RETURN TO MAIN INDEX
SVM135-B
July,2001
Power Wave 455/Power Feed 10
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 thought-
ful 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
World's Leader in Welding and Cutting Products
Premier Manufacturer of Industrial Motors
• 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
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.
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.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.
fumes and gases.When welding, keep
your head out of the fume. Use enough
• AC Welder with Reduced Voltage Control.
ventilation and/or exhaust at the arc to keep
fumes and gases away from the breathing zone. When
welding with electrodes which require special
ventilation such as stainless or hard facing (see
instructions on container or MSDS) or on lead or
cadmium plated steel and other metals or coatings
which produce highly toxic fumes, keep exposure as
low as possible and below Threshold Limit Values (TLV)
using local exhaust or mechanical ventilation. In
confined spaces or in some circumstances, outdoors, a
respirator may be required. Additional precautions are
also required when welding on galvanized steel.
3.c. In semiautomatic or automatic wire welding, the electrode,
electrode reel, welding head, nozzle or semiautomatic
welding gun are also electrically “hot”.
3.d. Always be sure the work cable makes a good electrical
connection with the metal being welded. The connection
should be as close as possible to the area being welded.
3.e. Ground the work or metal to be welded to a good electrical
(earth) ground.
5.b. Do not weld in locations near chlorinated hydrocarbon vapors
coming from degreasing, cleaning or spraying operations.
The heat and rays of the arc can react with solvent vapors to
form phosgene, a highly toxic gas, and other irritating
products.
3.f. Maintain the electrode holder, work clamp, welding cable and
welding machine in good, safe operating condition. Replace
damaged insulation.
3.g. Never dip the electrode in water for cooling.
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.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.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.i. When working above floor level, use a safety belt to protect
yourself from a fall should you get a shock.
3.j. Also see Items 6.c. and 8.
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 cir-
cuits. This can create fire hazards or overheat lifting chains
or cables until they fail.
8.a. Turn off input power using the disconnect
switch at the fuse box before working on
the equipment.
8.b. Install equipment in accordance with the U.S. National
Electrical Code, all local codes and the manufacturer’s
recommendations.
6.h. Also see item 1.c.
8.c. Ground the equipment in accordance with the U.S. National
Electrical Code and the manufacturer’s recommendations.
Mar ‘95
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iv
iv
SAFETY
5. Toujours porter des lunettes de sécurité dans la zone de
PRÉCAUTIONS DE SÛRETÉ
soudage. Utiliser des lunettes avec écrans lateraux dans les
zones où l’on pique le laitier.
Pour votre propre protection lire et observer toutes les instruc-
tions et les précautions de sûreté specifiques qui parraissent
dans ce manuel aussi bien que les précautions de sûreté
générales suivantes:
6. Eloigner les matériaux inflammables ou les recouvrir afin de
prévenir tout risque d’incendie dû aux étincelles.
7. Quand on ne soude pas, poser la pince à une endroit isolé de
la masse. Un court-circuit accidental peut provoquer un
échauffement et un risque d’incendie.
Sûreté Pour Soudage A L’Arc
1. Protegez-vous contre la secousse électrique:
a. Les circuits à l’électrode et à la piéce sont sous tension
quand la machine à souder est en marche. Eviter toujours
tout contact entre les parties sous tension et la peau nue
ou les vétements mouillés. Porter des gants secs et sans
trous pour isoler les mains.
8. S’assurer que la masse est connectée le plus prés possible
de la zone de travail qu’il est pratique de le faire. Si on place
la masse sur la charpente de la construction ou d’autres
endroits éloignés de la zone de travail, on augmente le risque
de voir passer le courant de soudage par les chaines de lev-
age, câbles de grue, ou autres circuits. Cela peut provoquer
des risques d’incendie ou d’echauffement des chaines et des
câbles jusqu’à ce qu’ils se rompent.
b. Faire trés attention de bien s’isoler de la masse quand on
soude dans des endroits humides, ou sur un plancher
metallique ou des grilles metalliques, principalement dans
les positions assis ou couché pour lesquelles une
grande partie du corps peut être en contact avec la
masse.
9. Assurer une ventilation suffisante dans la zone de soudage.
Ceci est particuliérement important pour le soudage de tôles
galvanisées plombées, ou cadmiées ou tout autre métal qui
produit des fumeés toxiques.
c. Maintenir le porte-électrode, la pince de masse, le câble
de soudage et la machine à souder en bon et sûr état
defonctionnement.
d.Ne jamais plonger le porte-électrode dans l’eau pour le
refroidir.
10. Ne pas souder en présence de vapeurs de chlore provenant
d’opérations de dégraissage, nettoyage ou pistolage. La
chaleur ou les rayons de l’arc peuvent réagir avec les
vapeurs du solvant pour produire du phosgéne (gas forte-
ment toxique) ou autres produits irritants.
e. Ne jamais toucher simultanément les parties sous tension
des porte-électrodes connectés à deux machines à soud-
er parce que la tension entre les deux pinces peut être le
total de la tension à vide des deux machines.
f. Si on utilise la machine à souder comme une source de
courant pour soudage semi-automatique, ces precautions
pour le porte-électrode s’applicuent aussi au pistolet de
soudage.
11. Pour obtenir de plus amples renseignements sur la sûreté,
voir le code “Code for safety in welding and cutting” CSA
Standard W 117.2-1974.
2. Dans le cas de travail au dessus du niveau du sol, se pro-
téger contre les chutes dans le cas ou on recoit un choc. Ne
jamais enrouler le câble-électrode autour de n’importe quelle
partie du corps.
PRÉCAUTIONS DE SÛRETÉ POUR
LES MACHINES À SOUDER À
TRANSFORMATEUR ET À
REDRESSEUR
3. Un coup d’arc peut être plus sévère qu’un coup de soliel,
donc:
a. Utiliser un bon masque avec un verre filtrant approprié
ainsi qu’un verre blanc afin de se protéger les yeux du
rayonnement de l’arc et des projections quand on soude
ou quand on regarde l’arc.
1. Relier à la terre le chassis du poste conformement au code
de l’électricité et aux recommendations du fabricant. Le dis-
positif de montage ou la piece à souder doit être branché à
une bonne mise à la terre.
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-inflamma-
bles.
2. Autant que possible, I’installation et l’entretien du poste
seront effectués par un électricien qualifié.
3. Avant de faires des travaux à l’interieur de poste, la
debrancher à l’interrupteur à la boite de fusibles.
4. Des gouttes de laitier en fusion sont émises de l’arc de
soudage. Se protéger avec des vêtements de protection
libres de l’huile, tels que les gants en cuir, chemise épaisse,
pantalons sans revers, et chaussures montantes.
