal machine compo-
nents during the remainder of the test proce-
dure.
14. After the test is completed and the prob-
lem successfully repaired, reconnect
plugs J30, J32 and J33 to the protection
board.
15. Reconnect plug J5 to the T2 transformer.
13. Check for the correct AC voltage at plugs
J32 and J33 as follows. (DO NOT CHECK
THE VOLTAGE ON THE PROTECTION
BOARD!)
16. Reconnect the 5 leads to the main con-
tactor CR1.
17. Install the PC board cover.
Test A: J33 - pin 1 (lead 32A) to J33 - pin
3 (lead 333) = 42 VAC
18. Install the machine case sides and top.
19. Install the handle and the lift bail rubber
gasket.
Test B: J33-1 (32A) to J33-4 (334) = 24
VAC
Test C: J32-1 (321) to J32-3 (323) = 24
VAC
Test D: J33-1 (leads 32A) to J33-6
(lead 336) = 115VAC.
If the voltage checks are good, then Auxiliary
Transformer #1 is good.
If Test C is good but Tests A and B are not cor-
rect, check the 5 amp circuit breaker (located
on the front panel of the machine). See the
Input and Auxiliary Circuit Wiring Diagram,
Figure F.6.
If all the secondary voltages are wrong or miss-
ing, check the associated wiring to the trans-
former primary. These voltages are most eas-
ily checked at the terminal strip. The correct
voltages are as follows:
H1 to H2 = 200 - 208 VAC
H1 to H3 = 220 - 230 VAC
H1 to H4 = 380 - 415 VAC
H1 to H5 = 440 - 460 VAC
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F-30
F-30
TROUBLESHOOTING & REPAIR
FIGURE F.6 – INPUT AND AUXILIARY CIRCUIT WIRING DIAGRAM
POWER WAVE 450
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F-31
F-31
TROUBLESHOOTING & REPAIR
AUXILIARY TRANSFORMER TEST #2
WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician or
machine operator and will invalidate your factory warranty. For your safety and to avoid elec-
trical shock, please observe all safety notes and precautions detailed throughout this manual.
If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou-
bleshooting assistance before you proceed. Call 1-800-833-9353 (WELD).
TEST DESCRIPTION
This test will determine if the correct voltage is being applied to the primary of Auxiliary
Transformer #2 and also if the correct voltages are being induced on the secondary wind-
ings of the transformer. Note: Transformer #2 is not present on all models.
MATERIALS NEEDED
Volt/Ohmmeter (Multimeter)
5/16" Nut driver
3/8" Nut driver
Input and Auxiliary Circuit Wiring Diagram – Figure F.8
This procedure takes approximately 35 minutes to perform.
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F-32
F-32
TROUBLESHOOTING & REPAIR
AUXILIARY TRANSFORMER TEST #2 (continued)
FIGURE F.7 - TRANSFORMER T1 AND T2 LOCATION
2
3
1
1. AUXILIARY TRANSFORMER T1 WITH
PLUG J73
2. PLUG J30
3. PROTECTION BOARD
TEST PROCEDURE
1. Remove main input supply power to the
machine.
7. After you have completed the capacitor
discharge procedure for all four switch
boards, remove the PC board cover. Use
the 5/16" nut driver.
2. With the 3/8" nut driver, remove the 4
screws that hold the handle to the machine.
8. Remove plug J73 from the T1 transformer.
T2 is connected in parallel with T1.
Leaving the two transformers connected
in parallel for the test might result in incor-
rect readings; therefore plug J73 should
be disconnected.
3. Remove the rubber gasket (cover seal) from
the lift bail.
4. With the 5/16" nut driver, remove the sheet
metal screws from the case top.
5. With the 5/16" nut driver, remove the
screws holding the right and left case sides.
Remove the case sides by lifting up and
out.
9. Remove plug J30 from the protection
board. See Figure F.1 for location of the
board and plug J30.
6. Perform the Capacitor Discharge Proce-
dure described earlier in this section of the
manual.
10. Remove the 5 leads ( 3 heavy and 2 small)
T1, T2, T3 from main input contactor CR1.
This is a safety precaution. It prevents
high voltage from being put on the
machine during the test. Wrap tape
around the lead ends to insulate them and
prevent them from touching.
WARNING
Before continuing with the
test procedure, perform the
capacitor discharge proce-
dure to avoid electric shock.
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F-33
F-33
TROUBLESHOOTING & REPAIR
AUXILIARY TRANSFORMER TEST #2 (continued)
11. To conduct this test, you will be measuring
If this voltage is wrong or missing, check the
associated wiring to the transformer primary.
the voltage between pin 2 and pin 5 of
plug J4. The plug is located in the
machine undercarriage and is somewhat
difficult to reach. It is probably easiest to
disconnect the plug and insert the probes
of your voltmeter alongside pins 2 and 5
before turning on input power, which is the
next step.
If the correct voltage IS applied to the primary
but the voltage at H1A to H3A is not correct,
the transformer may be faulty. Replace the
transformer. Refer to the T2 Auxiliary Trans-
former
Removal
and
Replacement
Procedure in this section of the manual.
14. After the test is completed and the prob-
lem successfully repaired, reconnect plug
J30 to the protection board.
12. Turn the main input supply power to the
machine back ON.
15. Reconnect plug J73 to the T1 transformer.
WARNING
16. Reconnect the 5 leads to the main con-
tactor CR1.
ELECTRIC SHOCK
can kill.
17. Install the PC board cover.
Proceed with caution. Be
careful not to touch any
internal machine components during the
remainder of the test procedure.
18. Install the machine case sides and top.
19. Install the handle and the lift bail rubber
gasket.
13. Check for the correct AC voltage between
plug J4 - pin 2 and J4 - pin 5. It should be
220 - 230 VAC.
If the voltage is correct, then Auxiliary
Transformer #2 is good.
If the voltage is wrong or missing, check the
associated wiring to the transformer primary.
See the Input and Auxiliary Circuit Wiring
Diagram, Figure F.8. These voltages are most
easily checked at the terminal strip. The cor-
rect voltages are as follows:
H1A to H3A = 220 - 230 VAC
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F-34
F-34
TROUBLESHOOTING & REPAIR
FIGURE F.8 – INPUT AND AUXILIARY CIRCUIT WIRING DIAGRAM
POWER WAVE 450
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F-35
F-35
TROUBLESHOOTING & REPAIR
AUXILIARY TRANSFORMER PRIMARY WIRING HARNESS TEST
WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician or
machine operator and will invalidate your factory warranty. For your safety and to avoid electri-
cal shock, please observe all safety notes and precautions detailed throughout this manual.
If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting
assistance before you proceed. Call 1-800-833-9353 (WELD).
TEST DESCRIPTION
This test will determine if there are any short circuits or other problems in the circuit feeding the
primary windings of the auxiliary transformers, which would cause the fuse (F1) on the recon-
nect panel to blow.
MATERIALS NEEDED
Volt/Ohmmeter (Multimeter)
5/16" Nut driver
3/8" Nut driver
Input and Auxiliary Circuit Wiring Diagram – Figure F.10
Machine Wiring Diagram in the Electrical Diagrams section of this manual
Protection PC Board Schematic in the Electrical Diagrams section of this manual
This procedure takes approximately 20 minutes to perform.
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F-36
F-36
TROUBLESHOOTING & REPAIR
AUXILIARY TRANSFORMER PRIMARY WIRING HARNESS TEST (continued)
FIGURE F.9 - RECONNECT PANEL/TERMINAL STRIP LOCATION
1
2
3
4
1. RECONNECT PANEL (ON LEFT SIDE)
2. TERMINAL STRIP
3. FAN MOTORS
4. AUXILIARY TRANSFORMERS
TEST PROCEDURE
1. Remove main input supply power to the
machine.
7. After you have completed the capacitor
discharge procedure for all four switch
boards, remove the PC board cover. Use
the 5/16" nut driver.
2. With the 3/8" nut driver, remove the 4
screws that hold the handle to the machine.
8. Remove the 5 leads ( 3 heavy and 2 small)
T1, T2, T3 from main input contactor CR1.
This is a safety precaution. It prevents
high voltage from being put on the
machine during the test. Wrap tape
around the lead ends to insulate them and
prevent them from touching.
3. Remove the rubber gasket (cover seal) from
the lift bail.
4. With the 5/16" nut driver, remove the sheet
metal screws from the case top.
5. With the 5/16" nut driver, remove the
screws holding the right and left case sides.
Remove the case sides by lifting up and
out.
9. Remove plug J30 from the protection
board. See Figure F.1 for location of the
board and plug J30.
6. Perform the Capacitor Discharge
Procedure described in this section of the
manual.
NOTE: If removing plug J30 solves the prob-
lem, check for a short circuit or a fault in the 24
VAC circuit (plug P71) and the main contactor
coil. See the Input and Auxiliary Circuit Wiring
Diagram, Figure F.10.
WARNING
Before continuing with the
test procedure, perform the
capacitor discharge proce-
dure to avoid electric shock.
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F-37
F-37
TROUBLESHOOTING & REPAIR
AUXILIARY TRANSFORMER PRIMARY WIRING HARNESS TEST (continued)
10. Check the wires that run from the recon-
nect panel to the terminal strip. Look for
shorts between wires caused by broken or
burned insulation. See the Input and
Auxiliary Circuit Wiring Diagram, Figure
F.10.
14. After the test is completed and the prob-
lem successfully repaired, reconnect plug
J30 to the protection board.
15. Reconnect plugs P70 and P71 to the T1
transformer.
16. Reconnect the 5 leads to the main con-
tactor CR1.
11. Check for shorts in the wires that run from
the terminal strip to the auxiliary trans-
formers and to the fan motors.
17. Install the PC board cover.
12. The fan motors or the auxiliary transformer
may be faulty. Disconnect these compo-
nents one at a time and see if fuse F1
blows when input power is applied. The
internal resistance of the fan motors
should be about 16 ohms.
18. Install the machine case sides and top.
19. Install the handle and the lift bail rubber
gasket.
13. Remove plug P70 from the transformer. If
this solves the problem, check for a short
in the secondary circuit. See the machine
Wiring Diagram and the Protection PC
Board Schematic in the Electrical
Diagrams section of this manual.
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F-38
F-38
TROUBLESHOOTING & REPAIR
FIGURE F.10 – INPUT AND AUXILIARY CIRCUIT WIRING DIAGRAM
POWER WAVE 450
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F-39
F-39
TROUBLESHOOTING & REPAIR
AUXILIARY TRANSFORMER #1 SECONDARY
AND WIRING HARNESS TEST
WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician or
machine operator and will invalidate your factory warranty. For your safety and to avoid elec-
trical shock, please observe all safety notes and precautions detailed throughout this manual.
If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou-
bleshooting assistance before you proceed. Call 1-800-833-9353 (WELD).
TEST DESCRIPTION
This test will determine if there are any short circuits or other problems in the load circuits
fed by the secondary windings of the auxiliary transformer, which would cause the trans-
former to overheat or the fuse (F1 - primary side) on the reconnect panel to blow.
MATERIALS NEEDED
Volt/Ohmmeter (Multimeter)
5/16" Nut driver
3/8" Nut driver
Auxiliary Transformer #1 Secondary Circuit Wiring Diagram – Figure F.12
This procedure takes approximately 30 minutes to perform.
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F-40
F-40
TROUBLESHOOTING & REPAIR
AUXILIARY TRANSFORMER #1 SECONDARY AND WIRING HARNESS TEST (continued)
FIGURE F.11 - PLUG AND RECEPTACLE INSPECTION POINTS
1
6
5
4
1. WIRE FEEDER RECEPTACLES
2. SQUARE WAVE TIG PROTECTION BOARD
3. DISPLAY BOARD
2
4. PROTECTION BOARD
5. CONTROL BOARD
6. POWER BOARD
3
7. After you have completed the capacitor dis-
TEST PROCEDURE
charge procedure for all four switch boards,
1. Remove main input supply power to the
remove the PC board cover. Use the 5/16"
machine.
nut driver.
2. With the 3/8" nut driver, remove the 4
8. Disconnect all plugs and wirefeeder recep-
screws that hold the handle to the machine.
tacles associated with the auxiliary trans-
former secondary. This is done to isolate
the machine electrically. Inspect all the dis-
connected plugs and receptacles, looking
for shorted pins and wires. See the
Auxiliary Transformer #1 Secondary Circuit
Wiring Diagram, Figure F.12, for the specif-
ic plugs and receptacles to check, which
include:
3. Remove the rubber gasket (cover seal) from
the lift bail.
4. With the 5/16" nut driver, remove the sheet
metal screws from the case top.
5. With the 5/16" nut driver, remove the
screws holding the right and left case sides.
Remove the case sides by lifting up and
out.
• WF2 Receptacle
6. Perform the Capacitor Discharge Proce-
dure described earlier in this section of the
manual.
• WF1 Receptacle
• Square Wave TIG Protection Board
• Display Board
• Power Board
WARNING
• Protection Board
Before continuing with the
test procedure, perform the
capacitor discharge proce-
dure to avoid electric shock.
9. Check for shorts on the associated PC
boards. See the Auxiliary Transformer #1
Secondary Circuit Wiring Diagram, Figure
F.12.
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F-41
F-41
TROUBLESHOOTING & REPAIR
AUXILIARY TRANSFORMER #1 SECONDARY AND WIRING HARNESS TEST (continued)
10. Check for shorts at plugs J33, J34, J35,
J37, and J38 on the protection board.
Inspect the board for evidence of arcing.
11. After the test is completed and the prob-
lem successfully repaired, reconnect all
plugs disconnected for the test.
12. Install the PC board cover.
13. Install the machine case sides and top.
14. Install the handle and the lift bail rubber
gasket.
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F-42
F-42
TROUBLESHOOTING & REPAIR
FIGURE F.12
AUXILIARY TRANSFORMER #1 SECONDARY CIRCUIT WIRING DIAGRAM
6
4 2 V
1
J 4 3
3 5 6
3 5 1
J 3 5
1
J 3 5
C O M M O N 3
J 4 3
3
C O M M O N 4
J 1 3
3 7 3
3 7 1
3 7 2
3 7 4
J 3 7
1
C O M M O N 2
J 3 7
J 1 2
2
I G T 2 R
2
4
J 1 3
J 1 2
J 3 7
4
1
R T I G
J 3 7
2
I G T 1 R
2 4 V
3
J 9 2
J 9 2
J 3 8
2 9 3
2 9 6
3
6
J 3 8
1 4
I G T 1 R
1 1 5 V
2 4 V
D
J
1 0 5 A
3 1 B
1 0 2 B
4 2 B
3 2 C
3 2 B
J 3 4
8
J 3 4
1 1
C
K
J 3 4
1 0
J 3 4
1 3
J 3 4
4 2 V
C O M M O N I
C O M M O N A
1 2
J 3 4
7
J 3 4
1
I G T 2 R
D
J
1 0 6 A
3 1 C
1 0 2 D
4 2 C
3 2 E
1 1 5 V
2 4 V
J 3 4
4
C
K
J 3 4
3
4 2 V
J 3 4
6
C O M M O N I
C O M M O N A
J 3 4
5
J 3 4
3 2 D
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F-43
F-43
TROUBLESHOOTING & REPAIR
INPUT POWER AND WIRING HARNESS TEST
WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician or
machine operator and will invalidate your factory warranty. For your safety and to avoid elec-
trical shock, please observe all safety notes and precautions detailed throughout this manual.
If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou-
bleshooting assistance before you proceed. Call 1-800-833-9353 (WELD).
TEST DESCRIPTION
This test will determine if there are any short circuits or other problems on the input power
circuit that would cause the input fuses to repeatedly blow.
MATERIALS NEEDED
Volt/Ohmmeter (Multimeter)
5/16" Nut driver
3/8" Nut driver
Input and Auxiliary Circuit Wiring Diagram – Figure F.14
This procedure takes approximately 20 minutes to perform.
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F-44
F-44
TROUBLESHOOTING & REPAIR
INPUT POWER AND WIRING HARNESS TEST
FIGURE F.13 - INPUT POWER INSPECTION POINTS
2
3
1
1. POWER SWITCH (S1)
2. MAIN CONTACTOR INPUT LEADS (TOP)
3. PROTECTION BOARD
7. After you have completed the capacitor dis-
charge procedure for all four switch boards,
remove the PC board cover. Use the 5/16"
nut driver.
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.
8. Manually check the power switch (S1) for
proper operation by turning it back and
forth. At the back of the front panel where
the switch is mounted, make a visual
inspection. Be sure the input and output
leads are not shorted together. Make sure
the switch contacts are not fused together
or shorted to another phase. (Because of
the high input voltage involved, you should
be able to see physical evidence if any of
these problems exist.) Remove the tape
covering the switch and check the switch
with an ohmmeter. High resistance should
be present.
3. Remove the rubber gasket (cover seal) from
the lift bail.
4. With the 5/16" nut driver, remove the sheet
metal screws from the case top.
5. With the 5/16" nut driver, remove the
screws holding the right and left case sides.
Remove the case sides by lifting up and
out.
6. Perform the Capacitor Discharge Pro-
cedure described earlier in this section of
the manual.
WARNING
Before continuing with the
test procedure, perform the
capacitor discharge proce-
dure to avoid electric shock.
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F-45
F-45
TROUBLESHOOTING & REPAIR
INPUT POWER AND WIRING HARNESS TEST (continued)
9. Check for shorts or fusing at the input
(top) leads to the main contactor.
10. Remove plug J30 from the protection
board. Check the resistance on the J30
header (the plug mounted on the board)
between pin 1 and pin 6. Resistance
should be very high. If resistance is low or
zero ohms, the protection board is faulty.
11. Check plug J30 and associated wires for
shorts or damaged connections. See the
Input and Auxiliary Circuit Wiring Diagram,
Figure F.14.
12. If any of the tests reveal signs of heavy
current flow, check the switch boards and
the input rectifier. Refer to the Switch
Board Test and the Input Rectifier
Resistance Test in this section of the
manual.
13. After the test is completed and the prob-
lem successfully repaired, reconnect all
plugs disconnected for the test.
14. Install the PC board cover.
15. Install the machine case sides and top.
16. Install the handle and the lift bail rubber
gasket.
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F-46
F-46
TROUBLESHOOTING & REPAIR
FIGURE F.14 – INPUT AND AUXILIARY CIRCUIT WIRING DIAGRAM
POWER WAVE 450
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F-47
F-47
TROUBLESHOOTING & REPAIR
INPUT RECTIFIER RESISTANCE TEST
WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician or
machine operator and will invalidate your factory warranty. For your safety and to avoid elec-
trical shock, please observe all safety notes and precautions detailed throughout this manual.
If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou-
bleshooting assistance before you proceed. Call 1-800-833-9353 (WELD).
TEST DESCRIPTION
This test will determine if any of the internal diodes in the three-phase rectifier are shorted
or open.
MATERIALS NEEDED
Analog Volt/Ohmmeter (Multimeter)
5/16" Nut driver
3/8" Nut driver
Machine Wiring Diagram in the Electrical Diagrams section of this manual
This procedure takes approximately 35 minutes to perform.
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F-48
F-48
TROUBLESHOOTING & REPAIR
INPUT RECTIFIER RESISTANCE TEST (continued)
FIGURE F.15 - RECONNECT SWITCH LOCATION
3
1
2
1. RECONNECT SWITCH
2. INPUT RECTIFIER
3. MAIN CONTACTOR
WARNING
TEST PROCEDURE
Before continuing with the
test procedure, perform the
capacitor discharge proce-
dure to avoid electric shock.
1. Remove main input supply power to the
machine.
2. With the 3/8" nut driver, remove the 4
screws that hold the handle to the machine.
3. Remove the rubber gasket (cover seal) from
the lift bail.
7. After you have completed the capacitor dis-
charge procedure for all four switch boards,
use the 5/16" nut driver to remove the two
5/16" sheet metal screws holding the
reconnect switch assembly. Twist the
reconnect switch out to access the lead
connections on the back.
4. With the 5/16" nut driver, remove the sheet
metal screws from the case top.
5. With the 5/16" nut driver, remove the
screws holding the right and left case sides.
Remove the case sides by lifting up and
out.
8. Use the 3/8" wrench to disconnect the two
negative leads from the reconnect switch.
By disconnecting the leads at the recon-
nect switch, you will not have to disturb the
silicon applied to the input rectifier.
Electrically isolate the leads from all other
leads.
6. Perform the Capacitor Discharge
Procedure described earlier in this section
of the manual.
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F-49
F-49
TROUBLESHOOTING & REPAIR
INPUT RECTIFIER RESISTANCE TEST (continued)
9. Check all leads connected to the input
11. After the test is completed and the prob-
lem successfully repaired, reconnect the
negative leads to the reconnect switch.
Fasten the reconnect switch assembly
back into position on the machine.
rectifier. Check for looseness or shorted
wires.
10. Using an analog type meter, perform the
resistance test Steps A through L accord-
ing to the Table F.1.
NOTE: If input rectifier was shorted, other
components may be faulty.
Perform Field Effect Transistor/
Switch Board Test and check for
“leaky” or “shorted” capacitors.
NOTE: If terminals AC1, AC2, and AC3 of
the input rectifier are not easily
accessible, use terminals T1, T2,
and T3, respectively, of main con-
tactor CR1 for the resistance mea-
surements. Similarly, if terminals
POS and NEG of the input rectifier
are not easily accessible, use ter-
minals POS and NEG of the recon-
nect switch for the resistance mea-
surements.
12. Install the machine case sides and top.
13. Install the handle and the lift bail rubber
gasket.
TABLE F.1 – INPUT RECTIFIER RESISTANCE VALUES
Place Place
+ Lead - Lead
Step
(See
Note) Test for
on . . .
on . . .
If . . .
Then . . .
A
B
C
D
E
F
G
H
I
1K Ohms
POS
AC1
>1K Ohms
<100 Ohms
Go to step B.
Tested failed.
1K Ohms
POS
POS
AC1
AC2
AC3
AC1
AC2
AC3
NEG
NEG
NEG
AC2
AC3
NEG
NEG
NEG
POS
POS
POS
AC1
AC2
AC3
>1K Ohms
<100 Ohms
Go to step C.
Tested failed.
1K Ohms
>1K Ohms
<100 Ohms
Go to step D.
Tested failed.
1K Ohms
>1K Ohms
<100 Ohms
Go to step E.
Tested failed.
1K Ohms
>1K Ohms
<100 Ohms
Go to step F.
Tested failed.
1K Ohms
>1K Ohms
<100 Ohms
Go to step G.
Tested failed.
<100 Ohms
<100 Ohms
<100 Ohms
<100 Ohms
<100 Ohms
<100 Ohms
<100 Ohms
>1K Ohms
Go to step H.
Test failed.
<100 Ohms
>1K Ohms
Go to step I.
Test failed.
<100 Ohms
>1K Ohms
Go to step J.
Test failed.
J
<100 Ohms
>1K Ohms
Go to step K.
Test failed.
K
L
<100 Ohms
>1K Ohms
Go to step L.
Test failed.
<100 Ohms
>1K Ohms
Input Rectifier OK
Test failed.
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F-50
F-50
NOTES
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F-51
F-51
TROUBLESHOOTING & REPAIR
OUTPUT SHUNT/WELDING FEEDBACK TEST
WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician or
machine operator and will invalidate your factory warranty. For your safety and to avoid elec-
trical shock, please observe all safety notes and precautions detailed throughout this manual.
If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou-
bleshooting assistance before you proceed. Call 1-800-833-9353 (WELD).
TEST DESCRIPTION
The following procedure will determine whether the shunt amplifier board is receiving the
correct supply voltage from the control board and providing the correct feedback voltage.
MATERIALS NEEDED
Volt/Ohmmeter (Multimeter)
5/16" Nut driver
3/8" Nut driver
Machine Wiring Diagram in the Electrical Diagrams section of this manual
Load Bank
This procedure takes approximately 40 minutes to perform.
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F-52
F-52
TROUBLESHOOTING & REPAIR
QUICK SHUNT TEST
TEST PROCEDURE
1. Remove main input supply power to the
Power Wave 450.
2. Disconnect the Output leads from the
machine.
3. If a wire feeder is connected to the Power
Wave 450, release the drive roll tension so
the unit will not feed wire when the trigger is
activated.
4. Turn on the Power Wave 450 and activate
the gun trigger and hold for several sec-
onds. Trigger the machine on and off sev-
eral times in this manner and observe the
display. The “I=” reading should be less
than five amps when the machine is trig-
gered and NOT welding.
5. If after several trigger cycles the “I=” value
is at or above 5 amps the shunt assembly is
suspect and should be replaced.
6. If the “I=” value is below 5 amps when the
trigger is activated and not welding, the sta-
bility of the shunt assembly is at an accept-
able level.
7. To further test the shunt assembly, continue
with the output shunt/welding feedback
test.
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F-53
F-53
TROUBLESHOOTING & REPAIR
OUTPUT SHUNT/WELDING FEEDBACK TEST (continued)
FIGURE F.16 - SHUNT AMPLIFIER BOARD LOCATION
1
1. SHUNT AMPLIFIER BOARD
TEST PROCEDURE
WARNING
1. Remove main input supply power to the
machine.
Before continuing with the
test procedure, perform the
capacitor discharge proce-
dure to avoid electric shock.
2. With the 3/8" nut driver, remove the 4
screws that hold the handle to the machine.
3. Remove the rubber gasket (cover seal) from
the lift bail.
7. After you have completed the capacitor dis-
charge procedure for all four switch boards,
locate plug J50 at the shunt amplifier
board. Locate the plug and insert your
voltmeter positive (+) probe into pin 3 and
negative probe (-) into pin 1. Right-angle
probes are recommended.
4. With the 5/16" nut driver, remove the sheet
metal screws from the case top.
5. With the 5/16" nut driver, remove the
screws holding the right and left case sides.
Remove the case sides by lifting up and
out.
6. Perform the Capacitor Discharge
Procedure described earlier in this section
of the manual.
8. Turn supply power to the machine ON.
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F-54
F-54
TROUBLESHOOTING & REPAIR
OUTPUT SHUNT/WELDING FEEDBACK TEST (continued)
12. If the supply voltage readings are correct,
WARNING
load the machine to 400 amps.
CAUTION
ELECTRIC SHOCK
can kill.
Do not run the machine under load for more
than 15 sec. with case removed.
Proceed with caution. Be
careful not to touch any inter-
nal machine components during the remainder
of the test procedure.
13. Use a current probe to check for 5 ma of
current through lead #218 (plug J50 - pin
4). This also reads approximately 1 VDC if
you use a voltmeter.
9. Check for +15 VDC between plug J50 -
pin 3+ and J50 - pin 1-.
14. If the current reading is NOT correct, the
shunt amplifier board may be faulty.
Replace the shunt amplifier assembly and
perform current calibration.
10. Carefully move the probes, placing the
negative probe (-) at plug J50 - pin 6 and
the positive (+) probe at J50 - pin 1.
Check for -15 VDC.
15. If the current reading IS correct, the con-
trol board may be faulty. Replace the con-
trol board. Refer to the Printed Circuit
Board Removal and Replacement proce-
dure in this section of the manual.
11. If the voltage readings are NOT correct,
check the associated wiring to the control
board. If the wiring is okay, the control
board may be faulty. Replace the control
board. Refer to the Printed Circuit Board
Removal and Replacement Procedure
in this section of the manual.
16. After the test is completed and the prob-
lem successfully repaired, install the
machine case sides and top.
17. Install the handle and the lift bail rubber
gasket.
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F-55
F-55
TROUBLESHOOTING & REPAIR
PIEZO-ELECTRIC ALARM BUZZER TEST
WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician or
machine operator and will invalidate your factory warranty. For your safety and to avoid elec-
trical shock, please observe all safety notes and precautions detailed throughout this manual.
If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou-
bleshooting assistance before you proceed. Call 1-800-833-9353 (WELD).
DESCRIPTION
The following procedure will determine whether the piezo-electric alarm buzzer is function-
ing properly.
MATERIALS NEEDED
Volt/Ohmmeter (Multimeter)
5/16" Nut driver
3/8" Nut driver
Machine Wiring Diagram in the Electrical Diagrams section of this manual
This procedure takes approximately 30 minutes to perform.
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F-56
F-56
TROUBLESHOOTING & REPAIR
PIEZO-ELECTRIC ALARM BUZZER TEST
FIGURE F.17 - ALARM BUZZER LOCATION
2
1. LEADS 300, 301 TO PLUG J15 ON
DISPLAY BOARD
2. PIEZO-ELECTRIC ALARM BUZZER
1
7. After you have completed the capacitor
discharge procedure for all four switch
boards, locate and remove plug J15 from
the display board. See Figure F.17 for
location.
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.
8. Using lead #300 as positive (+) and lead
#301 as negative (-), apply 12 to 15 VDC
to the piezo-electric buzzer.
3. Remove the rubber gasket (cover seal) from
the lift bail.
9. If the buzzer does not work, replace it.
4. With the 5/16" nut driver, remove the sheet
metal screws from the case top.
10. If the buzzer does work, the display board
may be faulty. Replace the display board.
Refer to the Display Board Replacement
procedure in this section of the manual.
5. With the 5/16" nut driver, remove the
screws holding the right and left case sides.
Remove the case sides by lifting up and
out.
11. After the test is completed and the prob-
lem successfully repaired, reconnect plug
J15 to the display board.
6. Perform the Capacitor Discharge
Procedure described earlier in this section
of the manual.
12. Install the machine case sides and top.
13. Install the handle and the lift bail rubber
gasket.
WARNING
Before continuing with the
test procedure, perform the
capacitor discharge proce-
dure to avoid electric shock.
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F-57
F-57
TROUBLESHOOTING & REPAIR
OUTPUT RECTIFIER DIODES TEST
WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician or
machine operator and will invalidate your factory warranty. For your safety and to avoid elec-
trical shock, please observe all safety notes and precautions detailed throughout this manual.
If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou-
bleshooting assistance before you proceed. Call 1-800-833-9353 (WELD).
TEST DESCRIPTION
The following procedure will determine whether one of the output rectifier diodes is
shorted. If one of the diodes is shorted, the output rectifier assembly must be replaced.
MATERIALS NEEDED
Analog Volt/Ohmmeter (Multimeter)
5/16" Nut driver
3/8" Nut driver
Machine Wiring Diagram in the Electrical Diagrams section of this manual
This procedure takes approximately 15 minutes to perform.
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F-58
F-58
TROUBLESHOOTING & REPAIR
OUTPUT RECTIFIER DIODES TEST
FIGURE F.18 - SNUBBER BOARD, OUTPUT TERMINAL LOCATION
1
2
1. PC BOARD FRONT/BOTTOM COVER
2. SNUBBER PC BOARD
3. NEGATIVE OUTPUT TERMINAL
4. POSITIVE OUTPUT TERMINAL
3
4
7. After you have completed the capacitor
discharge procedure for all four switch
boards, disconnect plug J62 from the
snubber board. See Figure F.18 for loca-
tion.
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.
8. Remove any output load that may be con-
nected to the machine.
3. Remove the rubber gasket (cover seal) from
the lift bail.
9. With the volt/ohmmeter, measure the
resistance between the positive and neg-
ative output terminals. IMPORTANT: The
positive (+) probe must be attached to
the positive (+) output terminal and the
negative probe (-) must be attached to
the negative (-) output terminal.
4. With the 5/16" nut driver, remove the sheet
metal screws from the case top.
5. With the 5/16" nut driver, remove the
screws holding the right and left case sides.
Remove the case sides by lifting up and
out.
10. If the reading is 40 ohms, the output recti-
fier diodes are good. If the reading is less
than 40 ohms, replace the output rectifier.
6. Perform the Capacitor Discharge
Procedure described earlier in this section
of the manual.
Refer
to
the
Output
Rectifier
Replacement Procedure in this section
of the manual.
11. After the test is completed and the prob-
lem successfully repaired, reconnect plug
J62 to the snubber board.
WARNING
Before continuing with the
test procedure, perform the
capacitor discharge proce-
dure to avoid electric shock.
12. Install the machine case sides and top.
13. Install the handle and the lift bail rubber
gasket.
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F-59
F-59
TROUBLESHOOTING & REPAIR
FIELD EFFECT TRANSISTOR/SWITCH BOARD TEST
OR
IGBT/SWITCH BOARD TEST
WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician or
machine operator and will invalidate your factory warranty. For your safety and to avoid elec-
trical shock, please observe all safety notes and precautions detailed throughout this manual.
If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou-
bleshooting assistance before you proceed. Call 1-800-833-9353 (WELD).
DESCRIPTION
The following procedure will determine if the four switch boards and their related circuitry
are functioning properly. This is a resistance test, not a voltage test. The machine does
not have to be powered up to perform the test, which is both safer for the technician and
less likely to result in accidental damage to the switch boards.
MATERIALS NEEDED
Analog Volt/Ohmmeter (Multimeter)
5/16" Nut driver
3/8" Nut driver
Machine Wiring Diagram in the Electrical Diagrams section of this manual
This procedure takes approximately 60 minutes to perform.
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F-60
F-60
TROUBLESHOOTING & REPAIR
FIELD EFFECT TRANSISTOR/SWITCH BOARD TEST
FIGURE F.19 – F.E.T. SWITCH BOARD LOCATION
1
1. FET OR IGBT SWITCH BOARD ASSEMBLY
TEST PROCEDURE
WARNING
1. Remove main input supply power to the
machine.
Before continuing with the
test procedure, perform the
following capacitor dis-
charge procedure to avoid
electric shock.
2. With the 3/8" nut driver, remove the screws
that hold the handle to the machine.
3. Remove the rubber gasket (cover seal) from
the lift bail.
4. With the 5/16" nut driver, remove the sheet
metal screws from the case top.
6. Obtain a high resistance and high wattage
resistor (25 - 1000 ohms and 25 watts min-
imum). This resistor is not supplied with the
machine. Secure this resistor to a piece of
insulating material such as a glastic board.
See Figure F.22. NEVER USE A SHORTING
STRAP FOR THIS PROCEDURE.
5. With the 5/16" nut driver, remove the
screws holding the right and left case sides.
Remove the case sides by lifting up and
out.
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F-61
F-61
TROUBLESHOOTING & REPAIR
FIELD EFFECT TRANSISTOR/SWITCH BOARD TEST (continued)
FIGURE F.20 - RESISTOR LOCATIONS
5 PAIRS OF RESISTORS
CHECK VOLTAGES BETWEEN
EACH TERMINAL AND FROM
EACH RESISTOR TO CASE
GROUND
7. Locate the two sets of two resistors on the
left side of the machine and three sets of
two resistors on the right side of the
machine. See Figure F.20. Do not touch
the resistors or any other internal machine
component. Using a DC voltmeter, check
for any DC voltage that may be present
across the terminals of each resistor and
from each resistor to case ground (20 mea-
surements in all). If a voltage is present, be
careful not to touch these resistors.
8. Locate terminals #9 and #12 on the switch
boards. They can be identified by the
“Discharge” labels, which are located on
each of the four switch boards. See Figure
F.21.
WARNING
ELECTRIC SHOCK
can kill.
Proceed with caution. Be
careful not to touch any
internal machine components during the dis-
charge procedure.
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F-62
F-62
TROUBLESHOOTING & REPAIR
FIELD EFFECT TRANSISTOR/SWITCH BOARD TEST (continued)
FIGURE F.21 - DISCHARGE LABEL
FIGURE F.22
RESISTOR WITH LEADS CONNECTED
D
I
D
I
D
I
S
C
H
A
R
G
E
S
C
H
A
R
G
E
S
C
H
A
R
G
E
D
I
D
I
S
C
H
A
R
G
E
S
C
H
A
R
G
E
9. Using insulated, needle nose type jumper
leads and insulated gloves, connect one
jumper lead to one end of the resistor
obtained in step 6. Connect the other
jumper lead to the other end of the resistor.
12. Repeat discharge procedure steps 9, 10,
and 11 for each of the other three switch
boards.
13. After you have completed the capacitor
discharge procedure for all four switch
boards, Visually inspect the switch
boards. If any of them appear burned or
overheated, replace all four switch boards
and input filter capacitors C1, C2, C3, and
C4. Refer to the FET Module Assembly
Removal and Replacement Procedure
in this section of the manual.
10. Carefully connect the needle nose end of
one of the jumper leads to terminal #9.
See Figure F.22. Connect the needle nose
end of the other jumper lead to terminal
#12. Terminals #9 and #12 are indicated
by the "Discharge" label. Leave the resis-
tor connected for 10 seconds. DO NOT
TOUCH TERMINALS, RESISTORS, OR
ANY INTERNAL MACHINE COMPO-
NENTS DURING THIS PROCEDURE!
14. If none of the switch boards shows physi-
cal damage, test each switch board
according to the procedures given below.
If any test shows that one of the switch
boards is damaged, replace all four switch
boards and input filter capacitors C1, C2,
C3, and C4. Refer to the FET Module
Assembly Removal and Replacement
Procedure in this section of the manual.
11. Check the voltage across terminals #9 and
#12 with the DC voltmeter. Terminal #9
has positive polarity and terminal #12 has
negative polarity. Voltage should be zero.
If any voltage remains, repeat this capaci-
tor discharge procedure.
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F-63
F-63
TROUBLESHOOTING & REPAIR
FIELD EFFECT TRANSISTOR/SWITCH BOARD TEST (continued)
FIGURE F.23 - SWITCH BOARD ASSEMBLY CONNECTION DECAL
3W
3R
2W
2R
TOP
406
3T
401
2T
12C
9C
9A
12A
1T
4T
405
402
4R
1R
4W
1W
3W
3R
2W
2R
408
3B
403
2B
12D
9D
9B
12B
1B
4B
407
404
4R
1R
4W
1W
M16740
POWER WAVE 450
4/98
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F-64
F-64
TROUBLESHOOTING & REPAIR
FIELD EFFECT TRANSISTOR/SWITCH BOARD TEST (continued)
Switch Board Test 1: (For Switch Board
Marked CAP 1 on the Switch Board Assem-
bly Connection Decal - See Figure F.23.)
B. With the volt/ohmmeter, measure the resis-
tance between terminals according to
Table F. 4. If any test fails, replace all four
switch boards. Refer to the FET Module
Assembly Removal and Replacement pro-
cedure in this section of the manual.
A. Disconnect all wiring harness leads from
switch board 1. Fold the leads up so that
they do not interfere with the exposed PC
board terminals.
If none of the tests fails, reconnect the
wiring harness leads to switch board 3 and
perform switch board test 4.
B. With the volt/ohmmeter, measure the resis-
tance between terminals according to
Table F. 2. See Figure F.23 for the locations
of the terminals. If any test fails, replace all
four switch boards. Refer to the FET
Module Assembly Removal and Re-
placement procedure in this section of the
manual.
Switch Board Test 4: (For Switch Board
Marked CAP 4 on the Switch Board Assem-
bly Connection Decal - See Figure F.23.)
A. Disconnect all wiring harness leads from
switch board 4. Fold the leads up so that
they do not interfere with the exposed PC
board terminals.
If none of the tests fails, reconnect the
wiring harness leads to switch board 1 and
perform switch board test 2.
B. With the volt/ohmmeter, measure the resis-
tance between terminals according to
Table F. 5. If any test fails, replace all four
switch boards. Refer to the FET Module
Assembly Removal and Replacement pro-
cedure in this section of the manual.
Switch Board Test 2: (For Switch Board
Marked CAP 2 on the Switch Board Assem-
bly Connection Decal - See Figure F.23.)
A. Disconnect all wiring harness leads from
switch board 2. Fold the leads up so that
they do not interfere with the exposed PC
board terminals.
If none of the tests fails, reconnect the
wiring harness leads to switch board 4.
IGBT Switch Board Test (G3165-1) See Table
B. With the volt/ohmmeter, measure the resis-
tance between terminals according to
Table F. 3. If any test fails, replace all four
switch boards. Refer to the FET Module
Assembly Removal and Replacement pro-
cedure in this section of the manual.
F.6.
A. Disconnect all wiring harness leads from
the switch boards. Fold the leads up so
that they do not interfere with the exposed
PC board terminals.
B. With the Volt/Ohmmeter, measure the
resistance between terminals according to
Table F.6. If any test fails, replace all four
switch boards. Refer to the FET Module
Assembly Removal and Replacement pro-
cedure in this section of the manual.
If none of the tests fails, reconnect the
wiring harness leads to switch board 2 and
perform switch board test 3.
Switch Board Test 3: (For Switch Board
Marked CAP 3 on the Switch Board Assem-
bly Connection Decal - See Figure F.23.)
If none of the tests fail, reconnect the wiring
harness leads to the switch boards.
A. Disconnect all wiring harness leads from
switch board 3. Fold the leads up so that
they do not interfere with the exposed PC
board terminals.
15. After the test is completed and the prob-
lem successfully repaired, install the
machine case sides and top.
16. Install the handle and the lift bail rubber
gasket.
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F-65
F-65
TROUBLESHOOTING & REPAIR
FIELD EFFECT TRANSISTOR/SWITCH BOARD TEST (continued)
TABLE F.2 – SWITCH BOARD 1 RESISTANCE TEST TABLE
Apply
Apply
Positive
Test
Negative
Test
Probe to
Terminal
Probe to
Terminal
Test
Result
Repair
Action
Next
Procedure
Conclusion
2T
12A
Greater
than 1K
ohm
OK
None
Continue
Less than
100 ohms
Replace 4
Switch
Boards
Snubber
Resistor
Test
Shorted
OK
12A
9A
2T
1T
Less than
100 ohms
None
Continue
Greater
than 1K
ohm
Open
Replace 4
Switch
Boards
Snubber
Resistor
Test
Greater
than 1K
ohm
OK
None
Continue
Less than
100 ohms
Shorted
Replace 4
Switch
Boards
Snubber
Resistor
Test
1T
2T
9A
9A
9A
2T
Less than
100 ohms
OK
None
Continue
Greater
than 1K
ohm
Open
Replace 4
Switch
Boards
Snubber
Resistor
Test
Less than
100 ohms
OK
None
Continue
Greater
than 1K
ohm
Open
Replace 4
Switch
Boards
Snubber
Resistor
Test
Greater
than 1K
ohm
OK
None
Continue
Less than
100 ohms
Shorted
Replace 4
Switch
boards
Snubber
Resistor
Test
NOTE: K ohm = ohm reading multiplied by 1000.
NOTE: Always make sure that all four Switch Boards are changed at the same time. Never mix
an old style (different part number) Switch Board with a new style (new part
number).
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F-66
F-66
TROUBLESHOOTING & REPAIR
FIELD EFFECT TRANSISTOR/SWITCH BOARD TEST (continued)
TABLE F.2 – SWITCH BOARD 1 RESISTANCE TEST TABLE (Continued)
Apply
Apply
Positive
Test
Negative
Test
Probe to
Terminal
Probe to
Terminal
Test
Result
Repair
Action
Next
Procedure
Conclusion
12A
1T
Less than
100 ohms
OK
None
Continue
Greater
than 1K
ohm
Open
OK
Replace 4
Switch
Boards
Snubber
Resistor
Test
1T
12A
Greater
than 1K
ohm
None
Continue
Less than
100 ohms
Shorted
OK
Replace 4
Switch
Boards
Snubber
Resistor
Test
12A
401
Greater
than 1K
ohm
None
Continue
Less than
100 ohms
Shorted
Replace 4
Switch
Boards
Snubber
Resistor
Test
401
9A
12A
402
9A
Less than
100 ohms
OK
None
Continue
Greater
than 1K
ohm
Open
Replace 4
Switch
Boards
Snubber
Resistor
Test
Less than
100 ohms
OK
None
Continue
Greater
than 1K
ohm
Open
Replace 4
Switch
Boards
Snubber
Resistor
Test
402
Greater
than 1K
ohm
OK
None
Continue
Less than
100 ohms
Shorted
Replace 4
Switch
boards
Snubber
Resistor
Test
NOTE: K ohm = ohm reading multiplied by 1000.
NOTE: Always make sure that all four Switch Boards are changed at the same time. Never
mix an old style (different part number) Switch Board with a new style (new part
number).
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F-67
F-67
TROUBLESHOOTING & REPAIR
FIELD EFFECT TRANSISTOR/SWITCH BOARD TEST (continued)
TABLE F.3 – SWITCH BOARD 2 RESISTANCE TEST TABLE
Apply
Apply
Positive
Test
Negative
Test
Probe to
Terminal
Probe to
Terminal
Test
Result
Repair
Action
Next
Procedure
Conclusion
2B
12B
Greater
than 1K
ohm
OK
None
Continue
Less than
100 ohms
Replace 4
Switch
Boards
Snubber
Resistor
Test
Shorted
OK
12B
9B
2B
1B
Less than
100 ohms
None
Continue
Greater
than 1K
ohm
Open
Replace 4
Switch
Boards
Snubber
Resistor
Test
Greater
than 1K
ohm
OK
None
Continue
Less than
100 ohms
Shorted
Replace 4
Switch
Boards
Snubber
Resistor
Test
1B
2B
9B
9B
9B
2B
Less than
100 ohms
OK
None
Continue
Greater
than 1K
ohm
Open
Replace 4
Switch
Boards
Snubber
Resistor
Test
Less than
100 ohms
OK
None
Continue
Greater
than 1K
ohm
Open
Replace 4
Switch
Boards
Snubber
Resistor
Test
Greater
than 1K
ohm
OK
None
Continue
Less than
100 ohms
Shorted
Replace 4
Switch
boards
Snubber
Resistor
Test
NOTE: K ohm = ohm reading multiplied by 1000.
NOTE: Always make sure that all four Switch Boards are changed at the same time. Never mix
an old style (different part number) Switch Board with a new style (new part
number).
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F-68
F-68
TROUBLESHOOTING & REPAIR
FIELD EFFECT TRANSISTOR/SWITCH BOARD TEST (continued)
TABLE F.3 – SWITCH BOARD 2 RESISTANCE TEST TABLE (Continued)
Apply
Apply
Positive
Test
Negative
Test
Probe to
Terminal
Probe to
Terminal
Test
Result
Repair
Action
Next
Procedure
Conclusion
12B
1B
Less than
100 ohms
OK
None
Continue
Greater
than 1K
ohm
Open
OK
Replace 4
Switch
Boards
Snubber
Resistor
Test
1B
12B
Greater
than 1K
ohm
None
Continue
Less than
100 ohms
Shorted
OK
Replace 4
Switch
Boards
Snubber
Resistor
Test
12B
403
Greater
than 1K
ohm
None
Continue
Less than
100 ohms
Shorted
Replace 4
Switch
Boards
Snubber
Resistor
Test
403
9B
12B
404
9B
Less than
100 ohms
OK
None
Continue
Greater
than 1K
ohm
Open
Replace 4
Switch
Boards
Snubber
Resistor
Test
Less than
100 ohms
OK
None
Continue
Greater
than 1K
ohm
Open
Replace 4
Switch
Boards
Snubber
Resistor
Test
404
Greater
than 1K
ohm
OK
None
Continue
Less than
100 ohms
Shorted
Replace 4
Switch
boards
Snubber
Resistor
Test
NOTE: K ohm = ohm reading multiplied by 1000.
NOTE: Always make sure that all four Switch Boards are changed at the same time. Never
mix an old style (different part number) Switch Board with a new style (new part
number).
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F-69
F-69
TROUBLESHOOTING & REPAIR
FIELD EFFECT TRANSISTOR/SWITCH BOARD TEST (continued)
TABLE F.4 – SWITCH BOARD 3 RESISTANCE TEST TABLE
Apply
Apply
Positive
Test
Negative
Test
Probe to
Terminal
Probe to
Terminal
Test
Result
Repair
Action
Next
Procedure
Conclusion
4T
12C
Greater
than 1K
ohm
OK
None
Continue
Less than
100 ohms
Replace 4
Switch
Boards
Snubber
Resistor
Test
Shorted
OK
12C
9C
4T
3T
Less than
100 ohms
None
Continue
Greater
than 1K
ohm
Open
Replace 4
Switch
Boards
Snubber
Resistor
Test
Greater
than 1K
ohm
OK
None
Continue
Less than
100 ohms
Shorted
Replace 4
Switch
Boards
Snubber
Resistor
Test
3T
4T
9C
9C
9C
4T
Less than
100 ohms
OK
None
Continue
Greater
than 1K
ohm
Open
Replace 4
Switch
Boards
Snubber
Resistor
Test
Less than
100 ohms
OK
None
Continue
Greater
than 1K
ohm
Open
Replace 4
Switch
Boards
Snubber
Resistor
Test
Greater
than 1K
ohm
OK
None
Continue
Less than
100 ohms
Shorted
Replace 4
Switch
boards
Snubber
Resistor
Test
NOTE: K ohm = ohm reading multiplied by 1000.
NOTE: Always make sure that all four Switch Boards are changed at the same time. Never mix
an old style (different part number) Switch Board with a new style (new part
number).