4. Garder tous les couvercles et dispositifs de sûreté à leur
place.
Mar. ‘93
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RETURN TO MAIN INDEX
v
v
MASTER TABLE OF CONTENTS FOR ALL SECTIONS
Page
i-iv
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section A
Technical Specifications - Power Feed 10 Wire Drive and Control Box . . . . . . . . . . . . . . . . . . . . . .
Technical Specifications - Power Wave 455 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Location and Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electrical Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cable Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Wire Feeder Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A-2
A-3
A-4
A-4
A-6
A-7
A-9
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section B
Operating Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
System Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Controls and Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Weld Mode Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electrode Routing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Wire Spindle Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Wire Reel Loading - Readi-Reels, Spools or Coils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Feeding Electrode and Brake Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Drive Roll Kit Installation (KP1505-[]) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Drive Roll Pressure Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Procedure For Setting Angle of Feedplate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Wire Feed Overload Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
B-2
B-2
B-2
B-3
B-6
B-6
B-7
B-7
B-9
B-9
B-9
B-9
B-10
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section C
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Power Wave Options and Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Wire Feeder Options and Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
C-2
C-3
C-3
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section D
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Periodic Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
D-2
D-2
D-2
Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section E
Troubleshooting and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section F
How to Use Troubleshooting Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PC Board Troubleshooting Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Test Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Component Replacement Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
F-2
F-3
F-5
F-23
F-61
Electrical Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section G
Parts
Parts List Power Wave 455 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Parts List Power Feed 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
P-291
P-306
POWER WAVE 455/POWER FEED 10
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SECTION A-1
SECTION A-1
INSTALLATION
TABLE OF CONTENTS
-INSTALLATION SECTION-
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section A
Technical Specifications - Power Feed 10 Wire Drive and Control Box . . . . . . . . . . . . . . . . . . . . . .
Technical Specifications - Power Wave 455 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Location and Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Stacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Feeder and Control Box Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electrical Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
High Frequency Interference Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Input Fuse and Supply Wire Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Input Voltage Reconnect Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cable Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Control Cable Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Flexible Connection Possibilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cable Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electrode and Work Leads — Electrode Positive Applications . . . . . . . . . . . . . . . . . . . . . . . . .
Electrode and Work Leads — Electrode Negative Applications . . . . . . . . . . . . . . . . . . . . . . . . .
Voltage Sensing at the Workpiece . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Wire Feeder Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Wire Drive Gear Ratio (High or Low Speed) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DIP Switch Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Gun and Cable Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
GMAW Shielding Gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Standard Panel Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A-2
A-3
A-4
A-4
A-4
A-4
A-4
A-4
A-6
A-6
A-6
A-6
A-6
A-7
A-7
A-7
A-8
A-8
A-9
A-9
A-9
A-9
A-11
A-15
A-15
A-16
POWER WAVE 455/POWER FEED 10
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A-2
A-2
INSTALLATION
TECHNICAL SPECIFICATIONS – POWER FEED 10 WIRE DRIVE AND
CONTROL BOX
WIRE DRIVE OR WIRE DRIVE SECTION OF FEEDER
SPEC # TYPE
LOW SPEED RATIO
HIGH SPEED RATIO
Wire Size
Solid
Wire Size
Solid Cored
Speed
Cored
Speed
K1540-1 Power Feed 10
Wire Drive
50-800 IPM
(1.27-20.3 m/m)
.025 - 3/32 in.
(0.6 - 2.4 mm)
.035 - .125 in.
(0.9 - 3.2 mm)
75 - 1200 IPM
(2.03 - 30.5 m/m)
.025 - 1/16 in.
(0.6 - 1.6 mm)
.035 - 5/64 in.
(0.9 - 2.0 mm)
K1538-1 Power Feed 10
50-800 IPM
.025 - 3/32 in.
(0.6 - 2.4 mm)
.035 - .125 in.
(0.9 - 3.2 mm)
75 - 1200 IPM
(2.03 - 30.5 m/m)
.025 - 1/16 in.
(0.6 - 1.6 mm)
.035 - 5/64 in.
(0.9 - 2.0 mm)
Boom Package# (1.27-20.3 m/m)
K1541-1 Power Feed 10
50-800 IPM
Bench Model (1.27-20.3 m/m)
Drive and
.025 - 3/32 in.
(0.6 - 2.4 mm)
.035 - .125 in.
(0.9 - 3.2 mm)
75 - 1200 IPM
(2.03 - 30.5 m/m)
.025 - 1/16 in.
(0.6 - 1.6 mm)
.035 - 5/64 in.
(0.9 - 2.0 mm)
Control Box
CONTROL BOX, WIRE DRIVE AND COMPLETE UNITS
SPEC.# TYPE
INPUT POWER
PHYSICAL SIZE•
TEMPERATURE RATING
Dimensions
Width
8.50 in.
Height
Depth
4.0 in.
Weight
Operating
Storage
K1539-1 Power
40 VDC
13.0 in.
8.5 lbs
(Control
Box
Only)*
Feed 10
Control
Box
(330 mm)
( 215 mm) (105 mm)
(3.8 kg)
K1540-1 Power
40 VDC
40 VDC
7.6 in.
(195 mm)
12.9 in.
(325 mm)
13.7 in.
(345 mm)
30 lbs
(13.6 kg)
+40˚C
to
-20˚C
+40˚C
to
-40˚C
(Wire
Drive
Only)*
Feed 10
Wire
Drive
K1541-1 Power
18.5 in.
13.5 in.
30.5 in.
62 lbs
Bench
Model
Feed 10
Bench Model
( 470 mm)
(345 mm)
(775 mm)
(28.1 kg.)
Feeder∆ Drive and
Control Box
* Included with K1538-1 Boom package and K1541-1 Bench Feeder.
∆ Dimensions do not include wire reel.
# For Control Box and Wire Drive dimensions and weights, see individual component listings.
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A-3
A-3
INSTALLATION
TECHNICAL SPECIFICATIONS – POWER WAVE 455
INPUT AT RATED OUTPUT - THREE PHASE ONLY
Rated Output @
100% Duty Cycle
Input
Current
Rated Output @
60% Duty Cycle
Input
Current
Input Volts
208V - 60Hz
230V - 60Hz
400V - 60Hz
460V - 60Hz
200V - 50Hz
220V - 50Hz
400V - 50Hz
440V - 50Hz
450A@38V 100%
450A@38V 100%
450A@38V 100%
450A@38V 100%
450A@38V 100%
450A@38V 100%
450A@38V 100%
450A@38V 100%
70
65
39
35
72
67
40
36
570A@43V 60%
570A@43V 60%
570A@43V 60%
570A@43V 60%
500A@40V 60%
500A@40V 60%
500A@40V 60%
500A@40V 60%
87
82
50
48
79
74
45
41
OUTPUT
Open
Circuit
Voltage
Pulse
Voltage
Range
Pulse and
Background
Time Range
Pulse
Frequency
Auxiliary
Power
Current Range
5 - 570
0.15 - 1000 Hz
75 VDC
5 - 55 VDC
100 MICRO SEC. -
3.3 SEC.
40 VDC AT
10 AMPS
115 VAC AT
10 AMPS
Process Current Ranges (DC)
Current
MIG/MAG
FCAW
SMAW
Pulse
50-570 Amps
40-570 Amps
30-570 Amps
5-750 Amps
RECOMMENDED INPUT WIRE AND FUSE SIZES
Type 75°C
Copper Wire in
Type 75°C
Ground Wire in
Type 75°C
(Super Lag)
or Breaker
Size (AMPS)
Input
Voltage /
Frequency
Duty
Cycle
Input Ampere Rating Conduit AWG[IEC] Conduit AWG[IEC]
on Nameplate (AMPS)
Sizes (mm2)
Sizes (mm2)
208/60/50
230/60/50
400/60/50
460/60/50
208/60/50
230/60/50
400/60/50
460/60/50
100%
100%
100%
100%
60%*
60%*
60%*
60%*
70/72
65/67
39/40
35/36
87/79
82/74
50/45
48/41
4 (25)
4 (25)
8 (10)
8 (10)
4 (25)
4 (25)
6 (10)
6 (10)
8 (10)
8 (10)
10 (6)
10 (6)
8 (10)
8 (10)
8 (6)
80
70
50
40
90
90
60
50
8 (6)
PHYSICAL DIMENSIONS
Height
26.10 in.
663 mm
Width
19.86 in.
505 mm
Depth
32.88 in.
835 mm
Weight
250 lbs
114 kg
TEMPERATURE RANGES
Operating Temperature Range
Storage Temperature Range
0°C to 40°C
-50°C to 85°C
*At 60% duty cycle with 50Hz input power, the machine is de-rated to 500 Amps at 40V.
POWER WAVE 455/POWER FEED 10
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A-4
A-4
INSTALLATION
LIFTING
SAFETY PRECAUTIONS
WARNING
Lift the machine by the lift bail only. The lift bail is
designed to lift the power source only. Do not
attempt to lift the Power Wave with accessories
attached to it.
ELECTRIC SHOCK
can kill.
• Only qualified personnel should per-
form this installation.
FEEDER AND CONTROL BOX
MOUNTING
• Turn off the input power to the power
source at the disconnect switch or
fuse box before working on this equip-
ment. Turn off the input power to any
other equipment connected to the
welding system at the disconnect
switch or fuse box before working on
this equipment.
SEPARATION FROM BENCH MODEL
The Control Box can be removed from the bench
model feeder and mounted in a different location.
See Figure A-1.
• Do not touch electrically hot parts.
FIGURE A.1 — SEPARATING CONTROL BOX
AND FEEDER.
• Always connect the Power Wave
grounding lug (located inside the
reconnect input access door) to a
WIRE
DRIVE
CONTROL
BOX
proper safety (Earth) ground.
-----------------------------------------------------------
CENTER
PANEL
CONNECTOR
LOCATION AND MOUNTING
Place the welder where clean cooling air can freely
circulate in through the rear louvers and out through
the case sides and bottom. Dirt, dust, or any foreign
material that can be drawn into the welder should be
kept at a minimum. Using filters on the air intake to
prevent dirt from building up restricts air flow. Do
not use such filters. Failure to observe these precau-
tions can result in excessive operating temperatures
and nuisance shutdowns.
MOUNTING
SCREW
BOTTOM
PANEL
Complete the following steps to remove the Control
Box:
STACKING
1. Remove the bottom and center option panels
from the front of the Control Box.
Power Wave machines can be stacked to a maxi-
mum of three high. The bottom machine must
always be placed on a firm, secure, level surface.
There is a danger of machines toppling over if this
precaution is not taken.
2. Disconnect the connector between the Control
Box and the wire drive located in the middle of
the Control Box back near the bottom of the
Control Box.
ENVIRONMENT
The Power Wave power source carries an IP21 envi-
ronmental rating. If subjected to occasional falling
water, such as rain, the machine should be sheltered.
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A-5
A-5
INSTALLATION
6. Replace all option panels removed from front of
Control Box.
3. Loosen the four screws inside the Control Box
located along the sides of the back of the Control
Box, two near the bottom and two near the mid-
dle.
7. Place plug button saved in step 2 into hole in
back panel of Control Box.
4. Push the Control Box upwards and then pull the
Control Box away from the wire drive.
CONTROL BOX POWER SOURCE MOUNTING
5. Remove plug button taped to inside of Control
Box and insert it into hole on front panel of wire
drive.
The Power Feed Control Box can be directly mount-
ed on the front of the power source. If this control
location is preferred, complete the following steps to
mount Control Box on the power source:
BOOM MOUNTING
1. Remove the bottom and center option panels
from the front of the Control Box.
If you wish to convert to a boom mount, the follow-
ing components are required to complete the conver-
sion process:
2. Mount Control Box to the power source, follow-
ing the instructions supplied with that specific
power source.
Item 1 K1549-1 Receptacle
Item 2 K1550-1 Receptacle
3. If the Control Box has an input Amphenol con-
nector mounted on right side of bottom, then dis-
connect it’s 6-pin electrical connector from the
input connector inside the Control Box.
Assemble the components above as follows:
1. Remove plug button and mount item 1 to the left
hole in the bottom of the Control Box.
NOTE: This input connector no longer functions.
2. Remove and save plug button and mount item 2
to the right hole in the bottom of the Control Box.
4. Connect 6-pin connector that comes out of the
back of the Control Box to the 6 pin connector.
(See specific power source instructions.)
3. Insert connector from item 1 into either 4-pin
connector on Control Box motherboard.
5. 67 sense lead from left bottom connector (if pre-
sent) should be connected to 67 sense lead con-
nection from 6-pin connector from motherboard.
4. Insert 6-pin connector that went to wire drive unit
into item 2.
6. Replace all option panels removed from front of
Control Box.
5. Connect sense lead from item 1 to sense lead
from 6-pin connector that went to wire drive unit.