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F-70
F-70
TROUBLESHOOTING & REPAIR
FIELD EFFECT TRANSISTOR/SWITCH BOARD TEST (continued)
TABLE F.4 – SWITCH BOARD 3 RESISTANCE TEST TABLE (Continued)
Apply
Apply
Positive
Test
Negative
Test
Probe to
Terminal
Probe to
Terminal
Test
Result
Repair
Action
Next
Procedure
Conclusion
12C
3T
Less than
100 ohms
OK
None
Continue
Greater
than 1K
ohm
Open
OK
Replace 4
Switch
Boards
Snubber
Resistor
Test
3T
12C
Greater
than 1K
ohm
None
Continue
Less than
100 ohms
Shorted
OK
Replace 4
Switch
Boards
Snubber
Resistor
Test
12C
405
Greater
than 1K
ohm
None
Continue
Less than
100 ohms
Shorted
Replace 4
Switch
Boards
Snubber
Resistor
Test
405
9C
12C
406
9C
Less than
100 ohms
OK
None
Continue
Greater
than 1K
ohm
Open
Replace 4
Switch
Boards
Snubber
Resistor
Test
Less than
100 ohms
OK
None
Continue
Greater
than 1K
ohm
Open
Replace 4
Switch
Boards
Snubber
Resistor
Test
406
Greater
than 1K
ohm
OK
None
Continue
Less than
100 ohms
Shorted
Replace 4
Switch
boards
Snubber
Resistor
Test
NOTE: K ohm = ohm reading multiplied by 1000.
NOTE: Always make sure that all four Switch Boards are changed at the same time. Never
mix an old style (different part number) Switch Board with a new style (new part
number).
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F-71
F-71
TROUBLESHOOTING & REPAIR
FIELD EFFECT TRANSISTOR/SWITCH BOARD TEST (continued)
TABLE F.5 – SWITCH BOARD 4 RESISTANCE TEST TABLE
Apply
Apply
Positive
Test
Negative
Test
Probe to
Terminal
Probe to
Terminal
Test
Result
Repair
Action
Next
Procedure
Conclusion
4B
12D
Greater
than 1K
ohm
OK
None
Continue
Less than
100 ohms
Replace 4
Switch
Boards
Snubber
Resistor
Test
Shorted
OK
12D
9D
4B
3B
Less than
100 ohms
None
Continue
Greater
than 1K
ohm
Open
Replace 4
Switch
Boards
Snubber
Resistor
Test
Greater
than 1K
ohm
OK
None
Continue
Less than
100 ohms
Shorted
Replace 4
Switch
Boards
Snubber
Resistor
Test
3B
4B
9D
9D
9D
4B
Less than
100 ohms
OK
None
Continue
Greater
than 1K
ohm
Open
Replace 4
Switch
Boards
Snubber
Resistor
Test
Less than
100 ohms
OK
None
Continue
Greater
than 1K
ohm
Open
Replace 4
Switch
Boards
Snubber
Resistor
Test
Greater
than 1K
ohm
OK
None
Continue
Less than
100 ohms
Shorted
Replace 4
Switch
boards
Snubber
Resistor
Test
NOTE: K ohm = ohm reading multiplied by 1000.
NOTE: Always make sure that all four Switch Boards are changed at the same time. Never mix
an old style (different part number) Switch Board with a new style (new part
number).
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F-72
F-72
TROUBLESHOOTING & REPAIR
FIELD EFFECT TRANSISTOR/SWITCH BOARD TEST (continued)
TABLE F.5 – SWITCH BOARD 4 RESISTANCE TEST TABLE (Continued)
Apply
Apply
Positive
Test
Negative
Test
Probe to
Terminal
Probe to
Terminal
Test
Result
Repair
Action
Next
Procedure
Conclusion
12D
3B
Less than
100 ohms
OK
None
Continue
Greater
than 1K
ohm
Open
OK
Replace 4
Switch
Boards
Snubber
Resistor
Test
3B
12D
Greater
than 1K
ohm
None
Continue
Less than
100 ohms
Shorted
OK
Replace 4
Switch
Boards
Snubber
Resistor
Test
12D
407
Greater
than 1K
ohm
None
Continue
Less than
100 ohms
Shorted
Replace 4
Switch
Boards
Snubber
Resistor
Test
407
9D
12D
408
9D
Less than
100 ohms
OK
None
Continue
Greater
than 1K
ohm
Open
Replace 4
Switch
Boards
Snubber
Resistor
Test
Less than
100 ohms
OK
None
Continue
Greater
than 1K
ohm
Open
Replace 4
Switch
Boards
Snubber
Resistor
Test
408
Greater
than 1K
ohm
OK
None
Continue
Less than
100 ohms
Shorted
Replace 4
Switch
boards
Snubber
Resistor
Test
NOTE: K ohm = ohm reading multiplied by 1000.
NOTE: Always make sure that all four Switch Boards are changed at the same time. Never
mix an old style (different part number) Switch Board with a new style (new part
number).
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F-73
F-73
TROUBLESHOOTING & REPAIR
IGBT/SWITCH BOARD TEST (G3165-1)
TABLE F.6 – NOTE: This test will NOT determine if an individual IGBT device is open.
Apply
Apply
Positive
Test
Negative
Test
Probe to
Terminal
Probe to
Terminal
Test
Result
Repair
Action
Next
Procedure
Conclusion
2/4
12
Greater than OK
1k ohms
None
Continue
Less
than 1K
ohms
Shorted
Replace
Switch
Boards
Snubber
Resistor
Test
9
1/3
Greater
than 1K
ohms
OK
None
Continue
Less than
1k ohms
Shorted
OK
Replace
Switch
Boards
Snubber
Resistor
Test
2/4
9
Less
None
Continue
than 100
ohms
Greater than Open
1k ohms
Replace
Switch
Boards
Snubber
Resistor
Test
9
2/4
Greater than OK
1k ohms
None
Continue
Less
than 1K
ohms
Shorted
Replace
Switch
Boards
Snubber
Resistor
Test
NOTE: K ohm = ohm reading multiplied by 1000.
NOTE: Always make sure that all four Switch Boards are changed at the same time. Never
mix an old style (different part number) Switch Board with a new style (new part
number).
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F-74
F-74
TROUBLESHOOTING & REPAIR
IGBT/SWITCH BOARD TEST (Continued)
TABLE F.6 (Continued)
Apply
Positive
Test
Apply
Negative
Test
Probe to
Terminal
Probe to
Terminal
Test
Result
Repair
Action
Next
Procedure
Conclusion
12
1/3
Less than
100 ohms
OK
None
Continue
Greater
than 1K
ohms
Open
OK
Replace
Switch
Boards
Snubber
Resistor
Test
1/3
12
Greater
than 1K
ohms
None
Continue
Less than
1k ohms
Shorted
OK
Replace
Switch
Boards
Snubber
Resistor
Test
12
401/403
405/407
Greater
than 1K
ohms
None
Continue
Less than
1k ohms
Shorted
Replace
Switch
Boards
Snubber
Resistor
Test
401/403
405/407
12
Less than
100 ohms
OK
None
Continue
Greater
than 1K
ohms
Open
Replace
Switch
Boards
Snubber
Resistor
Test
9
402/404
406/408
Less than
100 ohms
OK
None
Continue
Greater
than 1K
ohms
Open
Replace
Switch
Boards
Snubber
Resistor
Test
402/404
406/408
9
Greater
than 1K
ohms
OK
None
Continue
Less than
1k ohms
Shorted
Replace
Switch
boards
Snubber
Resistor
Test
NOTE: K ohm = ohm reading multiplied by 1000.
NOTE: Always make sure that all four Switch Boards are changed at the same time. Never
mix an old style (different part number) Switch Board with a new style (new part
number).
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F-75
F-75
TROUBLESHOOTING & REPAIR
SNUBBER AND BLEEDER RESISTOR TEST
WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician or
machine operator and will invalidate your factory warranty. For your safety and to avoid elec-
trical shock, please observe all safety notes and precautions detailed throughout this manual.
If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou-
bleshooting assistance before you proceed. Call 1-800-833-9353 (WELD).
TEST DESCRIPTION
This test will determine if the eight snubber resistors and two bleeder resistors are of the
proper value and their associated leads intact.
MATERIALS NEEDED
Volt/Ohmmeter (Multimeter)
5/16" Nut driver
3/8" Nut driver
Snubber and Bleeder Resistor Wiring Diagram – Figure F.25
This procedure takes approximately 30 minutes to perform.
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F-76
F-76
TROUBLESHOOTING & REPAIR
SNUBBER AND BLEEDER RESISTOR TEST
FIGURE F.24 - SWITCH BOARD ASSEMBLY CONNECTION DECAL
3W
3R
2W
2R
TOP
406
3T
401
2T
12C
9C
9A
12A
1T
4T
405
402
4R
1R
4W
1W
3W
3R
2W
2R
408
3B
403
2B
12D
9D
9B
12B
1B
4B
407
404
4R
1R
4W
1W
M16740
POWER WAVE 450
4/98
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F-77
F-77
TROUBLESHOOTING & REPAIR
SNUBBER AND BLEEDER RESISTOR TEST (continued)
C. With the volt/ohmmeter, check for 25
TEST PROCEDURE
ohms resistance between lead #402 and
#9E.
1. Remove main input supply power to the
machine.
If the measurement reads between 20 and
30 ohms, resistor R2 and leads #402 and
#9E are okay. Go to step D.
2. With the 3/8" nut driver, remove the 4
screws that hold the handle to the machine.
3. Remove the rubber gasket (cover seal) from
the lift bail.
If the measurement does not read between
20 and 30 ohms, check for continuity in
leads #402 and #9E. Then test for 25
ohms resistance across R2 directly. If the
measurement does not read between 20
and 30 ohms, replace resistor R2.
4. With the 5/16" nut driver, remove the sheet
metal screws from the case top.
5. With the 5/16" nut driver, remove the
screws holding the right and left case sides.
Remove the case sides by lifting up and
out.
D. With the volt/ohmmeter, check for 7.5 K-
ohms resistance between lead #12L (12E)
and #9L (9E).
6. Perform the Capacitor Discharge Proce-
dure described earlier in this section of the
manual.
If the measurement reads between 6.75
and 8.25 K-ohms, resistor R9 and leads
#12L(12E) and #9L (9E) are okay. Go to
step E.
WARNING
If the measurement does not read between
6.75 and 30 K-ohms, check for continuity
in leads #12L (12E) and #9L(9E). Then test
for 7.5 K-ohms resistance across R9
directly. If the measurement does not read
between 6.75 and 8.25 K-ohms, replace
resistor R9.
Before continuing with the
test procedure, perform the
capacitor discharge proce-
dure to avoid electric shock.
7. Perform the following tests on the four
switch boards:
E. Reconnect quick connect terminals #401,
#402, #9, and #12 on switch board 1.
Switch Board 1: (Switch Board 1 is Marked
CAP 1 on the Switch Board Assembly
Connection Decal - See Figure F.24.)
Switch Board 2: (Switch Board 2 is Marked
CAP 2 on the Switch Board Assembly
Connection Decal - See Figure F.24.)
A. Remove quick connect terminals #401,
#402, #9, and #12 from switch board 1.
A. Remove quick connect terminals #403,
#404, #9, and #12.
B. With the volt/ohmmeter, check for 25
ohms resistance between lead #401 and
#12E.
B. With the volt/ohmmeter, check for 25
ohms resistance between lead #403 and
#12F.
If the measurement reads between 20 and
30 ohms, resistor R1 and leads #401 and
#12E are okay. Go to step C.
If the measurement reads between 20 and
30 ohms, resistor R3 and leads #403 and
#12F are okay. Go to step C.
If the measurement does not read between
20 and 30 ohms, check for continuity in
leads #401 and #12E. Then test for 25
ohms resistance across R1 directly. If the
measurement does not read between 20
and 30 ohms, replace resistor R1.
If the measurement does not read between
20 and 30 ohms, check for continuity in
leads #403 and #12F. Then test for 25
ohms resistance across R3 directly. If the
measurement does not read between 20
and 30 ohms, replace resistor R3.
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F-78
F-78
TROUBLESHOOTING & REPAIR
SNUBBER AND BLEEDER RESISTOR TEST (continued)
C. With the volt/ohmmeter, check for 25
If the measurement reads between 6.75
ohms resistance between lead #404 and
#9F.
and 8.25 K-ohms, resistor R10 and leads
#12G (12M) and #9G (9M) are okay. Go to
step E.
If the measurement reads between 20 and
30 ohms, resistor R4 and leads #404 and
#9F are okay. Go to step D.
If the measurement does not read between
6.75 and 30 K-ohms, check for continuity
in leads #12G (12M) and #9G (9M). Then
test for 7.5 K-ohms resistance across R10
directly. If the measurement does not read
between 6.75 and 8.25 K-ohms, replace
resistor R10.
If the measurement does not read between
20 and 30 ohms, check for continuity in
leads #404 and #9F. Then test for 25 ohms
resistance across R4 directly. If the mea-
surement does not read between 20 and
30 ohms, replace resistor R4.
E. Reconnect quick connect terminals #405,
#406, #9, and #12 on switch board 3.
D. Reconnect quick connect terminals #403,
#404, #9, and #12 on switch board 2.
Switch Board 4: (Switch Board 4 is Marked
CAP 4 on the Switch Board Assembly
Connection Label - See Figure F.24.)
Switch Board 3: (Switch Board 3 is Marked
CAP 1 on the Switch Board Assembly
Connection Decal - See Figure F.24.)
A. Remove quick connect terminals #407,
#408, #9, and #12 from switch board 4.
A. Remove quick connect terminals #405,
#406, #9, and #12 from switch board 3.
B. With the volt/ohmmeter, check for 25
ohms resistance between lead #407 and
#12H.
B. With the volt/ohmmeter, check for 25
ohms resistance between lead #405 and
#12G.
If the measurement reads between 20 and
30 ohms, resistor R7 and leads #407 and
#12H are okay. Go to step C.
If the measurement reads between 20 and
30 ohms, resistor R5 and leads #405 and
#12G are okay. Go to step C.
If the measurement does not read between
20 and 30 ohms, check for continuity in
leads #407 and #12H. Then test for 25
ohms resistance across R3 directly. If the
measurement does not read between 20
and 30 ohms, replace resistor R7.
If the measurement does not read between
20 and 30 ohms, check for continuity in
leads #405 and #12G. Then test for 25
ohms resistance across R5 directly. If the
measurement does not read between 20
and 30 ohms, replace resistor R5.
C. With the volt/ohmmeter, check for 25
ohms resistance between lead #408 and
#9H.
C. With the volt/ohmmeter, check for 25
ohms resistance between lead #406 and
#9G.
If the measurement reads between 20 and
30 ohms, resistor R8 and leads #408 and
#9H are okay. Go to step D.
If the measurement reads between 20 and
30 ohms, resistor R6 and leads #406 and
#9G are okay. Go to step D.
If the measurement does not read between
20 and 30 ohms, check for continuity in
leads #408 and #9H. Then test for 25
ohms resistance across R8 directly. If the
measurement does not read between 20
and 30 ohms, replace resistor R8.
If the measurement does not read between
20 and 30 ohms, check for continuity in
leads #406 and #9G. Then test for 25
ohms resistance across R5 directly. If the
measurement does not read between 20
and 30 ohms, replace resistor R5.
D. Reconnect quick connect terminals #407,
#408, #9, and #12 on switch board 4.
D. With the volt/ohmmeter, check for 7.5 K-
ohms resistance between lead #12G (12M)
and #9G (9M).
8. Install the machine case sides and top.
9. Install the handle and the lift bail rubber
gasket.
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F-79
F-79
TROUBLESHOOTING & REPAIR
FIGURE F.25 – SNUBBER AND BLEEDER RESISTOR WIRING DIAGRAM
(401)
SWITCH
BOARD
#1
25Ω
R1
( 25W )
401
12A
(12E)
(12A)
(12L)
(9L)
TO RECONNECT SWITCH
7.5KΩ
(402)
R9
( )
25W
C
1
25Ω
R2
( 25W )
402
9A
(9E)
(9A)
TO RECONNECT SWITCH
(403)
SWITCH
BOARD
#2
25Ω
R3
( 25W )
403
12B
(12F)
(12B)
TO RECONNECT SWITCH
(404)
C
2
25Ω
R4
( 25W )
404
9B
(9F)
(9B)
TO RECONNECT SWITCH
(405)
SWITCH
BOARD
#3
25Ω
R5
( 25W )
405
12C
(12G)
(12C)
(12M)
(9M)
TO RECONNECT SWITCH
7.5KΩ
(406)
R10
( 25W )
C
3
25Ω
R6
( 25W )
406
9C
(9G)
(9C)
TO RECONNECT SWITCH
(407)
SWITCH
BOARD
#4
25Ω
R7
( 25W )
407
12D
(12H)
(12D)
TO RECONNECT SWITCH
(408)
C
4
25Ω
R8
( 25W )
408
9D
(9H)
(9D)
TO RECONNECT SWITCH
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F-80
F-80
NOTES
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F-81
F-81
TROUBLESHOOTING & REPAIR
RECONNECT SWITCH TEST 1
WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician or
machine operator and will invalidate your factory warranty. For your safety and to avoid elec-
trical shock, please observe all safety notes and precautions detailed throughout this manual.
If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou-
bleshooting assistance before you proceed. Call 1-800-833-9353 (WELD).
TEST DESCRIPTION
This test will determine if there are any short circuits between the leads connected to the
reconnect switch.
MATERIALS NEEDED
Volt/Ohmmeter (Multimeter)
5/16" Nut driver
3/8" Nut driver
Phillips head screw driver
Input and Reconnect Wiring Diagram – Figure F.27
This procedure takes approximately 40 minutes to perform.
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F-82
F-82
TROUBLESHOOTING & REPAIR
RECONNECT SWITCH TEST 1
FIGURE F.26 - RECONNECT SWITCH
1
1. RECONNECT PANEL
2. RECONNECT SWITCH
3. LEAD CONNECTIONS
3
2
TEST PROCEDURE
WARNING
1. Remove main input supply power to the
machine.
Before continuing with the
test procedure, perform the
capacitor discharge proce-
dure to avoid electric shock.
2. With the 3/8" nut driver, remove the 4
screws that hold the handle to the machine.
3. Remove the rubber gasket (cover seal) from
the lift bail.
7. Test the reconnect switch for short circuits
according to the voltage for which the machine
is wired:
4. With the 5/16" nut driver, remove the sheet
metal screws from the case top.
5. With the 5/16" nut driver, remove the
screws holding the right and left case sides.
Remove the case sides by lifting up and
out.
For 230 VAC:
A. Check that the following leads are con-
nected together at the reconnect switch:
#9A, #9B, #9C, #9D, #9K, #9J, and POS.
6. Perform the Capacitor Discharge
Procedure described earlier in this section
of the manual.
B. Check that the following leads are con-
nected together at the reconnect switch:
#12A, #12B, #12C, #12D, #12K, #12J, and
NEG.
C. With the volt/ohmmeter, check that there is
no continuity between the two groups of
leads in A and B above.
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F-83
F-83
TROUBLESHOOTING & REPAIR
RECONNECT SWITCH TEST 1 (continued)
For 380 or 460 VAC:
D. Remove leads #9A, #9B, #9C, #9D, #12A,
#12B, #12C, and #12D from the four
switch boards. If this eliminates the short,
check these leads to make sure they are
not exposed, damaged, or shorted. If the
leads are okay, perform the Switch Board
Test and the Snubber and Bleeder
Resistor Test to find the cause of the
short. Reconnect leads #9A, #9B, #9C,
#9D, #12A, #12B, #12C, and #12D to the
four switch boards before conduction
these tests.
A. Check that the following leads are connect-
ed together at the reconnect switch: #9A,
#9B, #9K, and POS.
B. Check that the following leads are con-
nected together at the reconnect switch:
#9C, #9D, #9J, #12A, #12B, and #12J.
C. Check that the following leads are con-
nected together at the reconnect switch:
#12C, #12D, #12K and NEG.
D. With the volt/ohmmeter, check that there is
no continuity between the three groups of
leads in A, B, and C above.
10. Replace the PC board cover and install the
machine case sides and top.
11. Install the handle and the lift bail rubber
gasket.
8. If any of the leads tested above are short-
ed, go to step 9. If none of the leads are
shorted, the test is complete. Install the
machine case sides, top, handle and the
lift bail rubber gasket.
9. Perform the following steps:
A. With the 5/16" nut driver, remove the
screws that hold the PC board cover.
Remove the cover.
B. Disconnect plug J31 from the protection
board. If this eliminates the short, the pro-
tection board may be faulty. Replace the
protection board. If the short persists, go
to step 9C.
C. With the Phillips head screw driver, remove
the POS and NEG leads from the recon-
nect switch. If this eliminates the short,
either the input rectifier or the harness
(leads POS and NEG) between the input
rectifier and the reconnect switch is faulty.
Check the harness and if it is not faulty,
perform the Input Rectifier Test.
Reconnect leads POS and NEG to the
input rectifier. If the short persists, go to
step 9D.
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F-84
F-84
TROUBLESHOOTING & REPAIR
FIGURE F.27 – INPUT AND RECONNECT WIRING DIAGRAM
POWER WAVE 450
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F-85
F-85
TROUBLESHOOTING & REPAIR
RECONNECT SWITCH TEST 2
WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician or
machine operator and will invalidate your factory warranty. For your safety and to avoid elec-
trical shock, please observe all safety notes and precautions detailed throughout this manual.
If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou-
bleshooting assistance before you proceed. Call 1-800-833-9353 (WELD).
TEST DESCRIPTION
This test will determine if any leads connected to the reconnect switch are damaged.
MATERIALS NEEDED
Volt/Ohmmeter (Multimeter)
5/16" Nut driver
3/8" Nut driver
Input and Reconnect Wiring Diagram – Figure F.29
This procedure takes approximately 40 minutes to perform.
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F-86
F-86
TROUBLESHOOTING & REPAIR
RECONNECT SWITCH TEST 2 (continued)
FIGURE F.28 - RECONNECT SWITCH
1
1. RECONNECT PANEL
2. RECONNECT SWITCH
3. LEAD CONNECTIONS
3
2
TEST PROCEDURE
WARNING
1. Remove main input supply power to the
machine.
Before continuing with the
test procedure, perform the
capacitor discharge proce-
dure to avoid electric shock.
2. With the 3/8" nut driver, remove the 4
screws that hold the handle to the
machine.
3. Remove the rubber gasket (cover seal)
from the lift bail.
4. With the 5/16" nut driver, remove the sheet
metal screws from the case top.
7. Visually check that the following leads are
not damaged or exposed. With the
volt/ohmmeter, also test the leads for con-
tinuity:
5. With the 5/16" nut driver, remove the
screws holding the right and left case
sides. Remove the case sides by lifting up
and out.
6. Perform the Capacitor Discharge
Procedure described earlier in this section
of the manual.
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F-87
F-87
TROUBLESHOOTING & REPAIR
RECONNECT SWITCH TEST 2 (continued)
• Lead #9A between the reconnect switch and
switch board #1.
8. With the volt/ohmmeter, test THAT THERE
IS CONTINUITY between the leads in the
following groups according to the voltage
for which the machine is wired:
• Lead #9B between the reconnect switch and
switch board #2.
• Lead #9C between the reconnect switch and
switch board #3.
For 200-230 VAC:
• Lead #9D between the reconnect switch and
switch board #4.
A. Test for continuity between leads #9A,
#9B, #9C, #9D, #9K, #9J, and POS con-
nected together at the reconnect switch.
• Lead #9J between the reconnect switch and
plug J31 - pin 10 of the protection board.
B. Test for continuity between leads #12A,
#12B, #12C, #12D, #12K, #12J, and NEG
connected together at the reconnect
switch.
• Lead #9K between the reconnect switch and
plug J31 - pin 14 of the protection board.
• Lead #12A between the reconnect switch
and switch board #1.
For 380 - 460 VAC:
A. Test for continuity between leads #9A,
#9B, #9K, and POS connected together at
the reconnect switch.
• Lead #12B between the reconnect switch
and switch board #2.
• Lead #12C between the reconnect switch
and switch board #3.
B. Test for continuity between leads #9C,
#9D, #9J, #12A, #12B, and #12J connect-
ed together at the reconnect switch.
• Lead #12D between the reconnect switch
and switch board #4.
C. Test for continuity between leads #12C,
#12D, #12K and NEG connected together
at the reconnect switch.
• Lead #12J between the reconnect switch
and plug J31 - pin 12 of the protection board.
• Lead #12K between the reconnect switch
and plug J31 - pin 1 of the protection board.
9. If there is continuity within the groups of
leads tested, the test is complete. Install
the machine case sides, top, handle and
the lift bail rubber gasket.
• Lead POS between the reconnect switch and
the input rectifier.
• Lead NEG between the reconnect switch
and the input rectifier.
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F-88
F-88
TROUBLESHOOTING & REPAIR
FIGURE F.29 – INPUT AND RECONNECT WIRING DIAGRAM
POWER WAVE 450
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F-89
F-89
TROUBLESHOOTING & REPAIR
STATIC CAPACITOR BALANCE TEST
WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician or
machine operator and will invalidate your factory warranty. For your safety and to avoid elec-
trical shock, please observe all safety notes and precautions detailed throughout this manual.
If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou-
bleshooting assistance before you proceed. Call 1-800-833-9353 (WELD).
TEST DESCRIPTION
This test will determine if, with no machine output, the input capacitors are balanced.
Before conducting this test, perform the following tests:
Switch Board Test - to ensure that none of the switch boards are faulty.
Snubber and Bleeder Resistance Test - to ensure that the bleeder resistors are properly
connected to the switch boards.
Reconnect Switch Test 1 and Reconnect Switch Test 2 - to ensure that input power is
properly connected to the switch boards.
MATERIALS NEEDED
Volt/Ohmmeter (Multimeter)
5/16" Nut driver
3/8" Nut driver
Snubber and Bleeder Resistor Wiring Diagram – Figure F.31
This procedure takes approximately 30 minutes to perform.
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F-90
F-90
TROUBLESHOOTING & REPAIR
STATIC CAPACITOR BALANCE TEST (continued)
FIGURE F.30 - BLEEDER RESISTORS R9 AND R10 LOCATION
1
1. RESISTORS R9 AND R10 (BLEEDER RESISTORS)
TEST PROCEDURE
WARNING
1. Remove main input supply power to the
machine.
Before continuing with the
test procedure, perform the
capacitor discharge proce-
dure to avoid electric shock.
2. With the 3/8" nut driver, remove the 4
screws that hold the handle to the
machine.
3. Remove the rubber gasket (cover seal)
from the lift bail.
7. After you have completed the capacitor
discharge procedure for all four switch
boards, use the 5/16" nut driver to remove
the two screws holding the PC board
cover. Remove the cover.
4. With the 5/16" nut driver, remove the sheet
metal screws from the case top.
5. With the 5/16" nut driver, remove the
screws holding the right and left case
sides. Remove the case sides by lifting up
and out.
8. If possible, set the machine up for 380 VAC
or above by setting the reconnect switch
and Jumper A to 380 VAC. If only 220 VAC
is available, perform the test that way.
Turn the machine on but have no output.
6. Perform the Capacitor Discharge
Procedure described earlier in this section
of the manual.
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F-91
F-91
TROUBLESHOOTING & REPAIR
STATIC CAPACITOR BALANCE TEST (continued)
For 380 VAC Input Voltage or Higher:
WARNING
If the difference is less than 75 VDC, static
capacitive balance is okay.
ELECTRIC SHOCK
can kill.
If the difference is more than 75 VDC, sta-
tic capacitive balance is not okay. Perform
With input supply power ON,
there are high voltages
the Input Rectifier Test. Also visually
check input filter capacitors C1, C2, C3,
and C4 for any signs of damage; replace
the FET or IGBT assembly.
inside the machine. Do not reach into the
machine or touch any internal part of the
machine, including resistors R9 and R10. Use
insulated gloves to measure the resistance
across these resistors.
For 220 VAC Input Voltage:
The two resistance measurements should
be the same. If one or both is less than
175 VDC, perform the Main Contactor
Test and the Input Rectifier Test. Also
visually check input filter capacitors C1,
C2, C3, and C4 for any signs of damage;
replace the FET or IGBT assembly.
9. Turn input supply power to the machine
ON. Machine output must be OFF.
10. Measure and record the DC voltage
across bleeder resistors R9 and R10.
Compare the voltage recorded to the
desired values in Table F.7, depending on
the input supply voltage setup.
12. After the test is completed and the prob-
lem successfully repaired, install the
machine case sides and top.
11. Determine the difference between the two
bleeder resistor voltages.
13. Install the handle and the lift bail rubber
gasket.
TABLE F.7
BLEEDER RESISTOR R9 AND R10 VOLTAGE VALUES
VAC INPUT
460 VAC
440 VAC
415 VAC
380 VAC
230 VAC
208 VAC
VDC ACROSS BLEEDER RESISTORS R9 AND R10
325 VDC
311 VDC
293 VDC
269 VDC
325 VDC
294 VDC
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F-92
F-92
TROUBLESHOOTING & REPAIR
Figure F.31 – SNUBBER AND BLEEDER RESISTOR WIRING DIAGRAM
SNUBBER AND BLEEDER RESISTOR WIRING DIAGRAM
(401)
SWITCH
BOARD
#1
25Ω
R1
( 25W )
401
12A
(12E)
(12A)
(12L)
(9L)
TO RECONNECT SWITCH
7.5KΩ
(402)
R9
( )
25W
C
1
25Ω
R2
( 25W )
402
9A
(9E)
(9A)
TO RECONNECT SWITCH
(403)
SWITCH
BOARD
#2
25Ω
R3
( 25W )
403
12B
(12F)
(12B)
TO RECONNECT SWITCH
(404)
C
2
25Ω
R4
( 25W )
404
9B
(9F)
(9B)
TO RECONNECT SWITCH
(405)
SWITCH
BOARD
#3
25Ω
R5
( 25W )
405
12C
(12G)
(12C)
(12M)
(9M)
TO RECONNECT SWITCH
7.5KΩ
(406)
R10
( 25W )
C
3
25Ω
R6
( 25W )
406
9C
(9G)
(9C)
TO RECONNECT SWITCH
(407)
SWITCH
BOARD
#4
25Ω
R7
( 25W )
407
12D
(12H)
(12D)
TO RECONNECT SWITCH
(408)
C
4
25Ω
R8
( 25W )
408
9D
(9H)
(9D)
TO RECONNECT SWITCH
POWER WAVE 450
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F-93
F-93
TROUBLESHOOTING & REPAIR
DYNAMIC CAPACITOR BALANCE TEST
WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician or
machine operator and will invalidate your factory warranty. For your safety and to avoid elec-
trical shock, please observe all safety notes and precautions detailed throughout this manual.
If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou-
bleshooting assistance before you proceed. Call 1-800-833-9353 (WELD).
TEST DESCRIPTION
This test will determine if, with no machine output, the control board is receiving the correct
frequency signal from the protection board.
NOTE: Conduct this test after the Static Capacitor Balance Test has been performed suc-
cessfully. The reconnect switch and Jumper A must be set for 380 VAC input voltage or
higher. The selected input voltage must be the actual voltage applied.
MATERIALS NEEDED
Volt/Ohmmeter (Multimeter)
Oscilloscope
5/16" Nut driver
3/8" Nut driver
Input and Reconnect Wiring Diagram – Figure F.33
This procedure takes approximately 45 minutes to perform.
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F-94
F-94
TROUBLESHOOTING & REPAIR
DYNAMIC CAPACITOR BALANCE TEST (continued)
FIGURE F.32- CONTROL BOARD PLUG LOCATIONS
TOP VIEW
1 2
1
1
1
1
1
1
PROTECTION BD
1
1
1
3
4
16
14
6
6
14
6
4
4
4
J30
J31
J32
J33
J34
J35
J39
J36
J37 J38
GROUND PLANE
CONTROL BD
2
1
1
1
1
1
4
1
1
1
1
4
8
8
12
14
10
6
4
6
J20
J21
J22
J23
J24
J25
J26 J27 J28
DISPLAY
TEST PROCEDURE
WARNING
1. Remove main input supply power to the
machine.
Before continuing with the
test procedure, perform the
capacitor discharge proce-
dure to avoid electric shock.
2. With the 3/8" nut driver, remove the 4
screws that hold the handle to the machine.
3. Remove the rubber gasket (cover seal) from
the lift bail.
7. After you have completed the capacitor dis-
charge procedure for all four switch boards,
use the 5/16" nut driver to remove the two
screws that hold the PC board cover.
Remove the cover.
4. With the 5/16" nut driver, remove the sheet
metal screws from the case top.
5. With the 5/16" nut driver, remove the
screws holding the right and left case sides.
Remove the case sides by lifting up and
out.
8. Connect the machine negative (-) output
terminal to earth ground. Connect the
oscilloscope case ground to earth ground.
6. Perform the Capacitor Discharge Proce-
dure described earlier in this section of the
manual.
9. Connect the oscilloscope to plug J23 - pin
4 (positive side) and plug J23 - pin 2 (nega-
tive side) on the control board. See Figure
F.32 for location If these connections are
reversed, you will not be able to see the fre-
quency train on the oscilloscope. Set the
oscilloscope to be DC coupled with 2
volts/division and 0.2 milliseconds/division.
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F-95
F-95
TROUBLESHOOTING & REPAIR
DYNAMIC CAPACITOR BALANCE TEST (continued)
14. Test leads #232 and #234 for continuity.
WARNING
These leads are between the protection
board and the control board. Lead #232 is
between J39 - pin 3 and J23 - pin 2. Lead
#234 is between J39 - pin 2 and J23 - pin
4. These leads must be intact for the fre-
quency signal to be measured, because
the transistor side of the optocoupler
needs the power from the control board.
ELECTRIC SHOCK
can kill.
With input power ON, there
are high voltages inside the
machine, including the pro-
tection board. Do not reach into the machine
or touch any internal part of the machine while
power is ON.
15. If all the leads tested in step 14 are okay,
make sure that the molex plugs are all
plugged in correctly and pushed far
enough into their headers. Check the fre-
quency again on the oscilloscope.
10. Turn input power ON. Machine output
must be OFF.
16. If the frequency is still incorrect, the pro-
tection board may be faulty. Replace the
protection board and perform the
Dynamic Capacitor Balance Test again.
11. Measure the frequency between J23 - pin
4 and J23 - pin 2 on the control board.
You should see between 3.2 and 5.3 divi-
sions per cycle (950 to 1550 Hz.). If you
do see this, the test is completed. If you
do not see this, go to the next step.
17. If the frequency is still incorrect, the con-
trol board may be faulty. Replace the con-
trol board.
12. Turn the power switch SW1 to the OFF
position, disconnect input power to the
machine, and perform the Capacitor
Discharge Procedure.
18. Install the machine case sides and top.
19. Install the handle and the lift bail rubber
gasket.
WARNING
Before continuing with the test procedure, per-
form the capacitor discharge procedure to
avoid electric shock.
13. After you have completed the capacitor
discharge procedure for all four switch
boards, with the volt/ohmmeter, test leads
9J, 9K, 12J, and 12K for continuity
between the between the reconnect
switch and the protection board.
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F-96
F-96
TROUBLESHOOTING & REPAIR
FIGURE F.33 – INPUT AND RECONNECT WIRING DIAGRAM
POWER WAVE 450
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F-97
F-97
TROUBLESHOOTING & REPAIR
INTERNAL AND AUXILIARY SUPPLY VOLTAGE TEST
WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician or
machine operator and will invalidate your factory warranty. For your safety and to avoid elec-
trical shock, please observe all safety notes and precautions detailed throughout this manual.
If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou-
bleshooting assistance before you proceed. Call 1-800-833-9353 (WELD).
TEST DESCRIPTION
This test will determine if the proper voltages are present at the protection board, the
power board, the control board, and the display board.
MATERIALS NEEDED
Volt/Ohmmeter (Multimeter)
5/16" Nut driver
3/8" Nut driver
Internal Auxiliary Supply Wiring Diagram – Figure F.34
This procedure takes approximately 45 minutes to perform.
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F-98
F-98
TROUBLESHOOTING & REPAIR
INTERNAL AND AUXILIARY SUPPLY VOLTAGE TEST (continued)
TEST PROCEDURE
WARNING
1. Remove main input supply power to the
machine.
ELECTRIC SHOCK
can kill.
2. With the 3/8" nut driver, remove the 4
screws that hold the handle to the machine.
With input power ON, there
are high voltages inside the
machine, including plug J30
3. Remove the rubber gasket (cover seal) from
the lift bail.
and the protection board. Do not reach into
the machine or touch any internal part of the
machine while power is ON.
4. With the 5/16" nut driver, remove the sheet
metal screws from the case top.
5. With the 5/16" nut driver, remove the
screws holding the right and left case sides.
Remove the case sides by lifting up and
out.
11. Turn input power ON. Machine output
must be OFF.
6. Perform the Capacitor Discharge
Procedure described earlier in this section
of the manual.
12. Verify the following voltage measure-
ments:
A. Protection Board:
115 VAC Between J33 - pin 6 and J33 -
pin 1 (Power Wave 450 only)
WARNING
Before continuing with the test procedure, per-
form the capacitor discharge procedure to
avoid electric shock.
42 VAC
Between J33 - pin 3 and J33 -
pin 1
24 VAC
Between J33 - pin 4 and J33 -
pin 1
If any of these voltages are not present on the
protection board, and the Auxiliary Transformer
1 Test has been completed successfully, do
the following: Turn the power switch SW1 OFF
and disconnect input power to the machine.
Check the pins of plug J33 to be sure they are
7. After you have completed the capacitor dis-
charge procedure for all four switch boards,
remove the PC board cover. Use the 5/16"
nut driver.
8. Remove the 5 leads ( 3 heavy and 2 small)
T1, T2, T3 from main input contactor CR1.
This is a safety precaution. It prevents high
voltage from being put on the machine dur-
ing the test. Wrap tape around the lead
ends to insulate them and prevent them
from touching.
not loose or broken.
Since Auxiliary
Transformer 1 Test determined that voltages
are present at plug J33, the fault must be that
these signals are not getting to header J33.
B. Protection Board:
115 VAC Between J34 - pin 1 and J34 -
pin 5 (Power Wave 450 only)
9. Remove plug J30 from the protection
board. See Figure F.1 for location of the
board and plug J30.
42 VAC
Between J34 - pin 3 and J34 -
pin 5
10. Make sure that none of the pins are loose
or open on the following molex plugs: J33,
J34, J35, J37, J38 (on the protection
board), J12, J13, J16 (on the display
board), J22 (on the control board), J42,
J43, and J44 (on the power board). See
the Internal Auxiliary Supply Wiring
Diagram, Figure F.34.
24 VAC
Between J34 - pin 4 and J34 -
pin 5
If any of these voltages are not present on the
protection board (and the voltages in part A,
above, were present, replace the protection
board.
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F-99
F-99
TROUBLESHOOTING & REPAIR
INTERNAL AND AUXILIARY SUPPLY VOLTAGE TEST (continued)
C. Protection Board:
+5 VDC
-5 VDC
-8 VDC
Between J44 - pin 11 and J44
- pin 12
115 VAC Between J34 - pin 8 and J34 -
pin 12 (Power Wave 450 only)
Between J44 - pin 9 and J44 -
pin 12
42 VAC
Between J34 - pin 10 and J34
- pin 12
Between J44 - pin 6 and J44 -
pin 12
24 VAC
Between J34 - pin 11 and J34
- pin 12
If any of these voltages are NOT present,
replace the power board. If these voltages ARE
present, check the wiring first. Then replace
the display board.
If any of these voltages are not present on the
protection board (and the voltages in part A,
above, were present, replace the protection
board.
F. Control Board:
D. Power Board:
+15 VDC Between J22 - pin 10 and J22
- pin 12
42 VAC
Between J43 - pin 1 and J43 -
pin 3
-15 VDC
Between J22 - pin 6 and J22-
pin 12
If this voltage is not present (and the voltages
in part A, above, were present), disconnect
plug J35 from the protection board and check
for 42 VAC at header J35 between pin 1 and
pin 6. If this voltage is NOT present, replace
the protection board. If this voltage IS present,
check the wiring between the boards. Then
replace the power board.
+5 VDC
Between J22 - pin 11 and J22
- pin 12
If any of these voltages are not present (and
the voltages in part D, above, were present),
disconnect plug J42 from the power board and
check the following voltages at header J42 on
the power board:
+15 VDC Between J42 - pin 10 and J42
- pin 12
E. Display Board:
+5 VDC
Between J16 - pin 2 and J16 -
pin 3
-15 VDC
Between J42 - pin 6 and J42 -
pin 12
+15 VDC Between J16 - pin 10 and J16
- pin 7
+5 VDC
Between J42 - pin 11 and J42
- pin 12
+5 VDC
-5 VDC
-8 VDC
Between J16 - pin 1 and J16 -
pin 7
If any of these voltages are NOT present,
replace the power board. If these voltages ARE
present, check the wiring. Then replace the
control board.
Between J16 - pin 9 and J16 -
pin 7
Between J16 - pin 6 and J16 -
pin 7
If any of these voltages are not present (and
the voltages in part D, above, were present),
disconnect plug J44 from the power board and
check the following voltages at header J44 on
the power board:
+5 VDC
Between J44 - pin 3 and J44 -
pin 2
+15 VDC Between J44 - pin 10 and J44
- pin 12
POWER WAVE 450
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F-100
F-100
TROUBLESHOOTING & REPAIR
INTERNAL AND AUXILIARY SUPPLY VOLTAGE TEST (continued)
13. With the Volt/ohmmeter, check the follow-
ing leads for continuity:
C. Between the protection board and the
square wave TIG protection board:
A. Between the Protection Board and Wire
Feeder 2 Receptacle:
Lead #296 Between J38 - pin 3 and J92
- pin 6
Lead #32D Between J34 - pin 5 and P82
- pin A
14. After the test is completed and the prob-
lem successfully repaired, disconnect
input power to the machine.
Lead #32E Between J34 - pin 6 and P82
- pin I
15. Connect the five leads to main input con-
tactor CR1 and insert plug J30 into the
protection board.
Lead #42C Between J34 - pin 3 and P82
- pin K
16. Install the machine case sides and top.
Lead #102D Between J34 - pin 4 and P82
- pin C
17. Install the handle and the lift bail rubber
gasket.
Lead #31C Between J34 - pin 1 and P82
- pin J
Lead #106A Between J34 - pin 7 and P82
- pin D
B. Between the Protection Board and Wire
Feeder 1 Receptacle:
Lead #32B Between J34 - pin 12 and
P83 - pin A
Lead #32C Between J34 - pin 13 and
P83 - pin I
Lead #42B Between J34 - pin 10 and
P83 - pin K
Lead #102B Between J34 - pin 11 and
P83 - pin C
Lead #31B Between J34 - pin 8 and P83
- pin J
Lead #105A Between J34 - pin 14 and
P83 - pin D
POWER WAVE 450
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F-101
F-101
TROUBLESHOOTING & REPAIR
FIGURE F.34 – INTERNAL AUXILIARY SUPPLY WIRING DIAGRAM
J 3 8
2
J 9 2
I G T 1 R
2 4 V
3
6
2 9 3
2 9 6
J 9 2
3
J 3 4
1 4
J 3 7
4
J 1 2
4
P 8 3
I G T 1 R
D
J
1 0 5 A
3 1 B
1 0 2 B
4 2 B
3 2 C
3 2 B
3 7 4
1 1 5 V
8
2 4 V
4 2 V
C
K
1 1
1 0
1 3
1 2
C O M M O N I
C O M M O N A
J 3 7
1
J 3 7
3
J 1 2
2
J 1 3
4
3 7 1
3 7 3
J 3 4
7
J 3 7
2
J 1 3
2
P 8 2
I G T 2 R
D
J
1 0 6 A
3 1 C
1 0 2 D
4 2 C
3 2 E
3 7 2
1
4
3
6
5
1 1 5 V
2 4 V
C
K
4 2 V
C O M M O N I
C O M M O N A
3 2 D
POWER WAVE 450
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F-102
F-102
NOTES
POWER WAVE 450
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F-103
F-103
TROUBLESHOOTING & REPAIR
MAIN CONTACTOR TEST
WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician or
machine operator and will invalidate your factory warranty. For your safety and to avoid elec-
trical shock, please observe all safety notes and precautions detailed throughout this manual.
If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou-
bleshooting assistance before you proceed. Call 1-800-833-9353 (WELD).
TEST DESCRIPTION
This test will determine if main input contactor CR1 and its associated wiring and compo-
nents are faulty or damaged.
MATERIALS NEEDED
Volt/Ohmmeter (Multimeter)
5/16" Nut driver
3/8" Nut driver
Slot head screw driver
Input and Reconnect Wiring Diagram – Figure F.36
This procedure takes approximately 45 minutes to perform.
POWER WAVE 450
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F-104
F-104
TROUBLESHOOTING & REPAIR
MAIN CONTACTOR TEST (continued)
FIGURE F.35 - MAIN CONTACTOR
L1 L2 L3
T3CR1
T1 T2
TEST PROCEDURE
WARNING
1. Remove main input supply power to the
machine.
Before continuing with the
test procedure, perform the
capacitor discharge proce-
dure to avoid electric shock.
2. With the 3/8" nut driver, remove the 4
screws that hold the handle to the machine.
3. Remove the rubber gasket (cover seal) from
the lift bail.
4. With the 5/16" nut driver, remove the sheet
metal screws from the case top.
7. After you have completed the capacitor dis-
charge procedure for all four switch boards,
visually inspect the input terminals L1, L2,
and L3 of the main contactor. Make sure
they are not shorted together. If they are
shorted, go to step 8. If they are not short-
ed, go to step 9.
5. With the 5/16" nut driver, remove the
screws holding the right and left case sides.
Remove the case sides by lifting up and
out.
6. Perform the Capacitor Discharge
Procedure described earlier in this section
of the manual.
8. With the slot head screw driver, remove
leads L1A and L3A from the main contactor.
POWER WAVE 450
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F-105
F-105
TROUBLESHOOTING & REPAIR
MAIN CONTACTOR TEST (continued)
A. With the power switch SW1 OFF, check to
If any of these measurements shows continu-
ity, replace the main contactor. If no continuity
is shown, go to step 12.
see if leads L1A and L3A are shorted
together. If they are shorted, visually
inspect the leads. If the leads are okay,
then power switch SW1 is faulty and must
be replaced.
12. Visually check the following leads for
damage, then check for continuity as
described:
B. Remove leads L1, L2, and L3 from the
main contactor. Check if the terminals of
the main contactor are still shorted. If they
are, the main contactor is faulty and must
be replaced. If the terminals are not short-
ed, the input lines themselves are shorted.
Reconnect leads L1, L2, L3, L1A, and L3A
to the main contactor.
Lead #324 Between the main contactor
and plug J32 - pin 4 of the
protection board
Lead #326 Between the main contactor
and plug J32 - pin 6 of the
protection board
Lead #321 Between plug J71 - pin 1 of
auxiliary Transformer 1 and
plug J32 - pin 1 of the protec-
tion board
9. Visually inspect terminals T1, T2, and T3
of the main contactor. Make sure they are
not shorted together in any way. If they
are not shorted, go to step 11. If they are
shorted, go to step 10.
Lead #323 Between plug J71 - pin 4 of
auxiliary Transformer 1 and
plug J32 - pin 3 of the protec-
tion board
10. Remove leads T1, T2, and T3 from the
main contactor.
A. Check if the terminals of the main contac-
tor are still shorted. If they are, the main
contactor is faulty and must be replaced.
Lead T1
Between the main contactor
and the protection board plug
J30 - pin 11
B. Reconnect leads T1, T2, and T3 to the
main contactor. Remove plug J30 from the
protection board. Make sure that leads T1
and T3 of plug J30 between the main con-
tactor and the protection board are not
damaged, exposed, or shorted together.
Check again for shorts across the contacts
of the main contactor. If the terminals are
not shorted now, the protection board is
faulty. Replace the protection board.
Lead T3
Between the main contactor
and the protection board plug
J30 - pin 16
Put the power switch SW1 in the ON position
for the next two continuity tests:
Lead H1B Between terminal L3 of the
main contactor and plug J30
- pin 6 of the protection board
Lead #321A Between terminal L1 of the
main contactor and plug J30
C. Visually inspect leads T1, T2, and T3
between the main contactor and the input
rectifier and between the main contactor
and the protection board. If these leads
are not damaged or exposed, then the
input rectifier may be faulty and should be
checked. Perform the Input Rectifier
Test described in this section of the man-
ual.
- pin 1 of the protection board
Put the power switch SW1 in the OFF position.
Replace any broken or damaged leads discov-
ered by these tests.
13. Connect any plugs disconnected for the
tests. Replace the PC board cover with
two sheet metal screws.
11. With the volt/ohmmeter, check for conti-
nuity between the following terminals of
the main contactor:
14. Install the machine case sides and top.
15. Install the handle and the lift bail rubber
gasket.
L1 and T1
L2 and T2
L3 and T3
POWER WAVE 450
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F-106
F-106
TROUBLESHOOTING & REPAIR
FIGURE F.36 – INPUT AND RECONNECT WIRING DIAGRAM
POWER WAVE 450
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F-107
F-107
TROUBLESHOOTING & REPAIR
SERIAL LOOP WIRING HARNESS TEST
WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician or
machine operator and will invalidate your factory warranty. For your safety and to avoid elec-
trical shock, please observe all safety notes and precautions detailed throughout this manual.
If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou-
bleshooting assistance before you proceed. Call 1-800-833-9353 (WELD).
TEST DESCRIPTION
This test will determine if there are any short circuits or other problems in the serial loop
wiring between the power board, the control board, the display board, wire feeder 1
amphenol (P83) and wire feeder 2 amphenol (P82).
MATERIALS NEEDED
Volt/Ohmmeter (Multimeter)
5/16" Nut driver
3/8" Nut driver
Serial Loop Wiring Diagram Figure – F.38
This procedure takes approximately 30 minutes to perform.