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A-6
A-6
INSTALLATION
INPUT FUSE AND SUPPLY WIRE
CONSIDERATIONS
ELECTRICAL CONNECTIONS
WARNING
Refer to the Technical Specifications at the begin-
ning of this Installation section for recommended fuse
and wire sizes. Fuse the input circuit with the recom-
mended super lag fuse or delay type breakers (also
called “inverse time” or “thermal/magnetic” circuit
breakers). Choose an input and grounding wire size
according to local or national electrical codes. Using
fuses or circuit breakers smaller than recommended
may result in “nuisance” shut-offs from welder inrush
currents, even if the machine is not being used at
high currents.
Only a qualified electrician should connect the
input leads to the Power Wave. Connections
should be made in accordance with all local and
national electrical codes and the connection dia-
gram located on the inside of the reconnect/input
access door of the machine. Failure to do so
may result in bodily injury or death.
-----------------------------------------------------------
Use a three-phase supply line. An access hole for
the input supply is located on the upper left case
back next to the input access door. Connect L1, L2,
L3 and ground according to the Input Supply
Connection Diagram decal located on the inside of
the input access door or refer to Figure A.2.
INPUT VOLTAGE RECONNECT
PROCEDURE
WARNING
GROUNDING
Turn main input power to the machine OFF
before performing reconnect procedure. Failure
to do so will result in damage to the machine.
DO NOT switch the reconnect bar with machine
power ON.
The frame of the welder must be grounded. A
ground terminal marked with the symbol
is
located inside the reconnect/input access door for
this purpose. See your local and national electrical
codes for proper grounding methods. Refer to the
Technical Specifications at the beginning of this
chapter for proper cable sizes.
-----------------------------------------------------------
Welders are shipped connected for the highest input
voltage listed on the rating plate. To connect to a dif-
ferent input voltage, refer to reconnect instructions
located on the inside of the input access door or in
Figure A.2. If the main reconnect switch is placed in
the wrong position, the welder will not produce output
power. If the Auxiliary (“A”) lead is placed in the
wrong position, there are two possible results. If the
lead is placed in a position higher than the applied
line voltage, the welder may not come on at all. If the
Auxiliary (“A”) lead is placed in a position lower than
the applied line voltage, the welder will not come on,
and the two circuit breakers in the reconnect area will
open. If this occurs, turn off the input voltage, prop-
erly connect the “A” lead, reset the breakers, and try
again.
HIGH FREQUENCY INTERFERENCE
PROTECTION
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.
POWER WAVE 455/POWER FEED 10
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A-7
A-7
INSTALLATION
FIGURE A.2 — CONNECTION DIAGRAM ON RECONNECT/INPUT ACCESS DOOR.
INPUT SUPPLY CONNECTION DIAGRAM
VOLTAGE=200-208V
W / L3
V / L2
U / L1
200-208V
220-230V
380-415V
440-460V
CR1
.
.
.
Disconnect input power before
inspecting or servicing machine.
'A'
'A'
Do not operate with covers
removed.
Do not touch electrically live parts.
.
Only qualified persons should install,
use or service this equipment.
VOLTAGE=220-230V
VOLTAGE=380-415V
VOLTAGE=440-460V
200-208V
220-230V
380-415V
440-460V
200-208V
220-230V
380-415V
440-460V
200-208V
220-230V
380-415V
440-460V
'A'
'A'
TYPICAL BENCH FEEDER CONNECTION
CABLE CONNECTIONS
Control cable is connected from Power Source (PS)
to Feed Head (FH). If the Control Box is separated
from the FH, a control cable will connect from the PS
to the control box, which will have two control cable
connectors. This could be the control box or the FH
control box depending on how the units were sepa-
rated. A second control cable would be connected
from the second connector on the control box to the
other FH control box.
CONTROL CABLE CONNECTIONS
• All system control cables are the same but can
vary in length.
• All control cables can be connected end to end to
extend their length.
• All system equipment must be connected to a
control cable.
TYPICAL BOOM FEEDER CONNECTION
Welding systems using the Power Feed 10 offer pre-
viously unprecedented flexibility in the connection of
system components. This system uses the same
type of control cable between each of the system
components. Connections can be “daisy chained”
from one system component to another. Since com-
munication over the control cables is done by a
robust communications network, the order of connec-
tion of the components makes no difference. The
cables can be connected anywhere that there is a
mating connector. See the flexible connections part
of this section for more details.
Control cable is connected from PS to the control
box. A second control cable would be connected
from the second connector on the control box to the
FH control box.
FLEXIBLE CONNECTION POSSIBILITIES
By using connector kits, a second connector can be
added to the Control box or the FH. This allows the
user to connect equipment types together in any
order.
NOTE: Maximum cable length between any two
nodes is 250 feet.
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A-8
A-8
INSTALLATION
When using an inverter type power source, use the
largest welding (electrode and ground) cables that
are practical. At least 2/0 copper wire — even if the
average output current would not normally require it.
When pulsing, the pulse current can reach very high
levels. Voltage drops can become excessive, lead-
ing to poor welding characteristics, if undersized
welding cables are used.
CONTROL CABLE SPECIFICATIONS
The cable is a five copper conductor cable in a SO-
type rubber jacket. There is one 20 gauge twisted
pair for network communications. This pair has an
impedance of approximately 120 ohms and a propa-
gation delay per foot of < 2.1 ns. There are two 12
gauge conductors that are used to supply the 40
VDC to the network. The fifth wire is 18 gauge and is
used as an electrode sense lead. It is typically con-
nected to the feed plate on the feed head when that
feed head is active.
ELECTRODE AND WORK LEADS —
ELECTRODE POSITIVE APPLICATIONS
Most welding applications run with the electrode
being positive (+). For those applications, connect
the electrode cable between the wire feeder and the
positive (+) output stud on the power source (located
beneath the spring loaded output cover near the bot-
tom of the case front). See Figure A.3.
AVAILABLE CABLE ASSEMBLIES
K1543 Control cable only. Available in lengths of
8, 16, 25, 50 and 100 feet.
2
K1544 Control cable and a 3/0 (85 mm ) electrode
cable with stud terminal. It is rated at 600
amps, 60% duty cycle and is available in
lengths of 8, 16, 25, and 50 feet.
FIGURE A.3 — ELECTRODE POSITIVE
APPLICATION.
POWER WAVE
2
K1545 Control cable and a 3/0 (85 mm ) electrode
cable with Twist-Mate™ connector on one
end and a stud terminal on the other. It is
rated at 500 amps, 60% duty cycle and is
available in lengths of 8, 16, 25, and 50 feet.
WIRE
FEEDER
TO
WORK
CABLE CONNECTIONS
To avoid interference problems with other equipment
and to achieve the best possible operation, route all
cables directly to the work or wire feeder. Avoid
excessive lengths, bundle the electrode and ground
cables together where practical, and do not coil
excess cable. Be sure the connection to the work
makes tight metal-to-metal electrical contact.
A work lead must be run from the negative (-) power
source output stud to the work piece. The work
piece connection must be firm and secure, especially
if pulse welding is planned. Excessive voltage drops
at the work piece connection often result in unsatis-
factory pulse welding performance.
Minimum work and electrode cables sizes are as fol-
lows:
Current
60% Duty
Minimum Copper Work Cable Size, AWG
Up to 100 ft Length (30m)
Cycle
400 Amps
2/0 (67 mm2)
500 Amps
600 Amps
3/0 (85 mm2)
3/0 (85 mm2)
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A-9
A-9
INSTALLATION
SELECTING THE PROPER GEAR RATIO
ELECTRODE AND WORK LEADS —
ELECTRODE NEGATIVE APPLICATIONS
See the Technical Specifications at the front of this
section for feed speed and wire size capabilities with
high and low speed gear ratios. To determine
whether you should be using the high or low speed
ratio, use the following guidelines:
When negative electrode polarity is required, such as
in some Innershield™ applications, install as above,
except reverse the output connections at the power
source (electrode cable to the negative (-) stud, and
work cable to the positive (+) stud). See Figure A.4.
- If you need to operate at wire feed speeds greater
than 800 IPM (20 m/m), you will need to install the
high speed gear (large, 30 tooth, 1.6 inch diameter
gear).
VOLTAGE SENSING AT THE WORK-
PIECE
- If you need to operate at wire feed speeds less than
800 IPM (20 m/m), you should use the low speed
gear (small, 20 tooth, 1.1 inch diameter gear).
Using the low speed ratio will provide the maximum
available wire driving force. Note: If you are feeding
only small diameter wires you may, at your option,
install the high speed ratio.
A four-pin voltage sense lead connector is located
beneath the output stud cover. In certain installa-
tions, where the work connection is poor, arc perfor-
mance may be improved by the use of an external
voltage sensing lead. Contact the factory for informa-
tion on connecting and using this feature.
FIGURE A.4 — ELECTRODE NEGATIVE
APPLICATION.
CHANGING THE WIRE DRIVE RATIO
POWER WAVE
Changing the ratio requires a gear change and a
switch position change located on the feed head PC
Board. The Power Feed 10 is shipped with both a
high speed and a low speed gear. As shipped from
the factory, the low speed (high torque) gear is
installed on the feeder. For identification purposes,
the low speed (high torque) gear has 20 teeth and is
1.1 inches in diameter. The high speed gear has 30
teeth and is 1.6 inches in diameter. See Figure A.5.
WIRE
FEEDER
TO WORK
FIGURE A.5 — CHANGING WIRE DRIVE RATIO.
WIRE
FEEDER
WIRE FEEDER SETUP
WIRE DRIVE GEAR RATIO (HIGH OR
LOW SPEED)
The speed range capability and drive torque of the
Power Feed 10 wire drive can be easily and quickly
changed by changing the external drive gear. The
Power Feed 10 is shipped with both a high speed
and a low speed gear. As shipped from the factory,
the low speed (high torque) gear is installed on the
feeder. If this is the desired gear ratio, no changes
need to be made.
PHILLIPS
HEAD SCREW
DRIVE
GEAR
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A-10
A-10
INSTALLATION
6. Tighten the screw on lower right face of feed
plate.
RATIO CHANGE PROCEDURE
1. Pull open the pressure door.
7. Re-attach feed plate to wire feeder if removed in
Step 2.
2. Remove the Phillips head screw retaining the
pinion gear to be changed and remove the gear.
If the gear is not easily accessible or difficult to
remove, remove the feed plate from the gearbox.
8. Feed plate will be rotated out-of-position due to
the gear change. Adjust the angle of the feed
plate by loosening the clamping collar screw
(Step 2a) and pivoting feed head.
To remove feed plate:
9. Set the High/Low switch code on Feed Head PC
board as follows:
a. Loosen the clamping collar screw using a
3/16 in. Allen wrench. The clamping collar
screw is accessed from the bottom of the
feed plate. It is the screw which is perpendic-
ular to the feeding direction.
a. Power down the Power Feed by turning off its
campanion Power Wave power source. For
maximum safety, disconnect the control cable
from the Power Feed.
b. Loosen the retaining screw, which is also
accessed from bottom of feeder, using a
3/16 in. Allen wrench. Continue to loosen the
screw until the feed plate can be easily
pulled off of the wire feeder.
b. Remove the cover from the back of the feed
head (2 screws).
c. Locate the 8-position DIP switch near the top
edge of the PC board, centered left to right.
The setting will be made on the right most
switch, S8.
3. Loosen, but do not remove, the screw on the
lower right face of the feed plate with a 3/16 in.
Allen wrench.
d. Using a pencil or other small object, slide the
switch down, to the “0” position, when the low
speed gear is installed. Conversely, slide the
switch up, to the “1” position, when the high
speed gear is installed. Refer to Figure A.6.
4. Remove the screw on the left face of the feed
plate. If changing from high speed (larger gear)
to low speed (smaller gear), line the upper hole
on the left face of the feed plate with the threads
on the clamping collar. Line the lower hole with
the threads to install larger gear for high speed
feeder. If feed plate does not rotate to allow
holes to line up, further loosen the screw on right
face of feed plate.
e. Replace the cover and screws. The PC board
will “read” the switch at power up, automati-
cally adjusting all control parameters for the
speed range selected.
5. Remove the small gear from the output shaft.
Lightly cover the output shaft with engine oil or
equivalent. Install gear onto output shaft and
secure with flat washer, lock washer, and Phillips
head screw which were previously removed.
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A-11
A-11
INSTALLATION
ON
ON
S1
S2
1
1
2
2
3
3
4
4
5
5
6
6
7
7
8
8
DIP SWITCH SETUP
SETTING DIP SWITCHES IN THE
CONTROL BOX
There are two DIP switch banks on the mother board
of the Control Box. They are labeled S1 and S2 and
are located and oriented as shown in Figure A.3.
FIGURE A.3
S1 DIP Switch Bank on Control Box Motherboard (For software version S24004-2 only)
Switch
Off
On
1
2
3
US 4-Step Trigger Logic
WFS Display = inches/minute
Left Display is always preset WFS
Euro 4-Step Trigger Logic
WFS Display = meters/minute
Left Display is preset WFS when weld current is not flowing
Left Display is actual weld current when weld current is flowing
CC modes override this switch regardless of position. Left Display is always preset weld cur-
rent when weld current is not flowing and actual weld current when weld current is flowing
4
Run-in = Minimum Speed Available
Run-in = weld WFS
If any option containing a Run-in setting is connected to the motherboard, it automatically
overrides this switch regardless of position.