POWER WAVE 450
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F-108
F-108
TROUBLESHOOTING & REPAIR
SERIAL LOOP WIRING HARNESS TEST (continued)
FIGURE F.37 - WIRE FEEDER AMPHENOL LOCATIONS
1
1. WIRE FEEDER CONNECTIONS (ON BACK PANEL)
TEST PROCEDURE
WARNING
1. Remove main input supply power to the
machine.
Before continuing with the
test procedure, perform the
capacitor discharge proce-
dure to avoid electric shock.
2. With the 3/8" nut driver, remove the 4
screws that hold the handle to the machine.
3. Remove the rubber gasket (cover seal) from
the lift bail.
4. With the 5/16" nut driver, remove the sheet
metal screws from the case top.
7. After you have completed the capacitor dis-
charge procedure for all four switch boards,
remove the PC board cover. Use the 5/16"
nut driver.
5. With the 5/16" nut driver, remove the
screws holding the right and left case sides.
Remove the case sides by lifting up and
out.
8. Perform the following test for faults on the
serial loop circuitry between wire feeder 1
amphenol (P83) and the control board.
6. Perform the Capacitor Discharge
Procedure described earlier in this section
of the manual.
A. Disconnect the wire feeder from the wire
feeder 1 amphenol (P83).
POWER WAVE 450
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F-109
F-109
TROUBLESHOOTING & REPAIR
SERIAL LOOP WIRING HARNESS TEST (continued)
B. Check for loose or broken leads between
A. Check for loose or broken leads between
the following pins:
the following pins:
P83 - pin L and J27 - pin 1 on the control
board (lead #111A)
J22 - pin 5 on the control board and J44 -
pin 5 on the power board (lead #5R)
P83 - pin M and J27 - pin 4 on the control
board (lead #112A)
J22 - pin 4 on the control board and J44 -
pin 4 on the power board (lead #5W)
C. Make sure that plug J27 is plugged into
the control board securely and that none of
its pins are loose.
B. Make sure that plug J22 is plugged into
the control board securely and that none of
its pins are loose. Also make sure that
plug J44 is securely plugged into the
power board and that none of its pins are
loose.
D. Reconnect the wire feeder to the wire
feeder 1 amphenol (P83).
9. Perform the following test for faults on the
serial loop circuitry between wire feeder 2
amphenol (P82) and the control board.
With the DC voltmeter, check for at least 30
VDC between plug J44 - pin 5 and pin 4 on the
power board. This is the voltage source for the
40 mA current for the serial loop. If the voltage
is low or not present, the power board may be
faulty. Replace the power board.
A. Disconnect the wire feeder from the wire
feeder 2 amphenol (P82).
B. Check for loose or broken leads between
the following pins:
12. After the test is completed and the prob-
lem successfully repaired, replace the PC
board cover with two sheet metal screws.
P82 - pin L and J28 - pin 1 on the control
board (lead #117A)
13. Install the machine case sides and top.
P82 - pin M and J28 - pin 4 on the control
board (lead #118A)
14. Install the handle and the lift bail rubber
gasket.
C. Make sure that plug J28 is plugged into
the control board securely and that none of
its pins are loose.
D. Reconnect the wire feeder to the wire
feeder 2 amphenol (P82).
10. Perform the following test for faults on the
serial loop circuitry between the display
board and the control board.
A. Check for loose or broken leads between
the following pins:
J26 - pin 3 on the control board and J14 -
pin 6 on the display board (lead #263)
J26 - pin 4 on the control board and J14 -
pin 3 on the display board (lead #264)
B. Make sure that plug J26 is plugged into
the control board securely and that none of
its pins are loose. Also make sure that
plug J14 is securely plugged into the dis-
play board and that none of its pins are
loose.
11. Perform the following test for faults on the
serial loop circuitry 40 mA current supply.
POWER WAVE 450
1/96
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F-110
F-110
TROUBLESHOOTING & REPAIR
FIGURE F.38 – SERIAL LOOP WIRING DIAGRAM
J22
(5R)
J44
5
5
40mA current supply
Serial Loop
Master
Transmit &
Receive Lines
TxD
RxD
DISPLAY BOARD
POWER BOARD
DK+
3
J26
J26
J27
J27
(263)
J14
6
TRN
REC
Display Board
Port Switch
Open: DK Board S.L.
Comunication
enabled
Closed: DK Board S.L.
Comunication
disabled
DK-
4
(264)
J14
3
WF1
14-pin
WF1
8-pin
WF+
1
(111A)
(112A)
P83
82(+)
H
L
TRN
REC
WF1
Port Switch
Open: WF1 S.L.
Comunication
enabled
Closed: WF1 S.L.
Comunication
disabled
WF-
4
P83
P82
81(-)
G
M
14-pin
WF2
WF2
8-pin
OPT+
1
(117A)
(118A)
J28
J28
82(+)
H
L
TRN
REC
WF2
Port Switch
Open: WF2 S.L.
Comunication
enabled
OPT-
4
P82
81(-)
G
M
Closed: WF2 S.L.
Comunication
disabled
POWER BOARD
J22
(5W)
J44
4
4
40mA
current path
CONTROL BOARD
POWER WAVE 450
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F-111
F-111
TROUBLESHOOTING & REPAIR
WIRE FEEDER 1 TRIGGER CIRCUIT TEST
WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician or
machine operator and will invalidate your factory warranty. For your safety and to avoid elec-
trical shock, please observe all safety notes and precautions detailed throughout this manual.
If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou-
bleshooting assistance before you proceed. Call 1-800-833-9353 (WELD).
TEST DESCRIPTION
This test will determine if there are any faults in the 24 VAC trigger circuit integral to the
Power Wave and the wire feeder 1 amphenol (P83).
MATERIALS NEEDED
Volt/Ohmmeter (Multimeter)
5/16" Nut driver
3/8" Nut driver
Short piece of jumper wire
Trigger Circuit Wiring Diagram – Figure F.40
This procedure takes approximately 30 minutes to perform.
POWER WAVE 450
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F-112
F-112
TROUBLESHOOTING & REPAIR
WIRE FEEDER 1 TRIGGER CIRCUIT TEST (continued)
FIGURE F.39 - DISPLAY BOARD PLUG LOCATIONS
J17 J16 J15
J14 J13 J12 J11 J10
TEST PROCEDURE
WARNING
1. Remove main input supply power to the
machine.
Before continuing with the
test procedure, perform the
capacitor discharge proce-
dure to avoid electric shock.
2. With the 3/8" nut driver, remove the 4
screws that hold the handle to the machine.
3. Remove the rubber gasket (cover seal) from
the lift bail.
4. With the 5/16" nut driver, remove the sheet
metal screws from the case top.
7. After you have completed the capacitor
discharge procedure for all four switch
boards, remove the PC board cover. Use
the 5/16" nut driver.
5. With the 5/16" nut driver, remove the
screws holding the right and left case sides.
Remove the case sides by lifting up and
out.
8. Remove plug J12 from the display board.
6. Perform the Capacitor Discharge
Procedure described earlier in this section
of the manual.
9. Place a jumper wire between pins C and D
of wire feeder receptacle #1.
10. Remove the 5 leads ( 3 heavy and 2 small)
T1, T2, T3 from main input contactor CR1.
This is a safety precaution. It prevents
high voltage from being put on the
machine during the test. Wrap tape
around the lead ends to insulate them and
prevent them from touching.
POWER WAVE 450
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F-113
F-113
TROUBLESHOOTING & REPAIR
WIRE FEEDER 1 TRIGGER CIRCUIT TEST (continued)
11. Remove plug J30 from the protection
board. See Figure F.1 for location of the
board and plug J30.
WARNING
ELECTRIC SHOCK can kill.
WARNING
With the input power ON, there are high volt-
ages inside the machine, including the protec-
tion board. Do not reach into the machine or
touch any internal parts.
ELECTRIC SHOCK
can kill.
With the input power ON,
there are high voltages
inside the machine. Do not
reach into the machine or touch any internal
parts.
17. Turn input power ON. The LCD display
will read: ERROR: S.L. NOT INITIALIZED.
Disregard this; the test can still be per-
formed.
18. Remove the jumper between pins C and D
of wire feeder #1 receptacle.
12. Turn input power ON.
19. With the volt/ohmmeter, measure the volt-
age drop across the 150 ohm resistor
between J26 - pins 1 and 2. With the
jumper removed, the reading should be
zero volts (NO voltage drop).
13. With the volt/ohmmeter, check for 24 VAC
between plug J12 - pin 2 and pin 4.
A. If 24 VAC IS present, go to step 14.
NOTE: A voltage of 5 to 10 VDC is normal
between these pins without the C to D
jumper installed in the wirefeeder recepta-
cle.
20. Replace the jumper between pins C and D
of wire feeder #1 receptacle. Measure the
voltage drop with the jumper installed.
The reading should be about 2 VDC
across the resistor.
B. If 24 VAC is NOT present, check for 24
VAC between plug J33 - pin 4 and pin 1.
See the Trigger Circuit Wiring Diagram,
Figure F.40.
A. If 2 VDC is NOT present, check the conti-
nuity and integrity of leads #262 and 261
and their associated pins and connectors.
The display board may be faulty -- replace
the display board.
C. If 24 VAC IS present between plug J33 pin
4 and pin 1, check the continuity and
integrity of leads #371, 374, 102B, and
105A and their associated pin connectors.
See the Trigger Circuit Wiring Diagram. If
the continuity checks are good, the pro-
tection board may be faulty. Replace the
protection board.
B. If 2 VDC IS present across the resistor, the
control board may be faulty -- replace the
control board.
21. Turn input power to the machine OFF and
connect the five leads to the main contac-
tor. Connect all molex plugs to the PC
boards and replace the cover with two
sheet metal screws. Install the machine
case sides, top, handle, and lift bail rubber
gasket.
D. If 24 VAC is NOT present between plug
J33 pin 4 and pin 1, check Auxiliary
Transformer #1, the 5 amp circuit breaker,
and the associated wiring. See the Trigger
Circuit Wiring Diagram, Figure F.40.
14. Turn input power to the machine OFF and
perform the Capacitor Discharge
Procedure.
15. Remove plug J26 from the control board.
Attach a 150 ohm resistor between plug
J26 - pin 1 and J26 - pin 2 (the J26 plug,
not the header on the control board).
16. Replace plug J12 into the display board.
POWER WAVE 450
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F-114
F-114
TROUBLESHOOTING & REPAIR
FIGURE F.40 – TRIGGER CIRCUIT WIRING DIAGRAM
P 7 0
P 7 0
( 2 9 6 ) ( 2 9 3 )
POWER WAVE 450
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F-115
F-115
TROUBLESHOOTING & REPAIR
WIRE FEEDER 2 TRIGGER CIRCUIT TEST
WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician or
machine operator and will invalidate your factory warranty. For your safety and to avoid elec-
trical shock, please observe all safety notes and precautions detailed throughout this manual.
If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou-
bleshooting assistance before you proceed. Call 1-800-833-9353 (WELD).
TEST DESCRIPTION
This test will determine if there are any faults in the 24 VAC trigger circuit integral to the
Power Wave and the wire feeder 2 amphenol (P82).
MATERIALS NEEDED
Volt/Ohmmeter (Multimeter)
5/16" Nut driver
3/8" Nut driver
Short piece of jumper wire
Trigger Circuit Wiring Diagram – Figure F.42.
This procedure takes approximately 30 minutes to perform.
POWER WAVE 450
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F-116
F-116
TROUBLESHOOTING & REPAIR
WIRE FEEDER 2 TRIGGER CIRCUIT TEST (continued)
FIGURE F.41 - DISPLAY BOARD PLUG LOCATIONS
J17 J16 J15
J14 J13 J12 J11 J10
TEST PROCEDURE
WARNING
1. Remove main input supply power to the
machine.
Before continuing with the
test procedure, perform the
capacitor discharge proce-
dure to avoid electric shock.
2. With the 3/8" nut driver, remove the 4
screws that hold the handle to the machine.
3. Remove the rubber gasket (cover seal) from
the lift bail.
4. With the 5/16" nut driver, remove the sheet
metal screws from the case top.
7. After you have completed the capacitor
discharge procedure for all four switch
boards, remove the PC board cover. Use
the 5/16" nut driver.
5. With the 5/16" nut driver, remove the
screws holding the right and left case sides.
Remove the case sides by lifting up and
out.
8. Remove plug J13 from the display board.
6. Perform the Capacitor Discharge
Procedure described earlier in this section
of the manual.
9. Place a jumper wire between pins C and D
of wire feeder receptacle #2.
10. Remove the 5 leads ( 3 heavy and 2 small)
T1, T2, T3 from main input contactor CR1.
This is a safety precaution. It prevents
high voltage from being put on the
machine during the test. Wrap tape
around the lead ends to insulate them and
prevent them from touching.
POWER WAVE 450
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F-117
F-117
TROUBLESHOOTING & REPAIR
WIRE FEEDER 2 TRIGGER CIRCUIT TEST (continued)
11. Remove plug J30 from the protection
WARNING
board. See Figure F.1 for location of the
board and plug J30.
ELECTRIC SHOCK can kill.
WARNING
With the input power ON, there are high volt-
ages inside the machine, including the protec-
tion board. Do not reach into the machine or
touch any internal parts.
ELECTRIC SHOCK
can kill.
With the input power ON,
there are high voltages inside
the machine. Do not reach
17. Turn input power ON. The LCD display
will read: ERROR: S.L. NOT INITIALIZED.
Disregard this; the test can still be per-
formed.
into the machine or touch any internal parts.
18. Remove the jumper between pins C and D
of wire feeder #2 receptacle.
12. Turn input power ON.
13. With the volt/ohmmeter, check for 24 VAC
between plug J13 - pin 2 and pin 4.
19. With the volt/ohmmeter, measure the volt-
age drop across the 150 ohm resistor
between J26 - pins 1 and 2. With the
jumper removed, the reading should be
zero volts (NO voltage drop).
A. If 24 VAC IS present, go to step 14.
NOTE: A voltage of 5 to 10 VDC is normal
between these pins without the C to D
jumper installed in the wirefeeder recepta-
cle.
20. Replace the jumper between pins C and D
of wire feeder #2 receptacle. Measure the
voltage drop with the jumper installed.
The reading should be about 2 VDC
across the resistor.
B. If 24 VAC is NOT present, check for 24
VAC between plug J33 - pin 4 and pin 1.
See the Trigger Circuit Wiring Diagram,
Figure F.42.
A. If 2 VDC is NOT present, check the conti-
nuity and integrity of leads #265 and 266
and their associated pins and connectors.
The display board may be faulty -- replace
the display board.
C. If 24 VAC IS present between plug J33 pin
4 and pin 1, check the continuity and
integrity of leads #373, 372, 102D, and
106A and their associated pin connectors.
See the Trigger Circuit Wiring Diagram. If
the continuity checks are good, the pro-
tection board may be faulty. Replace the
protection board.
B. If 2 VDC IS present across the resistor, the
control board may be faulty -- replace the
control board.
21. Turn input power to the machine OFF and
connect the five leads to the main contac-
tor. Connect all molex plugs to the PC
boards and replace the cover with two
sheet metal screws. Install the machine
case sides, top, handle, and lift bail rubber
gasket.
D. If 24 VAC is NOT present between plug
J33 pin 4 and pin 1, check Auxiliary
Transformer #1, the 5 amp circuit breaker,
and the associated wiring. See the Trigger
Circuit Wiring Diagram, Figure F.42.
14. Turn input power to the machine OFF and
perform the Capacitor Discharge
Procedure.
15. Remove plug J26 from the Protection-
Control board. Attach a 150 ohm resistor
between plug J26 - pin 5 and J26 - pin 6
(the J26 plug, not the header on the con-
trol board).
16. Replace plug J13 into the display board,
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F-118
F-118
TROUBLESHOOTING & REPAIR
FIGURE F.42 – TRIGGER CIRCUIT WIRING DIAGRAM
P 7 0
P 7 0
( 2 9 6 ) ( 2 9 3 )
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F-119
F-119
TROUBLESHOOTING & REPAIR
TRIGGER CIRCUIT AND WIRING HARNESS TEST
WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician or
machine operator and will invalidate your factory warranty. For your safety and to avoid elec-
trical shock, please observe all safety notes and precautions detailed throughout this manual.
If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou-
bleshooting assistance before you proceed. Call 1-800-833-9353 (WELD).
TEST DESCRIPTION
This test will determine if there are any short circuits or other problems in the trigger circuit
wiring or if there are any faulty PC boards, which would cause the 5 amp circuit breaker to
trip repeatedly.
MATERIALS NEEDED
Volt/Ohmmeter (Multimeter)
5/16" Nut driver
3/8" Nut driver
Short piece of jumper wire
Auxiliary Transformer #1 Secondary Circuit Wiring Diagram – Figure F.44.
This procedure takes approximately 25 minutes to perform.
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F-120
F-120
TROUBLESHOOTING & REPAIR
TRIGGER CIRCUIT AND WIRING HARNESS TEST (continued)
FIGURE F.43 - PROTECTION BOARD PLUG/HEADER LOCATIONS
1
1
1 4 7 1
1
1 2 1
PROTECTION BD
1
1
1
4
16
14
6
6 11
14
6
4
4
4
J30
J31
J32
J33
J34
J35
J39
J36
J37
J38
3
C. With the volt/ohmmeter, check for continu-
ity again between J37 - pin 1 and J37 - pin
4 of header J37. There should be continu-
ity now. Remove the jumper.
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.
D. With the volt/ohmmeter, check for continu-
ity between J37 - pin 2 and J37 - pin 3 of
header J37. There should be no continuity.
3. Remove the rubber gasket (cover seal) from
the lift bail.
E. Connect a jumper between J34 - pin 4 and
J34 - pin 7 of header J34 on the protection
board. This simulates the closing of the
trigger on wire feeder 2.
4. With the 5/16" nut driver, remove the sheet
metal screws from the case top.
5. With the 5/16" nut driver, remove the
screws holding the right and left case sides.
Remove the case sides by lifting up and
out.
F. With the volt/ohmmeter, check for continu-
ity again between J37 - pin 2 and J37 - pin
3 of header J37. There should be continu-
ity now. Remove the jumper and connect
plugs J34, J37, and J38 back into the pro-
tection board.
6. Perform the Capacitor Discharge
Procedure described earlier in this section
of the manual.
If the continuity tests above detect a fault,
replace the protection board.
WARNING
9. Remove plug J37 from the protection
board and inspect its pins and leads.
Make sure that the TRIG 1, TRIG 2, and
COMMON pins of plug J37 are not short-
ed together (pins 1, 2, 3, 4, respectively).
Make sure that leads #371, #372, #373,
and #374 are not exposed. See the
Auxiliary Transformer #1 Secondary
Circuit Wiring Diagram, Figure F.44.
Before continuing with the
test procedure, perform the
capacitor discharge proce-
dure to avoid electric shock.
7. After you have completed the capacitor dis-
charge procedure for all four switch boards,
remove the PC board cover. Use the 5/16"
nut driver.
10. Connect plug J37 to the Protection board.
If you found no problem with plug J37 pins
and leads, replace the display board.
8. Remove plugs J34, J37, and J38 from the
protection board. See Figure F.1 for loca-
tion. Continue with the following checks:
11. After the tests are completed and the
problem successfully repaired, reconnect
all plugs to their respective boards.
Replace the PC board cover with the two
sheet metal screws.
NOTE: Do not remove plug J33 from the pro-
tection board.
A. With the volt/ohmmeter, check for continu-
ity between J37 - pin 1 and J37 - pin 4 of
header J37. There should be no continuity.
12. Install the machine case sides and top.
13. Install the handle and the lift bail rubber
gasket.
B. Connect a jumper between J34 - pin 11
and J34 - pin 14 of header J34 of the pro-
tection board. This simulates the closing of
the trigger on wire feeder 1 or the remote.
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F-121
F-121
TROUBLESHOOTING & REPAIR
FIGURE F.44
AUXILIARY TRANSFORMER #1 SECONDARY CIRCUIT WIRING DIAGRAM
6
4 2 V
1
J 4 3
3 5 6
3 5 1
J 3 5
1
J 3 5
C O M M O N 3
J 4 3
3
C O M M O N 4
J 1 3
3 7 3
3 7 1
3 7 2
3 7 4
J 3 7
1
C O M M O N 2
J 3 7
J 1 2
2
I G T 2 R
2
4
J 1 3
J 1 2
J 3 7
4
1
R T I G
J 3 7
2
I G T 1 R
2 4 V
3
J 9 2
J 9 2
J 3 8
2 9 3
2 9 6
3
6
J 3 8
1 4
I G T 1 R
1 1 5 V
2 4 V
D
J
1 0 5 A
3 1 B
1 0 2 B
4 2 B
3 2 C
3 2 B
J 3 4
8
J 3 4
1 1
C
K
J 3 4
1 0
J 3 4
1 3
J 3 4
4 2 V
C O M M O N I
C O M M O N A
1 2
J 3 4
7
J 3 4
1
I G T 2 R
D
J
1 0 6 A
3 1 C
1 0 2 D
4 2 C
3 2 E
1 1 5 V
2 4 V
J 3 4
4
C
K
J 3 4
3
4 2 V
J 3 4
6
C O M M O N I
C O M M O N A
J 3 4
5
J 3 4
3 2 D
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F-122
F-122
NOTES
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F-123
F-123
TROUBLESHOOTING & REPAIR
INTERNAL REMOTE CONTROL TEST
WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician or
machine operator and will invalidate your factory warranty. For your safety and to avoid elec-
trical shock, please observe all safety notes and precautions detailed throughout this manual.
If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou-
bleshooting assistance before you proceed. Call 1-800-833-9353 (WELD).
TEST DESCRIPTION
This test will determine if there is a fault in the circuitry that reads the control knob com-
mands of the K941-1 Remote Control Kit.
MATERIALS NEEDED
Volt/Ohmmeter (Multimeter)
5/16" Nut driver
3/8" Nut driver
Trigger Circuit Wiring Diagram – Figure F.46
This procedure takes approximately 45 minutes to perform.
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F-124
F-124
TROUBLESHOOTING & REPAIR
INTERNAL REMOTE CONTROL TEST (continued)
FIGURE F.45 - DISPLAY BOARD PLUG LOCATIONS
J17 J16 J15
J14 J13 J12 J11 J10
TEST PROCEDURE
WARNING
1. Remove main input supply power to the
machine.
Before continuing with the
test procedure, perform the
capacitor discharge proce-
dure to avoid electric shock.
2. With the 3/8" nut driver, remove the 4
screws that hold the handle to the machine.
3. Remove the rubber gasket (cover seal) from
the lift bail.
7. After you have completed the capacitor dis-
charge procedure for all four switch boards,
remove the PC board cover. Use the 5/16"
nut driver.
4. With the 5/16" nut driver, remove the sheet
metal screws from the case top.
5. With the 5/16" nut driver, remove the
screws holding the right and left case sides.
Remove the case sides by lifting up and
out.
8. Remove the 5 leads (3 heavy and 2 small)
T1, T2, T3 from main input contactor CR1.
This is a safety precaution. It prevents high
voltage from being put on the machine dur-
ing the test. Wrap tape around the lead
ends to insulate them and prevent them
from touching.
6. Perform the Capacitor Discharge
Procedure described earlier in this section
of the manual.
9. Remove plug J30 from the protection
board. See Figure F.1 for location of the
board and plug J30.
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F-125
F-125
TROUBLESHOOTING & REPAIR
INTERNAL REMOTE CONTROL TEST (continued)
A. No continuity between J10 - pin 10 and P1
WARNING
- pin A (of the remote amphenol):
ELECTRIC SHOCK
can kill.
• Check lead #177A between the remote
amphenol and the square wave TIG pro-
tection board for continuity.
With input power ON, there
are high voltages inside the
machine, including the pro-
tection board. Do not reach
• Check lead #294 between the square
wave TIG protection board and the dis-
play board for continuity.
into the machine or touch any internal part.
• Check plugs J10, J92, and J93 to make
sure the pins are seated properly and not
opened up or loose.
10. Turn input power ON.
11. Turn the knob on the Remote Control Kit
all the way counterclockwise.
• Replace the square wave TIG protection
board.
12. With the volt/ohmmeter, check the voltage
between plug J10 - pin 6 (positive) and
J10 - pin 7 (negative) on the display board.
It should be about zero volts.
B. No continuity between J10 - pin 6 and P1
- pin B (of the remote amphenol)
• Check lead #176A between the remote
amphenol and the square wave TIG pro-
tection board for continuity.
13. With the Power Wave set in the SMAW
(CC) mode of operation, turn the knob on
the Remote Control Kit clockwise. The
voltage between plug J10 - pin 6 and J10
- pin 7 should increase smoothly to about
10.25 volts. If this happens but the dis-
play shows no change in the preset cur-
rent value (SET = ), replace the display
board. If the voltage between pins 6 and 7
does not increase smoothly, test the asso-
ciated wiring as follows:
• Check lead #291 between the square
wave TIG protection board and the dis-
play board for continuity.
• Check plugs J10, J92, and J93 to make
sure the pins are seated properly and not
opened up or loose.
• Replace the square wave TIG protection
board.
C. No continuity between J10 - pin 7 and P1
- pin C (of the remote amphenol)
A. Turn power switch SW1 to the OFF posi-
tion and disconnect input power to the
machine.
• Check lead #175A between the remote
amphenol and the square wave TIG pro-
tection board for continuity.
B. Perform the Capacitor Discharge Proce-
dure described earlier in this section of the
manual.
• Check lead #292 between the square
wave TIG protection board and the dis-
play board for continuity.
WARNING
Before continuing with the test procedure, per-
form the capacitor discharge procedure to
avoid electric shock.
• Check plugs J10, J92, and J93 to make
sure the pins are seated properly and not
opened up or loose.
• Replace the square wave TIG protection
board.
C. Remove plug J10 from the display board.
Check for continuity between the following
pins:
15. Connect all the plugs disconnected for the
tests above.
16. Connect plug J30 into the protection
board and replace the PC board cover
with two sheet metal screws.
J10 - pin 10 and P1 - pin A (of the remote
amphenol)
J10 - pin 6 and P1 - pin B (of the remote
amphenol)
17. Connect the five leads to the main con-
tactor.
J10 - pin 7 and P1 - pin C (of the remote
amphenol)
18. Install the machine case sides and top.
19. Install the handle and the lift bail rubber
gasket.
14. If you find no continuity between any of
these pins, do the following:
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F-126
F-126
TROUBLESHOOTING & REPAIR
FIGURE F.46 – TRIGGER CIRCUIT WIRING DIAGRAM
P 7 0
P 7 0
( 2 9 6 ) ( 2 9 3 )
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F-127
F-127
TROUBLESHOOTING & REPAIR
K941-1 REMOTE CONTROL KIT TEST
WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician or
machine operator and will invalidate your factory warranty. For your safety and to avoid elec-
trical shock, please observe all safety notes and precautions detailed throughout this manual.
If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou-
bleshooting assistance before you proceed. Call 1-800-833-9353 (WELD).
TEST DESCRIPTION
This test will determine if the K941-1 Remote Control Kit is faulty.
MATERIALS NEEDED
Volt/Ohmmeter (Multimeter)
Trigger Circuit Wiring Diagram – Figure F.48
This procedure takes approximately 20 minutes to perform.
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F-128
F-128
TROUBLESHOOTING & REPAIR
K941-1 REMOTE CONTROL KIT TEST (continued)
FIGURE F.47 - 6-PIN AMPHENOL LOCATION
1
1. MACHINE FRONT PANEL
2. REMOTE CONTROL AMPHENOL RECEPTACLE (6-PIN)
2
D. Set the Output Terminals switch to the OFF
position. With the volt/ohmmeter, check
the continuity between pins D and E of the
amphenol. There should be NO continuity.
TEST PROCEDURE
1. Remove the Remote Control Kit from the
power source.
2. Perform the following tests. If any test fails,
the Remote Control Kit is faulty and should
be replaced.
E. With the volt/ohmmeter, check the resis-
tance between pins A and C of the amphe-
nol. There should be 10 Kohm (+/- 10%)
resistance between these pins at all times.
A. With the volt/ohmmeter, check the conti-
nuity between pin F of the 6-pin amphenol
and the case of the Remote Control Kit.
The reading should be zero ohms.
F. Turn the knob of the Remote Control Kit all
the way counterclockwise. With the
volt/ohmmeter, check the resistance
between pins A and B of the amphenol.
There should be 10 Kohm (+/- 10%) resis-
tance between these pins now. Turn the
knob clockwise. The resistance between
pins A and B should smoothly decrease to
zero ohms (+/- 10%).
B. With the volt/ohmmeter, check the conti-
nuity between pin F and the other five pins
of the 6-pin amphenol. The reading should
be open (no continuity).
C. Set the Output Terminals switch to the ON
position. With the volt/ohmmeter, check
the continuity between pins D and E of the
amphenol. There SHOULD BE continuity
(zero ohms).
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F-129
F-129
TROUBLESHOOTING & REPAIR
FIGURE F.48 – TRIGGER CIRCUIT WIRING DIAGRAM
P 7 0
P 7 0
( 2 9 6 ) ( 2 9 3 )
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F-130
F-130
NOTES
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F-131
F-131
TROUBLESHOOTING & REPAIR
K941-1 REMOTE CONTROL KIT TRIGGER CIRCUIT TEST
WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician or
machine operator and will invalidate your factory warranty. For your safety and to avoid elec-
trical shock, please observe all safety notes and precautions detailed throughout this manual.
If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou-
bleshooting assistance before you proceed. Call 1-800-833-9353 (WELD).
TEST DESCRIPTION
This test will determine if there are any faults in the 24 VAC trigger circuit between the
Power Wave and the K941-1 Remote Control Kit.
MATERIALS NEEDED
Volt/Ohmmeter (Multimeter)
5/16" Nut driver
3/8" Nut driver
Short piece of jumper wire
Trigger Circuit Wiring Diagram – Figure F.50
This procedure takes approximately 30 minutes to perform.
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F-132
F-132
TROUBLESHOOTING & REPAIR
K941-1 REMOTE CONTROL KIT TRIGGER CIRCUIT TEST (continued)
FIGURE F.49 - DISPLAY BOARD PLUG LOCATIONS
J17 J16 J15
J14 J13 J12 J11 J10
TEST PROCEDURE
WARNING
NOTE: Before troubleshooting the remote con-
trol trigger circuit, troubleshoot the
remote control kit itself. Refer to the
K941-1 Remote Control Kit Test in
this section of the manual. If that test is
successful, perform the trigger circuit
test below.
Before continuing with the
test procedure, perform the
capacitor discharge proce-
dure to avoid electric shock.
7. After you have completed the capacitor
discharge procedure for all four switch
boards, remove the PC board cover. Use
the 5/16" nut driver.
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.
8. Remove plug J12 from the display board.
3. Remove the rubber gasket (cover seal) from
the lift bail.
9. Place a jumper wire between pins D and E
of the six-pin amphenol.
4. With the 5/16" nut driver, remove the sheet
metal screws from the case top.
10. Remove the 5 leads ( 3 heavy and 2 small)
T1, T2, T3 from main input contactor CR1.
This is a safety precaution. It prevents
high voltage from being put on the
machine during the test. Wrap tape
around the lead ends to insulate them and
prevent them from touching.
5. With the 5/16" nut driver, remove the
screws holding the right and left case sides.
Remove the case sides by lifting up and
out.
6. Perform the Capacitor Discharge
Procedure described earlier in this section
of the manual.
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F-133
F-133
TROUBLESHOOTING & REPAIR
K941-1 REMOTE CONTROL KIT TRIGGER CIRCUIT TEST (continued)
11. Remove plug J30 from the protection
board. See Figure F.1 for location of the
board and plug J30.
15. Remove plug J26 from the protection
board. Attach a 150 ohm resistor between
plug J26 - pin 1 and J26 - pin 2 (the J26
plug, not the header on the control board).
WARNING
16. Replace plug J12 into the display board,
ELECTRIC SHOCK can kill.
WARNING
With the input power ON, there are high volt-
ages inside the machine. Do not reach into the
machine or touch any internal parts.
ELECTRIC SHOCK can kill.
With the input power ON,
there are high voltages inside
the machine, including the
protection board. Do not
reach into the machine or
touch any internal parts.
12. Turn input power ON.
13. With the volt/ohmmeter, check for 24 VAC
between plug J12 - pin 2 and pin 4.
A. If 24 VAC IS present, go to step 14.
NOTE: A voltage of 5 to 10 VDC is normal
between these pins without the D
to E jumper installed in the six-pin
amphenol receptacle.
17. Turn input power ON. The LCD display
will read: ERROR: S.L. NOT INITIALIZED.
Disregard this; the test can still be per-
formed.
B. If 24 VAC is NOT present, check for 24
VAC between plug J33 - pin 4 and pin 1.
See the Trigger Circuit Wiring Diagram,
Figure F.50.
18. Remove the jumper between pins D and E
of the six-pin amphenol receptacle.
19. With the volt/ohmmeter, measure the volt-
age drop across the 150 ohm resistor
between J26 - pins 1 and 2. With the
jumper removed, the reading should be
zero volts (NO voltage drop).
C. If 24 VAC IS present between plug J33 pin
4 and pin 1, check the continuity and
integrity of leads #371, 374, 102C, 105B,
296, and 293 and their associated pin con-
nectors. See the Trigger Circuit Wiring
Diagram. If the continuity checks are
good, check the square wave TIG protec-
tion board by checking the continuity
through the following pins. See the Trigger
Circuit Wiring Diagram, Figure F.50.
20. Replace the jumper between pins D and E
of the six-pin amphenol receptacle.
Measure the voltage drop with the jumper
installed. The reading should be about 2
VDC across the resistor.
A. If 2 VDC is NOT present, check the conti-
nuity and integrity of leads #262 and 261
and their associated pins and connectors.
The display board may be faulty -- replace
the display board.
Plug J92 - pin 6 to plug J93 - pin 5.
Normal resistance is 4 ohms.
Plug J92 - pin 3 to plug J93 - pin 7.
Normal resistance is 4 ohms.
B. If 2 VDC IS present across the resistor, the
control board may be faulty -- replace the
control board.
If the square wave TIG protection board is
good, then the protection board may be faulty.
Replace the protection board.
21. Turn input power to the machine OFF and
connect the five leads to the main contac-
tor. Connect all molex plugs to the PC
boards and replace the cover with two
sheet metal screws. Install the machine
case sides, top, handle, and lift bail rubber
gasket.
D. If 24 VAC is NOT present between plug
J33 pin 4 and pin 1, check Auxiliary
Transformer #1, the 5 amp circuit breaker,
and the associated wiring. See the Trigger
Circuit Wiring Diagram, Figure F.50.
14. Turn input power to the machine OFF and
perform the capacitor discharge proce-
dure.
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F-134
F-134
TROUBLESHOOTING & REPAIR
FIGURE F.50 – TRIGGER CIRCUIT WIRING DIAGRAM
P 7 0
P 7 0
( 2 9 6 ) ( 2 9 3 )
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F-135
F-135
TROUBLESHOOTING & REPAIR
LCD DISPLAY TEST
WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician or
machine operator and will invalidate your factory warranty. For your safety and to avoid elec-
trical shock, please observe all safety notes and precautions detailed throughout this manual.
If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou-
bleshooting assistance before you proceed. Call 1-800-833-9353 (WELD).
TEST DESCRIPTION
This test will determine if there are any faults in the LCD display on the front panel or in the
associated hardware and wiring harness.
MATERIALS NEEDED
Volt/Ohmmeter (Multimeter)
5/16" Nut driver
3/8" Nut driver
Internal Auxiliary Supply Wiring Diagram – Figure F.52
This procedure takes approximately 30 minutes to perform.
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F-136
F-136
TROUBLESHOOTING & REPAIR
LCD DISPLAY TEST (continued)
FIGURE F.51 - DISPLAY BOARD PLUG LOCATIONS
J17 J16 J15
J14 J13 J12 J11 J10
TEST PROCEDURE
WARNING
1. Remove main input supply power to the
machine.
Before continuing with the
test procedure, perform the
capacitor discharge proce-
dure to avoid electric shock.
2. With the 3/8" nut driver, remove the 4
screws that hold the handle to the machine.
3. Remove the rubber gasket (cover seal) from
the lift bail.
7. After you have completed the capacitor dis-
charge procedure for all four switch boards,
remove the PC board cover. Use the 5/16"
nut driver.
4. With the 5/16" nut driver, remove the sheet
metal screws from the case top.
5. With the 5/16" nut driver, remove the
screws holding the right and left case sides.
Remove the case sides by lifting up and
out.
8. Remove the 5 leads ( 3 heavy and 2 small)
T1, T2, T3 from main input contactor CR1.
This is a safety precaution. It prevents high
voltage from being put on the machine dur-
ing the test. Wrap tape around the lead
ends to insulate them and prevent them
from touching.
6. Perform the Capacitor Discharge
Procedure described earlier in this section
of the manual.
9. Remove plug J30 from the protection
board. See Figure F.1 for location of the
board and plug J30.
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F-137
F-137
TROUBLESHOOTING & REPAIR
LCD DISPLAY TEST (continued)
13. Perform the following tests to locate the
problem: Auxiliary Transformer 1 Test
and Internal and Auxiliary Voltage
Supply Test. If these tests show no com-
ponent failures, go to step 14.
WARNING
ELECTRIC SHOCK
can kill.
14. Make sure plug J19 is plugged into the
display board securely and that none of its
pins are loose or broken. If the pins are all
okay, replace the LCD display.
With input power ON, there
are high voltages inside the
machine. Do not reach into the machine or
touch any internal part.
15. If the problem persists after replacing the
LCD display, replace the display board.
10. Turn input power ON.
16. After the problem has be repaired, install
the machine case sides and top. Install
the handle and the lift bail rubber gasket.
11. With the volt/ohmmeter, check the follow-
ing voltages between plug J16 pins at the
display board (without removing plug J16
from the display board):
+5 VDC
Between J16 - pin 2 and J16 -
pin 3
+15 VDC Between J16 - pin 10 and J16
- pin 7
+5 VDC
-5 VDC
-8 VDC
Between J16 - pin 1 and J16 -
pin 7
Between J16 - pin 9 and J16 -
pin 7
Between J16 - pin 6 and J16 -
pin 7
12. Turn power switch SW1 to the OFF posi-
tion and disconnect input power to the
machine. Connect plug J30 into the pro-
tection board. Connect the five leads to
the main contactor.
If the voltages checked in step 11 were cor-
rect, go to step 14.
If any of the voltages in step 11 were not cor-
rect, go to step 13.
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F-138
F-138
TROUBLESHOOTING & REPAIR
FIGURE F.52 – INTERNAL AUXILIARY SUPPLY WIRING DIAGRAM
J 3 8
2
J 9 2
I G T 1 R
2 4 V
3
6
2 9 3
2 9 6
J 9 2
3
J 3 4
1 4
J 3 7
4
J 1 2
4
P 8 3
I G T 1 R
D
J
1 0 5 A
3 1 B
1 0 2 B
4 2 B
3 2 C
3 2 B
3 7 4
1 1 5 V
8
2 4 V
4 2 V
C
K
1 1
1 0
1 3
1 2
C O M M O N I
C O M M O N A
J 3 7
1
J 3 7
3
J 1 2
2
J 1 3
4
3 7 1
3 7 3
J 3 4
7
J 3 7
2
J 1 3
2
P 8 2
I G T 2 R
D
J
1 0 6 A
3 1 C
1 0 2 D
4 2 C
3 2 E
3 7 2
1
4
3
6
5
1 1 5 V
2 4 V
C
K
4 2 V
C O M M O N I
C O M M O N A
3 2 D
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F-139
F-139
TROUBLESHOOTING & REPAIR
CALIBRATION PROCEDURES
POWER WAVE PC BOARD
REPLACEMENT CALIBRATION
PROCEDURES
If the display board is replaced, 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. If the sensor calibration is not done, the display
board may have some problems sensing the correct
overlay on power up.
WARNING
The display is shipped with the water cooler disabled.
If an internal water cooler is being used with the Power
Wave, you must use the Setup Overlay L9770-0 to
enable the water cooler before using the system.
If the control board is replaced, the voltage calibration
and current calibration must be performed for opti-
mum performance. If the calibration is not done, the
voltage may be accurate only to within 3 volts and the
current will be accurate only to within 15 amps.
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F-140
F-140
NOTES
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F-141
F-141
TROUBLESHOOTING & REPAIR
SENSOR CALIBRATION TEST (FOR DISPLAY BOARD)
WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician or
machine operator and will invalidate your factory warranty. For your safety and to avoid elec-
trical shock, please observe all safety notes and precautions detailed throughout this manual.
If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou-
bleshooting assistance before you proceed. Call 1-800-833-9353 (WELD).
TEST DESCRIPTION
This procedure recalibrates the eight overlay sensors of the Power Wave.
MATERIALS NEEDED
Power Wave Test and Calibration Overlay – L9660-255
Set-Up Overlay – L9660
This procedure takes approximately 15 minutes to perform.
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F-142
F-142
TROUBLESHOOTING & REPAIR
SENSOR CALIBRATION TEST (FOR DISPLAY BOARD) (continued)
FIGURE F.53 - SENSOR LOCATION BEHIND OVERLAY
1. LEADS 300, 301 TO PLUG J15 ON
DISPLAY BOARD
2. PIEZO-ELECTRIC ALARM BUZZER
6. If the calibration procedure is successful,
the display reads:
PROCEDURE
1. Turn the machine ON with no overlay in
place. The overlay ID number displayed
should be 255.
CALIBRATION
SUCCESSFUL
2. When the display reads SELECT A FUNC-
TION, place the TEST overlay on the
machine.
After a few seconds the display changes to
read:
INSERT CAL OVRLY
PRESS ENTER . . .
3. Press key #34 - OVERLAY CALIBRATE.
The OVERLAY CALIBRATE light turns on
and for a few seconds the display reads:
7. Press key #133 - ENTER. the OVERLAY
CALIBRATE LED turns off, the machine
exits the OVERLAY CALIBRATE function
and the display reads:
OVERLAY SENSOR
CALIBRATION
Then the display changes to read:
SELECT A FUNCTION
INSERT REF OVRLY
PRESS ENTER . . .
8. Turn the power switch SW1 to the OFF
position. To use the machine, place the
appropriate overlay in position and turn
power switch SW1 to the ON position.
Insert set-up overlay
4. Press key #133 - ENTER. The machine will
begin to calibrate the eight overlay sensors.
NOTE: Turn power switch SW1 to the OFF
position and get the overlay that was
not recognized by the power wave.
Replace the TEST overlay with this
overlay and turn the machine ON. The
machine should recognize the overlay
now. If it does not, the overlay is faulty.
5. If one of the sensors could not be calibrat-
ed, the display reads:
SENSOR X FAILED
ENTER TO RETRY
Make sure the overlay is lined up properly and
press key #133 - ENTER. This will cause the
machine to try to calibrate the sensor again. If
a particular sensor continues to fail. Clean
sensor or replace display board.
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F-143
F-143
TROUBLESHOOTING & REPAIR
QUICK VOLTAGE CALIBRATION
WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician or
machine operator and will invalidate your factory warranty. For your safety and to avoid elec-
trical shock, please observe all safety notes and precautions detailed throughout this manual.
If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou-
bleshooting assistance before you proceed. Call 1-800-833-9353 (WELD).
PROCEDURE DESCRIPTION
This procedure is a quick way of calibrating the voltage sensing points (leads), provided that
the existing display board is capable of displaying the calibration numbers that are stored in
the display board.
MATERIALS NEEDED
A known “good” replacement display board
A Test and Calibration overlay L9660-255
This procedure takes approximately 15 minutes to perform.
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F-144
F-144
TROUBLESHOOTING & REPAIR
QUICK VOLTAGE CALIBRATION (continued)
FIGURE F.54 - TEST AND CALIBRATION OVERLAY
5. Repeat the process by pressing the Voltage
PROCEDURE
Calibration function again. The next sens-
ing lead may be selected by pressing the
down Arrow Key (101). The above proce-
dure must be repeated six times to obtain
and record the calibration number for six
different voltage sensing points. These
points are the following:
1. Before changing or disturbing the display
board, power up the machine with the
L9660-255 Test and Calibration overlay in
place. See Figure F.54.
2. Press the Voltage Calibration function (32).
The machine should display the following:
+ Polarity (+67A)
+ Polarity (+67B)
- Polarity (+21A)
- Polarity (+21B)
+ Polarity
VOLTAGE WIRE
+ POLARITY (+67A)
3. Press the Enter Key (133) on the lower right
side of the overlay. The machine should
display the following:
- Polarity
ADJUST TO 30V
CALIBRATION #=XX
6. Install the “new” replacement display
board.
NOTE: Here “XX” indicates a particular cali-
bration number for a given voltage sensing
point.
7. With the L9660-255 overlay installed, apply
power to the machine. Press the Voltage
Calibration function (32). Enter the re-
corded calibration numbers for each of the
six voltage sensing points. The calibration
numbers are entered by selecting the prop-
er sensing point (lead), pressing the Enter
Key (133) and obtaining the display that
reads:
WARNING
The machine’s output terminals will be electri-
cally “HOT” when the Enter Key is pressed.
ADJUST TO 30V
CALIBRATION #=XX
4. Record the number displayed for the +67
wire and press the Enter Key (133) again.
The calibration number is changed using the
up/down Arrow Keys (100, 101). Press the
Enter Key when the desired number is dis-
played.
8. Repeat the process for all six sensing
points (leads).
9. Perform the Sensor Calibration Test.
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F-145
F-145
TROUBLESHOOTING & REPAIR
FULL VOLTAGE CALIBRATION
WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician or
machine operator and will invalidate your factory warranty. For your safety and to avoid elec-
trical shock, please observe all safety notes and precautions detailed throughout this manual.
If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou-
bleshooting assistance before you proceed. Call 1-800-833-9353 (WELD).
PROCEDURE DESCRIPTION
This procedure is necessary if the display board is replaced and the Quick Voltage Calibration
is NOT possible. The Full Voltage Calibration is also necessary if the snubber and/or control
boards are replaced.
MATERIALS NEEDED
A Test and Calibration Overlay L9660-255
A 300 amp, 30 volt resistive grid load. (A MIG welding load may be used if a grid load is
not available. Choose an argon rich 30 volt spray procedure.) See the topic Full
Voltage Calibration Using a Welding Arc in this section of the manual.
A calibrated DC voltmeter accurate to 30.0 volts +/- 0.1 volt.
A set of jumper leads to access the remote voltage sensing leads in the wire feeder
amphenol receptacles.
SETUP PROCEDURE
1. Using the jumper leads, connect 21A (H) and 67A (N), located in wire feeder receptacle
#1, to the machine’s positive output terminal.
2. Using the jumper leads, connect 21B (H) and 67B (N), located in wire feeder receptacle
#2, to the machine’s positive output terminal.
3. Connect the resistive grid load (or wire feeder) to the machine’s output terminals.
4. Connect the DC voltmeter to the machine’s output terminals. Do not connect the volt-
meter to the load. This avoids erroneous readings due to cable drop.
This procedure takes approximately 45 minutes to perform.
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F-146
F-146
TROUBLESHOOTING & REPAIR
FULL VOLTAGE CALIBRATION(continued)
FIGURE F.55 - TEST AND CALIBRATION OVERLAY
6. With the machine loaded, monitor the refer-
PROCEDURE
ence voltage only (external voltmeter). It is
the only important reading. Adjust the volt-
age using the Arrow Keys (100 and 101)
until the reference voltmeter reads 30.0
volts. Press the Enter Key.
1. The voltage calibration numbers are stored
in the display board. They are program-
mable from the front panel using the Test
and Calibration Overlay.
2. Change the PC board in question.
6a. If using a synergic 7 wire feeder, press
enter then adjust to the desired w.f.s Note
the gun will be electrically “hot” at this
time.
3. Install the Test and Calibration Overlay
L9660-255 and power up the machine. See
Figure F.55.
4. Press the Voltage Calibration function (32).
The machine should display the following:
CAUTION
VOLTAGE WIRE
WHEN LOADING THE MACHINE WITH THE
CASE PARTS REMOVED, BE CAREFUL NOT
TO OVERHEAT THE MACHINE.
+ POLARITY (+67A)
5. Press the Enter Key (133) on the lower right
side of the overlay. The machine should
display the following:
7. Repeat the process by pressing the Voltage
Calibration function again. The next volt-
age sensing point (lead) may be selected by
pressing the down Arrow Key (101). The
above procedure must be repeated six
times to set the six sensing points (leads) to
30.0 volts. The six test points (leads) are
the following:
ADJUST TO 30V
CALIBRATION #=XX
NOTE: Here “XX” indicates a particular cali-
bration number for a given voltage
sensing point.
+ Polarity (+67A)
+ Polarity (+67B)
- Polarity (+21A)
- Polarity (+21B)
+ Polarity
WARNING
The machine’s output terminals will be electri-
cally “HOT” when the Enter Key is pressed.
- Polarity
8. If the display board is replaced or dis-
turbed, perform the Sensor Calibration
Test.
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F-147
F-147
TROUBLESHOOTING & REPAIR
FULL VOLTAGE CALIBRATION USING A WELDING ARC
WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician or
machine operator and will invalidate your factory warranty. For your safety and to avoid elec-
trical shock, please observe all safety notes and precautions detailed throughout this manual.
If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou-
bleshooting assistance before you proceed. Call 1-800-833-9353 (WELD).