5
6
7
8
Spare
Acceleration, MSB (Sets acceleration rate for wire drive) see below
Acceleration
(Sets acceleration rate for wire drive) see below
Acceleration, LSB (Sets acceleration rate for wire drive) see below
S2 DIP Switch Bank on Control Box Motherboard (For software version S24004-2 only)
Switch
Off
On
1
2
3
4
5
6
7
8
Network Group ID, MSB (Assigns Control Box to a specific group) (Off is factory setting)
Network Group ID, LSB (Assigns Control Box to a specific group ) (Off is factory setting)
Spare
Spare
Spare
Spare
Spare
Reserved
Note: the factory shipped settings for all of the S1 and S2 switches is “OFF”.
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A-12
A-12
INSTALLATION
S1 DIP Switch Bank on Control Box Motherboard (For software version S24004-3 & up)
Switch
Off
On
1
2
3
Standard speed gearbox limits adjustable
WFS Display = inches/minute
Left Display is always preset WFS
High speed gearbox limits adjustable
WFS Display = meters/minute
Left Display is preset WFS when weld current is not flowing
Left Display is actual weld current when weld current is flowing
CC modes override this switch regardless of position. Left Display is always preset weld cur-
rent when weld current is not flowing and actual weld current when weld current is flowing
4
Run-in = Minimum Speed Available
Run-in = weld WFS
If any option containing a Run-in setting is connected to the motherboard, it automatically
overrides this switch regardless of position.
5
6
7
8
Memory change with trigger disabled
Acceleration, MSB (Sets acceleration rate for wire drive) see below
Acceleration (Sets acceleration rate for wire drive) see below
Acceleration, LSB (Sets acceleration rate for wire drive) see below
Memory change with trigger enabled
S2 DIP Switch Bank on Control Box Motherboard (For software version S24004-3 & up)
Switch
Off
On
1
2
3
4
5
6
7
8
Network Group ID, MSB (Assigns Control Box to a specific group) (Off is factory setting)
Network Group ID, LSB (Assigns Control Box to a specific group ) (Off is factory setting)
Spare
Spare
Spare
Must be off for normal operation
Must be off for normal operation
Must be on for European units only
Adjust lower limits
Adjust upper limits
Note: the factory shipped settings for all of the S1 and S2 switches is “OFF”.
MSB - Most Significant Bit or Byte. This is the bit in a binary number or DIP switch bank that is furthest to the left.
LSB - Least Significant Bit or Byte. This is the bit in a binary number or DIP switch bank that is furthest to the right.
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A-13
A-13
S1 DIP Switch Bank on Control Box Motherboard (For software version S24456)
INSTALLATION
Switch
Off
On
1
2
3
Standard speed gearbox limits adjustable
WFS Display = inches/minute
Left Display is always preset WFS
High speed gearbox limits adjustable
WFS Display = meters/minute
Left Display is preset WFS when weld current is not flowing
Left Display is actual weld current when weld current is flowing
CC modes override this switch regardless of position. Left Display is always preset weld cur-
rent when weld current is not flowing and actual weld current when weld current is flowing
4
Run-in = Minimum Speed Available
Run-in = weld WFS
If any option containing a Run-in setting is connected to the motherboard, it automatically
overrides this switch regardless of position.
5
6
7
8
Memory change with trigger disabled
Acceleration, MSB (Sets acceleration rate for wire drive) see below
Acceleration (Sets acceleration rate for wire drive) see below
Acceleration, LSB (Sets acceleration rate for wire drive) see below
Memory change with trigger enabled
Note: the factory shipped settings for the S1 switches are as follows:
PF-10 (and Dual) Domestic - All switches “OFF”
PF-11 Domestic - switches 2-8 “OFF”, 1 “ON”
PF-10 (and Dual) European - switches 1 & 3-8 “OFF”, 2 “ON”
PF-11 European - switches 3-8 “OFF”, 1,2 “ON”
S2 DIP Switch Bank on Control Box Motherboard (For software version S24456)
Switch
Off
On
1
2
3
4
5
6
7
8
Network Group ID, MSB (Assigns Control Box to a specific group) (Off is factory setting)
Network Group ID, LSB (Assigns Control Box to a specific group ) (Off is factory setting)
4-Step Domestic Configuration
Power Feed 10 / Dual
4-Step European Configuration
Power Feed 11
Procedure Change with Trigger “OFF” Procedure Change with Trigger “ON”
Set lower limits
Set upper limits
Must be on for all units (Permits selection of extended modes)
Note: the factory shipped settings for the S2 switches are as follows:
PF-10 (and Dual) Domestic - switches 1-7 “OFF”, 8 “ON”
PF-11 Domestic - switches 1-3,5-7 “OFF”, 4,8 “ON”
PF-10 (and Dual) European - switches 1,2,4-7 “OFF”, 3,8 “ON”
PF-11 European - switches 1,2,5-7 “OFF”, 3,4,8 “ON”
MSB - Most Significant Bit or Byte. This is the bit in a binary number or DIP switch bank that is furthest to the left.
LSB - Least Significant Bit or Byte. This is the bit in a binary number or DIP switch bank that is furthest to the right.
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A-14
A-14
INSTALLATION
Setting Wire Drive Acceleration Rate Using
DIP Switch S1 on the Control Box Motherboard
(All software versions)
DIP SWITCH 6
Off
DIP SWITCH 7
DIP SWITCH 8
Acceleration 1 (slow)
Acceleration 2
Off
On
On
Off
Off
On
Off
On
Off
Off
Off
Off
On
Off
Acceleration 3
Acceleration 4
Acceleration 5 (fast ) (factory setting)
SETTING DIP SWITCHES IN THE WIRE
DRIVE
ON
1
2
3
4
5
6
7
8
There is one DIP switch bank on the control board of
the wire drive. It’s labeled S1 and is located and ori-
ented as shown in Figure A.4.
FIGURE A.4
S1 DIP Switch on Wire Drive Control Board (For software version S24029-All & S24467)
Switch
Off
On
1
2
3
4
5
6
7
Network Group ID, MSB (Assigns Wire Drive to a specific group)
Network Group ID, LSB (Assigns Wire Drive to a specific group )
Network Feed Head ID, MSB (Assigns feed head number to wire drive)
Network Feed Head ID
(Assigns feed head number to wire drive)
Network Feed Head ID, LSB (Assigns feed head number to wire drive)
Spare
Electrode Sense Polarity = Positive
Switch position must match polarity of weld cable attached to feed plate.
Gear Box Ratio = Low Gear Box Ratio = High
Switch position must match actual gear box ratio of wire drive.
Electrode Sense Polarity = Negative
8
Note: the factory shipped settings for all of the S1 switches is “OFF”.
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A-15
A-15
INSTALLATION
GMAW SHIELDING GAS
GUN AND CABLE ASSEMBLIES
GUN AND CABLE ASSEMBLIES WITH
STANDARD CONNECTION
WARNING
The Power Feed 10 wire feeder is equipped with a
factory installed K1500-2 gun connection kit. This kit
is for guns having a Tweco™ #2-#4 connector. The
Power Feed 10 has been designed to make connect-
ing a variety of guns easily and inexpensively with the
K1500 series of gun connection kits. Gun trigger and
dual procedure lead connections connect to the single
five pin receptacle on the front of the feed head box.
See Gun Adapters in Accessories section.
CYLINDER may explode if damaged.
• Keep cylinder upright and chained to
support.
• Keep cylinder away from areas where it
may be damaged.
• Never lift welder with cylinder attached.
• Never allow welding electrode to touch
cylinder.
GENERAL GUN CONNECTION GUIDELINES
The instructions supplied with the gun and K1500
series gun adapter should be followed when
installing and configuring a gun. What follows are
some general guidelines that are not intended to
cover all guns.
• Keep cylinder away from welding or
other live electrical circuits.
BUILDUP OF SHIELDING GAS may
harm health or kill.
a. Check that the drive rolls and guide tubes
are proper for the electrode size and type
being used. If not, change them per drive
roll installation instructions in the Operation
section.
• Shut off shielding gas supply when not
in use.
SEE AMERICAN NATIONAL STANDARD Z-49.1,
“SAFETY IN WELDING AND CUTTING” PUB-
LISHED BY THE AMERICAN WELDING
SOCIETY.
b. Lay the cable out straight. Insert the connec-
tor on the welding conductor cable into the
brass conductor block on the front of the wire
drive head. Make sure it is all the way in and
tighten the hand clamp. Keep this connec-
tion clean and bright. Connect the trigger
control cable polarized plug into the mating
five cavity receptacle on the front of the wire
drive unit.
-----------------------------------------------------------
Customer must provide a cylinder of shielding gas, a
pressure regulator, a flow control valve, and a hose
from the flow valve to the gas inlet fitting of the wire
drive unit.
Connect a supply hose from the gas cylinder flow
valve outlet to the 5/8-18 female inert gas fitting on
the back panel of the wire drive or, if used, on the
inlet of the Gas Guard Regulator. See Accessories
section.
NOTE: For Fast-Mate and European connector style
guns, connect gun to gun connector making sure all
pins and gas tube line up with appropriate holes in
connector. Tighten gun by turning large nut on gun
clockwise.
c. For GMA gun cables with separate gas fit-
tings, connect the 3/16 in. I.D. gas hose
from the wire drive unit to the gun cable
barbed fitting.
d. For water cooled guns, refer to the instruc-
tions supplied with the kit.
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A-16
A-16
INSTALLATION
CV/GOUGE PANEL
STANDARD PANEL INSTALLATION
NOTE: Installation Instructions for the standard
equipment panels will be required only if you have
removed a standard panel and wish to reinstall it.
CONTROL/DISPLAY PANEL
NOTE: Installation Instructions for the standard
equipment panels will be required only if you have
removed a standard panel and wish to reinstall it.
The CV/Gouge Panel fits into the lower position of
the Control Box.
The Control/Display Panel fits into the upper or mid-
dle slots of the Control Box, and is used to adjust
WFS, Amps, Voltage, and Trim. It is also the location
of the Status indicator, a diagnostic tool provided for
system troubleshooting.
Installation is as follows:
1. Turn off power.
2. Remove the two screws from the front of the
Control Box panel. Save the screws, discard the
old panel or save for future use.
Installation is as follows:
1. Turn off power.
3. Tilt the new option panel away from the front
opening of the Control Box cabinet. Plug the
electrical connector into the proper connector on
the right side of the main printed circuit board
(12 pin). Make sure the connector latches in
place.
2. Remove the two screws from the front of the
blank option panel at the location you choose to
install your new panel, (top or middle), of the
Control Box cabinet. Discard the blank panel or
save for future use and save the screws.
4. Position the panel to the opening, taking care not
to damage the switch connections on the back.
3. Tilt the new panel away from the front opening of
the Control Box cabinet. Plug the electrical con-
nector into the proper connector on the right side
of the main printed circuit board (14 pin). Make
sure the connector latches in place.
5. Align the screw holes, replace the two screws
and tighten.
4. Position the new panel, taking care not to dam-
age the printed circuit boards on the back and
align the screw holes.
OPTIONAL PANELS FOR CONTROL BOX
All optional panels for the control box are described
in the Accessories section of this manual.
5. Replace the two screws and tighten.
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SECTION B-1
SECTION B-1
OPERATION
TABLE OF CONTENTS
-OPERATION SECTION-
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section B
Operating Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
System Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Recommended Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Duty Cycle and Welding Capabilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Limitations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Controls and Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Power Wave Controls and Status Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Power Feed Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Display Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Board Level Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Weld Mode Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Constant Voltage (CV/MIG) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Arc Gouging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electrode Routing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Wire Spindle Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Wire Reel Loading - Readi-Reels, Spools or Coils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
To Mount a 30 lb (14 kg) Readi-Reel Package
B-2
B-2
B-2
B-2
B-3
B-3
B-3
B-3
B-4
B-5
B-6
B-6
B-6
B-6
B-6
B-7
B-7
(Using the Molded Plastic K363-P Readi-Reel Adapter) (Figure B.4): . . . . . . . . . . . . . . . . .
To Mount 10 to 44 lb (4.5 to 20 kg) Spools [12 in. (300 mm) Diameter]
B-7
or 14 lb (6 kg) Innershield Coils (Figure B.4): . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
To Mount a 50 to 60 lb (22.7 to 27.2 kg) Coil (Using K1504-1 Coil Reel) (Figure B.5): . . . . . . .
Feeding Electrode and Brake Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Drive Roll Kit Installation (KP1505-[]) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Drive Roll Pressure Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Procedure For Setting Angle of Feedplate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Wire Feed Overload Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
B-8
B-8
B-9
B-9
B-9
B-9
B-10
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B-2
B-2
OPERATION
OPERATING INSTRUCTIONS
SYSTEM DESCRIPTION
Read and understand this entire section of operating
instructions before operating the machine.