PROCEDURE DESCRIPTION
This procedure is necessary if the display board is replaced and the Quick Voltage Calibration
or the Normal Full Voltage Calibration is NOT possible.
MATERIALS NEEDED
A Test and Calibration overlay L9660-255 (the test procedure can be done within this)
A Synergic 7 wire feeder.
A calibrated DC voltmeter accurate to 0.1 volts at 30.0 volts.
The proper welding wire and gas combination to produce a Spray Arc. For example,
0.035 L-50 wire with a 90% Argon and 10% CO blend of gas.
2
SETUP PROCEDURE
1. Connect a DC voltmeter to the machine’s negative output terminal and the conductor
block of the wire feeder.
2. Connect the Synergic 7 wire feeder to the Wire Feeder 1 amphenol on the back of the
Power Wave.
This procedure takes approximately 45 minutes to perform.
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F-148
F-148
TROUBLESHOOTING & REPAIR
FULL VOLTAGE CALIBRATION(continued)
FIGURE F.55a - TEST AND CALIBRATION OVERLAY
6. Adjust the wire feed speed on the Synergic
PROCEDURE
7 to 500 IPM (some wire feed speed to get
into the spray range).
1. The voltage calibration numbers are stored
in the display board. They are programma-
ble from the front panel using the Test and
Calibration Overlay.
NOTE: When the Enter Key is pressed it will
clear the wire feed speed to 200 IPM.
The wire feed speed must be adjusted
after pressing the Enter Key but before
starting to weld.
2. Change the display board in question.
3. Install the Test and Calibration overlay
L9660-255 (or do not insert any overlay into
the machine) and power up the machine.
See Figure F.55a. If the -255 overlay is not
available, use Figure F.55a as a guide to see
which keys to press.
7. Pull the trigger on the torch and start to
weld. Hold a long stick out. This is not nor-
mally a welding technique. The starting will
be poor. The welding may be poor. Main-
tain a long, steady welding arc. While weld-
ing, monitor the reference voltage only
(external voltmeter). It is the only important
reading. Adjust the voltage using the Arrow
Keys (100 and 101) until the reference volt-
meter reads 30.0 volts. Record the number
on the display, “xx”. Press the Enter Key.
Release the trigger on the torch.
4. Press the Voltage Calibration function (32).
The machine should display the following:
VOLTAGE WIRE
+ POLARITY (+67A)
5. Press the Enter Key (133) on the lower right
side of the overlay. The machine should
display the following:
8. Repeat the process by pressing the Voltage
Calibration function (32) again. The next
voltage sensing point may be selected by
pressing the down Arrow Key (101). Repeat
steps 5, 6, and 7 for the following test
points.
ADJUST TO 30V
CALIBRATION# = XX
NOTE: Here “xx” indicates a particular cali-
bration number for a given voltage
sense point.
WARNING
The machine’s output terminals will be electri-
cally “HOT” when the Enter Key is pressed.
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F-149
F-149
TROUBLESHOOTING & REPAIR
FULL VOLTAGE CALIBRATION(continued)
– POLARITY (+21A)
+ POLARITY
– POLARITY
NOTE: Do not attempt to weld for –Polarity
(+21A). Set the number to the same as
recorded for +Polarity (+67A). Also for
+Polarity and –Polarity, move the volt-
meter sense lead from the conductor
block of the wire feeder to the positive
output terminal on the front of the
machine.
9. Turn the machine off. Connect the
Synergic 7 to the Wire feeder 2 amphenol
on the back of the Power Wave machine.
10. Put the voltmeter sense lead back on the
wire feeder conductor block and repeat
the calibration process steps 5, 6, and 7
for the following test points:
+POLARITY (+67B)
–POLARITY (+21B)
NOTE: Do not attempt to weld for –Polarity
(+21B). Set the number to the same as
recorded for +Polarity (+67B).
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F-150
F-150
NOTES
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F-151
F-151
TROUBLESHOOTING & REPAIR
CURRENT CALIBRATION
WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician or
machine operator and will invalidate your factory warranty. For your safety and to avoid elec-
trical shock, please observe all safety notes and precautions detailed throughout this manual.
If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou-
bleshooting assistance before you proceed. Call 1-800-833-9353 (WELD).
PROCEDURE DESCRIPTION
This procedure is necessary if the control and/or the shunt amplifier boards are replaced. The
current control is the most critical function in the Power Wave machine.
MATERIALS NEEDED
Test and Calibration Overlay L9660-255
A 300 amp, 30 volt resistance grid load
A small trimmer screwdriver
A calibrated DC ammeter accurate to read 300.0 amps +/- 1.0 amps.
A machine output triggering device such as the K941-1 Remote Control Kit.
SETUP PROCEDURE
1. Remove and install the replacement board in question.
This procedure takes approximately 45 minutes to perform.
FIGURE F.56 – PC BOARD REMOVED BUT STILL CONNECTED
Lay Control Board on top of machine.
Make sure it is snapped into the ground
plane assembly and insulated from the
case and other components.
Leads
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F-152
F-152
TROUBLESHOOTING & REPAIR
CURRENT CALIBRATION (continued)
2. Locate the 10 turn trimmer potentiometer
CAUTION
located on the control board. It is the only
trimmer on the board. If the trimmer is not
accessible with the control board installed,
then the board must be removed and laid
on the top of the PC board compartment.
Be sure the control board is insulated from
the other boards and the case parts. All
wiring plugs must be connected to the con-
trol board. See Figure F.56.
WHEN LOADING THE MACHINE WITH THE
CASE PARTS REMOVED. BE CAREFUL NOT
TO OVER HEAT THE MACHINE.
3. NOTE: If a wire feeder is NOT connected
to the Power Wave the machine
may not display output volts.
4. Connect the resistance grid load to the
machine’s output terminals. Connect the
reference ammeter in series with the grid
load. See Figure F.57.
WARNING
WHEN THE MACHINE CASE IS REMOVED
HIGH VOLTAGE POINTS ARE EXPOSED.
STAND DIRECTLY IN FRONT OF MACHINE
UNDER TEST.
EXPLODING PARTS CAN CAUSE INJURY.
FAILED PARTS CAN EXPLODE OR CAUSE
OTHER PARTS TO EXPLODE WHEN POWER
IS APPLIED. ALWAYS WEAR A FACE SHIELD
AND LONG SLEEVES WHEN SERVICING.
FIGURE F.57 – RESISTANCE GRID LOAD CONNECTIONS
POWER WAVE
VOLT METER
–
+
AMMETER
RESISTANCE
GRID
LOAD
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F-153
F-153
TROUBLESHOOTING & REPAIR
CURRENT CALIBRATION (continued)
FIGURE F.58 – TEST AND CALIBRATION OVERLAY
PROCEDURE
WARNING
1. Install the Test and Calibration Overlay and
apply power to the machine. See Figure
F.58.
The machine’s output terminals will be electri-
cally “HOT” when the trigger circuit is
activated.
2. Press the Manual Procedure Entry Key (64).
The machine should display the following:
PROCESS 1 SETUP
1-0
5. Adjust the potentiometer until the reference
(external ammeter) reads 304 amps +/- 1.0
amps. The load voltage should be greater
than 15 volts but less than 35 volts.
3. Toggle the Arrow Keys (100 and 101) until
the display reads:
6. Remove power to the machine.
7. If necessary re-install the control board.
8. Replace the machine case parts.
PROCESS 1 SETUP
1-6
4. Activate the external trigger device.
(K941-1) and load the machine.
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F-154
F-154
NOTES
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F-155
F-155
TROUBLESHOOTING & REPAIR
T1 AUXILIARY TRANSFORMER REMOVAL AND REPLACEMENT
WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician or
machine operator and will invalidate your factory warranty. For your safety and to avoid elec-
trical shock, please observe all safety notes and precautions detailed throughout this manual.
If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou-
bleshooting assistance before you proceed. Call 1-800-833-9353 (WELD).
DESCRIPTION
The following procedure will aid the technician in removing the T1 auxiliary transformer for
maintenance or replacement.
MATERIALS NEEDED
5/16" Nut driver
3/8" Nut driver or socket wrench
Wire cutters
Machine Wiring Diagram in the Electrical Diagrams section of this manual
This procedure takes approximately 35 minutes to perform.
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F-156
F-156
TROUBLESHOOTING & REPAIR
T1 AUXILIARY TRANSFORMER REMOVAL AND REPLACEMENT (continued)
FIGURE F.59 - T1 AUXILIARY TRANSFORMER LOCATION
1. AUXILIARY TRANSFORMER T1
2. MOUNTING SCREW (2)
2
1
7. After you have completed the capacitor
discharge procedure for all four switch
boards, disconnect plugs P70, P71, and
P73 that attach to the transformer. See
Figure F.59 for location.
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.
8. With the wire cutters, cut any necessary
cable ties (necessary for removal of the
transformer). Note the location of these
cable ties for reassembly.
3. Remove the rubber gasket (cover seal) from
the lift bail.
4. With the 5/16" nut driver, remove the sheet
metal screws from the case top.
9. With the 3/8" nut driver or socket wrench,
remove the two screws that mount the
transformer to the machine base.
Remove the T1 auxiliary transformer.
5. With the 5/16" nut driver, remove the
screws holding the right and left case sides.
Remove the case sides by lifting up and
out.
10. To install the T1 auxiliary transformer,
carefully position it onto the machine base
and tighten the two mounting screws.
Connect plugs P70, P71, and P73 to their
respective receptacles on the transformer.
6. Perform the Capacitor Discharge Proce-
dure described earlier in this section of the
manual.
WARNING
11. Install the machine case sides and top.
12. Install the handle and the lift bail rubber
gasket.
Before continuing with the
test procedure, perform the
capacitor discharge proce-
dure to avoid electric shock.
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F-157
F-157
TROUBLESHOOTING & REPAIR
WATER COOLER REMOVAL AND REPLACEMENT
For later model coolers (Inlet & Outlet on lower left of machine back)
Refer to IM645-A
WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician or
machine operator and will invalidate your factory warranty. For your safety and to avoid elec-
trical shock, please observe all safety notes and precautions detailed throughout this manual.
If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou-
bleshooting assistance before you proceed. Call 1-800-833-9353 (WELD).
DESCRIPTION
The following procedure will aid the technician in removing the machine water cooler
assembly for maintenance or replacement.
MATERIALS NEEDED
5/16" Nut driver
9/16" Open end or box wrench
3/8" Nut driver or socket wrench
3/4" Open end wrench
11/16" Open end wrench
Machine Wiring Diagram in the Electrical Diagrams section of this manual
This procedure takes approximately 60 minutes to perform.
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F-158
F-158
TROUBLESHOOTING & REPAIR
WATER COOLER REMOVAL AND REPLACEMENT (continued)
FIGURE F.60 - WATER COOLER LOCATION
2
1
3
1. WATER COOLER ACCESS DOOR (ON
BACK PANEL)
2. WATER COOLING FITTINGS
3. CIRCUIT BREAKER
PROCEDURE
WARNING
NOTE: These instructions may vary slightly
with later model coolers. See instruc-
tions included with cooler kit.
Before continuing with the
test procedure, perform the
capacitor discharge proce-
dure to avoid electric shock.
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.
7. After you have completed the capacitor dis-
charge procedure for all four switch boards,
use the 5/16" nut driver to remove the water
cooler access door. See Figure F.60 for
location.
3. Remove the rubber gasket (cover seal) from
the lift bail.
4. With the 5/16" nut driver, remove the sheet
metal screws from the case top.
8. With the 3/8" open end or socket wrench,
remove the two water cooler assembly
mounting screws. Slide the assembly to
the left to better access the circuit breaker,
which will be removed in a moment.
5. With the 5/16" nut driver, remove the
screws holding the right and left case sides.
Remove the case sides by lifting up and
out.
6. Perform the Capacitor Discharge Proce-
dure described earlier in this section of the
manual.
9. With the 5/16" nut driver, remove the two
sheet metal screws holding the lower case
back panel.
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F-159
F-159
TROUBLESHOOTING & REPAIR
WATER COOLER REMOVAL AND REPLACEMENT (continued)
10. With the 9/16" open end wrench, remove
the circuit breaker.
15. To install the water cooler, slide the
assembly into the machine base. Make
sure the cooler fits under the retaining
clips. Connect the water lines to the back
panel and connect the plastic strain reliev-
ers where they hold the water lines to the
subframe.
11. Locate and disconnect plug J4, behind
the water cooler. Plug J 4, a large molex
plug, has two leads (H1A and H3A).
Double-check that these are the leads
feeding the plug; there is another large
molex plug in the same area that is not
connected to the water cooler.
16. Connect plugs 3 and 4, behind the water
cooler assembly.
12. Disconnect Plug 3, a small molex plug
with four leads. This plug is also located
behind the water cooler.
17. Attach the circuit breaker. Use the 9/16"
open end wrench.
18. Install the two 5/16" sheet metal screws
that hold the lower case back panel.
13. Slide out the water cooler assembly. Take
care not to damage the reservoir tank and
cooling coils.
19. Install the two 3/8" water cooler assembly
mounting screws.
14. If complete removal is required, with the
3/4" and 11/16" open end wrenches, dis-
connect the water cooler lines from the
machine back panel. Disconnect the
plastic strain relievers that hold the water
lines to the subframe.
20. Connect the water cooler lines to the back
panel using the 3/4" and 11/16" wrenches.
21. Set the tabs of the water cooler access
door in place and secure the door with the
two 5/16" screws.
If disassembly of the water cooler is required,
refer to the Water Cooler Disassembly
Procedure in this section of the manual.
22. Install the machine case sides and top.
23. Install the handle and the lift bail rubber
gasket.
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F-160
NOTES
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F-161
F-161
TROUBLESHOOTING & REPAIR
WATER COOLER DISASSEMBLY
WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician or
machine operator and will invalidate your factory warranty. For your safety and to avoid elec-
trical shock, please observe all safety notes and precautions detailed throughout this manual.
If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou-
bleshooting assistance before you proceed. Call 1-800-833-9353 (WELD).
DESCRIPTION
The following procedure will aid the technician in disassembly of the machine water cooler
assembly for maintenance or part replacement for early model coolers.
MATERIALS NEEDED
Phillips head screw driver
Pliers
3/4" Open end wrench
5/16" Box wrench
This procedure takes approximately 60 minutes to perform.
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F-162
F-162
TROUBLESHOOTING & REPAIR
WATER COOLER DISASSEMBLY (continued)
FIGURE F.61 - WATER COOLER DISASSEMBLY (EARLY MODEL)
1
2
1. RESERVOIR
2. TUBE SUPPORT BRACKET
3. ASSEMBLY FLOOR
3
PROCEDURE
WARNING
1. Remove main input supply power to the
machine.
Before continuing with the
test procedure, perform the
capacitor discharge proce-
dure to avoid electric shock.
2. With the 3/8" nut driver, remove the 4
screws that hold the handle to the machine.
3. Remove the rubber gasket (cover seal) from
the lift bail.
4. With the 5/16" nut driver, remove the sheet
metal screws from the case top.
5. With the 5/16" nut driver, remove the
screws holding the right and left case sides.
Remove the case sides by lifting up and
out.
6. Perform the Capacitor Discharge Proce-
dure described earlier in this section of the
manual.
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F-163
F-163
TROUBLESHOOTING & REPAIR
WATER COOLER DISASSEMBLY (continued)
Reservoir Removal
Motor/Pump/Fan Assembly Removal
A. After you have completed the capacitor
discharge procedure for all four switch
boards, remove the water cooler assembly.
Refer to the Water Cooler Removal and
Replacement Procedure in this section of
the manual.
A. Perform the Reservoir Removal procedure.
B. With the 3/4" open end wrench, remove
the two coolant hoses attached to the
motor/pump assembly.
C. Remove the four wires leading from the
motor to the terminal block. Note the lead
numbers and locations for reassembly.
B. Empty the coolant from the reservoir.
Dispose of the coolant in a proper and
approved manner.
D. With the Phillips head screw driver and the
5/16" box wrench, remove the four screws
and nuts mounting the motor/pump/fan
assembly to the mounting platform.
C. With the Phillips head screw driver, remove
the two screws holding the reservoir to the
cooling tube support bracket.
E. Carefully lift out the motor/pump/fan
assembly.
D. With the Phillips head screw driver, remove
the four screws holding the reservoir to the
floor of the assembly.
F. Install the motor/pump/fan assembly by
carefully setting in onto the mounting plat-
form and attaching it with the four screws
and nuts. Connect the four wire leads from
the motor to the terminal block. Attach the
two coolant hoses to the motor/pump
assembly using the 3/4" open end wrench.
E. With the pliers, carefully remove the two
coolant hoses from the reservoir.
F. Carefully slide out and lift the reservoir free
from the motor and fan blade.
G. After repair, install the reservoir by careful-
ly setting it in place around the motor and
fan blade. With the pliers, install the two
coolant hoses to the reservoir. With the
Phillips head screw driver, install the four
screws holding the reservoir to the floor of
the assembly and the two screws that hold
it to the cooling tube support bracket.
Replace the old coolant with fresh coolant
and install the water cooler assembly into
the machine according to the Water
Cooler Removal and Replacement
Procedure in this section of the manual.
7. Install the reservoir according to the direc-
tions in the Reservoir Removal procedure.
Install the water cooler assembly according
to the Water Cooler Removal and Replace-
ment procedure in this section of the man-
ual.
8. Install the machine case sides and top.
9. Install the handle and the lift bail rubber
gasket.
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F-164
F-164
NOTES
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F-165
F-165
TROUBLESHOOTING & REPAIR
T2 AUXILIARY TRANSFORMER REMOVAL AND REPLACEMENT
WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician or
machine operator and will invalidate your factory warranty. For your safety and to avoid elec-
trical shock, please observe all safety notes and precautions detailed throughout this manual.
If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou-
bleshooting assistance before you proceed. Call 1-800-833-9353 (WELD).
DESCRIPTION
The following procedure will aid the technician in removing the T2 auxiliary transformer for
maintenance or replacement.
MATERIALS NEEDED
5/16" Nut driver
3/8" Nut driver or socket wrench
Machine Wiring Diagram in the Electrical Diagrams section of this manual
This procedure takes approximately 30 minutes to perform.
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F-166
F-166
TROUBLESHOOTING & REPAIR
T2 AUXILIARY TRANSFORMER REMOVAL AND REPLACEMENT (continued)
FIGURE F.62 - T2 AUXILIARY TRANSFORMER LOCATION
1. BASE
2. AUXILIARY TRANSFORMER T2
3. MOUNTING SCREW (2)
3
2
1
7. After you have completed the capacitor
discharge procedure for all four switch
boards, proceed to remove the T2 auxil-
iary transformer. First you will have to
remove the water cooler; follow the Water
Cooler Removal and Replacement
Procedure in this section of the manual.
PROCEDURE
1. Remove main input supply power to the
machine.
2. With the 3/8" nut driver, remove the 4
screws that hold the handle to the machine.
3. Remove the rubber gasket (cover seal) from
the lift bail.
8. Disconnect the single molex plug
attached to the transformer. See Figure
F.62 for location.
4. With the 5/16" nut driver, remove the sheet
metal screws from the case top.
9. The 3/8" nut driver or socket wrench,
remove the two screws that mount the trans-
former to the machine base. Remove the T2
auxiliary transformer.
5. With the 5/16" nut driver, remove the
screws holding the right and left case sides.
Remove the case sides by lifting up and
out.
10. To install the T2 auxiliary transformer,
carefully position it onto the machine base
and tighten the two mounting screws.
Connect the molex plug to its receptacle
on the transformer.
6. Perform the Capacitor Discharge Proce-
dure described earlier in this section of the
manual.
11. Install the water cooler. Refer to the
Water
Cooler
Removal
and
WARNING
Replacement Procedure in this section
Before continuing with the test procedure, per-
form the capacitor discharge procedure to
avoid electric shock.
of the manual.
12. Install the machine case sides and top.
13. Install the handle and the lift bail rubber
gasket.
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F-167
F-167
TROUBLESHOOTING & REPAIR
FAN MOTOR REMOVAL AND REPLACEMENT
WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician or
machine operator and will invalidate your factory warranty. For your safety and to avoid elec-
trical shock, please observe all safety notes and precautions detailed throughout this manual.
If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou-
bleshooting assistance before you proceed. Call 1-800-833-9353 (WELD).
DESCRIPTION
The following procedure will aid the technician in removing the machine fan motor for main-
tenance or replacement.
MATERIALS NEEDED
5/16" Nut driver
3/8" Nut driver
3/4" Open or box end wrench
Wire cutters
Slot head screw driver
Machine Wiring Diagram in the Electrical Diagrams section of this manual
This procedure takes approximately 30 minutes to perform.
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F-168
F-168
TROUBLESHOOTING & REPAIR
FAN MOTOR REMOVAL AND REPLACEMENT (continued)
FIGURE F.63 - FAN MOTOR LOCATION
1
2
3
1. MACHINE BACK
2. TERMINAL STRIP
3. FAN MOTOR AND MOUNTING BRACKET
PROCEDURE
WARNING
1. Remove main input supply power to the
machine.
Before continuing with the
test procedure, perform the
capacitor discharge proce-
dure to avoid electric shock.
2. With the 3/8" nut driver, remove the 4
screws that hold the handle to the machine.
3. Remove the rubber gasket (cover seal) from
the lift bail.
7. After you have completed the capacitor dis-
charge procedure for all four switch boards,
use the wire cutters to cut any necessary
cable ties (necessary for removal of the fan
motor) holding the fan motor leads togeth-
er. Note the location of these cable ties for
reassembly.
4. With the 5/16" nut driver, remove the sheet
metal screws from the case top.
5. With the 5/16" nut driver, remove the
screws holding the right and left case sides.
Remove the case sides by lifting up and
out.
6. Perform the Capacitor Discharge
Procedure described earlier in this section
of the manual.
8. Remove the fan motor leads from the ter-
minal strip.
9. With the 5/16" nut driver, remove the water
cooler access door. Then remove the four
screws from the lower rear panel.
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F-169
F-169
TROUBLESHOOTING & REPAIR
FAN MOTOR REMOVAL AND REPLACEMENT (continued)
FIGURE F.64 - MACHINE BACK SECURED TO LIFT BAIL.
2
1
1. MACHINE BACK
2. LIFT BAIL
11. With the 3/4" wrench, remove the lead
connected to the rear positive (+) output
terminal.
17. To install the fan motor, do the following:
Carefully position the fan motor into place
on the mounting bracket with the leads
toward the terminal strip. Install the flat
washers, split-ring lock washers, and nuts
to the motor mounting bolts. Carefully
slide the fan blade all the way onto the
motor shaft. The side of the hub with the
metal clip goes toward the motor. Install
the clip so that it grips the rounded side of
the D-shaped shaft, not the flat. Swing
the back panel back down, being careful
not to damage the RS232 connector or
the wire feeder receptacles. Install the
lead to the rear positive (+) output termi-
nal. Install the case back lower sides and
the lower rear panel with the 5/16" screws.
Attach the fan motor leads to the terminal
strip and replace the tie wraps cut during
removal so that the motor leads are held
away from the fan blades.
12. Swing the back panel up and secure it to
the lift bail. See Figure F.64. Use heavy
string or wire. BE CAREFUL NOT TO
DAMAGE THE RS232 CONNECTOR OR
THE WIREFEEDER RECEPTACLES.
13. With the slot head screw driver, remove
the clip holding the fan blade onto the
motor shaft.
14. Remove the fan blade by carefully sliding
it off the motor shaft.
15. With the 11/32" nut driver or socket
wrench, remove the two fan motor mount-
ing nuts. Remove the split-ring lock
washers and flat washers.
16. Remove the fan motor by sliding it out of
the mounting bracket and free of the
machine.
18. Install the machine case sides and top.
NOTE: Repeat this procedure to remove the
second fan motor if necessary.
19. Install the handle and the lift bail rubber
gasket.
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F-170
F-170
NOTES
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F-171
F-171
TROUBLESHOOTING & REPAIR
INPUT RECTIFIER REMOVAL AND REPLACEMENT
WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician or
machine operator and will invalidate your factory warranty. For your safety and to avoid elec-
trical shock, please observe all safety notes and precautions detailed throughout this manual.
If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou-
bleshooting assistance before you proceed. Call 1-800-833-9353 (WELD).
DESCRIPTION
The following procedure will aid the technician in removing the input rectifier for mainte-
nance or replacement.
MATERIALS NEEDED
5 mm Allen wrench
Phillips head screw driver
10 mm Open end wrench
RTV Silicone sealant (Lincoln E2861)
Dow Corning 340 Joint Compound (Lincoln E1868)
S18491 M.O.V. Assembly (if necessary)
Machine Wiring Diagram in the Electrical Diagrams section of this manual
This procedure takes approximately 45 minutes to perform.
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F-172
F-172
TROUBLESHOOTING & REPAIR
INPUT RECTIFIER REMOVAL AND REPLACEMENT (continued)
FIGURE F.65 - INPUT RECTIFIER LOCATION
1
CR1
2
3
4
5
6
1. MAIN CONTACTOR
2. M.O.V. ASSEMBLY
3. SILICONE SEALANT
4. INPUT RECTIFIER
5. 5MM ALLEN SCREW
6. HEAT SINK PANEL
PROCEDURE
WARNING
1. Remove main input supply power to the
machine.
Before continuing with the
test procedure, perform the
capacitor discharge proce-
dure to avoid electric shock.
2. With the 3/8" nut driver, remove the 4
screws that hold the handle to the machine.
3. Remove the rubber gasket (cover seal) from
the lift bail.
7. After you have completed the capacitor dis-
charge procedure for all four switch boards,
peel the silicone sealant away from the
M.O.V. assembly in order to expose the
heads of the screws that attach the three
heavy leads from the main input contactor
to the input rectifier. See Figure F.65.
4. With the 5/16" nut driver, remove the sheet
metal screws from the case top.
5. With the 5/16" nut driver, remove the
screws holding the right and left case sides.
Remove the case sides by lifting up and
out.
6. Perform the Capacitor Discharge
Procedure described earlier in this section
of the manual.
8. With the Phillips head screw driver, remove
the three heavy leads from the input
rectifier.
9. With the Phillips head screw driver, remove
the positive (+) and negative (-) leads from
the input rectifier.
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F-173
F-173
TROUBLESHOOTING & REPAIR
INPUT RECTIFIER REMOVAL AND REPLACEMENT (continued)
10. With the 5 mm Allen wrench and the 10
mm open end wrench, remove the two
screws mounting the input rectifier to the
heat sink panel.
13. With the Phillips head screw driver, attach
the positive (+) and negative (-) leads to
the input rectifier. Attach the three heavy
leads and the M.O.V. assembly to the
input rectifier. Replace the M.O.V. assem-
bly if it appears damaged.
11. When replacing the input rectifier, apply a
thin, even coating of Dow Corning 340
Joint Compound (Lincoln T12837) to the
mating surfaces between the input rectifi-
er and the heat sink panel. Avoid applying
the compound to either the mounting
holes or the mounting hardware.
14. Apply silicone sealant to the M.O.V.
assembly connections.
15. Install the machine case sides and top.
16. Install the handle and the lift bail rubber
gasket.
12. Mount the input rectifier to the heat sink
panel and tighten the two mounting
screws with the 5 mm Allen wrench and
the 10 mm open end wrench. Be sure to
tighten the screws evenly.
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F-174
F-174
NOTES
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F-175
F-175
TROUBLESHOOTING & REPAIR
PRINTED CIRCUIT BOARD REMOVAL AND REPLACEMENT
(CONTROL BOARD, POWER BOARD,
AND PROTECTION BOARD)
WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician or
machine operator and will invalidate your factory warranty. For your safety and to avoid elec-
trical shock, please observe all safety notes and precautions detailed throughout this manual.
If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou-
bleshooting assistance before you proceed. Call 1-800-833-9353 (WELD).
DESCRIPTION
The following procedure will aid the technician in removing the control, power, or protection
printed circuit boards for maintenance or replacement.
MATERIALS NEEDED
5/16" Nut driver
3/8" Nut driver
Machine Wiring Diagram in the Electrical Diagrams section of this manual
This procedure takes approximately 30 minutes to perform.
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F-176
F-176
TROUBLESHOOTING & REPAIR
PRINTED CIRCUIT BOARD REMOVAL AND REPLACEMENT
(CONTROL BOARD, POWER BOARD, AND PROTECTION BOARD) (continued)
FIGURE F.66 - PC BOARD REMOVAL
1
2
1. PC BOARD COVER
2. PC BOARD ASSEMBLY
3. RETAINER CLIPS
3
PROCEDURE
WARNING
1. Remove main input supply power to the
machine.
Before continuing with the
test procedure, perform the
capacitor discharge proce-
dure to avoid electric shock.
2. With the 3/8" nut driver, remove the 4
screws that hold the handle to the machine.
3. Remove the rubber gasket (cover seal) from
the lift bail.
7. After you have completed the capacitor dis-
charge procedure for all four switch boards,
use the 5/16" nut driver to remove the two
screws holding the printed circuit board
cover in place. Slide the cover forward and
lift up to remove it.
4. With the 5/16" nut driver, remove the sheet
metal screws from the case top.
5. With the 5/16" nut driver, remove the
screws holding the right and left case sides.
Remove the case sides by lifting up and
out.
6. Perform the Capacitor Discharge
Procedure described earlier in this section
of the manual.
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F-177
F-177
TROUBLESHOOTING & REPAIR
PRINTED CIRCUIT BOARD REMOVAL AND REPLACEMENT
(CONTROL BOARD, POWER BOARD, AND PROTECTION BOARD) (continued)
10. When reinstalling the PC board, make cer-
tain the tabs at the bottom of the board fit
into the slots on the compartment floor.
CAUTION
Be sure to follow the recommended static-free
methods for handling printed circuit boards.
Failure to do so can result in permanent dam-
age to the equipment.
When the board is properly seated, the
retainer clips will snap into the locked
position.
11. Install the molex plugs removed earlier.
Be sure to fit the each plug into its respec-
tive receptacle on the board.
8. Remove the molex plugs from the PC board
you are removing.
12. Perform appropriate calibration procedure
per flowchart in Figure F.67.
NOTE: The plugs are numbered in order from
left to right.
13. Install the PC board cover and tighten the
two screws with the 5/16" nut driver.
9. Depress the two PC board retainer clips
located on the left and right sides of the
board. Lift the board by the clips to remove
it.
14. Install the machine case sides and top.
15. Install the handle and the lift bail rubber
gasket.
FIGURE F.67 – PC BOARD REPLACEMENT CALIBRATION REQUIREMENTS
SHUNT
AMPLIFIER
BOARD
CONTROL
BOARD
REPLACED
DISPLAY
BOARD
REPLACED
SNUBBER
BOARD
REPLACED
REPLACED
IF POSSIBLE
QUICK
VOLTAGE
CALIBRATION
CURRENT
CALIBRATION
FULL
VOLTAGE
CALIBRATION
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F-178
F-178
NOTES
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F-179
F-179
TROUBLESHOOTING & REPAIR
DISPLAY BOARD REMOVAL AND REPLACEMENT
WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician or
machine operator and will invalidate your factory warranty. For your safety and to avoid elec-
trical shock, please observe all safety notes and precautions detailed throughout this manual.
If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou-
bleshooting assistance before you proceed. Call 1-800-833-9353 (WELD).
DESCRIPTION
The following procedure will aid the technician in removing the display board for mainte-
nance or replacement.
MATERIALS NEEDED
5/16" Nut driver
3/8" Nut driver
This procedure takes approximately 45 minutes to perform.
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F-180
F-180
TROUBLESHOOTING & REPAIR
DISPLAY BOARD REMOVAL AND REPLACEMENT (continued)
FIGURE F.68 - DISPLAY BOARD REMOVAL
3
2
4
5
1
1. MOLEX PLUG HEADERS (8)
2. KEY PAD RIBBON CONNECTOR
3. LCD DISPLAY WINDOW
4. LCD CONNECTOR
5. MOUNTING PIN HOLE
NOTE: Before changing or disturbing the dis-
play board follow the procedure outlined under
QUICK VOLTAGE CALIBRATION (Fig. F.54)
in this section.
WARNING
Before continuing with the
test procedure, perform the
capacitor discharge proce-
dure to avoid electric shock.
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.
CAUTION
3. Remove the rubber gasket (cover seal) from
the lift bail.
Be sure to follow the recommended static-free
methods for handling printed circuit boards.
Failure to do so can result in permanent dam-
age to the equipment.
4. With the 5/16" nut driver, remove the sheet
metal screws from the case top.
5. With the 5/16" nut driver, remove the
screws holding the right and left case sides.
Remove the case sides by lifting up and
out.
7. After you have completed the capacitor dis-
charge procedure for all four switch boards,
carefully remove the eight molex plugs from
the lower portion of the display board.
6. Perform the Capacitor Discharge
Procedure described earlier in this section
of the manual.
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F-181
F-181
TROUBLESHOOTING & REPAIR
DISPLAY BOARD REMOVAL AND REPLACEMENT (continued)
8. Carefully remove the key pad ribbon con-
nector from the right side of the display
board.
11. Reinstall the display board by carefully
pressing it onto its mounting pins. Install
the LCD display connector, the key pad
connector, and the eight molex plugs that
fit along the bottom portion of the display
board.
9. Carefully remove the connector to the LCD
display.
12. After you have installed the display board
(a new one or the old one), you must per-
form the Display Board Sensor
Calibration Test and necessary voltage
calibration. Refer to this test in the test
portion of this section of the manual.
CAUTION
Do not touch the sensors located on the left
side of the display board when you handle it
for removal or replacement. Failure to do so
can result in permanent damage to the sen-
sors.
13. After performing the Display Board
Sensor Calibration Test, install the
machine case sides and top.
14. Install the handle and the lift bail rubber
gasket.
10. Carefully remove the display board from
the its mounting pins. Remove the display
board by lifting up and out.
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F-182
F-182
NOTES
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F-183
F-183
TROUBLESHOOTING & REPAIR
MAIN INPUT CONTACTOR (CR1) REMOVAL
AND REPLACEMENT
WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician or
machine operator and will invalidate your factory warranty. For your safety and to avoid elec-
trical shock, please observe all safety notes and precautions detailed throughout this manual.
If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou-
bleshooting assistance before you proceed. Call 1-800-833-9353 (WELD).
DESCRIPTION
The following procedure will aid the technician in removing the main input contactor for
maintenance or replacement.
MATERIALS NEEDED
Slot head screw driver
5/16" Nut driver
3/8" Open end wrench
Machine Wiring Diagram in the Electrical Diagrams section of this manual
This procedure takes approximately 45 minutes to perform.
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F-184
F-184
TROUBLESHOOTING & REPAIR
MAIN INPUT CONTACTOR (CR1) REMOVAL AND REPLACEMENT (continued)
FIGURE F.69 - MAIN CONTACTOR
L1 L2 L3
T3CR1
T1 T2
PROCEDURE
WARNING
1. Remove main input supply power to the
machine.
Before continuing with the
test procedure, perform the
capacitor discharge proce-
dure to avoid electric shock.
2. With the 3/8" nut driver, remove the 4
screws that hold the handle to the machine.
3. Remove the rubber gasket (cover seal) from
the lift bail.
7. After you have completed the capacitor dis-
charge procedure for all four switch boards,
with the slot head screw driver, remove the
three heavy leads from the output side of
the contactor.
4. With the 5/16" nut driver, remove the sheet
metal screws from the case top.
5. With the 5/16" nut driver, remove the
screws holding the right and left case sides.
Remove the case sides by lifting up and
out.
8. With the slot head screw driver, remove the
two small leads (L1A and L3A) from the
input side of the contactor.
6. Perform the Capacitor Discharge Proce-
dure described earlier in this section of the
manual.
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F-185
F-185
TROUBLESHOOTING & REPAIR
MAIN INPUT CONTACTOR (CR1) REMOVAL AND REPLACEMENT (continued)
9. With the slot head screw driver, remove
the two small leads (T1 and T3) from the
output side of the contactor.
13. For replacement, mount the contactor to
the vertical mounting panel with the two
3/8" mounting screws and nuts.
10. With the slot head screw driver, remove
the two contactor coil leads (#324 and
#326) from the contactor.
14. Attach all the contactor leads: coil leads
#324 and #326; small leads T1 and T3 to
the output side; three heavy leads to the
output side; small leads L1A and L3A and
three input leads to the input side. Tighten
all evenly with the slot head screw driver.
11. With the slot head screw driver and 3/8"
wrench, loosen the two mounting screws
and nuts holding the contactor to the ver-
tical mounting panel.
15. Install the machine case sides and top.
12. Remove the contactor by lifting up and
out.
16. Install the handle and the lift bail rubber
gasket.
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F-186
F-186
NOTES
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F-187
F-187
TROUBLESHOOTING & REPAIR
OUTPUT RECTIFIER BRIDGE REMOVAL
AND REPLACEMENT
WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician or
machine operator and will invalidate your factory warranty. For your safety and to avoid elec-
trical shock, please observe all safety notes and precautions detailed throughout this manual.
If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou-
bleshooting assistance before you proceed. Call 1-800-833-9353 (WELD).
DESCRIPTION
The following procedure will aid the technician in removing the output rectifier bridge for
maintenance or replacement.
MATERIALS NEEDED
Slot head screw driver
5/16" Nut driver
3/8" Nut driver
7/16" Open end wrench
Wire cutters
Machine Wiring Diagram in the Electrical Diagrams section of this manual
This procedure takes approximately 1 hour 30 minutes to perform.
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F-188
F-188
TROUBLESHOOTING & REPAIR
OUTPUT RECTIFIER BRIDGE REMOVAL AND REPLACEMENT (continued)
FIGURE F.70 - OUTPUT RECTIFIER BRIDGE LOCATION
1
1. OUTPUT RECTIFIER BRIDGE
PROCEDURE
WARNING
1. Remove main input supply power to the
machine.
Before continuing with the
test procedure, perform the
capacitor discharge proce-
dure to avoid electric shock.
2. With the 3/8" nut driver, remove the 4
screws that hold the handle to the machine.
3. Remove the rubber gasket (cover seal) from
the lift bail.
7. After you have completed the capacitor dis-
charge procedure for all four switch boards,
cut all necessary cable ties (necessary for
removal of the output rectifier bridge) on the
left side of the machine.
4. With the 5/16" nut driver, remove the sheet
metal screws from the case top.
5. With the 5/16" nut driver, remove the
screws holding the right and left case sides.
Remove the case sides by lifting up and
out.
8. Disconnect all necessary leads from the left
side of the output rectifier bridge (two
heavy and two small leads). Place the fas-
tener hardware back together to avoid loss.
6. Perform the Capacitor Discharge
Procedure described earlier in this section
of the manual.
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F-189
F-189
TROUBLESHOOTING & REPAIR
OUTPUT RECTIFIER BRIDGE REMOVAL AND REPLACEMENT (continued)
9. Cut all necessary cable ties on the right
side of the machine and disconnect all
necessary leads (two heavy and two small
leads) from the right side of the output
rectifier bridge. Place the fastener hard-
ware back together onto the lead ends to
avoid loss.
11. With the 7/16" wrench, remove the bolts,
top and bottom, that connect the heat
sink and glastic insulated angle mounting
piece at the middle. With the side bolts
already removed, it is easier to access the
middle bolts.
12. With the 7/16" wrench, remove the bolt,
nut, and split-ring lock washer from the
tab connection at the bottom of the heat
sink. The input rectifier bridge can now be
removed. You may have to bend the bot-
tom tab slightly in order to get it past the
main transformer.
10. On the right side of the machine, use the
7/16" open end wrench to remove the bolt
that connects the heat sink at the top to
the glastic insulated angle mounting
piece. Then remove the carriage bolt that
holds the glastic insulated angle mounting
piece at the bottom to the subframe.
Repeat the same procedure on the left
side of the machine. Save the shake-
proof washers and nuts for reassembly.
FIGURE F.71 – HEAT SINK REMOVAL
1
4
2
3
1. GLASTIC INSULATED ANGLE MOUNTING
PIECE (TOP)
2. BOTTOM TAB CONNECTION
3. GLASTIC INSULATED ANGLE MOUNTING
PIECE (BOTTOM)
4. HEAT SINK
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F-190
F-190
TROUBLESHOOTING & REPAIR
OUTPUT RECTIFIER BRIDGE REMOVAL AND REPLACEMENT (continued)
FIGURE F.72 – CABLE TIE LOCATIONS
SECONDARY HARNESS ASSEMBLY (WHITE)
PRIMARY HARNESS ASSEMBLY (BLACK)
13. For reassembly, 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. Then attach and tighten down
the top and bottom bolts that hold the
heat sink on both sides of the machine.
15. Install the machine case sides and top.
16. Install the handle and the lift bail rubber
gasket.
14. Reconnect the leads on both sides of the
bridge. Install new cable ties according to
Figure F.72.
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F-191
F-191
TROUBLESHOOTING & REPAIR
FET MODULE REMOVAL AND REPLACEMENT
WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician or
machine operator and will invalidate your factory warranty. For your safety and to avoid elec-
trical shock, please observe all safety notes and precautions detailed throughout this manual.
If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou-
bleshooting assistance before you proceed. Call 1-800-833-9353 (WELD).
DESCRIPTION
The following procedure will aid the technician in removing the FET modules and main
transformer for maintenance or replacement.
MATERIALS NEEDED
Slot head screw driver
Phillips head screw driver
5/16" Nut driver
3/8" Nut driver
5/16" Open end or box wrench
7/16" Open end or box wrench
3/8" Socket wrench
1/2" Socket wrench
Wire cutters
Machine Wiring Diagram in the Electrical Diagrams section of this manual
This procedure takes approximately 3 hours 30 minutes to perform.
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F-192
F-192
TROUBLESHOOTING & REPAIR
FET MODULE REMOVAL AND REPLACEMENT (continued)
FIGURE F.73 - FET MODULE LOCATION
4
3
1
1. FET MODULE
2. PIEZO ALARM BUZZER
3. FET MODULE LOCKING BAR
4. RESISTORS
2
PROCEDURE
WARNING
1. Remove main input supply power to the
machine.
Before continuing with the
test procedure, perform the
capacitor discharge proce-
dure to avoid electric shock.
2. With the 3/8" nut driver, remove the 4
screws that hold the handle to the machine.
3. Remove the rubber gasket (cover seal) from
the lift bail.
7. After you have completed the capacitor dis-
charge procedure for all four switch boards,
use the 5/16" nut driver to remove the two
screws holding the printed circuit board
cover in place. Slide the cover forward and
lift up to remove it.
4. With the 5/16" nut driver, remove the sheet
metal screws from the case top.
5. With the 5/16" nut driver, remove the
screws holding the right and left case sides.
Remove the case sides by lifting up and
out.
6. Perform the Capacitor Discharge Proce-
dure described earlier in this section of the
manual.
CAUTION
Be sure to follow the recommended static-free
methods for handling printed circuit boards.
Failure to do so can result in permanent dam-
age to the equipment.
8. Remove the molex plugs from the PC
boards except the display board.
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F-193
F-193
TROUBLESHOOTING & REPAIR
FET MODULE REMOVAL AND REPLACEMENT (continued)
FIGURE F.74 - LIFT BAFFLE/BAIL REMOVAL
1
2
1. LIFT BAIL
2. LIFT BAIL BAFFLE
3. SUBFRAME STAND
3
9. With the wire cutters, cut all necessary
cable ties.
17. With the 3/8" wrench, remove the six
resistors that are attached to the top of the
subframe (four on the top right, two on the
top left). Note the physical placement and
wiring for reassembly; labeling is recom-
mended. Also loosen the bottom resistors
closest to the FET module assembly. This
will allow the capacitors to clear the resis-
tors when the FET module assembly
slides forward for removal.
10. Disconnect the leads to the output rectifi-
er bridge. Cut all necessary cable ties.
11. Disconnect two plugs from the snubber
board.
12. Disconnect the output cable strap and pull
it through and free from the lift bail baffle
eyelet hole. Cut any necessary cable ties.
18. With the 5/16" nut driver, remove the
sheet metal screw holding the ground
leads to the right rear of the subframe. On
the left side, unclip the cable tie holding
the leads. Let the back of the subframe
swing out carefully; the harness will sup-
port it.
13. With the 3/8" nut driver, remove the two
screws that hold the lift bail baffle. See
Figure F.74. Remove the baffle.
14. With the 1/2" socket wrench, remove the
four bolts (two on each side of the
machine) from the lift bail. See Figure
F.74. Slide the lift bail up and free of the
machine.
19. With the 5/16" wrench, remove the two
sheet metal screws holding the subframe
bottom support section. Note the green
ground lead on the left side; be sure to
reconnect it during reassembly.
15. On the right side of the machine, cut any
necessary cable ties to free the wiring har-
ness from the subframe.
16. With the Phillips head screw driver,
remove the screw that holds the piezo-
electric alarm buzzer in place. Cut the
cable tie that holds the wire.
20. With the 7/16" wrench, disconnect the
heavy current-carrying flat copper strap
running from the shunt amplifier to the
output rectifier bridge.
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F-194
F-194
TROUBLESHOOTING & REPAIR
FET MODULE REMOVAL AND REPLACEMENT (continued)
21. Remove the water cooler assembly in
Replacement of the FET Module Assembly:
order to access the retainer clips that hold
the bottom of the FET module assembly in
place. (Complete removal of the unit
should not be necessary.) Refer to the
27. Carefully set the assembly into the bottom
of the machine. The terminal label should
face the front (toward the main trans-
former).
Water
Cooler
Removal
and
Replacement Procedure in this section
of the module.
28. Connect all leads to their appropriate ter-
minals on the assembly. Use the Wiring
Diagram for reference.
22. Remove the locking bar from the top of
the subframe where it secures the FET
module assembly. Depress the top and
bottom retainer clips with the slot head
screw driver so that the FET module
assembly can slide forward.
29. Carefully position the subframe on top of
the FET module assembly. Slide the
assembly into place so that the retainer
clips snap into their slots, top and bottom.
Fit the locking bar into place on top of the
subframe to secure the FET module
assembly.
23. Slowly lift and remove the subframe, mak-
ing sure no clips, cable ties, or lead con-
nections are still holding it.
24. With the wire cutters, cut all necessary
cable ties holding the FET module assem-
bly to the wiring harness. Using needle
nose pliers, disconnect the leads attached
to the FET module assembly (all red and
white leads should remain connected).
Refer to the Wiring Diagram to determine
which leads should be disconnected. The
main transformer and the reconnect mod-
ule must be free of the FET module
assembly. Also disconnect the thermostat
lead.
25. Carefully lift the FET module assembly
and remove it from the machine.
26. With the FET module assembly removed,
the main transformer, background choke,
and output choke are now easily accessi-
ble. Refer to the Main Transformer
Removal and Replacement Procedure
in this section of the module.
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F-195
F-195
TROUBLESHOOTING & REPAIR
FET MODULE REMOVAL AND REPLACEMENT (continued)
30. Install the water cooler assembly. Refer to
35. Slide the lift bail into place. With the 1/2"
the Water Cooler Removal and Replace-
ment Procedure in this section of the
module.
socket wrench, install the four bolts (two
on each side of the machine) to secure the
lift bail. With the 3/8" nut driver, install the
two screws to secure the lift bail baffle.
Feed the output cable strap through the
lift bail baffle eyelet hole. Replace any
necessary cable ties.
31. With the 7/16" wrench, connect the heavy
current-carrying flat copper strap running
from the shunt amplifier to the output rec-
tifier bridge. With a 5/16" wrench, install
the two sheet metal screws holding the
subframe bottom support section.
Connect the green ground lead on the left
side.
36. Connect the two plugs to the snubber
board.
37. Connect the leads to the output rectifier
bridge. Replace all necessary cable ties.
32. Swing the back of the subframe into
place. With the 5/16" nut driver, install the
sheet metal screw holding the ground
leads to the right rear of the subframe. On
the left side, clip the cable tie to hold the
leads.
38. Install the molex plugs to the PC boards.
Refer to Figure F.1, PC Board Connector
Locations in this section of the manual.
39. Install the printed circuit board cover with
two 5/16" screws.
33. With the 3/8" wrench, install the six resis-
tors that are attached to the top of the
subframe (four on the top right, two on the
top left) according to the markings you
made during disassembly. Also tighten
the bottom resistors closest to the FET
module assembly.
40. Replace any necessary cable ties for the
wiring harness and other leads that were
cut during disassembly.
41. Install the machine case sides and top.
42. Install the handle and the lift bail rubber
gasket.
34. With the Phillips head screw driver, install
the screw that holds the piezo-electric
alarm buzzer in place. Replace the cable
tie that holds the wire.
43. Prior to applying full input power perform
the Pre-Power Up Switch Board Test.
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F-196
F-196
NOTES
POWER WAVE 450
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F-197
F-197
TROUBLESHOOTING & REPAIR
MAIN TRANSFORMER REMOVAL AND REPLACEMENT
WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician or
machine operator and will invalidate your factory warranty. For your safety and to avoid elec-
trical shock, please observe all safety notes and precautions detailed throughout this manual.
If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou-
bleshooting assistance before you proceed. Call 1-800-833-9353 (WELD).
DESCRIPTION
The following procedure will aid the technician in removing the main transformer for main-
tenance or replacement.
MATERIALS NEEDED
Slot head screw driver
Phillips head screw driver
5/16" Nut driver
3/8" Nut driver
5/16" Open end or box wrench
7/16" Open end or box wrench
3/8" Socket wrench
1/2" Socket wrench
Wire cutters
Machine Wiring Diagram in the Electrical Diagrams section of this manual
This procedure takes approximately 2 hours 30 minutes to perform.
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F-198
F-198
TROUBLESHOOTING & REPAIR
MAIN TRANSFORMER/CHOKE REMOVAL AND REPLACEMENT (continued)
FIGURE F.75 - MAIN TRANSFORMER LOCATION
1. MAIN TRANSFORMER
1
7. After you have completed the capacitor dis-
PROCEDURE
charge procedure for all four switch boards,
perform the FET Module Assembly
Removal Procedure. Refer to the proce-
1. Remove main input supply power to the
machine.
dure in this section of the manual. After the
FET module assembly has been removed,
the main transformer and chokes are easily
accessible.
2. With the 3/8" nut driver, remove the 4
screws that hold the handle to the machine.
3. Remove the rubber gasket (cover seal) from
the lift bail.
8. With the 3/8" socket wrench, remove the
four main transformer mounting bolts.
4. With the 5/16" nut driver, remove the sheet
metal screws from the case top.
9. Disconnect the heavy leads between the
main transformer and the choke assembly.
You will need to cut the cable ties on the
insulating sleeve and slide the sleeve for-
ward to access the connection.
5. With the 5/16" nut driver, remove the
screws holding the right and left case sides.
Remove the case sides by lifting up and
out.
6. Perform the Capacitor Discharge
Procedure described earlier in this section of
the manual.
10. Lift the main transformer out. Remove the
background or output chokes if necessary
by removing any mounting bolts holding
the chokes to the machine frame bottom.
WARNING
11. After reassembly test on high voltage
input and reconnect.
Before continuing with the test
procedure, perform the capaci-
tor discharge procedure to avoid
electric shock.
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F-199
F-199
TROUBLESHOOTING & REPAIR
PRE-POWERUP SWITCH BOARD TEST PROCEDURE
FOR REPLACEMENT OF SWITCH ASSEMBLY G2402-2
WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician or
machine operator and will invalidate your factory warranty. For your safety and to avoid elec-
trical shock, please observe all safety notes and precautions detailed throughout this manual.
If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou-
bleshooting assistance before you proceed. Call 1-800-833-9353 (WELD).
DESCRIPTION
The following tests and procedures must be performed if the main power FET module has
been replaced in the Power Wave. These tests are necessary to ensure that the FET
module has been installed and connected properly.
This procedure takes approximately 2 hours to perform.
BEWARE:
ISOLATED POWER SUPPLIES AND METERING MUST BE USED: CATASTROPHIC PC
BOARD DAMAGE WILL OCCUR IF THE VOLTAGE SUPPLIES AND METERING ARE NOT
COMPLETELY ELECTRICALLY ISOLATED.
MATERIALS NEEDED
Calibration and Test Overlay
Isolation transformer (for oscilloscope)
Isolation transformer 115vac @ 3 amps (min)
Isolation transformer 115vac @ 2 amps (min)
Variable transformer 3 amps (min)
Oscilloscope
L9660-255
circuit of figure #1
circuit of figure #3
*Current probe
Tektronic P6201
or equivalent
Voltmeters
Fuse 5 amps (2).
P70 adapter
Female connector
Male connector
Male pin
S18247-6
S18249-6
S8053-122
S8053-123
Female pin
P23 adapter
Male connector
Female pin
S18247-6
S8053-123
Toggle switch (SPST)
*An alternate method of testing using an isolated oscilloscope may be used.
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F-200
F-200
TROUBLESHOOTING & REPAIR
PRE-POWERUP SWITCH BOARD TEST PROCEDURE
FOR REPLACEMENT OF SWITCH ASSEMBLY G2402-2 (continued)
across one of the 7.5K ohm bleeder resistors
(R9 or R10). See wiring diagram.
FILTER CAPACITOR POLARITY
TEST
1. Perform this procedure with the input power
removed. Perform the CAPACITOR DIS-
CHARGE Procedure to remove any charge
from the input filter capacitors.
4. Attach the positive meter probe to wire #9
and the negative meter probe to lead #12.
The resistance should slowly increase to a
value between 3K ohms and 3.5K ohms.
2. Configure the machine for 230VAC opera-
tion.
5. Repeat the procedure for the other bleeder
(7.5K ohm) resistor.
3. Attach the ohmmeter (set to 1 K ohm range)
FIGURE F.76 - AC SUPPLY LEADS
FUSE
5A
INPUT RECTIFIER: AC1 (T1)
INPUT RECTIFIER: AC3 (T3)
PRIMARY
VOLTAGE
VARIABLE
ISOLATED
115 VAC
0
115 VAC
SETUP THE POWER WAVE FOR
PRETEST
WARNING
ALL AC SUPPLIES MUST BE ELECTRICALLY
ISOLATED (Isolation transformers). THE
PRINTED CIRCUIT BOARDS WILL BE DAM-
AGED IF THE AC SUPPLIES ARE NOT
ISOLATED.
1. Turn the input power switch to the OFF
position.
2. Unplug P73. See wiring diagram.
3. Install the L9660-255 Calibration & Test over-
lay into the Power Wave.
6. Monitor the filter capacitor voltage as per
4. Construct an isolated variable AC supply
circuit as shown in Figure F.76 using the
following equipment:
Figure F.77.
WARNING
Isolation transformer 115vac @ 3 amps.
5 amp Variac.
5 amp Fuse.
WARNING: ALL METERS AND OSCILLO-
SCOPES MUST BE ELECTRICALLY ISOLAT-
ED (Isolation transformers).
5. Connect the variable AC supply leads to the
Power Wave input rectifier terminals AC1 (T1),
and AC3 (T3). See Figure F.76. Make certain
the variac is at zero volts output.
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F-201
F-201
TROUBLESHOOTING & REPAIR
PRE-POWERUP SWITCH BOARD TEST PROCEDURE
FOR REPLACEMENT OF SWITCH ASSEMBLY G2402-2 (continued)
FIGURE F.77 - FILTER CAPACITOR VOLTAGE
R 9
+
+
9L
400 VDC
VOLTMETER
12L
R 10
9M
400 VDC
VOLTMETER
12M
WARNING
WARNING
MAKE SURE FILTER CAPACITORS ARE
DISCHARGED
ALL AC SUPPLIES MUST BE ELECTRICAL-
LY ISOLATED (isolation transformers). THE
PRINTED CIRCUIT BOARDS WILL BE
DAMAGED IF THE AC SUPPLIES ARE NOT
ISOLATED.
1. Construct a 115VAC pretest power supply
as per Figure F.78 using the following:
Switch (SPST)
Fuse (5 amp max)
P70 adapter
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F-202
F-202
TROUBLESHOOTING & REPAIR
PRE-POWERUP SWITCH BOARD TEST PROCEDURE
FOR REPLACEMENT OF SWITCH ASSEMBLY G2402-2 (continued)
FIGURE F.78 - PRETEST POWER SUPPLY
5A
FUSE
PRETEST POWER
SWITCH
ISOLATED
115 VAC
P70
P70
2
2
3
5
6
3
5
6
Connect the pretest power supply to plug P70 as
per Figure F.78. See wiring diagram.
1. Release wire tension and pull gun trigger.
2. Jumper pins C and D on wire feeder input con-
nector.
ARC START PW450 WITH WIREFEEDER
The arc start may be initiated by any of the follow-
ing methods:
3. Jumper pins D and E on front panel amphenol
connector near welding output terminals.
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F-203
F-203
TROUBLESHOOTING & REPAIR
PRE-POWERUP SWITCH BOARD TEST PROCEDURE
FOR REPLACEMENT OF SWITCH ASSEMBLY G2402-2 (continued)
ARC START FOR PW450 ROBOTIC
1. Construct and connect an arc start circuit as
per Figure F.79.
3. Leave plug J103 connected to the interface
board.
2. Install leads and an arc start switch into plug
J103 pin 10 to pin 11 on the interface PC
board. Make sure the arc start switch leads
are long enough to reach outside of the
machine case.
FIGURE F.79 - SHUNT CONNECTIONS
500
501
542
543
R
1
2
3
4
5
6
7
8
TO
J34
P83
INTERFACE
RECEPTACLE
U
B
INSTALL LEADS
AND SWITCH
539
541
544
545
512
522
67
9
J103
INTERFACE
10
11
12
13
14
15
16
BOARD
ARC START
SWITCH
PRETEST MACHINE CONNECTIONS
1. Make sure the machine shunt connections
are tight.
2. Remove one wire from the output diode
heat sink thermostat. The thermostat LED
should turn ON. See Wiring Diagram
2. Connect the Power Wave output terminals
to a grid load.
3. Reconnect the wire to the output diode heat
sink thermostat. The thermostat LED
should turn back OFF.
3. Turn the grid OFF.
PRETEST POWERUP
4. Turn off the pretest power switch See
1. Turn on the pretest power switch. See
Figure F.78. The Power Wave should beep
and display “SELECT A FUNCTION”.
Figure F.78.
FET DRIVE TEST
Construct plug jumper as per Figure F80.
THERMOSTAT TEST
1. Check the thermostat LED (upper right
hand corner of the Power Wave Display
Panel) it should be OFF.
POWER WAVE 450
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F-204
F-204
TROUBLESHOOTING & REPAIR
PRE-POWERUP SWITCH BOARD TEST PROCEDURE
FOR REPLACEMENT OF SWITCH ASSEMBLY G2402-2 (continued)
FIGURE F.80 - PC BOARD RECEPTACLE
P 23
2
3
5
6
1. Unplug P23 and insert jumper plug into PC
5. Turn ON the arc start switch. See Arc Start
board receptacle. See Figure F.80.
PW450 with wire Feeder or Figure F.79.
2. Turn ON the preset power switch. See
6. Attach the oscilloscope probes to each of the
following eight test points. Each test point
should look like the oscilloscope picture in
Figure F.81.
Figure F.78.
3. Press the MANUAL PROCEDURE ENTRY
(64) key on the Calibration & Test overlay and
using the arrow keys (100) and (101) change
the Power Wave to “Process 1 Setup 1-1”
mode.
WARNING
ALL METERS AND OSCILLOSCOPES MUST
BE ELECTRICALLY ISOLATED (isolation trans-
former).
4. Set the Oscilloscope for:
20 V/div.
20 uS/div.
POSITIVE PROBE
#1 P40 pin 14
#2 P40 pin 9
#3 P40 pin 6
#4 P40 pin 1
#5 P41 pin 15
#6 P41 pin 9
#7 P41 pin 7
#8 P41 pin 1
NEGATIVE PROBE
P40 pin 16
P40 pin 11
P40 pin 8
P40 pin 3
P41 pin 16
P41 pin 10
P41 pin 8
P41 pin 2
POWER WAVE 450
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F-205
F-205
TROUBLESHOOTING & REPAIR
PRE-POWERUP SWITCH BOARD TEST PROCEDURE
FOR REPLACEMENT OF SWITCH ASSEMBLY G2402-2 (continued)
FIGURE F.81 - FET DRIVE SIGNAL
0 V
20uS/Div
20V/Div
SNUBBER SIGNAL TEST
6. Attach the oscilloscope to each of the follow-
ing eight test points. Each test point should
look like the oscilloscope picture in Figure
F.82.
1. Adjust the grid for a “light” load.
2. Turn ON the variable AC supply applied to the
primary circuit. See Figure F.76.
WARNING
3. Slowly increase the voltage until the filter
capacitor voltage is 25VDC. See Figure
F.77.
ALL METERS AND OSCILLOSCOPES MUST
BE ELECTRICALLY ISOLATED Isolated
Transformer).
4. Adjust the grid load to get 5 amps output from
the Power Wave. DO NOT PULL MORE
THAN 7-8 AMPS OUTPUT FROM THE
POWER WAVE.
5. Set the Oscilloscope for:
5 V/div/
20 uS/div.
POSITIVE PROBE
NEGATIVE PROBE
R1
R2
R3
R4
R5
R6
R7
R8
12E or 12L
402
12F
404
405
406
12H
408
401
9E or 9L
403
9F
12G or 12M
9G or 9M
407
9H
Turn the variable AC primary supply to zero
Once the filter capacitor voltage drops to zero,
volts and then turn it OFF. See Figure F.76.
turn the arc start switch OFF. See Figure F.79.
POWER WAVE 450
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F-206
F-206
TROUBLESHOOTING & REPAIR
PRE-POWERUP SWITCH BOARD TEST PROCEDURE
FOR REPLACEMENT OF SWITCH ASSEMBLY G2402-2 (continued)
FIGURE F.82 - SNUBBER SIGNAL
0 V
20uS/Div
5V/Div
460VAC RECONNECT
1. Reconfigure the machine for 460VAC operation.
4. Slowly increase the voltage until the filter capac-
itor voltage is 25VDC. See Figure F.77.
2. Turn ON the variable AC supply applied to the
primary circuit. See Figure F.76.
5. Adjust the grid load to get 5 amps output from
the Power Wave. DO NOT DRAW MORE
THAN 7-8 AMPS OUTPUT FROM THE
POWER WAVE.
3. Turn on the arc start switch. See Arc Start
PW450 or Figure F.79.
4. Slowly increase the voltage until filter capacitor
voltage is 25VDC. NOTE: Monitor both capaci-
tor voltages. If the two voltages are not within 5
to 8 VDC of each other STOP and check wiring
to the FET switch board assembly and also the
individual switch boards. See Figure F.77.
6. Set the Oscilloscope for:
5 V/div.
10 uS/div.
WARNING
5. Adjust the grid load to get 5 amps output from
the Power Source. DO NOT PULL MORE
THAN 7-8 AMPS OUTPUT FROM THE
POWER WAVE.
ALL METERS AND OSCILLOSCOPES MUST BE
ELECTRICALLY ISOLATED.
6. Repeat the previous Snubber Signal Test by
7. Connect the positive oscilloscope probe to the
Power Wave positive welding output terminal
and the negative probe to the negative welding
output terminal. The output should look like the
oscilloscope picture in Figure F.83.
checking the eight test points.
OUTPUT SIGNAL TEST
1. Make certain the machine is configured for
460VAC operation.
2. Turn ON the variable AC supply applied to the
primary circuit. See Figure F.76.
3. Turn ON the arc start switch. See Arc Start
PW450 or Figure F.79.
POWER WAVE 450
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F-207
F-207
TROUBLESHOOTING & REPAIR
PRE-POWERUP SWITCH BOARD TEST PROCEDURE
FOR REPLACEMENT OF SWITCH ASSEMBLY G2402-2 (continued)
FIGURE F.83 - OUTPUT SIGNAL
0 V
10uS/Div
5V/Div
8. Turn the variable AC primary supply to zero
OUTPUT TESTS SETUP
volts and then turn it OFF. See Figure F.76.
The filter capacitors must be discharged
before continuing. Make sure the Power Wave
is configured for 460VAC operation.
1. Connect a power input cable to CR1. DO NOT
APPLY INPUT VOLTAGE AT THIS TIME.
9. Once the filter capacitor voltage drops to zero,
turn the arc start switch OFF. See Arc Start
PW450 or Figure F.79.
PREPARE MACHINE FOR NORMAL
OPERATION
2. Connect the grid load to the Power Wave out-
put terminals. Make sure the grid load is OFF.
1. Turn OFF the 115VAC pretest power circuit.
See Figure F.78
PRIMARY OVER CURRENT TEST
1. Connect a current probe to the oscilloscope
and set it for:
2. Make certain the filter capacitors are
completely discharged. Remove the variable
AC primary supply. See Figure F.76.
10 mV/div. (should be equal 10 mA/div.)
10 uS/div.
3. Remove the 115VAC pretest power circuit.
2. Put the current probe on lead 221 at J21
pin 1. See Wiring Diagram
See Figure F.78.
4. Reconnect plug P70.
3. Loosely assemble the sheet metal case to the
Power Wave.
5. Remove the jumper plug in P23. See
Figure F.80
4. Apply input power to the machine and turn the
Power Wave power switch ON.
6. Reconnect P23.
7. Reconnect P73.
POWER WAVE 450
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F-208
F-208
TROUBLESHOOTING & REPAIR
PRE-POWERUP SWITCH BOARD TEST PROCEDURE
FOR REPLACEMENT OF SWITCH ASSEMBLY G2402-2 (continued)
FIGURE F.84 - PRIMARY CURRENT SIGNAL
0 V
10uS/Div
10V/Div
5. Press the MANUAL PROCEDURE ENTRY
Key on the Calibration and Test Overlay and
change the Power Wave to “Process 1 Setup 1
-8” mode.
PREPARE MACHINE FOR NORMAL
OPERATION.
1. Turn the power switch OFF and remove input
power to the machine.
6. Turn the arc start switch ON. See Arc Start
2. The input capacitors must be discharged
before continuing.
PW450 or Figure F.79.
7. Adjust the output grid load to get 400 amps at
36VDC. The oscilloscope picture should look
like Figure F.84.
3. Remove the capacitor voltage monitoring
leads. See Figure F.77.
4. Remove the power input cable from CR1.
*ALTERNATE TEST (without current probe)
1. Connect a transformer isolated oscilloscope
as follows:
5. Remove the output cables from the Power
Wave.
6. Remove the arc start switch circuit.
Set oscilloscope for .2v/div and 10us/div
Probe
J21 pin 1 wire #211
7. Enable the water cooler if it was enabled at the
start of this test.
Common J21 pin 5 wire #215
2. Observe a waveform similar to Figure F.84.
Equal amplitude and symmetry of the pulses is
important.
3. Check the capacitor voltages. The capacitor
voltages must be within eight volts of each
other.
4. Turn the arc start switch OFF. See Arc Start
PW450 or Figure F.79
5. Turn OFF the Power Wave and remove the
input power. Make sure the filter capacitors are
completely discharged. See Figure F.77.
POWER WAVE 450
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G-1
G-1
TABLE OF CONTENTS
ELECTRICAL DIAGRAMS
Electrical Diagrams Section................................................................................................Section G
Wiring Diagram...........................................................................................................................G-2
Schematic Complete Machine ..................................................................................................G-3
Control PC Board Schematic (1 of 4).........................................................................................G-4
Control PC Board Schematic (2 of 4).........................................................................................G-5
Control PC Board Schematic (3 of 4).........................................................................................G-6
Control PC Board Schematic (4 of 4).........................................................................................G-7
Control PC Board Assembly ......................................................................................................G-8
Display PC Board Schematic (1 of 2).........................................................................................G-9
Display PC Board Schematic (2 of 2).......................................................................................G-10
Display PC Board Assembly ....................................................................................................G-11
Power PC Board Schematic ....................................................................................................G-12
Power PC Board Assembly......................................................................................................G-13
Protection PC Board Schematic ..............................................................................................G-14
Protection PC Board Assembly................................................................................................G-15
Square Wave Protection PC Board Schematic........................................................................G-16
Square Wave Protection PC Board Assembly.........................................................................G-17
Shunt PC Board Schematic .....................................................................................................G-18
Shunt PC Board Assembly.......................................................................................................G-19
Snubber PC Board Schematic.................................................................................................G-20
Snubber PC Board Assembly ..................................................................................................G-21
Switch PC Board Schematic....................................................................................................G-22
Switch PC Board Assembly .....................................................................................................G-23
RS232 Connections..................................................................................................................G-24
POWER WAVE 450
1/96
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G-2
G-2
ELECTRICAL DIAGRAMS
WIRING DIAGRAM - POWER WAVE 450
LEFT SIDE OF MACHINE
1
2
3
4
5
6
7
8
U
V
W
G
302
306
THIS AREA VIEWED FROM LEFT SIDE OF MACHINE
(MACHINE SHOWN CONNECTED FOR 440-460V)
DISPLAY BOARD
CONTROL BOARD
PROTECTION BOARD
POWER BOARD
TO J17
TO SW1
L1A
1
2
3
4
5
6
7
8
75
750
277
77
1
2
3
4
201
202
203
204
205
206
207
208
1
2
3
4
5
6
7
8
321A
H1B
T1
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
3W
3R
TO SW1
321B
303
307
12G
12M
TO SWITCH BD #3
TO R10
TO SWITCH BD #3
TO R10
9G
9M
GROUND
PLANE #1
GROUND
PLANE #2
TO SW1
L3A
TO
TO
A
SYSTEM GROUND PER
J20
5
J61
76
NATIONAL ELECTRICAL CODE.
291
292
276
275
294
6
7
8
4W
TO
P82
P83
J92
TO
SWITCH
BDS
20
P81
200-208V
TO
4R
3W
R5
25
R6
25
H2 TO TERM STRIP
220-230V
J10
9
J30
9
RS232
J40
SW1
CR1
F1
TO FUSE
321B
5A SLOW
BLOW FUSE
25W
25W
10
11
12
13
14
15
16
10
11
12
13
14
15
16
380-415V
440-460V
CONNECTOR
H3 TO TERM STRIP
L1
T1
L2
L3
'A'
TO J32
324
1
2
3
4
211
212
213
3
&
4
3R
H4 TO TERM STRIP
321A
TO
J36
J50
32D
A
B
TO J30
H5 TO TERM STRIP
4W
4R
J21
5
215
405
12H
TO SWITCH BD #3
406
9H
TO SWITCH BD #3
CR1
TO J30
H1B
6
7
8
W
R
T3
RECONNECT SWITCH
9A TO SWITCH BD #1
(TOP)
102D
106A
277
276
275
221A
32E
31C
C
D
E
F
G
H
I
J
K
L
326
1
2
3
4
453
454
1
2
3
4
5
6
7
12K
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
1W
1R
9B TO SWITCH BD #2
9K TO J31
9C TO SWITCH BD #3
3
4
11
H1
TO
TO
J10
J28
J34
J60
TO J32
LOAD
1
2
3
4
5
6
221
9D TO SWITCH BD #4
T2
T3
TO J30
T1
TERM STRIP
POS TO INPUT RECT.
POS TO INPUT RECT.
TO
J3
J11
5
TO SWITCH BD #4
TO SWITCH BD #4
5W
5R
TO CR1
6
7
8
TO
LINE
9J TO J31
TO
12J TO J31
455
456
2W
2R
1W
1R
22
L3A
T3
TO
J42
J44
J31
8
226
227
RECONNECT
SWITCH
BDS
42C
J22
7
J41
TO J30
9
SWITCH
117A (R)
118A (W)
167A
12C TO SWITCH BD #3
12D TO SWITCH BD #4
12K TO J31
L1A
8
9
10
11
12
12A TO SWITCH BD #1
12B TO SWITCH BD #2
10
11
12
13
14
9J
12J
9K
M
N
R7
25
25W
R8
25
25W
1
2
1
&
2
TO CR1
P82
371
374
223
224
225
SW1
POWER
TO
J12
3
TP4
NEG TO INPUT RECT.
NEG TO INPUT RECT.
J37
4
WIRE FEEDER
RECEPTACLE #2
N.B.
N.D.
2W
2R
TO
TP5
AC1
TP6
1
2
1
2
3
1
2
3
321
372
373
232
233
234
235
236
TO
407
R12
TO SWITCH BD #4
408
TO SWITCH BD #4
TO
J39
J13
3
OUTPUT
323
324
1
2
3
4
5
6
7
8
9
VOLTAGE=200-230V
VOLTAGE=380-460V
CR1
P71
J23
4
J37
RECT. THERM
SWITCH THERM
J32
4
4
LCD
DISPLAY
RECTIFIER
5
6
AC2
NEG
AC3
NEG
5
6
326
32A
32B
A
B
C12
C13
INPUT
RECTIFIER
1
2
3
261
262
264
266
265
263
221
226
TO
MAIN TRANSFORMER LEFT SIDE
1
2
3
4
5
6
7
J42
J43
J44
TO
1
2
3
J22
J14
4
TO
POS
102B
105A
77
76
75
121A
32C
31B
C
D
E
F
G
H
I
J
K
L
J26
TO SWITCH BD #3
3T
5
6
TO
J10
J27
J34
J60
333
334
S3
C. BREAKER
P70
227
223
224
225
J33
4
10
11
12
R13
5
6
336
31C
TO J19
1
2
300
301
TO
PIEZO
BUZZER
.0047/400V
10 2W
J24
8
POS
NEG
J15
3
9
1
2
3
4
5
6
7
1
2
3
4
356
351
4
SECONDARY
(TOP)
PRIMARY
(TOP)
10
11
12
13
14
TO
42B
42C
102D
32D
32E
106A
31B
111A (R)
112A (W)
67
J35
1
2
3
4
5
6
448
443
442
M
D1
P83
N
TO
P82
P83
D2
D3
1
2
3
4
5
6
7
8
9
TO
J40
J34
8
3W
3R
3W
3R
442
443
LEFT TOP
WIRE FEEDER
RECEPTACLE #1
TO CT
4T
1
2
3
4
5
9
TO
TO
444
449
445
446
447
J16
7
10
11
12
13
14
42B
102B
32B
32C
105A
5W
5R
TO
J16
J22
J44
TO R6
F3,F4
CONN.
D4
406
406
3T
F3
S4
8
9
10
11
12
444
N.E.
D5
J25
6
3T
TO PRIMARY
N.C.
445
446
447
448
449
TO REC. SWITCH
TO R5
12C
12G
9C
7
8
9
D6
+
ELECTRODE
12C
9C
10
11
12
TO SWITCH BD #4
3B
1
2
3
351
TO REC. SWITCH
C3
10
D7
-
TO R6
9G
1
2
3
4
5
302
303
TO
TO TERM STRIP
TO TERM STRIP
J35
4
D8
J43
4T
4T
TOP
FAN
1
2
3
261
262
263
264
265
266
TO
TO CT
TO R5
KEYPAD
5
6
CONNECTION FOR
TO
356
S3,S4
CONN.
TO
S3,S4
D7-D10
LEAD 461
TO CHOKE
D9
405
405
J17
6
J26
4
J14
SECONDARY
(BOTTOM)
PRIMARY
(BOTTOM)
P81
-
TO J62
7
8
9
306
307
TO
CT
D10
D11
D12
D13
D14
D15
D16
D17
D18
D19
D20
1
2
361
362
211
215
TO
J40
5
6
4R
4W
4R
4W
J36
3
TO TERM STRIP
TO TERM STRIP
SWITCH BOARD #3
LEFT BOTTOM
CONNECTION FOR
F3,F4
10
J21
4
TO J18
BOTTOM
FAN
1
2
111A
BUS
BAR #1
D1-D6
TO
TO
TO CT
4B
1
2
3
4
5
J27
3
TO
J12
J13
TO
1
2
371
372
373
374
S1,S2
CONN.
3W
3R
TO
SHUNT
3W
3R
P83
J40
4
112A
117A
J37
3
TERMINAL STRIP
F4
P4
4
TO
TO R8
TOP FAN
1
2
CONNECTION FOR
S1,S2
408
408
3B
J18
6
TO P73
H1
KEYPAD
TO
BOTTOM FAN
J28
3
D11-D14
7
8
9
1
2
TO PRIMARY
3B
12D
12H
9D
N.C.
P82
TO
4
118A
293
296
TO SW1
H1
TO P4
H1A
TO REC. SWITCH
J38
3
J92
TO R7
12D
9D
10
4
TO REC. SWITCH
C4
-
TO
F1,F2
CONN.
CURRENT
TRANSFORMER
N.D.
CONNECTION FOR
F1,F2
TO R8
9H
1
2
3
4
5
6
7
8
1
2
TO REC. SWITCH
H2
TO P73
H2
TO
D15-D20
234
232
233
4B
4B
J39
3
TO CT
TO R7
J23
4T
4
407
4R
407
4R
4B
TO
J40
1T
1B
TO
TO SWITCH THERM
237
4W
4W
SWITCH BOARD #4
RIGHT TOP
J19
9
(TO SWITCH BDS)
TOP FAN
LCD
TO P73
H3
C16
10
11
12
13
14
15
16
BOTTOM FAN
361
TO J36
362
RECT.
THERM
R16
2W
2W
TO
TO REC. SWITCH
H3
TO P4
HXA
J41
2R
2R
401
N.C.
TO F3,F4,
R11, WORK
401
235
N.D.
TO R1
TO
J21
TO
J20
TO J23
SWITCH
THERM
2T
2T
9A
TO PRIMARY
C15
4T
TO REC. SWITCH
H4
TO P73
H4
-
TO REC. SWITCH
TO R2
4B
R15
9A
9E
12A
12E
1T
TO J23
BUS BAR #1
1T
1B
C1
TO OUTPUT
RECTIFIER
TO P82, P83,
ELECTRODE
236
TO REC. SWITCH
12A
1T
.0047/400V
10 2W
TO R1
TO CT
(FROM TRANSFORMER)
400A
TO R2
SHUNT
402
402
TO REC. SWITCH
H5
TO P73
H5
12E
TO SWITCH BD #1
TO R9
9E
TO SWITCH BD #1
TO R9
9L
TO R2
9M
TO R6
TO
J41
1R
1W
1R
1W
TO RECT. THERM
237
12L
9L
TO J62
467
SWITCH BOARD #1
RIGHT BOTTOM
TO CT
1T
S1
-
R10
7.5K
25W
R9
R1
25
25W
R2
J50
J60
J61
J62
7.5K
25W
WORK
25
SNUBBER BD
TO
2W
2R
2W
2R
25W
AUXILIARY TRANSFORMER
(24V)
J41
SHUNT AMPLIFIER
BOARD
TO
1
4
321
323
J32
SECONDARY
(TOP)
PRIMARY
(TOP)
403
2B
403
2B
FOOT
TO R3
1
2
3
4
5
6
291
292
293
294
TO J62
462
A
B
C
D
E
F
177A
176A
175A
105B
102C
AMPTROL/
REMOTE
CONTROL
TO PRIMARY
TO REC. SWITCH
TO R4
N.C.
401
TO SWITCH BD #1
402
TO SWITCH BD #1
12L
TO R1
12M
TO R5
TO J93
J92
P71
6
TO J10,J38
-
H5
H5
H4
H3
H2
H1
9B
9F
12B
12F
1B
9B
(440-460)
H4
296
TO SWITCH BD #1
2T
C2
P1
R11
40
W
TO REC. SWITCH
TO R3
12B
1B
2
3
2
4
33
RECEPTACLE
(380-415)
H3
1
2
3
4
5
6
7
8
TO
TERM
STRIP
100W
F1
TO
N
177A
176A
175A
102C
TO CT
334
3
5
J33
(24V)
(220-230)
H2
404
404
C. BREAKER
333
TO R4
TO P1
PIEZO
+
J93
U
12F
TO SWITCH BD #2
9F
TO SWITCH BD #2
300
301
TO J62
464
TO J15
(42V)
TO
(200-208)
H1
1R
1W
BUZZER
1R
1W
-
J41
105B
R
SWITCH BOARD #2
336
6
1
TO J33
(115V)
P73
P70
TO CT
1B
32A
5A
CIRCUIT
BREAKER
S2
PROTECTION BD (SQUARE WAVE)
N.D.
R4
R3
25
25W
J12,J13,J15
J3,J4
25
J27,J28,J36
J37,J38,J39
J43
J14,J23,J26
J32,J33,J35
J50,J92
25W
NOTES
:
33
TO S3, S4 CONNECTION
J11,J20,J21
J62,J93
TO J11
TO P70
J17,J18,J25,J61
1
N.A. SINCE COMPONENTS OR CIRCUITRY OF
A
PRINTED
CIRCUIT BOARD MAY CHANGE WITHOUT AFFECTING
THE INTERCHANGEABILITY OF COMPLETE BOARD,
1
5
1
2
1
4
3
4
8
SECONDARY
(BOTTOM)
PRIMARY
(BOTTOM)
A
TO
403
TO SWITCH BD #2
404
TO SWITCH BD #2
THIS DIAGRAM MAY NOT SHOW THE EXACT
N.D.
WATER COOLER
COMPONENTS OR CIRCUITRY HAVING
CODE NUMBER.
A
COMMON
6
5
3
4
6
10
N.B. D1 THRU D6 OUTPUT DIODES ARE
A
MATCHED SET.
TO SWITCH BD #2
2B
P4
P3
J16,J22,J42,J44
1
J24,J31,J34
J10,J19,J30,J40,J41,J60
D7 THRU D14 OUTPUT DIODES ARE
A
MATCHED SET.
6
7
8
1
1
D15 THRU D20 OUTPUT DIODES ARE
A
MATCHED SET.
F2
TO
MAIN CHOKE
N.C. C1, C2, C3, C4 CAPACITORS ARE
N.D. THESE ITEMS ARE ONLY USED ON
A
MATCHED SET.
TERM
PROTECTION BD (SQUARE WAVE)
COOLER
STRIP
A
450 MACHINE
CIRCUIT
12
14
16
7
8
9
J4
WATER COOLER
BREAKER
J3
RIGHT SIDE
WITH
A
WATER COOLER.
CONNECTOR CAVITY NUMBERING SEQUENCE
(VIEWED FROM COMPONENT SIDE OF BOARD)
N.E. TOROID DOES NOT APPEAR ON EARLIER MODELS.
ELECTRODE
+
499
TO J60
ELECTRICAL SYMBOLS PER E1537
RIGHT SIDE OF MACHINE
8-28-98B
G3617-1
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The wiring diagram specific to your code is pasted inside one of the enclosure panels of your machine.
POWER WAVE 450
Download from Www.Somanuals.com. All Manuals Search And Download.
G-3
G-3
ELECTRICAL DIAGRAMS
SCHEMATIC - COMPLETE MACHINE
TRIGGER 24V, 42V,
&
115V FROM PROTECTION BD.
ARC & WORK VOLTAGES TO SNUBBER BD.
N
67
N
167A
H
C
D
121A
221A
102D
106A
H
C
D
102B
105A
31B
U
V
W
J
A
K
I
J
A
K
I
31C
32D
(N.E.) 115V
42V
32B
42B
321B
H1
42C
32E
ON
32C
P82
L
111A(R)
112A(W)
L
117A(R)
118A(W)
WF2 RECEPTACLE
L1A
L3A
TO
A
SYSTEM GROUND PER
OFF
M
E
M
E
NATIONAL ELECTRICAL CODE.
77
76
75
S1
POWER SWITCH
277
276
SWITCH BOARD #3
(LEFT TOP)
G
L3A
F
F
3R
3W
G
B
MAIN TRANSFORMER LEFT SIDE
G
B
275
406
L1A
L1
T1
L2
T2
L3
R6
25/25
SERIAL LOOP COMMUNICATION
FOR WIRE FEEDERS
324
326
8J34
115VAC,FROM 6J33
31B
3T
1J30
6J30
P83
321A
H1B
3T
4T
9C
C3
CR1
12J34
10J34
0VAC,FROM 1J33
42V,FROM 3J33
0VAC,FROM 1J33
32B
42B
9C
WF1 RECEPTACLE
SOFT START
RELAYS
.047/1200
.047/1200
LCD DISPLAY
13J34
32C
102B
105A
125/40
125/40
R10
T3
3500uF
450V
7.5K/25
T1
T3
11J30
16J30
T1
T3
24VAC,FROM 4J33
11J34
14J34
24VAC
24VAC WHEN WF1
TRIGGER CLOSE,TO 4J37
4J32
6J32
324
326
12C
4T
115VAC,FROM 6J33
0VAC,FROM 1J33
1J34
5J34
3J34
6J34
4J34
7J34
FEEDED
THRU CT
31C
R5
13J60
15J60
221A
0VAC
TP4
25/25
SNUBBER BD.
GND
-15 Va
167A
121A
67
DIVIDER
&
BUFFER
32D
42C
32E
TO SNUBBER BOARD
8J20
5J20
4J20
208
9J60
8J60
11J60
40mA
KEYPAD
TP5
AC1
TP6
405
4R
42VAC,FROM 3J33
0VAC,FROM 1J33
3W
3W
3R
1J40
9J40
205
204
+18 Vd
4W
TO SNUBBER BOARD
+15 Va
AC2
NEG
AC3
NEG
SNUBBER BOARD
102D
106A
24VAC,FROM 4J33
ELECT.VOLT.FEEDBACK
3J20
2J20
3J40
6J62
203
202
NOISE_GND
INPUT RECTIFIER
320V 160J
320V 160J
OUTPUT
RECTIFIER
24VAC WHEN WF2
TRIGGER CLOSE,TO 2J37
WF1 ARC VOLT.FEEDBACK
11J40
3R
POS
WF1 WORK VOLT.FEEDBACK
WF2 ARC VOLT.FEEDBACK
WF2 WORK VOLT.FEEDBACK
6J20
1J20
206
201
207
6J40
4W
.047/400
.047/400
SWITCH BOARD #4
(LEFT BOTTOM)
14J40
8J40
4W
4R
1
2
7J20
3W
3R
+5 Vb
V
302
306
1J17
7J17
2J17
RX
TX
A
10/2
.0047/400
16J40
2.7/10
2.7/10
3
4
5
6
7
4R
1J14
WF1
TRIGGER
5V=OPEN
1.5V=CLOSE
.047/1200
261
1J26
D1-D6
IN PARALLEL
408
5
Vc (RS232)
+15 Va
R8
9J17
d
380-460V
25/25
GRS232
GND
5V
303
307
4J17
8J17
3B
2J14
2J26
5J26
1J35
6J35
0
VAC,FROM 1J33
262
265
3J43
1J43
351
356
8
RECONNECT PANEL
208-230V
320V 160J
+5 Vb
3B
4B
9D
C4
42VAC SUPPLY, FROM PROTECTION BD.
ISOLATED
WF1 TRIGGER
CIRCUIT
FET BANK
DRIVER
A
FET BANK
A
9D
42VAC,FROM 3J33
1J19
2J19
3J19
5J42
1J22
221
5J14
WF2
TRIGGER
.047/1200
.047/1200
20
GATE SIGNAL
GD
+5Vb
5V=OPEN
1.5V=CLOSE
FREQ.MODULATED
3500uF
450V
4J19
5J19
6J19
A
GD
2J39
234
6J26
4J14
266
DIFFERENTIAL CAP.VOLT.
(1250Hz WHEN CAP.BALANCED)
P81
<
25uS
NEG
TRIGGER
CIRCUIT
MAIN CHOKE
12K
9J
1J31
ISOLATED
WF2 TRIGGER
CIRCUIT
CAP.VOLTAGE
SENSING CIRCUIT
RS232
+
(+)CAP3,4
10J22
6J22
223
226
10J42
6J42
+15 Va
+15 Va
-15 Va
7J19
8J19
10J31
CONNECTOR
ELECTRODE
(-)CAP1,2
POS
V
-15 Va
+5 Va
12D
A
NOISE_GND
12J31
14J31
12J
9K
4B
FEEDED
R7
9J19
232
3J39
4J39
50uS
11J42
11J22
12J22
GD
224
225
+5 Va
a_GND
25/25
THRU CT
10J19
40mA
6J14
3J14
263
264
3J26
4J26
12J42
SERIAL
COMM.
11J19
12J19
OUTPUT DISABLE
407
4R
233
40mA
NOISE_GND
V
(OV
5V
=
=
RUN
R11
40/100
a
d
1K
B
4W
DISABLE)
COUPLED TO 1J27
13J19
14J19
15J19
16J19
DEAD TIME
40mA
5J44
4J44
40mA CURRENT SOURCE
e_GND
5J22
4J22
5R
COUPLED TO 3J26
FROM 4J28
5R
RECONNECT PANEL
PROTECTION BD.
GND
5W
5W
40mA
SHUNT BOARD
WORK
SERIAL LOOP
CURRENT
e
4J10
5J10
1J10
3J10
8J10
10V
77
200-208V
220-230V
H2
H3
+15 Va
WIPER
76
1W
1W
1R
1J41
F1 5A
SLOW BLOW
FUSE
+18 Vd
75
9J41
SHUNT BD.
GND
GA
10V
277
276
2J41
H4
H5
380-415V
FET BANK
DRIVER
B
FET BANK
B
WIPER
9J42
7J22
227
10J41
1R
GATE SIGNAL
(+)
(-)
440-460V
"A"
275
294
291
292
9J10
10J10
6J10
3J36
4J36
211
215
GA
7J41
2W
POT.MAX
POT.WIPER
POT.MIN
10V
A
15J41
8J41
2W
2R
WIPER
V
(-)
7J10
361
362
B
1J36
2J36
TOP
FAN
GA
16J41
2R
(+)
1J11
3J11
453
454
455
456
(+)
(-)
SWITCH BOARD #1
(RIGHT TOP)
15
V
BOTTOM
FAN
d
2W
2R
7J11
8J11
PRESSURE
FREQ.MODULATED
CAP.DIFFERENTIAL VOLT.
4J23
2J23
3J23
234
232
402
R2
H1
H2
H
3
H
4
H
5
TERMINAL STRIP
25/25
FEEDED
1T
GA
233
OUTPUT DISABE
4J12
2J12
0V
374
371
1T
2T
NOISE_GND
24V
9A
C1
THRU CT
9A
WHEN WF1 TRIGGER
OR FOOT AMPTROL
CLOSE
.047/1200
.047/1200
211
215
1J21
5J21
RECTIFIED CT VOLT. (+)
RECTIFIED CT VOLT. (-)
H1 H1A
H2 H2A
H4 H4A
H5 H5A
1J37
4J37
H3 H3A
371
374
R9
7.5K/25
4J13
2J13
0V
24VAC WHEN WF1 OR
373
372
3500uF
450V
FOOT AMPTROL TRIGGER CLOSE
24V
WHEN WF2 TRIGGER
CLOSE
213
AUXILIARY TRANSFORMER #1
3J21
6J21
+15 Va
12A
373
372
3J37
2J37
24VAC WHEN
321
1J32
1
10J16
+15 Vb
447
448
8J44
PWR_DN
445
216
212
218
12A
CLOSE
2T
WF2 TRIGGER
24VAC SUPPLY
H5
R1
6
H5
1J16
9J16
6J16
7J16
2J16
3J16
8J16
+5 Vb
FOR
(24V)
P71
4
-15 Va
25/25
2J21
8J21
(440-460)
PROTECTION BD.
323
3J32
6J33
446
444
449
-5 Vb
-8 Vb
+15 Vb
+5 Vb
-5 Vb
10J44
447
448
446
444
449
SHUNT CURRENT
FROM SHUNT BD.
H4
5
401
1R
OUTPUT
RECTIFIER
(115V)
24VAC WHEN FOOT AMPTROL
CLOSE,TO 4J37
2J38
3J38
R
U
293
296
(380-415)
115V
(N.E.)
11J44
9J44
336
6
5
3
(
5mA AT 400A WELDING CURRENT)
1W
24VAC FROM 4J33
H34
H2
H1
D
A
(42V)
(24V)
443
442
445
+5 Vc
(RS232)
(220-230)
-8 Vb
b_GND
6J44
3J33
42V
333
NOISE_GND
GA
DISPLAY BD.GND GD
12J44
H23
23
1
N
PWR_DN
(XIRQ)
b
c
(200-208)
+5 Vc
c_GND
3J44
2J44
4J33
1J33
443
442
24V
0
334
33
GRS232
6J23
5J23
1J15
2J15
(+)
H1
300
301
10/2
.0047/400
SWITCH BOARD #2
(RIGHT BOTTOM)
W
15V
2
(-)
2R
2W
POWER BOARD
PROTECTION BOARD
P73
CONTROL BOARD
DISPLAY BOARD
P70
D15-D20
+
-
IN PARALLEL
404
PIEZO
BUZZER
R4
FEEDED
1B
25/25
237
1B
2B
9B
C2
THRU CT
9B
SWITCH BD.
TSTAT
OUTPUT RECTIFIER
TSTAT
.047/1200
.047/1200
3500uF
450V
CB
5A
ISOLATED DC SUPPLIES,TO DISPLAY BD.
12B
12B
2B
R3
25/25
DC SUPPLIES TO SHUNT BD.
SHUNT CURRENT FROM SHUNT BD.
MAIN TRANSFORMER RIGHT SIDE
CURRENT TRANSFORMER
403
1R
1W
4
PRIMARY LEADS 1T,1B,4T,4B
ARE FEEDED THRU CURRENT TRANSFORMER
P1
FOOT AMPTROL RECEPTACLE
AUXILIARY TRANSFORMER #2
(N.D.)
1
NOTES
:
N.A. SINCE COMPONENTS OR CIRCUITRY OF
CIRCUIT BOARD MAY CHANGE WITHOUT AFFECTING
THE INTERCHANGEABILITY OF COMPLETE BOARD,
A
PRINTED
H5
6
H5A
H4A
D
E
A
B
C
105B
7J93
5J93
(24V)
A
102C
177A
176A
175A
(440-460)
H4
THIS DIAGRAM MAY NOT SHOW THE EXACT
4
2
2J93
COMPONENTS OR CIRCUITRY HAVING
CODE NUMBER.
A
COMMON
5
3J93
W
WATER COOLER
(N.D.)
4J93
(380-415)
N.B. D1 THRU D6 OUTPUT DIODES ARE
A
MATCHED SET.
F
D7 THRU D14 OUTPUT DIODES ARE
A
MATCHED SET.
5J4
H3A
H2A
H1A
N
(24V)
D15 THRU D20 OUTPUT DIODES ARE
A
MATCHED SET.
(REMOTE)
PROTECTION BOARD
(220-230)
3
N.C. C1, C2, C3, C4 CAPACITORS ARE
A
MATCHED SET.
H23
N.D. NOT EXIST ON MACHINE WITHOUT WATER COOLER
23
ELECTRICAL SYMBOLS PER E1537
POWER WAVE
U
R
(42V)
N.E. NOT EXIST ON PW350 PW500
&
(200-208)
5
6
H1
(115V)
1
2J4
P5
MACHINE SCHEMATIC
7-21-95E
2990
G
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
POWER WAVE 450
Download from Www.Somanuals.com. All Manuals Search And Download.
G-4
G-4
ELECTRICAL DIAGRAMS
SCHEMATIC - CONTROL PC BOARD #1
2 2 4 G 1 - 1
+5V
+15V
+15V
J22
10
1
3
C13
X3
DZ4
32
26
44
20
20
14
14
14
2
4.7
Vdd
Vcc
24
24
18V
4
35V
1W
C21
0.1
50V
C27
0.1
50V
C19
0.1
50V
C20
C22
C16
0.1
50V
X10
X13
J22
12
C28
0.1
50V
C18
0.1
50V
C17
0.1
50V
C45
0.1
50V
C1
X15
X20
X16
C29
0.1
50V
X5
X1
X3
X12
X11
0.1
0.1
X26
0.1
50V
50V
NAND
50V
NOISE_GROUND
28F512
16
MC68HC11
PSD301
54HC08
7
54HC08
7
74HC573
10
74HC573
10
74AC646
12
74AC646
12
LM224
DZ3
18V
1W
C15
4.7
35V
Vss
1
GND
GND
12
34
7
11
D
-15V
+5V
J22
J22
6
A
D
11
DA-AD[0:7]
DZ2
6.2V
1W
C10
4.7
35V
C11
0.1
50V
(DSP1 DATA BUS)
DATA[0:15]
+5V
NOISE_GROUND
J22
J22
3
9
24
22
2
BtoA SRC
Vcc
BtoA CLK
AtoB CLK
OE
6A: PARALLEL COMMUNICATION
+5V
23
1
AtoB SRC
WRITE_1
RD_LOW
OE_LOW
(DSP1 PORT1)
(SHEET 2, X44)
(DSP1)
3
DIR
A0
A1
DIRECTION
221
221
4
21
20
19
18
17
16
15
14
13
DA-AD[0]
DA-AD[1]
DA-AD[2]
DA-AD[3]
DA-AD[4]
DA-AD[5]
DA-AD[6]
DA-AD[7]
R328
X11
221
221
221
221
5
DATA[0]
DATA[1]
DATA[2]
DATA[3]
DATA[4]
DATA[5]
DATA[6]
DATA[7]
B0
B1
R329
R331
R333
R335
47p
C3
100V
6
A2
A3
A4
A5
A6
A7
R330
4.75K
+5V
7
B2
B3
B4
B5
B6
B7
10K
221
221
8
R332
R334
1
9
DA-AD[0]
Vss
A0/D0
9
R5
19
10
11
DA-AD[1]
DA-AD[2]
DA-AD[3]
DA-AD[4]
DA-AD[5]
DA-AD[6]
DA-AD[7]
10K
/IRQ
A1/D1
A2/D2
A3/D3
A4/D4
A5/D5
A6/D6
A7/D7
OC3
A/D2
A/D3
A/D4
A/D5
A/D6
A/D7
A8
10
2
3
2.21K
MODB
MODA
/XIRQ
EXTAL
XTAL
VRH
RxD
11
12
13
14
15
16
29
47
49
44
46
48
50
42
41
40
39
38
37
36
35
5
D
12
74AC646
J25
GND
1
R34
475
R40
MODE_SLAVE
C26
47p
18
/XIRQ
+5V
1.00K
+5V
7
8
X10
100V
DZ8
5.1V
1W
10M
R6
D
52
R110
24
1/2W
Y2
20
31
22
BtoA SRC
Vcc
1.00K
+6
RXD
C6
0.1
OUTPUT_ON
(3)
2
23
1
OC5
OC2
OC4
IC1
AtoB SRC
BtoA CLK
AtoB CLK
OE
(DSP1 PORT1)
(SHEET 2, X44)
SLAVE
RESET
WRITE_1
RD_HIGH
OE_HIGH
D
50V
(DSP1)
DIRECTION
28
30
32
33
34
21
3
4
5
6
7
8
9
DIR
A0
A1
C5
8.0MHz
130
C4
AD[0:15]
22p
22p
21
20
19
18
17
16
15
14
13
(SHEET 4)
Vpp_CTRL
1.00K
2.21K
MACHINE CONNECTED IN PARALLEL
D
THERMAL
100V
100V
X12
DATA[8]
B0
B1
MODE_SLAVE
DATA[9]
DATA[10]
DATA[11]
DATA[12]
DATA[13]
DATA[14]
DATA[15]
IC2
A2
A3
A4
A5
A6
A7
AD[0]
SWITCH1
SWITCH2
D
J25
IC3
B2
B3
B4
B5
B6
B7
2
R39
R38
AD[8]
TxD
1.00K
1.00K
TXD
+5V
17
AD[9]
AD[10]
AD[11]
AD[12]
AD[13]
AD[14]
AD[15]
/RES
PAI
A9
DZ9
5.1V
1W
27
43
45
22
23
24
25
10
A10
+5V
(DSP 1)
LATCH_READ
I_CK
44
1
11
A/D0
A/D1
MISO
MOSI
SCK
/SS
A11
/BHE
Vcc
A19
+15V
12
74AC646
R/W
2
3
43
42
6
A12
R/W
/RES
PA0
PA1
PA2
PA3
PA4
PA5
PA6
PA7
GND
AS
GND
A13
PC2
PB5
PB6
PB0
PB1
RES
C25
47p
AD[0]
AD[1]
AD[2]
AD[3]
AD[4]
AD[5]
AD[6]
AD[7]
21
D
4.75K
A14
475
D2
100V
20
19
18
17
16
15
5
475
A15
CE_FLASH
C7
1.0
35V
Vdd
E
11
10
9
E
INPUT COMMAND
A14
X13
D
DATA[0:15]
X2
RES
51
6
R/W
AS-LE
VRL
R/W
AS
RES
J25
A15
3
4
+6
S-8054HN
26
4
Vdd
PB2
PB3
PB4
C2
1
A16
MC68HC11
Vss
0.1
10K
10K
10K
10K
8
3
9
C23
0.1
50V
DZ5
6.2V
1W
A17
X1
X1
50V
2
8
7
(3)
(3)
RD_HIGH
RD_LOW
X1
X1
10
12
13
RD_FLASH
BE
100
C49
C50
C51
22p
100V
34
14
12
GND
PC1
22p
22p
R25
J25
D
41
100V
100V
3E: HC11
4
5
11
R28
AS-LE
AD[8]
AD[9]
AD[10]
AD[11]
AD[12]
AD[13]
AD[14]
AD[15]
E
13
40
4
6
PC0
100
D
31
D
A8
PB7
D
+5V
32
33
35
36
37
38
39
22
23
24
25
26
27
28
29
30
2
3
4
5
6
7
8
9
19
DA-AD[0]
DA-AD[1]
DA-AD[2]
DA-AD[3]
DA-AD[4]
DA-AD[5]
DA-AD[6]
DA-AD[7]
DA-AD[0]
DA-AD[1]
DA-AD[2]
DA-AD[3]
DA-AD[4]
DA-AD[5]
DA-AD[6]
DA-AD[7]
A9
A0/D0
D0
Q0
Q1
3Ea: UNDER VOLTAGE LOCKOUT
SWDK
SWWF
SWOP
D
CONTROL
PORT SWITCHES
SERIAL
LOOP
74HC573
X20
SLAVE REFERENCE VOLTAGE
18
17
16
15
14
13
12
D1
D2
D3
A10
A11
A1/D1
A2/D2
A3/D3
A4/D4
A5/D5
A6/D6
A7/D7
Q2
Q3
Q4
Q5
Q6
Q7
4.75K
R336
+5V
E
A12
A13
A14
A15
E
N.C.
12
13
BE
11
X5
D4
D5
D6
D7
J25
J25
J25
5
+15V
I_AD
100K
PSD301
R11
475
R30
475
R31
BE
6
5
R29
267
4
5
X26
7
I_CK
1
6
11
1
LE
C8
X3
3
0.1
X5
OE
6
AD[8]
R/W
2
50V
7
R22
SLAVE
DZ7
5.1V
1W
C24
R109
267
DZ6
A
0.1
50V
D
Q2
600mA
40V
15.0K
1.00K
32
AD[0]
AD[1]
12
11
10
9
A0
A1
Vcc
15V
1W
R20
10K
31
30
24
13
14
15
17
18
19
20
21
2
/WE
NC
AD[2]
AD[3]
AD[4]
AD[5]
AD[6]
AD[7]
AD[8]
AD[9]
AD[10]
AD[11]
AD[12]
AD[13]
A2
A3
A4
A5
A6
A7
A17
26.7
J25
8
R24
R21
R23
D
/OE
DQ0
DQ1
DQ2
DQ3
DQ4
DQ5
DQ6
DQ7
NC
RD_FLASH
DA-AD[0]
26.7
26.7
8
DA-AD[0]
DA-AD[1]
DA-AD[2]
DA-AD[3]
DA-AD[4]
DA-AD[5]
DA-AD[6]
DA-AD[7]
2
3
4
5
6
7
8
9
19
18
17
16
15
14
13
12
A
X15
D0
D1
Q0
Q1
AS1
AS2
AS3
AS4
AS5
AS6
AS7
AS8
74HC573
X16
D
7
DA-AD[1]
DA-AD[2]
DA-AD[3]
DA-AD[4]
DA-AD[5]
DA-AD[6]
DA-AD[7]
CONTROL
VOLTAGE
SENSE
6
D2
D3
Q2
Q3
Q4
Q5
Q6
Q7
J25
J25
9
5
MATRIX
+15V
Vpp
10
27
26
23
25
4
A8
D4
D5
D6
D7
A9
+15V
A10
A11
A12
A13
A14
Vss
3Ee: 12 VOLT PROGRAMMING SUPPLY
+15V
10K
10K
OPTIONAL OUTPUT SLAVE CONTROL
BE
A16
9
10K
28
1
Vpp
A15
4
5
8
11
1
LE
Vpp
X3
29
16
3
6
10
DA-AD[0:7]
X5
A14
A15
OE
OPTIONAL INPUT SLAVE CONTROL
22
/CE
CE_FLASH
28F512
D46
Vpp_CTRL
R13
10K
10
9
D
X26
8
12
AD[9]
Q3
600mA
40V
BE
X26
14
12
13
10K
9
11
X3
13
WR_REF
8
X5
1.00K
AD[10]
10
Vpp
10K
3Ec: HC11 SUPPORT
15.0K
A
AD[0:15]
(HC11 ADDR/DATA BUS)
D
15.0K
HC11 CONTROL
-
SHEET
1
GENERAL INFORMATION
ELECTRICAL SYMBOLS PER E1537
LAST NO. USED
R- 345
C- 156
D- 52
DZ- 35
Q- 34
X- 93
TP-
5
NUMBERS NOT USED:
OSI-
8
CAPACITORS
RESISTORS
DIODES
=
MFD
(
.022/50V
1/4W
UNLESS OTHERWISE SPECIFIED)
UNLESS OTHERWISE SPECIFIED)
C9,12,14,58,71,72,74-76,78,82,89,92-94,99,131
Y-
2
LABELS
=
Ohms
(
A
D1,3,6-9,44,45,48,49
DZ1,23-26,28,29
OSI1
=
1A, 400V
(UNLESS OTHERWISE SPECIFIED)
SUPPLY
VOLTAGE NET
POWER SUPPLY SOURCE POINT
COMMON CONNECTION
Q1,11
R1,75-83,85,100-107,111-117,123-125,131-133,137,
139,140,172,176,190,265,267-269,272,320-326
TP1
FRAME CONNECTION
X4,6-9,17-19,22,23,31-36,40,47-49,51-53,57,
58-60,62,65-67,69,70,72-89
EARTH GROUND CONNECTION
FILE: G2241_2A1
Y1
NOTES
:
EQUIP.
TYPE
Ch’ge.Sht.No.
N.A. SINCE COMPONENTS OR CIRCUITRY ON
A
PRINTED CIRCUIT BOARD MAY CHANGE
UNLESS OTHERWISE SPECIFIED TOLERANCE
ON HOLES SIZES PER E-2056
POWER WAVE
THE LINCOLN ELECTRIC CO.
CLEVELAND, OHIO U.S.A.
WITHOUT AFFECTING THE INTERCHANGEABILITY OF COMPLETE BOARD, THIS DIAGRAM MAY
A
1-6-95B
NOT SHOW THE EXACT COMPONENTS OR CIRCUITRY OF CONTROLS HAVING
NUMBER.
A
COMMON CODE
ON
ON
2
3
PLACE DECIMALS IS
PLACE DECIMALS IS
+
+
.O2
.OO2
CONTROL SCHEMATIC
SUBJECT
8-11-95C
NONE
SCALE
DATE
ON ALL ANGLES IS
+
.5 OF
A
DEGREE
SHT.
1-30-98B
8-13-99B
MATERIAL TOLERANCE ("t") TO AGREE
WITH PUBLISHED STANDARDS
G 2241-1
JRF
11-25-92
CHK.
SUP’S’D’G.
DR.
NO.
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
POWER WAVE 450
Download from Www.Somanuals.com. All Manuals Search And Download.
G-5
G-5
ELECTRICAL DIAGRAMS
SCHEMATIC - CONTROL PC BOARD #2
2 2 4 G 1 - 2
+5V
D
(DSP1 ADDRESS BUS)
ADDR[0:11]
28
8
(DSP1 DATA BUS)
DATA[0:15]
A12
A11
A10
A9
VCC
A13
20
14
20
14
28
28
16
16
20
20
20
16
7
9
X46
C63
C42
C44
C65
C60
C62
6
10
27
22
20
11
C70
1.0
35V
ADDR[10]
ADDR[9]
ADDR[8]
ADDR[7]
ADDR[6]
ADDR[5]
ADDR[4]
ADDR[3]
ADDR[2]
ADDR[1]
ADDR[0]
C64
C67
C61
A14
C68
C66
C43
C155
C156
X25
X39
C69
C59
C130
1.0
35V
X45
X46
X38
X43
X42
X41
X27
5
0.1
50V
0.1
50V
0.1
50V
X21
X44
X28
X29
X30
0.1
50V
/WE
/OE
0.1
50V
0.1
50V
0.1
50V
/WE
0.1
50V
0.1
50V
0.1
50V
0.1
50V
0.1
50V
0.1
50V
0.1
50V
0.1
50V
0.1
50V
4
74AC04
TMS320E14
CY7C199
CY7C199
SCHMITT
NAND
A8
PAL16R4
10
74AC573
10
TMS320E14
74AC153
8
74AC573
10
74AC573
10
74AC573
10
/REN
74AC139
8
74AC139
8
3
/CE
A7
RAM_SEL
34
3
7
34
3
7
14
14
2
DATA[0]
DATA[1]
DATA[2]
DATA[3]
DATA[4]
DATA[5]
DATA[6]
DATA[7]
I/O
I/O
0
A6
1
12
13
15
16
17
18
19
1
A5
26
25
24
23
I/O
2
A4
A3
I/O
I/O
I/O
I/O
I/O
3
4
5
6
7
D
A2
A1
21
14
A0
GND
CY7C199
3D: ANALOG/DIGITAL CONVERTERS
+5V
3C: STATIC RAM
(DSP2 MISC. I/O BUS)
AD_DATA[0:15]
CURRENT
A/D CONVERSION
Vcc
C47
1.0
35V
C48
4
20
RD_CUR
I_AD
RD
DB0
DB1
AD_DATA[0]
AD_DATA[1]
X24
OUT
+Vref_I
+5V
CLK
(3)
0.1
50V
8
19
18
17
16
15
14
13
12
11
Vin
X14
3
AD_DATA[2]
AD_DATA[3]
AD_DATA[4]
AD_DATA[5]
AD_DATA[6]
AD_DATA[7]
AD_DATA[8]
AD_DATA[9]
25mhz
GND
S/H
DB2
DB3
DB4
DB5
DB6
DB7
DB8
DB9
D
STROBE_AD
9
Vref+
28
16
8
1
A12
VCC
A13
select
select
A0a
a
VCC
Y2a
6
DSP_REN
DSP_WE
DSP_A0
AVcc
7
9
15
2
6
X45
A11
A10
A9
b
RD_DSP2
DSP2_W0
1
DVcc
6
10
27
22
20
11
5
ADDR[10]
ADDR[9]
ADDR[8]
ADDR[7]
ADDR[6]
ADDR[5]
ADDR[4]
ADDR[3]
ADDR[2]
ADDR[1]
Y1a
Y0a
Y0b
A14
C35
C40
0.1
2
X43
INT
C34
D
18
C33
18
5
14
3
4
10.0K
A0b
A1a
/WE
/OE
0.1
/WE
7
15V
50V
Vref-
4
12
11
9
1
2
4
A8
DSP_A2
X21
/REN
5
CS
50V
15V
3
13
7
/CE
A7
A1b
Y1b
Y3b
Y2b
RAM_SEL
10
GND
ADC1061
2
DATA[8]
DATA[9]
I/O
I/O
0
A6
Y3a
8
1
12
13
15
16
17
18
19
10
3
1
A5
GND
+5V
X21
DSP2_W2
A
D
74AC139
26
25
24
23
DATA[10]
DATA[11]
DATA[12]
DATA[13]
DATA[14]
DATA[15]
I/O
2
A4
A3
I/O
I/O
I/O
I/O
I/O
3
4
5
6
7
A2
10K
A1
3A: BUS DECODE DSP
2
+5V
+Vref_V
16
+5V
1
21
14
VOLTAGE
A/D CONVERSION
/Ea
Vcc
Za
ADDR[0]
A0
15
7
/Eb
GND
OE_LOW
CY7C199
3
14
5
1
20
19
18
17
16
15
14
13
12
11
I3a
X44
S0
I1a
DVcc
DB0
DB1
AD_DATA[0]
AD_DATA[1]
AD_DATA[2]
AD_DATA[3]
AD_DATA[4]
AD_DATA[5]
AD_DATA[6]
AD_DATA[7]
AD_DATA[8]
AD_DATA[9]
DIRECTION
RD_LATCH
RD_LOW
4
J24
2
I2a
INT
(DSP1, PORT1)
(PSD301)
X37
13
ADDR[0]
ADDR[1]
ADDR[2]
ADDR[3]
ADDR[4]
ADDR[5]
ADDR[6]
ADDR[7]
ADDR[8]
ADDR[9]
ADDR[10]
ADDR[0:11]
12
13
6
3
I2b
I0a
I1b
S/H
DB2
DB3
DB4
DB5
DB6
DB7
DB8
DB9
STROBE_AD
11
10
9
4
I3b
RD
(DSP1, PORT1)
(PSD301)
RD_LATCH
RD_HIGH
RD_VOL
V_AD
C37
0.1
50V
C38
18
2
8
8
S1
I0b
Zb
16
Vin
1
15
2
select
select
A0a
a
VCC
Y0a
/REN
/WE
6
GND
15V
AVcc
4
OE_HIGH
b
74AC153
9
10.0K
Vref+
5
ADDR[0]
C39
18
Y1a
Y2a
Y0b
C41
475
R50
475
R51
X42
J24
5
0.1
CS
14
3
6
A0b
A1a
D
1
15V
READ_0
WRITE_0
50V
7
Vref-
12
11
10
9
DSP_A11
DZ11
5.1V
1W
10
6A: CONTROL DATA FLOW (DSP
DIRECTION HIGH.....HC11 -> DSP
1
1
<> HC11)
GND
ADC1061
13
A1b
Y1b
Y2b
Y3b
7
8
5
6
Y3a
X21
GND
NOISE_GROUND
A
D
DIRECTION LOW......DSP
1
-> HC11
DSP_A2
74AC139
ADDR[0:11]
WRITE_1
DSP_A11
(DSP1 ADDRESS BUS)
475
R52
475
R49
J24
DSP_A0
2
RD_LATCH
100K
O/D(0:15)
5
6
9
12
14
20
21
25
26
27 28
5
6
9
12
14
20
21
25
26
27 28
13
13
ADDR[0:11]
DZ17
5.1V
1W
3B: BUS DECODE DSP
1
20
33
1
33
64
63
62
61
4
4
Vcc1
Vcc2
D0
/OE
D0
D1
Vcc
Vcc1
D0
D1
Vcc2
D
RD_DSP2
DATA[0]
56
55
54
53
52
51
64
2
3
4
5
6
7
8
9
19
18
17
16
15
14
13
12
11
56
NOISE_GROUND
IOP0
IOP1
DATA[0]
O0
O1
O/D(0)
O/D(0)
IOP0
IOP1
AD_DATA[0]
AD_DATA[1]
AD_DATA[2]
AD_DATA[3]
AD_DATA[4]
AD_DATA[5]
AD_DATA[6]
AD_DATA[7]
AD_DATA[8]
AD_DATA[9]
X28
63
62
61
55
54
53
52
51
D1
DATA[1]
DATA[2]
DATA[3]
DATA[4]
DATA[5]
DATA[6]
DATA[7]
DATA[1]
DATA[2]
DATA[3]
DATA[4]
DATA[5]
DATA[6]
DATA[7]
O/D(1)
O/D(2)
O/D(3)
O/D(4)
O/D(5)
O/D(6)
O/D(7)
O/D(1)
O/D(2)
O/D(3)
O/D(4)
O/D(5)
O/D(6)
475
R44
475
R55
J24
IOP2
IOP3
IOP4
IOP5
IOP6
IOP7
IOP8
IOP9
IOP10
IOP11
/INT
D2
D3
D4
D5
D6
D2
D3
O2
O3
O4
O5
O6
O7
LE
D2
D3
D4
D5
D6
D7
IOP2
IOP3
IOP4
IOP5
IOP6
IOP7
IOP8
IOP9
IOP10
IOP11
IOP12
IOP13
IOP15
/REN
IOP14
/WE
3
+15V
DZ12
5.1V
1W
60
59
58
57
1
60
59
58
57
19
D4
D5
D6
10K
45
44
42
41
45
44
42
41
X38
X25
R262
DIRECTION
NOISE_GROUND
C31
0.1
50V
D7
D7
GND
O/D(7)
(3)
475
R45
475
R57
J24
10
CMP3
100K
CLKOUT
WRITE_0
R263
CLK
4
74AC573
X27
47
24
19
11
TXD
CLKIN
CLKOUT
D8
TCLK2/CLKX
Q6
C52
2N4401
LATCH_READ
DZ14
5.1V
1W
38
37
18
10
38
37
32
31
TCLK1/CLKR
CLKIN
D8
CLK
CLR_CAP
D
20
J22
1
24
50
49
46
43
40
39
36
35
34
/OE
D0
D1
Vcc
RD_DSP2
RD_CUR
1
820p
50V
50
49
46
43
40
39
36
35
2
3
4
5
6
7
8
9
19
18
17
16
15
14
13
12
11
+5V
TMS320E14
DATA[8]
DATA[9]
DATA[8]
DATA[9]
DATA[10]
DATA[11]
DATA[12]
DATA[13]
DATA[14]
DATA[15]
O0
O1
O/D(8)
O/D(9)
O/D(8)
O/D(9)
TMS320E14
STROBE_AD
NOISE_GROUND
D50
16
10K
/REN
/WE
/RS
(3)
(3)
D9
D9
1N4936
/REN
/WE
R264
Q7
15
29
16
R69
475
J24
475
R53
D10
DATA[10]
DATA[11]
DATA[12]
DATA[13]
DATA[14]
DATA[15]
D2
D3
O2
O3
O4
O5
O6
O7
LE
O/D(10)
O/D(11)
O/D(12)
O/D(13)
O/D(14)
O/D(15)
O/D(10)
O/D(11)
O/D(12)
O/D(13)
O/D(14)
O/D(15)
D10
2N4401
OUTPUT_ON
DSP_REN
RD_VOL
3A: DSP
2
DSP
1
*
D
17
1.00K
FET BANK
J22
A
5
R48
D11
D11
RESET
/WTD
10K
23
22
66
67
34
30
15
/WTD
NMI/MC/MP
D12
D4
D5
D6
D12
+5V
DZ15
5.1V
1W
D13
D13
+5V
DSP_WE
18
CMP4/CAP2/FSX
D14
D14
/INT
RD_HIGH
RD_LOW
22
2
NOISE_GROUND
CAP1
Vss1
D15
D7
GND
D15
NMI/MC/MP
Vss2
10
3
3
Vss2
Vss1
WRITE_0
475
R46
475
R56
J24
74AC573
X29
A
C30
330p
100V
6
C56
330p
AD_DATA[0:15]
20
1
CLK
Vcc
O3
O2
D3
D2
D1
20
CLK
7
2
68
11
10
48 65
D
8
32
31 30
29
1
17 23 67
47 48
68 65
66
1
2
7
8
Vcc
O0
O1
/OE
READ_0
O/D(0)
O/D(1)
O/D(2)
O/D(3)
O/D(4)
O/D(5)
O/D(6)
O/D(7)
100V
DZ13
5.1V
1W
CHA
CHB
2
3
4
5
6
7
8
9
19
18
17
16
15
14
13
12
11
I0
19
2
X39
DATA[0]
DATA[1]
DATA[2]
DATA[3]
DATA[4]
DATA[5]
DATA[6]
DATA[7]
D0
D1
+15V
I1
D
18
17
16
15
14
13
12
11
3
4
5
6
7
8
9
I2
NOISE_GROUND
D
RESET
CAP1
STROBE_AD
O2
O3
O4
O5
O6
O7
LE
D2
I3
RAM_SEL
(3)
D3
475
R47
475
R54
J24
I4
11
10
12
X21
X21
OUTPUT_ON
D4
7
I5
D0
O1
STROBE_AD
(4)
C32
0.1
50V
D5
10K
10K
10K
10K
10K
10K
D
16
17
GND
(2)
CLR_SHUNT
X41
12
13
CLR_CAP
DZ16
5.1V
1W
OVR_CUR
FAULT
D6
11
O0
OE
X41
1
4
OUTPUT_ON
(FROM HC11)
13
D7
Q5
10
3
6
X41
PAL16R4
5: PAL
10
2N4401
/XIRQ
C53
GND
2
5
NOISE_GROUND
DSP2_W2
/WTD
74AC573
J22
7
475
R42
475
R43
D
D
J24
820p
50V
D
D51
1N4936
8
D
20
1
2
3
4
5
6
7
8
9
Vcc
O0
O1
/OE
D0
D1
READ_0
O/D(8)
O/D(9)
O/D(10)
O/D(11)
O/D(12)
O/D(13)
O/D(14)
O/D(15)
Q4
3Eb: WATCH DOG
R64
2N4401
19
18
17
16
15
14
13
12
11
DATA[8]
DATA[9]
DATA[10]
DATA[11]
DATA[12]
DATA[13]
DATA[14]
DATA[15]
DZ10
5.1V
1W
*
X30
1.00K
FET BANK
J22
B
10K
3B: DSP
1
FUNCTION GENERATOR
O2
O3
O4
O5
O6
O7
LE
D2
D3
J24
14
D4
D5
D6
8
NOISE_GROUND
A
*
INDICATES CHANGE FROM "XRF" VERSION
LAST NO. USED
D7
GND
+15V
10
DSP2_W2
2O: MAIN FET DRIVE
74AC573
GENERAL INFORMATION
R- 345
C- 156
D- 52
DZ- 35
Q- 34
X- 93
ELECTRICAL SYMBOLS PER E1537
J24
CAPACITORS
RESISTORS
DIODES
=
MFD
(
.022/50V
1/4W
UNLESS OTHERWISE SPECIFIED)
UNLESS OTHERWISE SPECIFIED)
DATA[0:15]
9
O/D(0:15)
(DSP2 DATA BUS)
LABELS
SUPPLY
=
Ohms
(
=
1A, 400V
(UNLESS OTHERWISE SPECIFIED)
DSP / FUNCTION GENERATOR - SHEET 2
J24
J24
J24
VOLTAGE NET
10
11
POWER SUPPLY SOURCE POINT
COMMON CONNECTION
6B: PARALLEL COMMUNICATION
FRAME CONNECTION
EARTH GROUND CONNECTION
FILE: G2241_2A1
12
NOTES
:
EQUIP.
TYPE
Ch’ge.Sht.No.
N.A. SINCE COMPONENTS OR CIRCUITRY ON
A
PRINTED CIRCUIT BOARD MAY CHANGE
UNLESS OTHERWISE SPECIFIED TOLERANCE
ON HOLES SIZES PER E-2056
POWER WAVE
THE LINCOLN ELECTRIC CO.
CLEVELAND, OHIO U.S.A.
WITHOUT AFFECTING THE INTERCHANGEABILITY OF COMPLETE BOARD, THIS DIAGRAM MAY
A
NOISE_GROUND
1-6-98B
NOT SHOW THE EXACT COMPONENTS OR CIRCUITRY OF CONTROLS HAVING
NUMBER.
A
COMMON CODE
ON
ON
2
3
PLACE DECIMALS IS
PLACE DECIMALS IS
+
+
.O2
.OO2
CONTROL SCHEMATIC
SUBJECT
8-11-95C
1-30-98B
8-13-99B
NONE
SCALE
DATE
ON ALL ANGLES IS
+
.5 OF
A
DEGREE
SHT.
MATERIAL TOLERANCE ("t") TO AGREE
WITH PUBLISHED STANDARDS
G 2241-2
JRF
11-25-92
CHK.
SUP’S’D’G.
DR.
NO.
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
POWER WAVE 450
Download from Www.Somanuals.com. All Manuals Search And Download.
G-6
G-6
ELECTRICAL DIAGRAMS
SCHEMATIC - CONTROL PC BOARD #3
2 2 4 G 1 - 3
+15V
+5V
+5V
+15V
+5V
+5V
+5V
+5V
2E: CURRENT MODE CONTROL
13
14
14
4
18
Vdd
4
4
C152
0.1
20
20
20
C96
0.1
C81
0.1
50V
X56
267
C151
0.1
50V
50V
C132
C97
0.1
C98
0.1
50V
C150
0.1
50V
C100
C101
0.1
50V
50V
C148
0.1
C83
0.1
C84
0.1
O/D(0:15)
X92
X63
X64
X54
X71
X61
0.1
0.1
X90
X68
X55
C153
0.1
50V
50V
50V
50V
C87
0.1
50V
50V
50V
50V
54HC4066
54HC4066
MC1408
3
AD7545
AGND
33074A
11
74AC573
74AC573
33074A
11
33074A
11
74HC573
10
+2.5V
DGND
D
7
7
2
3
20
A
+
O/D(8)
O/D(9)
2
3
1
1
10
10
C133
0.1
50V
D0
D1
Vcc
O7
O6
O2
O3
O4
O5
01
A
+5V
A
X91
12
13
17
16
15
14
18
19
11
8
X90
A
A
A
REF
TL431
6
/OE
D2
D3
-5V
-
-15V
4
5
6
7
8
9
O/D(10)
O/D(11)
D
100K
A
-15V
R288
221K
D4
D5
D6
-5V
33.2K
R278
12
13
1
8
V+
+IN
-IN
V-
/Q OUT
200
R282
825
R283
D7
GND
00
2H: REFERENCE VOLTAGES
14
2
3
4
7
Q
OUT
GND
LE
OVR_CUR
10
DSP2_W0
X61
LE
X93
6
5
(DSP2, PORT2)
74AC573
10.0
C137
820p
50V
C138
820p
50V
R316
D
1
20
19
LT1016
OUT1
RFB
VREF
Vdd
R281
6.81K
20
1
2
/OE
D0
D1
Vcc
LE
AGND
A
A
C95
-5V
O/D(0)
O/D(1)
O/D(2)
O/D(3)
O/D(4)
O/D(5)
O/D(6)
O/D(7)
2
3
4
5
6
7
8
9
11
3
18
0.1
DGND
X68
1.00K
50V
A
15
17
19
18
17
16
15
14
13
12
O0
O1
DB0
X54
/WR
/CS
R170
10K
R172
10K
14
16
7
D2
D3
DB1
CLR_SHUNT
(DSP2)
CURRENT MODE CONTROL, DISABLE THE
FETS AS SOON AS SECONDARY CURRENT
IS GREATER THAN
+2.5V
1.00K
13
O2
O3
O4
O5
O6
O7
DB2
DB8
DB9
DB10
DB11
DB7
A
REFERENCE LEVEL
12
6
5
4
10
9
D4
D5
D6
DB3
R284
10K
R169
10K
200
R286
825
R287
Q14
2N4403
2
11
8
DB4
X71
R167
X61
1
10
DB5
475
3
C139
820p
50V
C140
820p
50V
9
8
D7
GND
DB6
10
AD7545
10.0
A
R285
6.81K
74AC573
O/D(0:15)
A
(DSP2 DATA BUS)
GENERATE
A
REFERENCE LEVEL
+15V
C57
+2.5V
-15V
1.00K
R275
6.81K
R276
22p
5
6
R314
100V
Q9
7
4.75K
R128
475
X71
2N4401
1.00K
R280
C134
820p
50V
C135
330p
100V
C136
150p
50V
CURRENT A/D
REFERENCE
Q33
2N4401
8
9
X21
CLR_SHUNT
(DSP2)
FILTER INCOMING
SECONDARY CURRENT
1.00K
10.0
+Vref_I
10K
CLEARING NETWORK
SECONDARY CURRENT REGULATION
33.2K
R129
A
SHUNT CONNECTION
CURRENT SIGNAL IN
+15V
+15V
10mA
=
800A OUTPUT
10.0
1.00K
A
3
33.2K
1
R155
150
C79
0.1
50V
X61
I_AD
CURRENT FEEDBACK
CLEARING NETWORK
2
26.7K
(2) TO CURRENT A/D
CLR_CAP
D10
1N914
A
(SHEET 2, X39)
J21
4.75K
A
8
R299
150
R154
V_LIMIT
+15V
Q13
600mA
+Vref_I
R66
Q12
1A
100V
D52
40V
47.5K
10.0
10
1N4936
4.75K
C85
22p
100V
R126
681
R310
C54
820p
50V
C88
0.27
50V
(HC11 ADDR/DATA BUS)
DA-AD[0:7]
Q8
8
R153
750
CURRENT FEEDBACK
AMPLIFIER
4.75K
R122
475
CURRENT FEEDBACK
INTERGATOR
X71
2N4401
VOLTAGE A/D
REFERENCE
+Vref_I
1N914
D11
9
-5V
12
16
4
A8
A7
Vee
A6
A5
A4
A3
A2
COMP
DZ27
15V
1W
GAIN
I_AD
=
=
5.0 to 6.9
5.0V 800A OUTPUT
1.00K
DA-AD[0]
2
3
4
5
6
7
8
9
19
11
3
D7
Q7
Io
CW
500
Q10
R97
R96
@
10.0
74HC573
X55
TRIM_DAC REFERENCE
VOLTAGE FEEDBACK
+Vref_V
DA-AD[1]
DA-AD[2]
DA-AD[3]
DA-AD[4]
DA-AD[5]
DA-AD[6]
DA-AD[7]
18
14
13
600mA
Vref+
D6
D5
Q6
1.00K
1.50K
R171
R98
40V
17
10
9
2
3
33.2K
R121
Q5
X56
Vcc
*
1.00K
R94
1.50K
1.00K
R120
16
15
1
1.00K
1
C73
0.1
50V
Vref-
D4
D3
D2
D1
Q4
X26
15
8
Q3
R
CON
10.0
1.00K
A
14
7
2
2C: SECONDARY CURRENT SENSE
2D: CURRENT FEEDBACK
Q2
GND
A1
13
6
5
Q1
A
C77
0.1
50V
MC1408
12
D0
Q0
A
1.00K
J20
3
R188
+_OUTPUT
WR_REF
A
11
1
LE
-_OUTPUT
67A
DA-AD[0:7]
OE
1.00K
1.00K
(SHEET 1, X5)
J20
2
R187
R189
R186
R191
2G: PROGRAMMABLE VREF
J20
1
67B
D
J20
6
1.00K
1.00K
21A
J20
7
21B
CLAMP CIRCUIT FOR
TRANSIENTS ABOVE 5.0V
SUPPLY RAIL
X63
KELVIN VOLTAGE
FEEDBACK SWITCH
MATRIX
3
POLE FILTER
J21
2
R271
-15V
1
2
FIRST STAGE CUTOFF FREQ
=
4.8 KHZ
+5V
+15V
V_LIMIT
100
SECOND STAGE CUTOFF FREQ
=
3.3 KHZ
13
6
J21
3
AS1
THIRD STAGE CUTOFF FREQ
=
3.4 KHZ
R270
100
+15V
X63
X64
X64
X64
X63
X63
X64
1.00K
VOLTAGE IDEALLY
EQUAL TO 10/210,
80V=3.81V
8
11
4
8
4
11
1
9
DZ34
15V
1W
DZ35
15V
1W
ALL GROUNDS MEET
HERE AND ONLY HERE
26.7
10K
AS2
PRECISION
RECTIFIER
R185
1.00K
C105
0.1
GAIN
=
2
J21
3
2
10K
10K
6
4
R289
3.32K
2.21K
10
3
CONNECTED IN
GRAPHICS ONLY
1
12
13
50V
Q15
2N4403
13
R291
332
R293
R295
R297
X92
D15
1N914
12
5
X71
22.1K
14
R184
475
14
AS3
AS4
X92
V_LIMIT
J21
J21
C141
C142
C143
.0047
50V
V_AD
I_AD
1N914
D13
1N914
D14
10.0
12
0.1
.022
50V
UNITY GAIN
DIFFERENTIAL AMPLIFIER
50V
475
D12
R303
1N914
+15V
D
A
NOISE_GROUND
10.0
6.81K
7
*
*
*
*
*
100K
R175
100K
R99
A
33.2K
R174
J20
NOISE_GROUND
NOISE_GROUND
4
8
9
6
9
AS5
5
6
V_AD
(TO VOLTAGE A/D)
X92
10K
R296
R290
3.32K
R178
150
2.21K
5.11K
100K
R141
33.2K
R181
J20
8
7
-15V
R292
332
R294
R298
X92
10
3
C144
C145
C146
.0047
50V
5
0.1
.022
50V
AS6
2I:
V
LIMIT
*
100K
50V
-15V
D16
1N914
475
475
R304
6.81K
10
2
A
12
J20
AS7
5
UNITY GAIN
AMPLIFIER
NOISE_GROUND
NOTES
:
A
13
AS8
N.A. SINCE COMPONENTS OR CIRCUITRY ON
A
PRINTED CIRCUIT BOARD MAY CHANGE
DZ18
DZ19
DZ20
DZ21
DZ22
WITHOUT AFFECTING THE INTERCHANGEABILITY OF COMPLETE BOARD, THIS DIAGRAM MAY
A
2F: VOLTAGE FEEDBACK
CONTROLED BY
SHEET 1, X16
NOT SHOW THE EXACT COMPONENTS OR CIRCUITRY OF CONTROLS HAVING
NUMBER.
A
COMMON CODE
(
)
5.1V
1W
5.1V
1W
5.1V
1W
5.1V
1W
5.1V
1W
GENERAL INFORMATION
ELECTRICAL SYMBOLS PER E1537
LAST NO. USED
R- 345
C- 156
D- 52
DZ- 35
Q- 34
X- 93
CAPACITORS
RESISTORS
DIODES
=
MFD
(
.022/50V
1/4W
UNLESS OTHERWISE SPECIFIED)
UNLESS OTHERWISE SPECIFIED)
A
LABELS
=
Ohms
(
=
1A, 400V
(UNLESS OTHERWISE SPECIFIED)
SUPPLY
VOLTAGE NET
POWER SUPPLY SOURCE POINT
COMMON CONNECTION
ANALOG CIRCUITRY - SHEET 3
3Ef: MULTIPLEXING THE V
INPU
A
T
RC
S
FRAME CONNECTION
EARTH GROUND CONNECTION
FILE: G2241_2A1
EQUIP.
TYPE
Ch’ge.Sht.No.
8-13-99B
POWER WAVE
UNLESS OTHERWISE SPECIFIED TOLERANCE
ON HOLES SIZES PER E-2056
THE LINCOLN ELECTRIC CO.
CLEVELAND, OHIO U.S.A.
1-6-95B
CONTROL SCHEMATIC
ON
ON
2
3
PLACE DECIMALS IS
PLACE DECIMALS IS
+
+
.O2
.OO2
SUBJECT
4-21-95J
8-11-95C
1-30-98B
NONE
SCALE
DATE
ON ALL ANGLES IS
+
.5 OF
A
DEGREE
SHT.
MATERIAL TOLERANCE ("t") TO AGREE
WITH PUBLISHED STANDARDS
G 2241-3
JRF
11-25-92
CHK.
SUP’S’D’G.
DR.
NO.
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
POWER WAVE 450
Download from Www.Somanuals.com. All Manuals Search And Download.
G-7
G-7
ELECTRICAL DIAGRAMS
SCHEMATIC - CONTROL PC BOARD #4
2 2 4 G 1 - 4
50V
C121
SER_LOOP
+15V
2700p
J26
3
DK+
R233
750
*
Q26
500mA
300V
2K
D29
Q25
500mA
300V
C120
820p
Q28
600mA
40V
ON
SWITCH
/
OFF
ON
SWITCH
/
OFF
50V
+5V
+5V
TP3
150V
45J
+15V
26.7
R235
10K
1
5
SWDK
10K
10K
+5.5V
+5.5V
V_LIMIT
2N4403
Q27
OCI7
CNY17-3
R240
1.3K
10K
DIS1
D22
DIS2
D42
C122
(SHEET 1, X20)
D24
200
.0047
400V
J26
1
J26
5
2
6
4
10K
D27
1N914
SWITCH1
(TO HC11)
SWITCH2
J23
6
(TO HC11)
R221
1.00K
THERMAL
(TO HC11)
1
5
1
5
D30
D26
OCI4
CNY17-3
OCI8
CNY17-3
DZ31
5.1V
1W
C119
0.1
56.2K
LOW
HIGH
=
=
NORMAL
FAULT
50V
2
6
4
2
6
4
C123
150p
50V
HIGH
LOW
=
=
TRIGGER OPEN
TRIGGER CLOSED
HIGH
LOW
=
=
TRIGGER OPEN
TRIGGER CLOSED
J23
D
5
R226
J26
2
J26
6
D28
R220
150
R256
150
J26
681
4
DK-
D
R225
10.0
TURN ON/OFF DISPLAY/KEYPAD FROM SERIAL LOOP
D
MUST BE ISOLATED FROM
ALL OTHER SIGNALS
MUST BE ISOLATED FROM
ALL OTHER SIGNALS
D
NOISE_GROUND
50V
C124
2700p
+15V
J27
2N: THERMAL OVERLOAD INPUT
1
WF+
R194
750
2M: ON/OFF SWITCHES
*
Q29
500mA
300V
+15V
2K
D38
Q17
500mA
C106
300V
820p
Q16
R230
26.7K
600mA
40V
+15V
J22
5
50V
TP5
150V
45J
R229
26.7K
26.7
R193
10K
26.7
50V
100K
3J23 INPUT FROM PROTECTION
1
5
J23
J23
C113
3
4
R228
1.00K
SWWF
+5V FOR FAULT CONDITION
0V FOR NORMAL CONDITION
2700p
1N914
D47
2N4403
Q31
OCI2
CNY17-3
R249
1.3K
C129
.0047
400V
(SHEET 1, X20)
9
200
CAP1
2
6
4
R258
100K
10K
D33
8
X41
1.00K
10
R218
750
(TO DSP2)
D34
DZ32
5.1V
1W
DZ33
Q20
600mA
40V
D39
5.1V
1W
Q24
500mA
300V
C128
150p
50V
C127
150p
50V
56.2K
Q21
500mA
300V
C110
150p
50V
J23
2
1
8
R259
681
NC
VCC
D
D36
7
2
3
ANODE
CATH
NC
VB
J27
TXD
2N4403
Q22
4
R204
1.3K
WF-
6
R260
10.0
VC
D
+5V
(FROM HC11)
C114
820p
50V
4
5
200
GND
10K
OCI5
J27
J27
J23
NOISE_GROUND
1
2
3
10K
10K
D21
TURN ON/OFF WIRE FEEDER 1 FROM SERIAL LOOP
2K
D25
FAULT
56.2K
50V
1N4936
D23
2K: PROTECTION BOARD INTERFACE
C109
DZ30
5.1V
1W
C112
150p
50V
+15V
Q34
2N4401
2700p
C111
0.1
50V
R317
10K
J28
D
1
OPT+
HIGH
LOW
=
=
NORMAL
FAULT
10K
TP2
150V
45J
R196
750
+15V
+5V
C118
.0047
400V
*
Q30
500mA
300V
D
+Vref_I
2K
D37
Q18
5.11K
3.32K
500mA
2L: GENERATE FAULT SIGNAL
C108
300V
820p
50V
Q19
600mA
40V
CT FEEDBACK
220 Primary Amps
1.257 Volts
*
26.7K
D4
1N914
RXD
(TO HC11)
=
D19
D18
R84
47.5K
TP4
150V
45J
Q23
600mA
40V
*
26.7
R215
R213
10K
R198
10K
J21
D5
1N914
5
6
1
R161
R87
2.67K
1
5
7
SWOP
8
7
6
5
1
4.75K
2.21K
VCC
VB
NC
X61
2N4403
Q32
OCI3
CNY17-3
R247
3.32K
4.75K
C91
.022
2
3
ANODE
CATH
NC
*
C115
150p
50V
C117
150p
50V
C125
.0047
400V
1.3K
(SHEET 1, X20)
200
VC
*
2
6
4
10K
C90
330p
100V
150K
10K
D32
4
GND
OCI6
150
PRIMARY OVER CURRENT
SHUTDOWN 214 AMPS
D17
@
D31
J21
D41
5
D20
221K
NORMAL X61-7
FAULT X61-7
@
MINUS RAIL
@
PLUS RAIL
C116
150p
50V
C126
330p
100V
56.2K
A
C107
150p
50V
D40
D
D35
J28
4
4
2
3
OPT-
D43
D
SER_LOOP
2J: PRIMARY CURRENT SENSE
J22
J28
J28
TURN ON/OFF OPT FROM SERIAL LOOP
SL
WIRE FEEDER TRANSMIT/RECEIVE FOR SERIAL LOOP
2A: SERIAL LOOP
2B: SERIAL LOOP PORT SWITCHES
GENERAL INFORMATION
COMPLETE BOARD, THIS DIAGRAM MAY
*
INDICATES CHANGE FROM "XRF" VERSION
LAST NO. USED
NOTES
:
N.A. SINCE COMPONENTS OR CIRCUITRY ON
A
PRINTED CIRCUIT BOARD MAY CHANGE
WITHOUT AFFECTING THE INTERCHANGEABILITY OF
A
R- 345
C- 156
D- 52
DZ- 35
Q- 34
X- 93
ELECTRICAL SYMBOLS PER E1537
NOT SHOW THE EXACT COMPONENTS OR CIRCUITRY OF CONTROLS HAVING
NUMBER.
A
COMMON CODE
CAPACITORS
RESISTORS
DIODES
=
MFD
(
.022/50V
1/4W
UNLESS OTHERWISE SPECIFIED)
UNLESS OTHERWISE SPECIFIED)
LABELS
SUPPLY
=
Ohms
(
=
1A, 400V
(UNLESS OTHERWISE SPECIFIED)
VOLTAGE NET
POWER SUPPLY SOURCE POINT
COMMON CONNECTION
SERIAL LOOP / PROTECTION INTERFACE - SHEET 4
FRAME CONNECTION
EARTH GROUND CONNECTION
FILE: G2241_2A1
EQUIP.
TYPE
Ch’ge.Sht.No.
UNLESS OTHERWISE SPECIFIED TOLERANCE
ON HOLES SIZES PER E-2056
POWER WAVE
THE LINCOLN ELECTRIC CO.
CLEVELAND, OHIO U.S.A.
1-6-95B
ON
ON
2
3
PLACE DECIMALS IS
PLACE DECIMALS IS
+
+
.O2
.OO2
CONTROL SCHEMATIC
SUBJECT
8-11-95C
NONE
SCALE
DATE
ON ALL ANGLES IS
+
.5 OF
A
DEGREE
SHT.
1-30-98B
8-13-99B
MATERIAL TOLERANCE ("t") TO AGREE
WITH PUBLISHED STANDARDS
G 2241-4
JRF
11-25-92
CHK.
SUP’S’D’G.
DR.
NO.
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
POWER WAVE 450
Download from Www.Somanuals.com. All Manuals Search And Download.
G-8
G-8
ELECTRICAL DIAGRAMS
PC BOARD ASSEMBLY-CONTROL
±
.04
11.25
ITEM
PART NO.
S16668-11
DESCRIPTION
.1/50
REQ’D
54
REQ’D
1
R223
R227
R209
ITEM
PART NO.
S24073-2
DESCRIPTION
500,1/2W,TRIMMER
C113
R218
Q30
D35
D37
R248
Q25
11.05
D38
R261
C129
C125
C1,C2,C6,C8,C11,C16,C17
C18,C19,C20,C21,C22,C23
C24,C27,C28,C29,C31,C32
C34,C37,C40,C41,C42,C43
C44,C45,C48,C59,C60,C61
C62,C63,C64,C65,C66,C67
C68,C69,C73,C77,C79,C81
C83,C84,C95,C97,C98,C100
C105,C111,C119,C155,C156
C3,C25,C26
C4,C5,C49,C50,C51,C57,C85
C7,C47,C70,C130
C10,C13,C15
C30,C56,C90,C126,C135
C33,C35,C38,C39
C52,C53,C54,C106,C108,C114
C120,C134,C137,C138,C139
C140
C87,C91,C96,C101,C132,C133
C141,C142,C144,C145,C148
C150,C151,C152,C153
C88
C107,C110,C112,C115,C116
C117,C123,C127,C128,C136
C109,C113,C121,C124
C118,C122,C125,C129
C143,C146
D2,D17,D18,D19,D20,D21,D22
D25,D26,D27,D28,D29,D30
D31,D32,D33,D34,D35,D36
D37,D38,D39,D40,D41,D42
D43,D46
R150
R194
Q17
C109
R196
R245
R244
R153,R160,R162,R163,R164
R165,R166,R225,R260,R305
R306,R307,R309,R312,R313
16
S19400-10R0
10 1/4W
Q26
C111
C124
R243
R242
D33
D39
D36
TP5
Q24
R202
DZ30
D23
C112
R208
Q18
C108
R198
C107
R200
R233
R236
R232
TP4
TP3
C106
R193
C110
R201
D32
R316
C120
R235
R155,R178,R220,R253,R256
6
S19400-1500
150 1/4W
D31
C123
R234
D27
R299
R159
1
8
S19400-1503
S19400-3321
150K 1/4W
3.32K 1/4W
D26
D28
TP2
R237
R195,R197,R207,R211,R212
R241,R289,R290
R200,R201,R208,R234
R204,R240,R247,R249
OCI7
OCI2
OCI3
OCI6
3
7
4
3
5
4
12
S16668-2
S16668-1
S13490-42
S13490-25
S16668-8
S13490-39
S16668-7
47pF/100
22pF/100
1.0/35
4.7/35
330pF/100
18/15
OCI5
R224
4
4
6
S19400-5622
S19400-1301
S19400-2000
56.2K 1/4W
1.3K 1/4W
200 1/4W
D29
D25
R205,R238,R250,R252,R282
R256
OCI4
D42
OCI8
R286
R206,R298
R215
2
1
4
4
3
1
5
2
2
8
S19400-5111
S19400-2671
S19400-2213
S19400-2001
S19400-6192
S19400-2212
S19400-6811
S19400-8250
S19400-3320
S19400-2210
5.11K 1/4W
2.67K 1/4W
221K 1/4W
2.0K 1/4W
61.9K
22.1K 1/4W
6.81K 1/4W
825 1/4W
332 1/4W
221 1/4W
R220
R219
820pF/50
R254
R255
D22
R231
R134
R257
C68
C22
C27
XX C6XXX
XXX
C69
C20
R217,R219,R254,R288
R224,R237,R248,R261
R236,R243,R245
R28
R25
XXXXXXXXXXXX
15
S16668-5
.022/50
C70
R23
R21
R36
R24
R22
R273
R61
R63
R62
R58
R276,R281,R285,R303,R304
X13
1
10
S13490-85
S16668-9
.27/50
150pF/100
R283,R287
R291,R292
X10
X2
X38
DZ6
R37
R43
R54
R328,R329,R330,R331,R332
R333,R334,R335
TP2,TP3,TP4,TP5
R38
R59
R60
R262
R39
R29
R34
4
4
2
27
S16668-4
S13490-3
S16668-6
T12199-1
2700pF/50
.0047/400
4700pF/50
1N4004
R40
XXXXXXXXX
XXXXXXXX
4
1
1
2
1
2
1
2
1
3
1
1
1
1
T13640-11
S17900-1
M15102-3
S17900-13
M15101-6
S19650-7
s21291-5
M15105-4
M15104-6
S17900-25
S19650-1
M14428-2
S21292-5
S15128-4
45J
R56
R53
R57
R35
DZ8
XXXXXRX5X
X1
X2
X3,X5
X10
X11,X12
X13
X14,X37
X15
X16,X20,X55
X21
X24
X25
QUAD 2-INPUT NAND (SS)
UNDERVOLT. SENSING CIR. (SS)
QUAD TWO INPUT AND GATE (SS)
MPU (SS)
IC,CMOS,TRNSCVR,BUS (SS)
ROM ASSEMBLY (SS)
IC,CMOS,CONVERTER,A/D (SS)
MPU (SS)
IC,CMOS,LATCH,3-STATE (SS)
HEX INVERTER (SS)
CRYSTAL,(MODULE),25.0MHZ
IC,CMOS,MCU,DSP (SS)
LM224 OP-AMP
R6
DZ9
R47
C3
DZ16
XXXXXXXXXXXXX
R55
R49
X15
R46
R48
DZ13
DZ15
DZ14
R51
X1
X45
Y2
R343
R45
R44
D4,D5,D10,D11,D12,D13,D14
D15,D16,D24,D47
D23,D50,D51,D52
11
T12705-22
1N914
XXXXXXXX
C45
X3
DZ12
X41
C18
R52
X46
X30
X29
X28
4
2
2
4
T12705-34
T12702-40
T12702-45
T12702-29
T12702-52
1N4936
1N4735
1N4746A
1N4744A
1N4733A
R42
DZ17
DZ10
R50
DZ2,DZ5
DZ3,DZ4
C61
X5
X42
R222
R221
DZ11
R338
DZ6,DZ27,DZ34,DZ35
DZ7,DZ8,DZ9,DZ10,DZ11,DZ12
DZ13,DZ14,DZ15,DZ16,DZ17
DZ18,DZ19,DZ20,DZ21,DZ22
DZ30,DZ31,DZ32,DZ33
J20,J21
R339
R345
R337
DZ31
20
C119
X26
R229
R226
R228
R259
R258
R230
X44
X20
X27,X28,X29,X30,X68,X90
X38
6
1
S19650-5
S21293-3
IC,CMOS,LATCH,3-STATE (SS)
DSP ASSEMBLY (SS)
X21
C128
C127
C48
D24
C66
X39
X41
X42,X43
X44
X45,X46
X54
1
1
2
1
2
1
1
3
2
1
1
1
S21294-1
S17900-24
S19650-3
S19650-6
M15104-11
M15105-11
M14513-4
S15128-18
S17900-22
S15128-10
S15128-21
S16665-5
IC,CMOS,PLD,GENERIC (SS)
QUAD SCHMITT NAND (SS)
1-OF-4 DECO/DEMUX (SS)
IC,CMOS,MUX,4-INPUT (SS)
C,CMOS,EEPROM,FLASH (SS)
CONVERTER,D/A (SS)
IC,CONVERTER,D/A (SS)
QUAD-OP AMP
QUAD ANALOG SWITCH (SS)
VOLTAGE REF.
IC,COMPARATOR,HI-SPD,5-V
8.0 MHZ
C60
C67
2
1
2
1
1
2
5
2
S20351-8
S20351-12
S20351-6
S20351-14
S20351-10
S20351-4
S15000-10
S15000-23
T12704-68
HEADER
HEADER
HEADER
HEADER
RT. ANGLE HEADER
HEADER
OPTO ISOLATOR
6N136 OPTOCOUPLER
2N4401
J22
J23,J26
J24
J25
R332
R333
R334
R335
R331
X43
5.63
D51
R330
R329
R328
X16
X55
R64
I
X24
C53
J27,J28
X56
X39
X11
X12
OCI2,OCI3,OCI4,OCI7,OCI8
OCI5,OCI6
Q2,Q3,Q4,Q5,Q6,Q7,Q8,Q9
Q10,Q13,Q16,Q19,Q20,Q23
Q28,Q33,Q34
Q5
Q4
X61,X71,X92
X63,X64
X91
X93
Y2
X27
C47
17
C130 XXXXXXXRX4X1 XX
X56
C85
Q12
1
6
4
4
T12704-73
T12704-69
T12704-35
T12704-47
S19400-1002
IC PKG MOSFET (SS)
2N4403
NPN TRANSISTOR
.5AMP / 300 VOLT PNP
10K 1/4W
X68
X90
Q14,Q15,Q22,Q27,Q31,Q32
Q17,Q18,Q21,Q25
Q24,Q26,Q29,Q30
CAPACITORS = MFD/VOLTS
INDUCTANCE = HENRIES
RESISTANCE = OHMS
X25
X14
R2,R4,R8,R9,R10,R12,R13
R14,R16,R18,R20,R32,R35
R41,R58,R59,R60,R61,R62
R63,R65,R72,R74,R158,R169
R170,R172,R185,R193,R198
R202,R210,R213,R222,R235
R239,R246,R251,R255,R257
R262,R264,R267,R268,R279
R284,R295,R296,R297,R317
R318,R319
R3,R7,R68,R70,R142,R154
R161,R214,R216,R302,R310
R314,R336,R337,R338,R339
R341,R342,R343,R344,R345
R5,R37,R87,R293,R294
R6
R11,R99,R141,R148,R175
R209,R223,R263,R266,R277
R15,R36,R38,R39,R40,R64
R67,R69,R71,R73,R89,R90
R91,R92,R93,R94,R97,R108
R110,R118,R120,R127,R135
R152,R156,R168,R171,R173
R179,R180,R183,R186,R187
R188,R189,R191,R192,R199
R203,R221,R228,R231,R258
R275,R280,R300,R301,R308
R311,R315
52
Q6
Q7
XXXXXXXXXXXX
X54
X
XXXXXXXX
X37
R264
R266
R319
R318
XXXXXXXXXXXX
C41
R268
R317
X93
X91
R32
R96
R97
X26
D47
21
S19400-4751
4.75K
R277
R279
R280
C57
5
1
10
S19400-2211
T14231-2
S19400-1003
2.21K 1/4W
10M 1/2W
100K 1/4W
C95
R316
X61
R315
R161
R163
R164
R160
R165
R162
C88
50
S19400-1001
1K 1/4W
C145
C90
R166
R155
R154
R66
Q12
R84
R159
D4
R150
R87
R146
R298
R128
C100
X71
R149
DZ18
R191
DZ19
R135
X63
R91
R89
C142
R186
C143
R297
R290
R295
R293
C141
R289
R188
C97
DZ22
R187
DZ21
DZ20
R189
R17,R19,R109
R21,R23,R24,R182,R227,R232
R242,R244
3
8
S19400-1502
S19400-26R7
15K 1/4W
26.7 1/4W
Q15
X92
R301
R182
X64
R93
R92
R90
Q8
R303
R22,R29,R274
3
4
28
S19400-2670
S19400-1000
S19400-4750
267 1/4W
100 1/4W
475 1/4W
.20
R25,R28,R270,R271
R26,R27,R30,R31,R34,R42
R43,R44,R45,R46,R47,R48
R49,R50,R51,R52,R53,R54
R55,R56,R57,R122,R128,R146
R147,R167,R177,R184
R33,R86,R229,R230
R66,R84
0
±
.04
8.00
4
2
2
7
S19400-2672
S19400-4752
S19400-1501
S19400-6810
26.7K 1/4W
47.5K 1/4W
1.5K 1/4W
681 1/4W
0
R96,R98
R119,R126,R134,R138,R226
R259,R327
R121,R129,R130,R174,R181
R278
R149,R194,R196,R218,R233
6
5
S19400-3322
S19400-7500
33.2K 1/4W
750 1/4W
.20
4.00
7.80
11-12-99C
G2861-2
NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your factory warranty. Individual Printed Circuit Board Components are not available from Lincoln Electric. This information is pro-
vided for reference only. Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician. Improper PC board repairs could result in damage to the
machine.
POWER WAVE 450
Download from Www.Somanuals.com. All Manuals Search And Download.
G-9
G-9
ELECTRICAL DIAGRAMS
SCHEMATIC - DISPLAY PC BOARD (SHEET 1)
- 1 9 3 2 2
G
+5V
+15V
J16
J16
9
448
449
1
+5V
8
X5
X5
10
44
3
11
13
3
10
12
4
C27
0.1
C22
0.1
C29
0.1
Vdd
3
1C.023
35V
26
Vcc
20
20
20
14
14
12
16
16
Vdd
Vdd
X11
X11
X11
X11
4
4
12
13
50V
50V
50V
C48
0.1
C57
0.1
C20
05.01 V
C12
05.01 V
DZ4
5.1V
1W
X8
PSD301
X14
X10
C50
05.01 V
C49
C56
C52
C55
C54
C25
05.01 V
C30
05.01 V
DZ5
5.1V
1W
X7
X13
11
C39
C40
X3
X9
X16
X12
X4
X11
74HC04
X5
X1
X2
7
W1
50V
50V
0.1
0.1
0.1
0.1
0.1
54HC08
MC14489
0.1
0.1
MC14489
MC68HC11
74HC4040
8
74HC573
74HC573
10
74HC573
10
74HC151
8
MC6850CS
1
C26
0.1
50V
50V
50V
50V
50V
LM224
11
LM224
11
50V
50V
C28
1.0
GND
GND
Vss
14
GA
Vss
1
12
34
Vss
14
GD
10
7
7
50V
GD
35V
J16
J16
-5V
446
447
9
-5V
12
13
GA
5
6
14
GD
X1
+15V
10
C21
C19
1.0
GD
LED15
LED19
LED18
LED13
0.1
50V
35V
-5V
J16
16
7
1
4
Q2
Q12
Q11
Q10
Q1
Vcc
Q3
Q4
Q5
Q6
Q7
Q8
Q9
D0
D1
443
2
+5RS232
FULL DUPLEX RS232 COMMUNICATION LINK
74HC151
X14
6
3
C38
0.1
C37
1.0
15
5
2
5
6
X12
D2
D3
Y
LED34
LED30
LED32
LED33
PIEZO BUZZER CIRCUITRY
50V
35V
14
9
3
1
+5RS232
750
J16
J16
+5V
2
15
14
13
12
D4
D5
D6
D7
442
444
3
6
+15V
10
4
/C
/Y
GRS232
-8V
5
16
J17
1
X15
11
8
13
12
LED14
LED16
LED17
LED12
R
J15
1
GND
C18
18
+
_
6.81K
74HC4040
D21
PIEZO
10K
Rx
11
10
9
A0
15V
+10RS232
BAUD0
BAUD1
BAUD2
C41
0.1
BUZZER
C44
1.0
J15
A1
GD
20
18
1
6
5
2
Q15
50V
35V
A2
C1+
C1-
Vdd
2
4
17
19
4
600mA
OCI7
H11L2
STROBE
+5V
7
40V
GND
C17
18
C16
Q3
J15
PIEZO
R115
X15
18
40V
3
LED29
LED31
LED28
LED27
2
J15
4
Vss
600mA
15V
15V
GD
3.32K
Vcc
C2-
+5RS232
C2+
(POWER DOWN)
XIRQ
475
R33
475
R34
C70
10K
J16
J16
C14
1
3
445
22.1K
8
330p
50V
GD
GRS232
C15
18
LED11
LED4
LED10
LED7
15V
C24
DZ2
5.1V
1W
-10RS232
BI-DL[0:15]
GD
0.1
11
50V
4.75K
RECEIVE
GRS232
J17
J17
J17
X16
3
5
1
7
IRQ
VSS
/IRQ
J17
J17
3
13
R/W
2
4
+5RS232
RxCLK
TxCLK
/DCD
/RTS
TxData
RxData
/CTS
E
R/W
D0
11
10
X15
4
22
21
20
19
18
17
16
15
8
BI-DL[0]
BI-DL[1]
BI-DL[2]
BI-DL[3]
BI-DL[4]
BI-DL[5]
BI-DL[6]
BI-DL[7]
BI-DL[15]
LED24
LED22
LED21
LED25
6
23
5
D1
/DCD
J17
10
GRS232
D2
-5V
LED8
LED5
6
D3
GRS232
Tx
Rx
2
D4
ISOLATED POWER
&
SIGNALS
24
D5
2.67K
R3
+5RS232
750
TEMPERATURE
COMPENSATION
14
10
1.00K
D6
Tx
+5V
CS1
D7
+5V
+5RS232
LED6
LED2
LED3
LED9
301
R13
11
RS
CS0
/CS2
J17
9
9
12
12
X15
9
6
5
VCC
/CS_RS232
R71
D2
X1
R49
MC6850CS
J17
8
7
4.75K
267
LED23
LED26
LED20
4.75K
6.81K
4.75K
BI-DL[11]
BI-DL[14]
22.1K
10K
GD
Q6
1
6
5
1
6
5
J19
2
600mA
40V
E
+5V
4
13
8
J17
7
X1
1
R70
1.00K
5
OCI5
4
Vo
OCI8
H11L2
X15
/DCD
P1
H11L2
Q5
3
C45
330p
50V
+5V
C46
330p
50V
40V
CW
DZ7
8.2V
1W
10K
2
2
600mA
R7
100K
R5
133K
R72
GD
10K
10K
GD
4.75K
GD
4
5
6
7
17
16
3
4
17
16
3
RESET
d
d
BANK5
BANK5
BANK4
Vdd
1.00K
X10
X13
TRANSMIT
GRS232
5
9
c
b
a
BANK4
Vdd
c
LCD
DISPLAY
Vdd
X17
X1
-5V
6
8
b
C60
0.1
DATA CARRIER DETECT
RES
GRS232
L1
15
13
9
7
15
13
10
BANK3
BANK2
BANK1
h
a
BANK3
S-8054HN
50V
12
10
GD
GD
DATA IN
/ENABLE
h
BANK2
-8V
2
6
-LEDB
C59
0.1
MOSI
OC5
OC5
Vss
.39mH
J19
J19
P1
10
19
9
2
1
/ENABLE
BANK1
50V
14
14
19
20
18
11
Vss
f
Vss
e
f
RS_LCD
R68
100
R61
100
RS
P1
1
20
12
g
g
GD
DZ6
2
18
8
e
DATA OUT
CLOCK
MC14489
DATA IN
CLOCK
DATA OUT
Rx
MC14489
RST
5.1V
1W
8
11
Rx
R62
7
1
R/W
SCK
J19
J19
P1
P1
1.50K
1.50K
GD
MAIN PROCESSOR
4.75K
GD
L2
1
BI-DL[0]
9
Vss
A0/D0
A1/D1
A2/D2
A3/D3
A4/D4
A5/D5
A6/D6
A7/D7
A8
150
150
150
150
150
150
150
LED
DRIVE
+LEDB
BI-DL[1]
R50
R59
R60
R63
R64
R65
R67
10K
10K
10K
25
2
10
11
/SS
R30
R40
R39
.39mH
BI-DL[2]
BI-DL[3]
BI-DL[4]
MODB
MODA
/XIRQ
XTAL
EXTAL
VRH
SCK
MOSI
MISO
TxD
GD
+5V
3
12
13
14
15
16
42
41
40
19
39
38
37
36
35
5
18
8
XIRQ
BI-DL[5]
X7
10M
7
BI-DL[6]
BI-DL[7]
1/2W
+5V
BI-DL[0:15]
1K
52
24
23
22
21
20
27
28
29
30
43
45
47
49
44
46
48
+5V
R240
R38
BI-DL[8]
BI-DL[9]
BI-DL[10]
44
SCK
MOSI
R31
GD
23
24
25
26
27
28
29
30
31
BI-DL[0]
BI-DL[1]
BI-DL[2]
BI-DL[3]
BI-DL[4]
BI-DL[5]
BI-DL[6]
BI-DL[7]
BI-DL[8]
BI-DL[9]
BI-DL[10]
2
19
A0/D0
A1/D1
A2/D2
A3/D3
A4/D4
A5/D5
A6/D6
A7/D7
A8
Vcc
PA0
PA1
J18
BI-DL[0]
P1
19
18
17
16
15
14
13
12
2
BI-DL[0]
BI-DL[1]
BI-DL[2]
BI-DL[3]
BI-DL[4]
BI-DL[5]
D0
Q0
4
VDD
D0
D1
C36
INFRA1
INFRA2
INFRA3
INFRA4
INFRA5
INFRA6
INFRA7
INFRA8
Q0
Q1
1
R9
R8
R10
R4
A9
D1 74HC573
74HC573
X9
J19
J19
J19
J19
J19
J19
J19
J19
J19
J19
P1
P1
P1
P1
P1
P1
P1
P1
P1
P1
21
20
19
18
17
16
15
14
J18
J18
J18
75.0
75.0
75.0
75.0
3
4
5
6
7
8
9
18
0.1
BI-DL[1]
BI-DL[2]
BI-DL[3]
BI-DL[4]
BI-DL[5]
BI-DL[6]
BI-DL[7]
3
4
5
6
7
8
9
Q1
4.9152MHz
Y1
P1
P1
P1
9
D0
D1
10K
3
5
A10
50V
17
D2
D3
D4
D5
D6
D7
X3
Q2
10
11
12
13
14
15
16
8
Q2
Q3
Q4
D2
D3
D4
D5
D6
D7
IRQ
/IRQ
A11
TRN
REC
16
PA2
PA3
PA4
PA5
PA6
PA7
PB0
GND
PB1
GD
Q3
C33
22p
100V
D2
D3
D4
D5
D6
BI-DL[11]
BI-DL[12]
BI-DL[13]
7
RxD
C32
22p
100V
15
Q4
TRIM1
TRIM2
TRIM3
TRIM4
PAI
A12
RS_LCD
BAUD0
BAUD1
BAUD2
TRIG1
14
Q5
X8
Q5
Q6
OC2
OC3
OC4
A/D1
A/D2
A/D3
A/D4
A/D5
A/D6
A/D7
OC5
Vdd
A13
13
BI-DL[6]
BI-DL[7]
Q6
BI-DL[14]
BI-DL[15]
A14
12
Q7
GD
Q7
A15
E
D7
E
E
CRYSTAL
32
11
A9
/E_LCD
R36
LE
11
1
R/W
AS
11
1
LE
6
GD
R/W
AS
34
LE_INFRA
GD
LE_KEY
TRIG2
33
12
A10
100
OE
OE
4
SPTIG
10
9
GND
A11
100
DZ3
5.1V
1W
PIEZO
RST
17
50
32
33
34
51
/RES
A/D8
IC1
SPWF2
SPWF1
35
36
37
38
39
22
2
BI-DL[11]
BI-DL[12]
BI-DL[13]
BI-DL[14]
BI-DL[15]
E
PB2
PB3
PB4
PB5
PB7
PC0
/CSI
PB6
PC1
PC2
/OE_KEY
WATER
/PB4
GD
SENSE
8
3
VSS
A12
J19
P1
THERMAL
7
A13
GD
GD
C34
0.1
C31
C35
0.1
IC2
PRESSURE
FLAG
6
A14
0.1
FAN
/E_LCD
31
1
2
1
IC3
OC5
(2)
A
B
G
H
K
N
Q
R
S
/PB4
X11
50V
50V
50V
4
A15
3
6
/PB7
+5V
26
X5
X5
LE_KEY
VRL
2
40
43
5
MC68HC11
E
/CS_RS232
E
R/W
R/W
AS
4
5
GD
+5V
13
3
10.0K
AS
RST
R28
R29
R32
LE_INFRA
+5V
9
8
41
42
10.0K
10.0K
/PB7
X11
/RES
/BHE
1
+5V
PSD301
6.81K
267
C
D
I
L
GD
R27
J18
J18
2
3
4
5
6
7
8
9
19
18
17
16
15
14
13
12
P1
P1
BI-DL[0]
D0
D1
Q0
Q1
1.00K
LAST NO. USED
J
O
T
2
R22
R21
R20
R18
R23
R19
74HC573
X4
GENERAL INFORMATION
ELECTRICAL SYMBOLS PER E1537
75.0
C1
BI-DL[1]
BI-DL[2]
BI-DL[3]
BI-DL[4]
BI-DL[5]
BI-DL[6]
BI-DL[7]
D- 24
X- 17
R- 240
C- 101
DZ- 28
TP-
OCI- 18
4
0.1
J18
J18
75.0
75.0
75.0
75.0
75.0
1
P1
P1
D2
D3
Q2
Q3
Q4
Q5
Q6
Q7
50V
6
8
CAPACITORS
RESISTORS
DIODES
=
MFD
(
(
.022/50V
UNLESS OTHERWISE SPECIFIED)
LED- 34 Q- 29
LABELS
SUPPLY VOLTAGE NET
=
Ohms
1A, 400V
1/4W UNLESS OTHERWISE SPECIFIED)
(UNLESS OTHERWISE SPECIFIED)
E
F
M
P
U
V
J18
J18
P1
P1
D4
D5
D6
D7
=
9
GD
R99-R106 ARE NOT ASSIGNED
10
POWER SUPPLY SOURCE POINT
COMMON CONNECTION
FILE NAME: G2239_1DA
FRAME CONNECTION
+5V
11
EARTH GROUND CONNECTION
SHEET
1
OF
2
GD
LE
OE
1
EQUIP.
TYPE
Ch’ge.Sht.No.
/OE_KEY
NOTES
:
THE LINCOLN ELECTRIC CO.
CLEVELAND, OHIO U.S.A.
INVERTEC V400
DISPLAY/KEYPAD PCB SCHEMATIC
KEYPAD INTERFACE
GD
1-6-95B
12-8-95E
N.A. SINCE COMPONENTS OR CIRCUITRY ON
A
PRINTED CIRCUIT BOARD MAY CHANGE
SUBJECT
WITHOUT AFFECTING THE INTERCHANGEABILITY OF COMPLETE BOARD, THIS DIAGRAM MAY
A
NONE
1-26-94
SCALE
DATE
NOT SHOW THE EXACT COMPONENTS OR CIRCUITRY OF CONTROLS HAVING
NUMBER.
A
COMMON CODE
SHT.
G
DB
CHK.
SUP’S’D’G.
2239-1
DR.
NO.
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
POWER WAVE 450
Download from Www.Somanuals.com. All Manuals Search And Download.
G-10
G-10
ELECTRICAL DIAGRAMS
SCHEMATIC - DISPLAY PC BOARD (SHEET 2)
2 - 9 3 2 2
G
+15V
100
100
+5V
+5V
+5V
+5V
+5V
J11
R195
2
4
+15V
C97
200
DZ24
0.1
15V
1W
THERMAL FAN
J11
150
150
50V
150
150
150
10K
1.00K
R203
R197
100
GA
J11
THERMAL
5
6
3
4
1
3
4
1
3
4
1
3
4
1
3
4
1
C99
0.1
DZ26
10K
GD
75.0
OCI10
OCI12
5.1V
OCI17
OCI18
OCI11
50V
OPTEK OPB706
OPTEK OPB706
1W
OPTEK OPB706
OPTEK OPB706
OPTEK OPB706
681
J11
R204
2
2
2
2
2
SENSE
INFRA7
SENSE
Q29
FAN
SENSE
SENSE
SENSE
DZ25
15V
600mA
40V
10.0
R198
681
Q24
Q13
Q22
Q23
Q9
1W
600mA
40V
600mA
40V
600mA
40V
600mA
40V
600mA
40V
INFRA6
R177
6.81K
R179
6.81K
INFRA4
R176
6.81K
INFRA5
R182
6.81K
INFRA8
R103
6.81K
C98
330p
100V
GA
75.0
GD
GA
22.1K
22.1K
22.1K
22.1K
C90
C91
22.1K
C88
C89
C68
GD
GD
GD
GD
GD
+15V
NOTE:
8
MULTIPLEXED SIGNALS (UNDER SOFTWARE CONTROL) ARE SAMPLED AT THIS NODE
SENSE
(9)
+15V
4
5
+5V
+5V
+5V
J16
J16
47.5K
1.50K
133K
33.2K
33.2K
10.0K
R46
+
1.50K
J11
1
TRIM4
1.00K
t
56
TRIM1
TRIM3
C95
0.1
J11
TRIM2
PRESSURE
7
8
33.2K
R208
150
150
150
WATER COOLER
J11
C100
DZ27
5.1V
50V
0.1
10K
3.32K
6.81K
50V
681
1W
3
6.81K
22.1K
J11
3
4
1
12
6.81K
22.1K
6.81K
22.1K
6.81K
22.1K
R210
3
4
1
3
4
1
J16
OCI16
OCI14
OCI15
Q17
Q20
Q18
Q19
OPTEK OPB706
GD
OPTEK OPB706
OPTEK OPB706
10.0
2N4401
2N4401
2N4401
2N4401
2
2
2
Q28
DZ23
15V
SENSE
600mA
40V
SENSE
SENSE
WATER
GA
R190
475
C77
C75
C78
C79
1W
Q27
Q26
Q25
600mA
40V
600mA
40V
600mA
40V
INFRA3
R185
6.81K
INFRA1
R121
INFRA2
R183
6.81K
6.81K
C96
GA
75.0
GD
330p
100V
22.1K
22.1K
22.1K
C92
GD
C94
C93
+15V
10K
GD
+15V
GD
GD
1.00K
R213
J14
J10
FLAG
15
6
C101
DZ28
0.1
5.1V
26.7
50V
50V
C69
1W
100K
2700p
GD
100K
R107
750
J10
Q12
16
+15V
600mA
40V
REFERENCE CIRCUIT
475
Q10
+5V
500mA
300V
Q11
500mA
300V
4.75K
R160
1
8
7
6
5
NC
VCC
VB
3
Q21
2
1
+10V
TRN
R155
X2
2
3
2N4401
ANODE
CATH
NC
1
2N4403
Q14
J10
J10
J10
J10
R111
1.3K
14
3
VC
2
C62
820p
50V
4
200
GND
10K
10.0
1.00K
OCI13
10K
4
L3
+5V
+5V
R145
681
R227
1.00K
R228
D20
10
R129
33.2K
.39mH
DZ8
+
C76
0.1
t
56
R83
J13
2
R74
475
50V
221
DZ15
100K
4.75K
1N4936
D10
+
t
+10V
56
1.00K
D4
D23
15V
1W
100K
47.5K
DZ11
5.1V
1W
3.3V
1W
C72
2K
D22
10.0
3.32K
R229
3.32K
R230
3.32K
R231
3.32K
R232
3.32K
R234
DZ10
GD
150p
50V
C65
20V
5W
0.1
J14
TRIG2
50V
5
100K
1
5
10K
D6
D7
OCI2
CNY17-3
J14
4
C61
20
D3
GA
50V
DZ9
20V
5W
2
6
4
100K
TP1
150V
45J
+15V
J10
12
+5V
J10
10
9
J13
6
R148
100K
C74
475
R149
475
R143
4
8
.0047
400V
X2
SPTIG
Q7
D5
C81
0.1
600mA
40V
DZ17
100K
GA
J13
J13
10V
1W
C80
C82
0.1
5.11K
DZ16
5.1V
1W
1
+10V
3.32K
50V
0.1
24VAC ISOLATED TRIGGER CIRCUIT
R147
1.00K
50V
50V
REC
10K
3
100K
GD
D12
D11
Q16
6
-
PIN
600mA
40V
R117
R116
10K
REMOTE
GD
2.67K
8
7
6
5
1
VCC
VB
NC
100K
3.32K
4.75K
2
3
ANODE
CATH
NC
C71
C73
J10
J10
150p
50V
150p
50V
VC
11
8
+5V
4
GND
OCI3
12
R165
100K
+5V
D8
150
681
R214
1.00K
R215
14
X2
R163
475
R173
475
SPWF2
DZ14
13
DZ20
10V
C85
221K
R94
J12
0.1
100K
D14
+10V
4.75K
DZ19
2
R93
475
C83
C67
0.1
C64
150p
50V
C63
1W
50V
221
5.1V
1W
0.1
+
330p
100V
t
56
R169
D19
D17
D24
50V
50V
3.3V
1W
1.00K
3.32K
R216
3.32K
R217
3.32K
R218
3.32K
R219
3.32K
R220
D9
DZ13
20V
5W
TRIG1
J14
J14
100K
100K
1
14
-
PIN
1
5
4
D13
GA
REMOTE
GD
10K
OCI4
2
C66
D15
CNY17
J14
20
3
50V
WIRE FEEDER COMM.
DZ12
20V
5W
2
6
GD
D18
D16
J10
J10
2
5
5
R166
100K
J12
7
4
X2
6
R162
475
R171
475
SPWF1
Q8
C86
DZ18
600mA
40V
0.1
10V
1W
DZ21
GENERAL INFORMATION
ELECTRICAL SYMBOLS PER E1537
C84
C87
0.1
50V
LAST NO. USED
100K
J12
J12
R164
1.00K
5.1V
1W
24VAC ISOLATED TRIGGER CIRCUIT
0.1
10K
1
R-
C-
D-
_
_
_
D-
C-
D-
_
_
_
R-
C-
D-
_
_
_
50V
50V
CAPACITORS
RESISTORS
DIODES
=
MFD
Ohms
1A, 400V
(
.022/50V
UNLESS OTHERWISE SPECIFIED)
1/4W UNLESS OTHERWISE SPECIFIED)
(UNLESS OTHERWISE SPECIFIED)
3
LABELS
=
(
GA
14
-
PIN
REMOTE
J10
J10
J10
J10
=
1
NOTES
:
SUPPLY VOLTAGE NET
L4
.39mH
GD
POWER SUPPLY SOURCE POINT
COMMON CONNECTION
N.A. SINCE COMPONENTS OR CIRCUITRY ON
A
PRINTED CIRCUIT BOARD MAY CHANGE
7
GD
WITHOUT AFFECTING THE INTERCHANGEABILITY OF COMPLETE BOARD, THIS DIAGRAM MAY
A
NOT SHOW THE EXACT COMPONENTS OR CIRCUITRY OF CONTROLS HAVING
NUMBER.
A
COMMON CODE
9
FILE NAME: G2239_1DA
SHEET
R170
FRAME CONNECTION
13
EARTH GROUND CONNECTION
2
OF
2
+
t
56
EQUIP.
TYPE
Ch’ge.Sht.No.
INVERTEC V400
DISPLAY/KEYPAD PCB SCHEMATIC
THE LINCOLN ELECTRIC CO.
CLEVELAND, OHIO U.S.A.
1-6-95B
12-8-95E
SUBJECT
NONE
1-17-94
SCALE
DATE
SHT.
G2239-2
DB
CHK.
SUP’S’D’G.
DR.
NO.
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
POWER WAVE 450
Download from Www.Somanuals.com. All Manuals Search And Download.
G-11
G-11
ELECTRICAL DIAGRAMS
PC BOARD ASSEMBLY-DISPLAY
G
2 8 6 2 - 1
REQ’D
16
ITEM
PART NO.
S16668-11
DESCRIPTION
.1/50
ITEM
PART NO.
S19400-1500
DESCRIPTION
REQ’D
45
R50,R59,R60,R63,R64,R65
R67,R88,R104,R105,R110
R150,R151,R152,R153,R154
R51,R102,R114,R122,R126
R134,R135,R140,R174
R175,R178,R180,R181
R184,R191,R199
R73
R79,R95
R80,R90,R97
R85,R115,R120,R123,R127,R216
R217,R218,R219,R220,R229
R230,R231,R232,R234
R89
150 1/4W
C1,C12,C20,C21,C22,C24,C25
C26,C27,C29,C30,C31,C34
C35,C36,C38,C39,C40,C41
C48,C49,C50,C52,C54,C55
C56,C57,C59,C60,C65,C67
C76,C80,C81,C82,C83,C84
C85,C86,C87,C95,C97,C99
C100,C101
C2,C3,C4,C5,C6,C7,C8,C9
C10,C11,C68,C70,C75,C77
C78,C79,C88,C89,C90,C91
C92,C93,C94
16
S19400-2212
22.1K 1/4W
.04
12.00
1
2
3
15
T10812-41
10K 1/2W TRIMMER
221 1/4W
221K 1/4W
S19400-2210
S19400-2213
S19400-3321
23
S16668-5
.022/50
11.75
3.32K 1/4W
C14,C45,C46,C63,C96,C98
C15,C16,C17,C18
C100,C101
6
4
S16668-8
S13490-39
330pF/100
18/15
1
1
1
2
1
S19400-2001
S19400-26R7
S19400-1301
S19400-2000
S19400-5111
2.0K 1/4W
26.7 1/4W
1.3K 1/4W
200 1/4W
5.11K 1/4W
R109
R111
R112,R196
R118
C32,C33
C61,C66
C62
2
2
1
4
1
1
S16668-1
S13490-73
S16668-7
S16668-9
S16668-4
S13490-3
22pF/100
20/50
820pF/50
150pF/100
2700pF/50
.0047/400
C64,C71,C72,C73
C69
R128,R130,R202,R209
R129,R137,R139,R158
4
4
S19400-10R0
S19400-3322
10 1/4W
33.2K 1/4W
C74
D2,D3,D4,D5,D6,D7,D8,D9
D11,D12,D13,D14,D15,D16
D17,D18,D19,D20,D21,D22
D23,D24
22
T12199-1
1N4004
R156,R167
R198,R204,R210,R214,R227
2
5
S19400-4752
S19400-6810
47.5K 1/4W
681 1/4W
D10
1
T12705-34
T12702-52
1N4936
1N4733
TP1
W1
1
1
T13640-11
CJ000001
45J
DZ2,DZ3,DZ4,DZ5,DZ6,DZ11
DZ16,DZ19,DZ21,DZ26,DZ27
DZ28
12
E2387-#20-2.00 (JUMPER)
DZ7
DZ8,DZ14
DZ9,DZ10,DZ12,DZ13
DZ15,DZ23,DZ24,DZ25
DZ17,DZ18,DZ20
1
2
4
4
3
T12702-55
T12702-53
T12702-25
T12702-29
T12702-27
1N4738A
1N4728A
1N5357B
1N4744A
1N4740
X1,X2
X3,X4,X9
X5
X7
2
3
1
1
1
2
1
1
1
1
1
1
S15128-4
S17900-25
S17900-13
S23996
S21290-4
S20496-1
S17900-2
S17900-6
S17900-26
S20353-1
S20603-1
M15102-3
LM224 OP-AMP
IC,CMOS,LATCH,3-STATE (SS)
QUAD TWO INPUT AND GATE (SS)
HC11 MICROPROCESSOR(SS)
ROM ASSEMBLY(SS)
LED DRIVER (SS)
HEX INVERTER (SS)
12 STAGE BINARY COUNTER (SS)
SELECT/MULTIPLX(SS)
IC,CMOS,DRVR/RCVR,EIA232
IC,CMOS,ACIA,2.0MHZ,68B50P
RESET I.C. UNDERVOLT. SENSING CIR. (SS)
8.27
X8
X10,X13
X11
X12
X14
X15
X16
X17
J10
J11
J12,J13,J15
J14
J16
J17
J18
J19
1
1
3
1
1
1
1
1
S18248-16
S18248-8
S18248-4
S18248-6
S18248-12
S18248-10
S19365-10
S18899-16
HEADER
CONNECTOR
HEADER
HEADER
HEADER
HEADER
RT. ANGLE HEADER
ST. HEADER
Y1
1
S16665-6
CRYSTAL,QUARTZ,4.9152MHZ
L1,L2,L3,L4
4
T12218-9
T13657-3
.39mH
LED2,LED3,LED4,LED5,LED6
LED7,LED8,LED9,LED10,LED11
LED12,LED13,LED14,LED15
LED16,LED17,LED18,LED19
LED20,LED21,LED22,LED23
LED25,LED26,LED27,LED28
LED29,LED30,LED31,LED32
LED33,LED34
32
GREEN LED
XXXXXXXX
XXXXX
CAPACITORS = MFD/VOLTS
INDUCTANCE = HENRIES
RESISTANCE = OHMS
6.00
LED24
1
T13657-4
YELLOW LED
XXXXXXXX
XX
XX
OCI2,OCI4
OCI3,OCI13
OCI5,OCI7,OCI8
OCI10,OCI11,OCI12,OCI14
OCI15,OCI16,OCI17,OCI18
2
2
3
8
S15000-10
S15000-23
S15000-19
S15000-24
OPTO ISOLATOR
XXXXXXXXX
6N136 OPTOCOUPLER
IC,OPTOISOLATER
OPTOSENSOR,REFLECTIVE
4.73
Q3,Q5,Q6,Q7,Q8,Q9,Q12,Q13
23
T12704-68
2N4401
Q15,Q16,Q17,Q18,Q19,Q20
Q21,Q22,Q23,Q24,Q25,Q26
Q27,Q28,Q29
XX
XXXXXXX
XX
Q10
Q11
Q14
1
1
1
T12704-47
T12704-35
T12704-69
.5AMP/300V PNP
NPN TRANSISTOR
2N4403
R2,R6,R11,R12,R14,R16,R24
R27,R66,R70,R101,R124,R131
R132,R147,R164,R169,R203
R208,R213,R215,R228,R240
R3,R117
23
S19400-1001
1K 1/4W
2
13
S19400-2671
S19400-75R0
2.67K 1/4W
75 1/4W
R4,R8,R9,R10,R18,R19,R20
R197
R5,R161
2
17
S19400-1333
S19400-1003
133K 1/4W
100K 1/4W
R7,R44,R45,R87,R106,R108
R125,R146,R148,R165,R166
R168,R172,R225,R226,R238
R239
R13
1
4
16
S19400-3010
S19400-1501
S19400-6811
301 1/4W
1.5K 1/4W
6.81K 1/4W
1.23
R17,R35,R159,R207
R25,R42,R53,R103,R121,R133
R136,R138,R141,R142,R176
R177,R179,R182,R183,R185
R26,R57
R28,R29,R30,R31,R32,R39
R40,R41,R47,R52,R55,R58,R77
R78,R86,R98,R99,R113,R116
R157,R201,R205,R211,R212
.95
2
24
S19400-2670
S19400-1002
267 1/4W
10K 1/4W
.25
0
R33,R34,R74,R93,R143,R149
R155,R162,R163,R171,R173
R190
R36,R37,R61,R68,R194,R195
R197
R38
R43,R54,R107
R46,R83,R94,R145,R170
R48,R49,R56,R62,R71,R72
R81,R84,R100,R119,R160
12
7
S19400-4750
S19400-1000
475 1/4W
100 1/4W
0
1
3
5
11
T14231-2
S19400-7500
S18380-1
10M 1/2W
750 1/4W
PTC THERMISTOR
4.75K
.04
S19400-4751
.25
9.00
4.50
9-27-96K
EQUIP.
INVERTER WELDERS
DISPLAY/KEYPAD P.C. BOARD ASSEMBLY
THE LINCOLN ELECTRIC CO.
TYPE
1-6-95B
2-10-95F
8-11-95C
3-21-97D
CLEVELAND, OHIO U.S.A.
SUBJECT
1-7-2000E
SCALE
FULL
9-22-94
SHT.
12-8-95E
1-26-96
G2407-1
MP
DRS
REF.
2862-1
DR
DATE
CHK
SUP’S’D’G
NO.
G
NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your factory warranty. Individual Printed Circuit Board Components are not available from Lincoln Electric. This information is pro-
vided for reference only. Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician. Improper PC board repairs could result in damage to the
machine.
POWER WAVE 450
Download from Www.Somanuals.com. All Manuals Search And Download.
G-12
G-12
ELECTRICAL DIAGRAMS
SCHEMATIC - POWER PRINTED CIRCUIT BOARD
G
0 4 2 2
INVERTER POWER SUPPLIES
PRIMARY SWITCHING CIRCUIT
GND
d
VOLTAGE
USE
TRANS
T1
BRD
FET
N.B.
N.C.
J43
18Vd
+5Va
+15Va
-15Va
+5Vb
+15Vb
-5Vb
FET DRIVER
2
3
1
D1
D2
8A
400V
WELD
WELD
WELD
&
&
&
CURRENT CONTROL
CURRENT CONTROL
CURRENT CONTROL
1K
5W
1K
5W
1K
5W
N.B.
8A
VOLTAGE
a
T2
CTRL
400V
FEEDBACK
J43
J43
Vcc(+15)
C1
C2
D5
D6
L3
3900
3900
80V
C42
1N4936
1N4936
DISPLAY KEYPAD
DISPLAY KEYPAD
DISPLAY KEYPAD
DISPLAY KEYPAD
RS 232
80V
TP1
42VAC
1mH
Q13
.0047
320V
160J
1A
3000V
D7
D8
b
T3
T4
D/K
D/K
100V
1N4936
1N4936
C3
4.7
Vcc(+15)
DZ2
15V
1W
-8Vb
D3
8A
400V
D4
8A
400V
C40
.0047
3000V
J43
C41
35V
TP2
TP3
26.7
320V
160J
320V
160J
c
e
+5Vc
40mAe
1
.0047
+5Vref
3000V
N.C.
CURRENT SOURCE
4
Q1
C7
0.1
20t
20t
R12
100
600mA
40V
200
200
200
200
D
S
D10
1N4007
C6
D9
1N4007
2
50V
Q5
1
1
1
0.1
18A
G
50V
R17
26.7
200V
Vcc(+15)
3
267
Vcc(+15)
C4
20t
20t
20t
20t
20t
20t
4.7
3
4
40V
C9
3
3
3
35V
R13
100
600mA
Q2
475
100
10K
.001
400V
SWITCH_GND
4.75K
DZ3
15V
1W
14
4
13
12
Vref
Ot
C
4t
8
C1
C2
E1
DT CON
1+IN
5
5
5
5
C15
0.1
C13
0.1
C14
11
X2
1
3
2
T1
PRI.
T3
PRI.
T4
PRI.
X1
TL494
T2
PRI.
1.0
50V
9
50V
35V
COMP IN
1-IN
LM2901
100
18.2K
Vcc(+15)
12
22.1K
Vcc
E2
Rt
C5
12
15
10
6
7
4.7
2-IN
X1
D58
1N4936
35V
7
TL494
GND
2+IN
Q6
Q3
18A
5
16
200
200
200
200
D46
Ct
R14
100
600mA
40V
200V
D
S
2.21K
1.00K
1.00K
G
1.00K
C8
.0047
50V
R18
26.7
500
CW
40V
C10
R15
100
600mA
Q4
DZ4
1W
C16
0.1
.001
400V
Vcc(+15)
15V
50V
10K
PWR DN
Vcc(+15)
D47
100
12.1K
12.1K
D30
DISPLAY KEYPAD
OVERCURRENT
PROTECTION
1.00M
1.00K
R177
D28
L9
+5Vb
1N4936
10K
10K
X7
IN
+15Vb
1N4936
D27
OUT
1mH
5
4
7
+15Vb
R185
R24
10K
C32
0.1
60mA
2.43K
2.43K
2.43K
2.43K
2
9
8
1
C166
CNY17-3
OCI1
47.5K
X2
X2
C30
4.7
GND
1
5
0.1
50V
14
6
68.1K
D29
X2
R25
10K
+5Vref
50V
Q15
35V
1N4936
DZ5
12V
1W
C175
2N4403
10K
4.75K
C11
10
0.1
1.0
D33
X8
50V
100
100
1.00M
.5
2
6
4
10
35V
+5Vref
5W
D31
X2
R26
L10
C12
9t
8t
8t
9t
13
Vdd
1N4936
.022
50V
1.00K
10K
11
+5Vb
200mA
X3
RES
9
8
IN
OUT
1mH
10K
PWR_DN
C165
0.1
C34
S-8054HN
D32
221K
C33
13.7K
0.1
SWITCH_GND
GND
1N4936
Vss
D12
35V
50V
50V
D11
1000
T3
SEC.
CR1
12Vdc
CR2
12Vdc
b
b
DZ6
C35
4.7
C36
C37
0.1
6.2V
1W
100K
R21
7
6
0.1
Q12
35V
50V
50V
2N4401
D35
100
1N4936
DZ17
6.2V
1W
Q7
2N4401
R190
C178
D60
GND
1N4936
D34
L11
CR2
IN
OUT
4
8
R32
100K
R33
X9
-5Vb
1mH
100K
b
15mA
D36
D20
X4
100
R186
-8Vb
250mA
C176
N.D.
J42
J44
D18
1
1
L6
Vcc(+15)
CR1
+15Va
1N4936
J42
J42
J42
J42
J42
J42
J42
J42
J42
J42
J42
J44
4
8
IN
OUT
1mH
2
2
TESTVa
4.75K 4.75K 4.75K 4.75K
380mA
WELD
&
CURRENT CONTROL
c
C21
C20
GND
N.D.
N.D.
OPTIONAL 13VDC FAN
J44
J44
J44
J44
J44
J44
J44
J44
J44
J44
C139
0.1
0.1
3
3
+5Vb
+5Vc
4.7
D19
301
50V
35V
1N4936
50V
TESTVa
R193
4
4
-8Vb
D39
R110
301
100
D23
e
10
5
5
R191
gate
1
40mAe
-8Vb
C177
D21
3A
1N4936
D37
L12
+5Vc
9t
L7
CR1
+5Va
600V
6
6
-15Va
IN
OUT
X10
13
9
X5
IN
OUT
1mH
9
8
.22mH
1.00K
1.00K
1.00K
30mA
C22
C140
C39
350mA
N.B.
N.C.
Used on -1A
Used on -1B
N.C.
Used on -1B
D22
7
7
C23
0.1
C38
4.7
D38
1N4936
T2
SEC.
4.7
0.1
GND
0.1
3A
C159
8t
8t
9t
RS232
35V
50V
ADJ
50V
600V
243
R86
50V
35V
0.1
8
8
PWR_DN
-5Vb
50V
2.21K
2.21K
2.21K
C25
9
9
gate
2
C141
0.1
0.1
c
C24
4.7
50V
1.50K
1.50K
10
50V
7
6
35V
GND
10
11
12
10
11
12
+15Va
+5Va
+15Vb
+5Vb
100
D24
L8
2.21K
2.21K
2.21K
-15Va
15t
1N4936
R194
301
C189
9
7
X6
T4
SEC.
IN
OUT
1mH
a
1N4936
L119
L116
R192
CR2
150
40mAe
40mA
50mA
D40
13
9
R107
R109
301
30t
.39mH
1mH
D25
Q111
@
27V
1N4936
6
100V
1A
R156
150
a
b
60mA limit
D26
D41
C102
2
CURRENT SOURCE
1N4936
C190
DZ115
.1
150V
100V
1A/20.4usec max
5.1V
1W
Q8
4A
100V
J41
J40
J40
J40
J40
J40
J40
J40
J40
J40
J40
J40
J40
J40
J40
J40
J40
1N4936
D42
D13
3A
600V
FET DRIVER SUPPLY
C191
1
1
18Vd
18Vd
FET DRIVE
1
FET DRIVE
2
18.2K
18.2K
18.2K
18.2K
18.2K
L4
.22mH
J41
J41
J41
J41
J41
J41
J41
J41
J41
J41
J41
J41
J41
J41
J41
0.1
18Vd
18.2K
9
2
9
L120
50V
3
3
T5
T6
3
D59
.39mH
GATE
4
GATE
4
1
1
1N5402
D43
1N4936
10
7
11
6
1.50K
1.50K
D14
3A
600V
e
C18
2
C27
4.7
DRIVE
C29
4.7
DRIVE
5
5
DZ7
1W
15V
2.67K
150V
35V
35V
2
2
GATE
GATE
NOTES
:
C26
0.1
C28
0.1
15
8
14
8
D17
Q10
4A
Q11
4A
10
4.75K
1.3K
N.A. SINCE COMPONENTS OR CIRCUITRY ON
A
PRINTED CIRCUIT BOARD MAY CHANGE
6
6
1N4936
50V
50V
gate
1
gate
2
WITHOUT AFFECTING THE INTERCHANGEABILITY OF COMPLETE BOARD, THIS DIAGRAM MAY
A
GENERAL INFORMATION
ELECTRICAL SYMBOLS PER E1537
LAST NO. USED
R36
100V
100V
NOT SHOW THE EXACT COMPONENTS OR CIRCUITRY OF CONTROLS HAVING
NUMBER.
A
COMMON CODE
DZ16
27V
5W
C19
4.7
R-198
C-191
D-60
16
3
16
2
T1
SEC.
2.21K
DZ10
DZ13
R80
CAPACITORS
RESISTORS
DIODES
=
MFD
(
.022/50V
UNLESS OTHERWISE SPECIFIED)
27V
5W
27V
5W
Q9
500mA
300V
35V
19t
LABELS
=
Ohms
1A, 400V
(
1/4W UNLESS OTHERWISE SPECIFIED)
(UNLESS OTHERWISE SPECIFIED)
3.32K
DZ9
DZ12
=
15V
1W
15V
1W
6
4
4
SUPPLY VOLTAGE NET
C17
2.7
10K
10K
D16
3A
DZ11
27V
5W
DZ14
27V
5W
POWER SUPPLY SOURCE POINT
COMMON CONNECTION
5
5
50V
DZ8
15V
1W
600V
4.75K
6
7
FRAME CONNECTION
11
12
13
14
10
12
13
15
EARTH GROUND CONNECTION
FILE: G2240_1D2
D15
3A
EQUIP.
Ch’ge.Sht.No.
THE LINCOLN ELECTRIC CO.
CLEVELAND, OHIO U.S.A.
INVERTER WELDERS
d
d
TYPE
600V
d
(cosmetic trace connecting ground planes)
1-6-95B
3-29-96L
7-9-99F
SCHEMATIC, POWER P.C. BOARD
SUBJECT
a
NONE
SCALE
SHT.
RM
G2240
DB
6-26-94
CHK.
SUP’S’D’G.
DR.
DATE
NO.
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
POWER WAVE 450
Download from Www.Somanuals.com. All Manuals Search And Download.
G-13
G-13
ELECTRICAL DIAGRAMS
PC BOARD ASSEMBLY-POWER
G
2 1 6 3 - 1
ITEM
REQ’D
2
PART NO.
S13490-141
S13490-25
DESCRIPTION
C1,C2
3900/80V
4.7/35
C3,C4,C5,C19,C20,C22,C24
C27,C29,C30,C35,C38
12
C6,C7,C13,C15,C16,C21,C23
C25,C26,C28,C32,C34,C36
C37,C39,C139,C140,C141
C159,C165,C166,C175,C191
C8
C9,C10
C11,C14
C12,C176,C177,C178,C189
C17
C18,C102
C33
23
S16668-11
.
1/50
.04
8.00
1
2
2
5
1
2
1
3
1
2
4
S16668-6
4700pF/50
.001/400
1.0/35
.022/50
2.7/50
POWER WAVE POWER
G2163-1
S13490-76
S13490-42
S16668-5
S13490-40
S13490-68
S13490-121
T11577-58
T11577-26
S13929-8
7.80
J44
J42
J41
J40
J43
2/150
R76
R180
R55
C40,C41,C42
C190
CR1,CR2
.0047/3000V
.1/100
RELAY, 12V DC
DIODE HS ASBLY
D1,D2,D3,D4
S18395-22
R130
R1
R35
D9
X10
D5,D6,D7,D8,D17,D18,D19
D24,D25,D27,D28,D29,D31
D32,D34,D35,D37,D38,D40
D41,D42,D43,D58
23
T12705-34
1N4936
D10
C32
C40
R31
R30
R195
T5
T6
D60
D9,D10
2
T12199-2
T12199-1
1N4007
1N4004
D11,D12,D20,D23,D26,D30
D33,D36,D39,D46,D47,D60
D13,D14,D15,D16,D21,D22
D59
12
D39
6
1
7
T12705-59
T12705-14
T12702-29
600V/3A
DIODE
R93
R92
C28
D30
C159
DZ2,DZ3,DZ4,DZ7,DZ8,DZ9
DZ12
1N4744A
C166
C30
C26
D4
D1
DZ5
DZ6,DZ17
DZ10,DZ11,DZ13,DZ14,DZ16
DZ115
J40,J41
J42,J44
J43
1
2
5
1
2
2
1
8
2
2
1
4
3
2
T12702-19
T12702-40
T12702-17
T12702-52
S20351-16
S20351-12
S20351-4
T12218-12
T12218-11
T12218-9
1N4742A
1N4735
1N5361B ZENER DIODE
1N4733A
HEADER
HEADER
HEADER
CHOKE
INDUCTOR
.39mH
Q10
C29
Q11
C37
C27
C35
R185
C175
R184
DZ5
DZ14
DZ13
Q13
DZ10
DZ11
C25
DZ12
R89
Q111
L3,L6,L8,L9,L10,L11,L12,L116
L4,L7
D2
D3
C12
R29
DZ2
C34
D33
R23
R25
R24
L119,L120
OCI1
Q1,Q3,Q7,Q12
Q2,Q4,Q15
Q5,Q6
C11
C165
R170
S15000-10
T12704-68
T12704-69
T12704-61
OPTO ISOLATOR
2N4401
2N4403
R27
R28
R26
R169
R168
R167
X
X
X
X
X6
X
X
X
TRANSISTOR
(SS)
X
X
Q8
R156
R107
X
X
X
X
X
X
D27
R22
R61
R21
X
D47
Q9
1
3
1
1
3
T12704-35
T12704-80
S18395-19
T12704-37
T14648-19
NPN TRANSISTOR
TRANSISTOR-NMF
PNP TRANSISTOR H.S. ASBLY
TRANSISTOR-P
X
X
X4
X5
X
X
R4
R3
R157
R108
R106
R105
R104
R103
Q8,Q10,Q11
Q13
Q111
R1,R130,R139
X
X
X
X
R59
4.00
X
X
X
DZ6
C6
R5
C16
C5
X
X
D26
DZ7
R37
1K 5W
X
X
R57
R56
DZ17
R196
C19
X
X
R2,R103,R104,R105,R106,
R108,R157
7
S19400-1822
1
8.2K 1/4W
C141
X
X
R9
D20
R135
C139
X
X
R162
R163
R164
R187
R188
R143
R142
R144
R145
D23
C140
X
X
R33
R32
R3,R4,R12,R13,R14,R15,R56
R57,R61,R186,R190,R191,R194
R5,R35,R36,R40,R135,R136
R137,R138
13
S19400-1000
100 1/4W
D58
C7
C18
X
DZ115
R7
R6
R2
X
X
X
X
X
X
C191
8
S19400-4751
4.75K
R39
Q9
R40
DZ8
Q12
R136
R137
R138
X
D12
C22
X
X
X
X
C8
R10
C4
X
X
X
R6
1
8
S19400-2212
S19400-1001
22.1K 1/4W
1K 1/4W
X
X
X
X
X
X
X
R7,R11,R16,R26,R34,R162
R163,R164
R8
R9,R22,R23,R24,R25,R29,R31
R76,R88,R89,R180
R10,R142,R143,R144,R145
R187,R188,R197
R17,R18,R196
R19
R21,R32,R33
R27,R177
R28
R30,R195
R37
Q7
X
R16
R11
C20
X
X
X
X
1
11
T10812-62
S19400-1002
500 1/2W TRIMMER
10K 1/4W
X
X
C177
X
X
C13
C14
X
X
X
D11
D17
X
X
8
S19400-2211
2.21K 1/4W
26.7 1/4W
X
X
X
X
X
X
3
1
3
2
1
2
1
1
1
1
8
S19400-26R7
T12300-80
S19400-1003
S19400-1004
S19400-1372
S19400-1212
S19400-2671
S19400-1301
S19400-2213
S19400-2670
S19400-2000
X
X
X
X
5
WATT 0.5 OHM RESISTOR
Q3
Q4
X
X
X
100K 1/4W
1M 1/4W
13.7K 1/4W
12.1K 1/4W
2.67K 1/4W
1.3K 1/4W
221K 1/4W
267 1/4W
X
X
X
X
X
X
X
Q1
Q2
C10
X
X
X
X
X
X
X
X
X
X X
X
C9
R39
R55
R59
D38
D37
R63,R64,R65,R66,R67,R68
200 1/4W
R69,R70
R80
1
4
1
S19400-3321
S19400-1501
S19400-2430
3.32K 1/4W
1.5K 1/4W
243 1/4W
R83,R92,R93,R150
R86
R107,R156
2
S19400-1500
150 1/4W
1
1
1
1
R109,R110,R192,R193
R167,R168,R169,R170
R184
R185
R198
T1
4
4
1
1
1
1
1
1
S19400-3010
S19400-2431
S19400-6812
S19400-4752
S19400-4750
M16744-1
301 1/4W
2.43K 1/4W
68.1K 1/4W
47.5K 1/4W
475 1/4W
TRANSFORMER
TRANSFORMER
TRANSFORMER
.20
0
T2
T3
M16744-4
M16744-3
T4
T5,T6
TP1,TP2,TP3
X1
1
2
3
1
M16744-2
T12737-7
T13640-18
M15458-3
TRANSFORMER
PULSE TRANSFORMER
160J
PWM CONTROLLER,IC
X2
X3
X4
X5
X6
X7
X8
1
1
1
1
1
1
1
S15128-11
M15102-3
S18395-8
S18395-7
S15128-12
S15128-6
S18395-13
14 PIN QUAD COMPARATOR
RESET I.C. UNDERVOLT. SENSING CIR. (SS)
REGULATOR ASSEMBLY
0
.20
5.63
.04
11.25
11.05
S15128-15 ON S18104-5
IC
IC
-
-
VOLT REG
VOLT REG
5V REG. ASBLY
X9
X10
1
1
S15128-7
S15128-5
IC
IC
-
-
VOLT REG
VOLT REG
CAPACITORS
RESISTORS
=
MFD/VOLTS
=
OHMS
Ch’ge. Sht. No.
1-6-95B
EQUIP.
TYPE
INVERTER WELDERS
THE LINCOLN ELECTRIC CO.
CLEVELAND, OHIO U.S.A.
3-29-96K
3-29-96L
POWER P.C. BOARD ASSEMBLY
SUBJECT
SCALE FULL
SHT.
7-25-97K
7-9-99F
FM
3-9-94
DB/FV
CHK
REF.
2163-1
DR
DATE
SUP’S’D’G
NO.
G
NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your factory warranty. Individual Printed Circuit Board Components are not available from Lincoln Electric. This information is pro-
vided for reference only. Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician. Improper PC board repairs could result in damage to the
machine.
POWER WAVE 450
Download from Www.Somanuals.com. All Manuals Search And Download.
G-14
G-14
ELECTRICAL DIAGRAMS
SCHEMATIC - PROTECTION PRINTED CIRCUIT BOARD
1 5 4 2
G
D15
AUXILIARY
WIRE FEEDER
2
WIRE FEEDER
1
POWER BD
DISPLAY BD
AMPTROL
R1
24VAC
+24V
150
R2
X4
IN
OUT
221
150
R3
1
2
3
4
5
6
1
2
3
4
5
6
7
8
9
10
11
12
13
14
1
2
3
4
5
6
1
2
3
4
1
2
3
4
L1
D11
D13
ADJ
1
150
R4
J36
.39mH
J32
J32
C10
C12
3
24VAC FROM
AUXILIARY
TRANSFORMER
FROM CURRENT
TRANSFORMER
3300
50V
TP2
50V
15J
4.7
150
R5
2
35V
L2
C11
150
R162
3
6.81K
10K
C1
.39mH
J32
J36
1
+
t
.25
D12
D14
TO CONTROL BD
50V
START
4
J36
2
105
POWER SUPPLY
106
J36
4
SECONDARY
-
4000V ISOLATION FROM PRIMARY CIRCUITS
TO LOAD SIDE OF CONTACTOR
+24V
16
11
2
3
4
5
7
8
2
1
CR2
200
20W
200
20W
200
20W
200
20W
200
20W
200
20W
CR1
24 VDC
24 VDC
+24V
+24V
C13
D19
1
.0027
50V
HIGH VOLTAGE DIVIDERS
+10Vp
2
ENABLE
CAP1 FAULT
NO FAULT
SOFT START
4
4
3
J31
5
CR1
CR2
33.2K
DISABLE
FAULT
PRIMARY
-
2500V ISOLATION
UPPER CAP
VOLTAGE MONITOR
SOFT START
R47
10K
3
J31
12
10K
FROM ALL CIRCUITS
33.2K
SOFT START DISABLE
2
R137
475
3
2
R46
Q9
1
X7
A
R60
2N4401
1
X5
A
3
2
CW
2K
3
5.11K
Vupcap
X6
A
R52
10K
1
D16
D18
C24
18
VOLTAGE
MONITOR
.016 V/V
Q6
22.1K
C29
600mA
40V
C26
15V
1
SOFT START
+10Vp
GAIN
=
15.0K
10K
UNDER VOLTAGE
VERIFY CHARGE
&
6
1
9
10
12
13
14
15
Vfault
22.1K
J31
Vupcap
>
170 VDC
14
R6
TO LOAD SIDE OF INPUT SWITCH
1.00K
2
5
+24V
J31
X6
B
7
3
24VAC
D17
J31
6
V
<
170V
4
DISABLE RM
J31
C14
50V
6
8.25K
V
>
170V
.0027
J31
3.32K
3.32K
ENABLE RM
7
J31
J31
10
R75
R140
200
START
10K
+24V
33.2K
+24V
6
5
1
6
4
R74
TO CONTACTOR COIL
26.7
C36
0.1
7
OUTPUT
DISABLE
OCI5
3043
MT2
MT1
X5
B
Vupcap or 0V
TRI1
CW
2K
ENABLE
J32
D35
50V
RUN MODE
6
G
R130
4.75K
2
C25
.1
133K
133K
VOLTAGE
MONITOR
.016 V/V
DISABLE
J32
J32
J39
400V
4
5
4
R13
100
RUN MODE
R79
2
CAP2 FAULT
R139
1.00K
150K
GAIN
=
13
12
RUN MODE DISABLE
R82
475
10
9
R76
10K
Q12
14
X7
C
R85
2N4401
150K
8
X5
D
10
9
22.1K
R77
X6
C
R80
10K
8
Vlowcap
+24V
1
5
C16
100
20V
D21
D22
8
150K
TO CONTROL BD
J31
DZ15
Q11
C34
OCI4
FAULT
LOWER CAP
VOLTAGE MONITOR
6.2V
1W
9
150K
600mA
40V
C27
0.1
RUN MODE
CNY17-3
C15
50V
J31
50V
.0027
11
2
6
4
J31
NO FAULT
13
33.2K
J31
ENABLE
OUTPUT
GND
J31
R104
33.2K
R12
1
10K
DISABLE
OUTPUT
9
56.2K
R103
R89
D24
5
6
8
68.1K
X5
C
X7
B
Vupcap
+
Vlowcap
7
CW
2K
10
C35
150p
50V
OR Vlowcap
475
VOLTAGE
MONITOR
SECONDARY
-
4000V ISOLATION FROM PRIMARY
3
C17
18
Vfault
GAIN
=
.016 V/V
10K
R95
15V
15.0K
Q14
C28
Q17
600mA
40V
12
13
2N4401
R142
14
22.1K
+10Vp
X8
D
R113
R119
R143
22.1K
100K
+24V
V/F CONVERTER
1.50K
+24V
R116
10K
J39
J39
2
13
12
2
1
R9
X8
A
2.43K
R112
1
6
5
14
100
X8
B
33.2K
R124
X6
D
R159
681
R117
10K
+10Vp
3
7
9
+10V PREC.
X8
C
2.43K
R111
8
DZ13
10V
+10Vp
+10Vp
10
R109
100K
R110
100K
1W
R120
1.50K
D28
DZ14
6.2V
1W
1
5
TO CONTROL BD
1N4936
+10Vp
100K
100K
OCI3
CNY17-3
2
6
4
R158
Q15
1.0
1A
1K
1W
100V
CAP DELTA
J39
Q16
1A
CW
3
C18
GND
12
13
(ADDS GAIN
SHIFTS Fc)
+
0.27
100V
R123
2.21K
X7 D
50V
14
R125
2.21K
C30
4.7
GND
R10
56.2K
DZ11
2.67K
1.00K
35V
+24V
GENERAL INFORMATION
ELECTRICAL SYMBOLS PER E1537
LAST NO. USED
DZ12
15V
15V
1W
+
1
R- 162
C- 36
D- 35
Q- 17
DZ- 15
1W
8
CAPACITORS
RESISTORS
DIODES
=
MFD
(
.022/50V
UNLESS OTHERWISE SPECIFIED)
C33
150p
50V
X9
CAP DELTA MONITOR
LABELS
TL431
=
Ohms
(
1/4W UNLESS OTHERWISE SPECIFIED)
(UNLESS OTHERWISE SPECIFIED)
REF
6
-
=
1A, 400V
SECONDARY
-
4000V ISOLATION FROM PRIMARY
SUPPLY VOLTAGE NET
FREQ RANGE
CAP1=CAP2
CAP1>CAP2
CAP1<CAP2
DEADBAND
0-2.5KHz
Fc=1.25KHz
F<1.25KHz
F>1.25KHz
+/- 375 Hz
4
4
4
4
POWER SUPPLY SOURCE POINT
COMMON CONNECTION
C20
C21
X6
C22
C23
X8
X5
X7
FRAME CONNECTION
EARTH GROUND CONNECTION
LM224
LM224
11
LM224
11
FILENAME: G2451_2DA
33074A
11
NOTES
:
EQUIP.
TYPE
Ch’ge.Sht.No.
1-6-95B
10-27-95G
1-10-97D
11
N.A. SINCE COMPONENTS OR CIRCUITRY ON
A
PRINTED CIRCUIT BOARD MAY CHANGE
INVERTEC
PROTECTION PC BOARD SCHEMATIC
THE LINCOLN ELECTRIC CO.
CLEVELAND, OHIO U.S.A.
WITHOUT AFFECTING THE INTERCHANGEABILITY OF COMPLETE BOARD, THIS DIAGRAM MAY
A
GAIN
.25 KHz/V
NOT SHOW THE EXACT COMPONENTS OR CIRCUITRY OF CONTROLS HAVING
NUMBER.
A
COMMON CODE
SUBJECT
NONE
12-26-91
SCALE
DATE
SHT.
TEL
G2451
TEL
CHK.
SUP’S’D’G.
DR.
NO.
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
POWER WAVE 450
Download from Www.Somanuals.com. All Manuals Search And Download.
G-15
G-15
ELECTRICAL DIAGRAMS
PC BOARD ASSEMBLY-PROTECTION
3 1 9 6 - 1
G
ITEM
REQ’D
IDENTIFICATION
PART NO.
C 1
1
T 1 1 5 7 7 - 5 0
S 1 3 4 9 0 - 9 2
S 1 6 6 6 8 - 5
4 . 0 M F D, 5 0 V C A PA C I T O R
C 1 0
1
3 3 0 0
/
5 0
C 1 1 , C 2 0 , C 2 1 , C 2 2 , C 2 3 , C 2 6
1 1
. 0 2 2 / 5 0
C 2 7 , C 2 8 , C 2 9 , C 3 1 , C 3 2
C 1 2 , C 3 0
C 1 3 , C 1 4 , C 1 5
C 1 6
2
3
1
2
1
1
2
2
S 1 3 4 9 0 - 2 5
S 1 6 6 6 8 - 4
S 1 3 4 9 0 - 9 7
S 1 3 4 9 0 - 3 9
S 1 3 4 9 0 - 8 5
T 1 1 5 7 7 - 5 7
S 1 6 6 6 8 - 9
S 1 6 6 6 8 - 1 1
4 . 7 / 3 5
2 7 0 0 p F / 5 0
1 0 0
1 8
/
2 0
C 1 7 , C 2 4
C 1 8
/
1 5
.20
5.63
11.05
. 2 7 / 5 0
0 . 1 / 4 0 0
1 5 0 p F / 1 0 0
. 1 / 5 0
C 2 5
C 3 3 , C 3 5
C 3 4 , C 3 6
C R 1 , C R 2
2
S 1 5 1 2 2 - 4
R E L AY
.04
D 1 , D 2 , D 3 , D 4 , D 2 8
D 1 1 , D 1 2 , D 1 3 , D 1 4 , D 1 5 , D 1 6
D 1 7 , D 1 8 , D 1 9 , D 2 1 , D 2 2 , D 2 4
D 3 5
5
T 1 2 7 0 5 - 3 4
T 1 2 1 9 9 - 1
1 N 4 9 3 6
1 N 4 0 0 4
8.00
1 3
7.80
PROTECTION
G3196-1
D Z 1 1 , D Z 1 2
D Z 1 3
2
1
2
T 1 2 7 0 2 - 2 9
T 1 2 7 0 2 - 2 7
T 1 2 7 0 2 - 4 0
1 N 4 7 4 4 A
1 N 4 7 4 0
1 N 4 7 3 5
Q9
R61
R60
R72
R44
C13
R45
R73
R101
D Z 1 4 , D Z 1 5
R83
C22
R84
J 3 0
1
2
3
4
S 2 0 3 5 1 - 1 6
S 2 0 3 5 1 - 1 4
S 2 0 3 5 1 - 6
S 2 0 3 5 1 - 4
H E A D E R
H E A D E R
H E A D E R
H E A D E R
C29
R59
R58
R54
R55
J 3 1 , J 3 4
C20
J 3 2 , J 3 3 , J 3 5
J 3 6 , J 3 7 , J 3 8 , J 3 9
C16
R102
R79
R76
R77
R78
R82
R47
R46
X7
X4
L 1 , L 2
2
T 1 2 2 1 8 - 9
.
3 9 m H
C24
D35
X5
R130
R74
R75
C14
R92
R93
R137
O C I 3 , O C I 4
O C I 5
2
1
S 1 5 0 0 0 - 1 0
S 1 5 0 0 0 - 1 1
O P T O I S O L AT O R
3 0 4 3
Q11
R103
R104
Q17
R81
C27
R90
R152
R153
C28
Q 6 , Q 9 , Q 1 1 , Q 1 2 , Q 1 4 , Q 1 7
Q 1 5 , Q 1 6
6
2
T 1 2 7 0 4 - 6 8
T 1 2 7 0 4 - 7 3
2 N 4 4 0 1
C15
C11
I C P K G M O S F E T ( S S )
Q6
R53
C26
R95
R96
R 1 , R 2 , R 3 , R 4 , R 5
5
6
6
S 1 9 4 0 0 - 1 5 0 0
S 1 9 4 0 0 - 1 0 0 1
S 1 9 4 0 0 - 3 3 2 1
1 5 0 1 / 4 W
1 K 1 / 4 W
C17
R 6 , R 8 , R 1 1 , R 1 0 7 , R 1 3 9 , R 1 5 7
Q14
R 7 , R 1 0 8 , R 1 2 8 , R 1 3 8 , R 1 5 4
3 . 3 2 K 1 / 4 W
R91
R89
R85
R86
C21
R52
D18
D22
R 1 5 5
R112
C10
R 9 , R 1 3
2
S 1 9 4 0 0 - 1 0 0 0
S 1 9 4 0 0 - 5 6 2 2
S 1 9 4 0 0 - 2 6 7 3
1 0 0 1 / 4 W
D24
R80
R159
DZ13
R113
R115
R114
R111
R 1 0 , R 1 2 , R 9 0
3
5 6 . 2 K 1 / 4 W
2 6 7 K 1 / 4 W
R50
R51
R 4 0 , R 4 1 , R 4 2 , R 4 3 , R 6 8 , R 6 9
1 2
R 7 0 , R 7 1 , R 9 7 , R 9 8 , R 9 9 , R 1 0 0
R49
R48
R7
R 4 4 , R 7 2 , R 1 0 1
3
3
9
T 1 0 8 1 2 - 7 3
2 K 1 / 2 W T R I M M E R
5 . 6 2 K 1 / 4 W
R116
C23
X6
R 4 5 , R 7 3 , R 1 0 2
S 1 9 4 0 0 - 5 6 2 1
S 1 9 4 0 0 - 1 0 0 2
R 4 6 , R 5 1 , R 5 2 , R 7 4 , R 8 0 , R 1 0 3
1 0 K 1 / 4 W
R108
R 1 1 1 , R 1 1 2 , R 1 3 6
R110
D17
D16
D21
R 4 7 , R 5 8 , R 7 5 , R 9 2 , R 1 0 4 , R 1 2 4
6
7
S 1 9 4 0 0 - 3 3 2 2
S 1 9 4 0 0 - 2 2 1 2
3 3 . 2 K 1 / 4 W
2 2 . 1 K 1 / 4 W
R144
R119
R120
R117
R124
R 4 8 , R 5 9 , R 8 5 , R 1 4 2 , R 1 4 3 , R 1 4 4
C31
R 1 5 2
X8
R 4 9
1
9
S 1 9 4 0 0 - 8 2 5 1
S 1 9 4 0 0 - 1 5 0 2
8 . 2 5 K 1 / 4 W
1 5 K 1 / 4 W
R107
R157
C36
R143
R123
R109
R106
R 5 0 , R 5 3 , R 6 1 , R 8 1 , R 8 6 , R 9 3
4.00
CR1
D19
R 9 5 , R 9 6 , R 1 5 3
D28
R122
DZ11
R125
X9
R 5 4
1
2
1
4
3
2
1
1
5
2
2
4
1
6
S 1 9 4 0 0 - 4 7 5 2
S 1 9 4 0 0 - 6 8 1 2
S 1 9 4 0 0 - 5 1 1 1
S 1 9 4 0 0 - 1 5 0 3
S 1 9 4 0 0 - 4 7 5 0
S 1 9 4 0 0 - 1 3 3 3
T 1 0 8 1 2 - 6 8
4 7 . 5 K 1 / 4 W
6 8 . 1 K 1 / 4 W
5 . 1 1 K 1 / 4 W
1 5 0 K 1 / 4 W
4 7 5 1 / 4 W
TP2
R142
Q15
R 5 5 , R 8 9
OCI5
R139
R 6 0
R105
R158
R 7 6 , R 7 7 , R 7 8 , R 7 9
C30
R 8 2 , R 9 1 , R 1 3 7
DZ12
R126
C18
R 8 3 , R 8 4
1 3 3 K 1 / 4 W
1 K 1 / 2 W T R I M M E R
2 . 6 7 K 1 / 4 W
1 0 0 K 1 / 4 W
2 . 4 3 K 1 / 4 W
1 . 5 K 1 / 4 W
R 1 0 5
R 1 0 6
S 1 9 4 0 0 - 2 6 7 1
S 1 9 4 0 0 - 1 0 0 3
S 1 9 4 0 0 - 2 4 3 1
S 1 9 4 0 0 - 1 5 0 1
S 1 9 4 0 0 - 2 2 1 1
S 1 9 4 0 0 - 1 8 2 1
T 1 4 9 0 0 - 1
Q16
R 1 0 9 , R 1 1 0 , R 1 1 3 , R 1 1 4 , R 1 1 5
R155
R154
R11
R 1 1 6 , R 1 1 7
R127
C32
TRI1
R 1 1 9 , R 1 2 0
R 1 2 2 , R 1 2 3 , R 1 2 5 , R 1 2 6
2 . 2 1 K 1 / 4 W
1 . 8 2 K 1 / 4 W
2 0 0 2 0 W
C34
R8
R 1 2 7
D4
R 1 2 9 , R 1 3 2 , R 1 5 0 , R 1 5 1 , R 1 6 0
XXXXXXXXXXXXXXXXXXXXXXXXXXXX
CR2
D3
D2
D1
R5
R4
R3
R2
R1
R 1 6 1
R 1 3 0
R 1 3 4
R 1 3 5
R 1 4 0
R 1 4 1
R 1 5 8
R 1 5 9
R 1 6 2
1
1
1
1
1
1
1
1
S 1 9 4 0 0 - 4 7 5 1
S 1 9 4 0 0 - 2 2 1 0
S 1 9 4 0 0 - 6 8 1 1
S 1 9 4 0 0 - 2 0 0 0
S 1 9 4 0 0 - 2 6 R 7
T 1 2 3 0 0 - 7 9
4 . 7 5 K
OCI4
OCI3
2 2 1 1 / 4 W
6 . 8 1 K 1 / 4 W
2 0 0 1 / 4 W
2 6 . 7 1 / 4 W
C1
XXXXXXXXXXXXXXXXXXXXXXXXXXXX
C25
1
WAT T
1
O H M 1 % R E S I S T O R
S 1 9 4 0 0 - 6 8 1 0
S 1 8 3 8 0 - 4
6 8 1 1 / 4 W
P T C T H E R M I S T O R
1 5 J
R162
XXXXXXXXXXXXXXXXXXXXXXXX
T P 2
1
1
T 1 3 6 4 0 - 1 5
S 1 8 3 9 5 - 9
T R I 1
S 1 5 1 6 1 - 2 7 O N S 1 8 1 0 4 - 5
XXXXXXXXXXXXXXXXXXXXXXXXXXXX
X 4
1
3
1
1
S 1 8 3 9 5 - 7
S 1 5 1 2 8 - 4
S 1 5 1 2 8 - 1 8
S 1 5 1 2 8 - 1 0
S 1 5 1 2 8 - 1 5 O N S 1 8 1 0 4 - 5
L M 2 2 4 O P - A M P
X 5 , X 6 , X 7
XXXXXXXXXXXXXXXXXXXXXXXXXXXX
J30
XXXXXXXXXXXXXXXXXXXXXXXX
J31
X 8
X 9
Q U A D - O P A M P
J39
J38
J37
J36
V O LTA G E R E F.
J35
J34
J33
J32
CAPACITORS = MFD/VOLTS
.20
INDUCTANCE = HENRIES
RESISTORS = OHMS
0
11.25.04
0
Ch’ge. Sht. No.
EQUIP.
TYPE
THE LINCOLN ELECTRIC CO.
CLEVELAND, OHIO U. S. A.
INVERTER WELDERS
XA
1-9-98D
8-27-99B
PROTECTION P.C. BOARD ASSEMBLY
SUBJECT
DRS
FULL
SCALE
SHT.
NO.
DRS
2-27-97
G2453-2
REF.
3196-1
DR.
DATE
CHK.
G
NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your factory warranty. Individual Printed Circuit Board Components are not available from Lincoln Electric. This information is pro-
vided for reference only. Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician. Improper PC board repairs could result in damage to the
machine.
POWER WAVE 450
Download from Www.Somanuals.com. All Manuals Search And Download.
G-16
G-16
ELECTRICAL DIAGRAMS
SCHEMATIC -SQUARE WAVE PROTECTION PRINTED CIRCUIT BOARD
M
1 6 1 1 5
L4
J23
J23
J23
J23
J23
J22
J22
J22
J22
J22
J22
1
2
3
4
5
5
4
1
2
6
3
.39mH
C4
.0047
3000V
L5
.39mH
C5
.0047
3000V
L1
.39mH
C1
.0047
3000V
L2
.39mH
C2
.0047
3000V
L6
.39mH
C6
.0047
3000V
L3
J23
J23
7
.39mH
C3
.0047
8
3000V
GENERAL INFORMATION
LAST NO. USED
R-
C-
D-
_
_
_
ELECTRICAL SYMBOLS PER E1537
CAPACITORS =
RESISTORS = Ohms (
DIODES = 1A, 400V
MFD ( .022/50V
UNLESS OTHERWISE SPECIFIED)
1/4W UNLESS OTHERWISE SPECIFIED)
(UNLESS OTHERWISE SPECIFIED)
LABELS
SUPPLY VOLTAGE NET
POWER SUPPLY SOURCE POINT
COMMON CONNECTION
NOTES :
N.A. SINCE COMPONENTS OR CIRCUITRY ON A PRINTED CIRCUIT BOARD MAY CHANGE
WITHOUT AFFECTING THE INTERCHANGEABILITY OF A COMPLETE BOARD, THIS DIAGRAM MAY
NOT SHOW THE EXACT COMPONENTS OR CIRCUITRY OF CONTROLS HAVING A COMMON CODE
NUMBER.
FRAME CONNECTION
EARTH GROUND CONNECTION
Ch’ge. Sht. No.
5-29-90SPA
EQUIP.
TYPE
SQUARE WAVE TIG 350
THE LINCOLN ELECTRIC CO.
CLEVELAND, OHIO U.S.A.
PROTECTION P.C. BOARD SCHEMATIC
SUBJECT
NONE
SCALE
MK/DRS
SHT.
NO.
1-12-90
GM/BS
REF.
16115
DR
M
DATE
CHK
SUP’S’D’G
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
POWER WAVE 450
Download from Www.Somanuals.com. All Manuals Search And Download.
G-17
G-17
ELECTRICAL DIAGRAMS
PC BOARD ASSEMBLY-SQUARE WAVE PROTECTION
M
1 6 0 6 2 - 1
REQ’D
IDENTIFICATION
PART NO.
T11577-58
T12218-9F
S18248-6
S18248-8
ITEM
AICF
6
6
1
1
.0047/3000 V
.39 mH
HEADER
C1, C2, C3, C4, C5, C6
L1, L2, L3, L4, L5, L6
J22
J23
HEADER
CAPACITORS = MFD/VOLTS
+.05
-.02
3.60
SQUARE WAVE
3.40
B
PROTECTION
.12
L6
3.10
M16062-1
L4
L5
J23
C4
C5
C1
C2
C3
L1
L2
L3
J22
.12
.60
C6
.20
0
.12
.50
3.40
.20
+.05
-.02
3.60
0
Ch’ge. Sht. No.
EQUIP.
SQUAREWAVE TIG 300 & 350
PROTECTION P.C. BOARD ASSEMBLY
THE LINCOLN ELECTRIC CO.
CLEVELAND, OHIO U.S.A.
TYPE
12-8-89B
11-30-90B
SUBJECT
DOUBLE
SCALE
SHT.
NO.
L8088-1
FV
9-8-89
DEC
REF.
16062-1
DR
DATE
CHK
SUP’S’D’G
M
NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your factory warranty. Individual Printed Circuit Board Components are not available from Lincoln Electric. This information is pro-
vided for reference only. Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician. Improper PC board repairs could result in damage to the
machine.
POWER WAVE 450
Download from Www.Somanuals.com. All Manuals Search And Download.
G-18
G-18
ELECTRICAL DIAGRAMS
SCHEMATIC - SHUNT PRINTED CIRCUIT BOARD
2 1 1 5 1
S
+15V
R10
100
3
J50
J50
DZ1
15V
1W
7
C2
0.1
VOLTAGE TO CURRENT
50mV = 5mA
50V
X1
1
TO
SHUNT
DIODE
BRIDGE
OP27
C3
0.1
G
DZ2
15V
1W
PADS IN
GRAPHICS
ONLY
4
50V
R5
-15V
R11
100
6
392K
J50
J50
5
2
1
8
R1
R2
X1
NULL
INPUT
INPUT
NULL
7
511
2
3
4.75K
C1
-
V
CC
Vin
6
5
+
OUT
4
V
EE
NC
J50
R3
R4
OP27
511
4.75K
562
500
1.30K
TO NEGATIVE
OUTPUT STUD
G
-Vin * 74.51
(R7 + 392)
Iout =
A
R8
392K
4
J50
NOTES :
FILE: S21151_2BA
LABELS
GENERAL INFORMATION
ELECTRICAL SYMBOLS PER E1537
N.A.
SINCE COMPONENTS OR CIRCUITRY ON
CIRCUIT BOARD
A PRINTED
FRAME CONNECTION
MAY CHANGE WITHOUT AFFECTING
SUPPLY
VOLTAGE NET
MFD
CAPACITORS =
(
.022/50V
1/4W UNLESS OTHERWISE SPECIFIED)
(UNLESS OTHERWISE SPECIFIED)
UNLESS OTHERWISE SPECIFIED)
THE INTERCHANGEABILITY
THIS DIAGRAM MAY NOT
OF A COMPLETE
BOARD.
POWER SUPPLY SOURCE POINT
COMMON CONNECTION
RESISTORS = Ohms (
DIODES = 1A, 400V
SHOW THE EXACT COMPONENTS
EARTH GROUND CONNECTION
OR CIRCUITRY OF
CONTROLS HAVING A COMMON CODE NUMBER.
EQUIP.
TYPE
Ch’ge.Sht.No.
INVERTEC V400
SHUNT AMPLIFIER PCB SCHEM.
THE LINCOLN ELECTRIC CO.
CLEVELAND, OHIO U.S.A.
1-6-95
11-21-97G
SUBJECT
NONE
2-7-94
SCALE
SHT.
DB
21151
DR.
DATE
CHK.
SUP’S’D’G.
NO.
S
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
POWER WAVE 450
Download from Www.Somanuals.com. All Manuals Search And Download.
G-19
G-19
ELECTRICAL DIAGRAMS
PC BOARD ASSEMBLY- SHUNT
M
1 7 1 5 0 - 2
PA RT N O
S16668-5
S16668-11
T12702-29
S18248-6
D E S C R I P T I O N
.022/50
.1/50
I T E M
R E Q ’ D
C1
C2,C3
1
2
DZ1,DZ2
J50
2
1
1N4744A
HEADER
.13
R1,R3
R2,R4
R5,R8
R6
R7
R9
2
2
2
1
1
1
2
S19400-5110
S19400-4751
S19400-3923
S19400-5620
S16296-3
511 1/4W
4.75K
392K 1/4W
562 1/4W
500 1/2W TRIMMER
1.3K 1/4W
100 1/4W
+.04
-
1.75
S19400-1301
S19400-1000
R10,R11
1.63
X1
1
S15128-13
PRECISION OP AMP IC
R1
C1
R2
CAPACITORS = MFD/VOLTS
X1
0
+.04
-
2.25
0
Ch’ge. Sht. No.
EQUIP.
TYPE
INVERTER WELDERS
THE LINCOLN ELECTRIC CO.
CLEVELAND, OHIO U.S.A.
11-21-97G
4-20-2000D
SHUNT AMPLIFIER P.C. BD. ASSEMBLY
SUBJECT
FULL
SCALE
SHT.
NO.
M17150-1
LJB
11-4-97
J.J.
REF.
17150-2
DR
DATE
CHK
SUP’S’D’G
M
NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your factory warranty. Individual Printed Circuit Board Components are not available from Lincoln Electric. This information is pro-
vided for reference only. Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician. Improper PC board repairs could result in damage to the
machine.
POWER WAVE 450
Download from Www.Somanuals.com. All Manuals Search And Download.
G-20
G-20
ELECTRICAL DIAGRAMS
SCHEMATIC - SNUBBER PRINTED CIRCUIT BOARD
M
1 6 7 6 1
+15V
D5
J60
12
R3
R10
8
67A
(67)
J61
14
6
100K
.5W
100K
.5W
X1
13
(202)
+15V
R20
D4
J60
J60
10.0K
10
9
R11
R12
15
9
67B
J61
J61
+15V
8
(167A)
7
100K
.5W
100K
.5W
X1
(201)
(206)
D3
5
R21
R14
R8
21A
7
10.0K
(121A)
10
100K
.5W
100K
.5W
X1
6
+15V
R22
D2
J60
J60
10.0K
3
2
R17
R9
13
11
21B
J61
J61
1
(221A)
8
9
100K
.5W
100K
.5W
X2
(207)
(203)
+15V
D1
5
R23
R6
R4
+OUTPUT
(499)
7
10.0K
100K
.5W
100K
.5W
X2
6
DZ1
5.1V
1W
DZ3
5.1V
1W
DZ5
5.1V
1W
DZ7
5.1V
1W
DZ9
R24
5.1V
J61
1W
10.0K
5
(205)
10K
10K
10K
10K
10K
C5
C6
C7
C8
C9
820p
50V
820p
50V
820p
50V
820p
50V
820p
50V
COSMETIC TRACE
(J62-4 TO J61-5)
4
+15V
J61
4
1
R18
100
+15V
(204)
DZ2
5.1V
1W
DZ4
5.1V
1W
DZ6
5.1V
1W
DZ8
5.1V
1W
DZ10
5.1V
1W
C13
0.1
C12
0.1
X2
X1
50V
50V
33074A
33074A
J61
J61
J61
2
4
3
R19
100
-15V
(208)
11
11
3
2
J62
J62
(462)
J62
1
2
L3
1
(461)
X1
C3
TP3
.0047
400V
2.7
10W
2.7
10W
DZ11
15V
1W
DZ12
15V
C10
0.1
C11
0.1
320V
160J
J60
J60
J60
J60
J60
J60
J60
J60
J60
J60
J60
1W
50V
1
50V
CHASSIS
R11
TP2
10
9
40/100W
6
320V
160J
2
8
X2
C2
C4
3
TP1
.0047
400V
.047
320V
160J
1200V
4
J62
GENERAL INFORMATION
J62
J62
LAST NO. USED
(464)
12
13
5
7
8
4
-OUTPUT
(467)
R- 24
DZ- 12
ELECTRICAL SYMBOLS PER E1537
14
6
C1
X2
C- 13
CAPACITORS =
RESISTORS = Ohms (
DIODES =
MFD
(
.022/50V
UNLESS OTHERWISE SPECIFIED)
.1
D-
5
LABELS
1/4W UNLESS OTHERWISE SPECIFIED)
(UNLESS OTHERWISE SPECIFIED)
7
1000V
1A, 400V
SUPPLY VOLTAGE NET
BACKGND
(468)
10
12
14
16
POWER SUPPLY SOURCE POINT
COMMON CONNECTION
NOTES :
J62
J62
5
3
N.A. SINCE COMPONENTS OR CIRCUITRY ON A PRINTED CIRCUIT BOARD MAY CHANGE
WITHOUT AFFECTING THE INTERCHANGEABILITY OF A COMPLETE BOARD, THIS DIAGRAM MAY
NOT SHOW THE EXACT COMPONENTS OR CIRCUITRY OF CONTROLS HAVING A COMMON CODE
NUMBER.
FRAME CONNECTION
EARTH GROUND CONNECTION
FILE: M16761_1BA
Ch’ge.Sht.No.
1-6-95A
EQUIP.
THE LINCOLN ELECTRIC CO.
CLEVELAND, OHIO U.S.A.
INVERTER WELDERS
SNUBBER P.C. BD. SCHEMATIC
TYPE
SUBJECT
NONE
SCALE
DATE
SHT.
DB
DB
16761
1-31-93
CHK.
SUP’S’D’G.
M
DR.
NO.
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
POWER WAVE 450
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G-21
G-21
ELECTRICAL DIAGRAMS
PC BOARD ASSEMBLY- SNUBBER
ITEM
REQ’D
IDENTIFICATION
.1/1000
.0047/400
.047/1200
820pF/50
.1/50
PART NO.
C1
C2,C3
C4
1
2
1
5
4
S20500-1
S13490-3
S13490-112
S16668-7
S16668-11
C5,C6,C7,C8,C9
C10,C11,C12,C13
3.08
D1,D2,D3,D4,D5
5
T12199-1
1N4004
DZ1,DZ2,DZ3,DZ4,DZ5,DZ6
DZ7,DZ8,DZ9,DZ10
10 T12702-52
1N4733A
.04
4.05
DZ11,DZ12
2
T12702-29
1N4744A
SNUBBER
L9579-1
C13
X2
J60
J61
J62
1
1
1
S18248-16
S18248-10
S18248-8
HEADER
HEADER
CONNECTOR
3.85
R1,R7,R13,R15,R16,R20,R21
R22,R23,R24
10 S19400-1002 10K 1/4W
R2,R5
2
T14649-7
2.7 10W
R3,R4,R6,R8,R9,R10,R11,R12
R14,R17
R18,R19
10 S20620-1003 100K 1/2W
R2
R5
C4
2
3
2
S19400-1000 100 1/4W
D5
D4
TP1,TP2,TP3
X1,X2
T13640-18
S15128-18
160J
C12
QUAD-OP AMP
X1
CAPACITORS = MFD/VOLTS
C1
C3 C2
R18
.45
0
J62
J61
J60
.04
5.00
4.80
0
.20
3.05
C A D
NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your factory warranty. Individual Printed Circuit Board Components are not available from Lincoln Electric. This information is pro-
vided for reference only. Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician. Improper PC board repairs could result in damage to the
machine.
POWER WAVE 450
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G-22
G-22
ELECTRICAL DIAGRAMS
SCHEMATIC-SWITCH PRINTED CIRCUIT BOARD
D4
1N4936
W
221
D2
Q2
100
1N4936
D3
1A
1N4936
100V
47.5
IRFD110
1
22.1K
Q7
1/2W
600mA
40V
R16
DZ6
2N4403
POSITIVE
INPUT
1.00K
6.2V
1W
9
D9
B
1.00K
1N4936
Q6
Q3
1A
600mA
DZ1
10V
1W
C1
40V
C1 C2 C3 C4 C5
A1
G1
2N4403
R8
100V
DZ5
6.2V
1W
SNUBBER
RESISTOR
10.0
G2
G3
G4
G5
IRFD110
A2
Q5
DZ4
15V
1W
A2
600mA
40V
R17
10.0
M16100-23
1
Q4
M16100-23
C1
2N4403
1/2W
600mA
40V
DZ3
E1 E2 E3 E4
E5
R6
15.0K
10V 1W
2N4401
10.0
20
402 406
D5
1N4936
475
475
R9
---
---
404 408
C2
10.0
2700p
50V
R33
10.0
C3
100
.047
1.50K
1200V
C7
1
3
TRANSFORMER
PRIMARY
R
-
C2
A2
M16100-23
A2
R38
R39
INPUT
D1
39.2K
39.2K
1N4936
FILTER
W
R41
R40
CAPACITOR
39.2K
39.2K
221
100
D6
Q1
1N4936
D7
1A
C2
1N4936
100V
47.5
IRFD110
A1
1
22.1K
Q11
1/2W
M16100-26
A2
600mA
40V
DZ9
R23
2
-
TRANSFORMER
PRIMARY
2N4403
1.00K
6.2V
1W
4
D10
1.00K
A
1N4936
Q9
C4
Q10
600mA
40V
DZ2
10V
1W
C5
.047
1A
C1 C2 C3 C4 C5
1200V
2N4403
100V
DZ8
6.2V
1W
G1
R19
10.0
IRFD110
G2
G3
G4
G5
A1
Q8
DZ7
15V
1W
600mA
40V
401
---
405
---
R26
10.0
M16100-26
1
Q12
2N4403
403 407
1/2W
600mA
40V
DZ10
E1 E2 E3 E4
E5
15.0K
10V 1W
R25
10.0
2N4401
A1
20
D8
1N4936
475
475
SNUBBER
RESISTOR
R27
10.0
C8
A1
2700p
50V
R34
10.0
M16100-26
C1
100
1.50K
C6
NEGATIVE
INPUT
R
12
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
POWER WAVE 450
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G-23
G-23
ELECTRICAL DIAGRAMS
PC BOARD ASSEMBLY-SWITCH
G
2 3 9 0 - 1
ITEM
PART NO.
DESCRIPTION
REQ’D
A1
A2
1
1
M16100-8
M16100-7
ELECTRONIC MODULE (SS)
ELECTRONIC MODULE (SS)
B1,B2,B3,B5,B6,B7,B9,B10
B11,B12
10
T13157-6
TAB TERMINAL
C1,C5,C6,C7
C2,C8
C3,C4
{
4
2
2
S16668-5
S16668-4
S13490-112
.022/50
2700pF/50
.047/1200
B 1 0
B 7
B 1 2
B 1 1
B 9
B 3
B 6
B 2
B 1
B 5
D1,D2,D3,D4,D5,D6,D7,D8,D9
D10
10
T12705-34
1N4936
6.50
DZ1,DZ2,DZ3,DZ12
DZ4,DZ7
DZ5,DZ6,DZ8,DZ9
4
2
4
T12702-27
T12702-29
T12702-40
1N4740
1N4744A
1N4735
C 3
R3
R1
C 4
Q1,Q2,Q3,Q10
{
4
2
6
T12704-73
T12704-68
T12704-69
IC PKG MOSFET (SS)
2N4401
2N4403
D4
D2
D1
D6
Q4,Q12
Q5,Q6,Q7,Q8,Q9,Q11
R1,R3,R5,R24
R2,R4
R6,R8,R9,R17,R19,R25,R26
4
2
10
S19400-1000
S19400-2210
S19400-10R0
100 1/4W
221 1/4W
10 1/4W
R14
R16
R23
R21
R27,R33,R34
R38,R39,R40,R41
R7,R30
R10,R32
R11,R15,R22,R28,R43,R44
R45,R46
R12,R14,R20,R21
R13,R31
R16,R23
R18,R29,R37,R42
R35,R36
4
2
2
8
S19400-3922
S19400-1501
S19400-1502
S19400-2R00
39.2K 1/4W
1.5K 1/4W
15K 1/4W
1
2
1/4W
R13
R5
R31
R24
D8
4
2
2
4
2
S19400-1001
S19400-20R0
S19400-2212
S19400-4750
S19400-47R5
1K 1/4W
20 1/4W
22.1K 1/4W
475 1/4W
47.5 1/4W
D5
DZ5
DZ8
R30
R20
R2
R7
R12
R4
CAPACITORS = MFD/VOLTS
INDUCTANCE = HENRIES
RESISTANCE = OHMS
Q1
Q2
B8
B4
A1
Q10
Q3
A2
R33
R34
R9
R6
R27
R25
R26
R19
2.41
R17
R8
C7
C6
R29
R37
R18
R42
DZ4
R35
D3
DZ7
R36
D7
D9
D10
DZ2
DZ1
C8
C2
R32
R10
G2390-1 V400 SWITCH
0
4.13
8.25
0
Ch’ge. Sht. No.
9-22-2000
EQUIP.
TYPE
INVERTER WELDERS
THE LINCOLN ELECTRIC CO.
1-6-95B
5-19-95F
8-25-95A
CLEVELAND, OHIO U.S.A.
SWITCH P.C. BOARD ASSEMBLY
SUBJECT
SCALE
FULL
SHT.
7-25-97F
7-25-97J
L8982-1
JLV
2-16-94
R.M.
REF.
2390-1
DR
DATE
CHK
SUP’S’D’G
NO.
G
NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your factory warranty. Individual Printed Circuit Board Components are not available from Lincoln Electric. This information is pro-
vided for reference only. Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician. Improper PC board repairs could result in damage to the
machine.
POWER WAVE 450
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G-24
G-24
ELECTRICAL DIAGRAMS
POWER WAVE RS 232 CONNECTIONS
9 PIN
RS 232
J17 MOLEX
POWER WAVE
NULL
MODEM
CABLE
FROM PC
CONNECTOR
DISPLAY BOARD
INTERNAL WIRING
#302
DCD
RD
1
2
3
4
5
6
7
8
9
1
1
2
3
4
5
6
7
8
9
2 TD
TD
3 RD
4 RTS
5 CTS
6 DSR
7 GND
8 DCD
#303
DTR
GND
DSR
RTS
CTS
RI
#306
#307
20DTR
22RI
NOTE: Lincoln Electric assumes no responsibility for liabilities resulting from board level troubleshooting. PC
Board repairs will invalidate your factory warranty. This Printed Circuit Board schematic is provided for
reference only. It may not be totally applicable to your machine’s specific PC board version. This dia-
gram is intended to provide general information regarding PC board function. Lincoln Electric discour-
ages board level troubleshooting and repair since it may compromise the quality of the design and may
result in Danger to the Machine Operator or Technician. Improper PC board repairs could result in
damage to the machine.
POWER WAVE 450
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SVM ERROR REPORTING FORM
We need to know if there are errors in our manuals. We also value any suggestions as to
additional tests or procedures that would make this SVM a better tool for you.
If you discover new or different “Problems or Symptoms” that are not covered in the three col-
umn troubleshooting chart, please share this information with us. Please include the
machine’s code number and how the problem was resolved.
Thank You,
Technical Services Group
Lincoln Electric Co.
22801 ST. Clair Ave.
Cleveland, Ohio 44117-1199
FAX 216-481-2309
SVM Number ___________________________
Page Number if necessary__________________
Your Company__________________________
Your Name_____________________________
Please give detailed description below:
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
SD287 01/99
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