The Power Wave 455 is a high performance, digitally
controlled inverter welding power source capable of
complex, high-speed waveform control. The Power
Feed 10 is a high performance, digitally controlled,
modular wire feeder. Properly equipped, they can
support the GMAW, GMAW-P, and FCAW processes.
SAFETY INSTRUCTIONS
WARNING
Operating as a system, each component in the sys-
tem has special circuitry to “talk with” the other sys-
tem components, so each component (power source,
wire feeder, electrical accessories) knows what the
other is doing at all times. This shared information
lays the groundwork for a system with superior weld-
ing performance.
ELECTRIC SHOCK
can kill.
• Do not touch electrically live parts or
electrodes with your skin or wet cloth-
ing.
The Power Feed 10 is a four driven roll feeder that
operates on 40 VDC input power, and is available
configured in both boom and bench models. In addi-
tion, the Control Box and wire feed unit can also be
purchased separately. The bench model is designed
so that it can easily be converted to a boom feeder.
• Insulate yourself from the work and
ground.
• Always wear dry insulating gloves.
-----------------------------------------------------------
FUMES AND GASES
can be dangerous.
RECOMMENDED EQUIPMENT
• Keep your head out of fumes.
The Power Feed 10 must be used with the Power
Wave 455.
• Use ventilation or exhaust to remove
fumes from breathing zone.
-----------------------------------------------------------
WELDING SPARKS
can cause fire or explosion.
• Keep flammable material away.
• Do not weld on containers that have
held combustibles.
-----------------------------------------------------------
ARC RAYS
can burn.
• Wear eye, ear, and body protection.
Observe additional Safety Guidelines detailed in
the beginning of this manual.
-----------------------------------------------------------
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B-3
B-3
OPERATION
DUTY CYCLE AND WELDING
CAPABILITIES
CONTROLS AND SETTINGS
POWER WAVE CONTROLS AND
STATUS LIGHTS
The Power Feed 10 wire feeder is capable of welding
at a 100% duty cycle (continuous welding). The
power source will be the limiting factor in determining
system duty cycle capability.
All operator controls and adjustments are located on
the case front of the Power Wave. See Figure B.1.
The Power Wave 455 is rated 450 amps at 38 volts,
100% duty cycle, and 570 amps at 43 volts, 60%
duty cycle. On 50 Hz, the 60% rating is 500 amps at
40 volts, 60% duty cycle. The duty cycle is based
upon a ten minute period. A 60% duty cycle repre-
sents six minutes of welding and four minutes of
idling in a ten minute period.
FIGURE B.1 — POWER WAVE CONTROLS
AND STATUS LIGHTS.
HIGH
TEMPERATURE
LIGHT
SPRING LOADED
OUTPUT COVER
(CUTAWAY)
STATUS
LIGHT
If the duty cycle is exceeded, a thermostat will shut
off the output until the machine cools to a reasonable
operating temperature.
ON/OFF
SWITCH
115 VAC
AUXILIARY
RECEPTACLE
NEGATIVE
TERMINAL
LIMITATIONS
• The Power Wave is not recommended for process-
es other than those listed.
• The Power Wave can only be used with Power
Feed wire feeders. Other models of Lincoln feed-
ers, or any models of non-Lincoln wire feeders,
cannot be used.
POSITIVE
TERMINAL
CIRCUIT
BREAKERS
CONTROL
CABLE
CONNECTOR
1. POWER SWITCH: Controls input power to the
Power Wave.
2. STATUS LIGHT: A two color light that indicates
system errors. Normal operation is a steady
green light. Error conditions are indicated as fol-
lows:
NOTE: The Power Wave 455 status light will flash
green, and sometimes red and green, for up to one
minute when the Power Wave 455 is first turned on.
This is a normal situation as the machine goes
through a self test at power up.
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B-4
B-4
OPERATION
FIGURE B.2 — WIRE FEEDER CONTROLS.
Light
Condition
Meaning
CONTROL BOX
(SHOWN ATTACHED
TO WIRE FEEDER)
Steady Green System OK. Power source communicating
normally with wire feeder and its
components.
Blinking
Green
Nothing connected to Wire Feeder
Receptacle.
Alternating
Green and
Red
Recoverable system fault. See
Troubleshooting Section.
Steady Red Non-recoverable system fault. Must turn
power source off, find source of error, and
turn power back on to reset. See
Troubleshooting Section.
Blinking Red See Troubleshooting Section.
3. HIGH TEMPERATURE LIGHT (thermal overload):
A yellow light that comes on when an over tem-
perature situation occurs. Output is disabled until
the machine cools down. When cool, the light
goes out and output is enabled.
2. COLD FEED/
GAS PURGE
SWITCH
COLDFEED
STATUS
4-STEP
2-STEP
3. STATUS
LIGHT
4. 10 AMP WIRE FEEDER CIRCUIT BREAKER:
Protects 40 volt DC wire feeder power supply.
1. 2-STEP/
4-STEP
SWITCH
5. 10 AMP AUXILIARY POWER CIRCUIT BREAK-
ER: Protects 115 volt AC receptacle.
When the switch is in the 4-step position, the gun
trigger functions as follows:
4-Step Operation (Current interlock):
1. Closing trigger initiates gas preflow time followed
by run in speed and strike voltage until welding
current is established.
POWER FEED CONTROLS
2. Once current is established, the trigger may be
released and welding will continue.
1. 2-STEP/4-STEP SWITCH OPERATION
3. When the trigger is closed again, welding will
continue but the current interlock function will be
disabled.
The Power Feed head unit has a 2-Step/4-Step
switch shown in Figure B.2. This switch has no
effect in CC modes of operation such as stick weld-
ing. When in the 2-step position, the gun trigger func-
tions as follows:
4. Releasing the trigger stops the wire feed and ini-
tiates burnback followed by gas postflow.
2. COLD FEED/GAS PURGE SWITCH
2-Step Operation:
The Power Feed head unit has a Cold Feed/Gas
Purge switch. When left untouched, this switch
returns to a center position where no action results.
1. Closing the gun trigger initiates gas preflow time
followed by run in speed and strike voltage until
welding current is established.
2. Opening the gun trigger during a weld stops wire
feed and initiates burnback time, followed by gas
postflow time.
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B-5
B-5
OPERATION
Cold feed function:
1. Indicator Lights:
When this switch is held in the up position, the unit
automatically feeds wire, but does not activate output
to the power source or gas solenoid. The speed of
this cold feed is factory preset to 200 IPM. It can be
adjusted while the switch is held up, by rotating the
WFS encoder knob on the Control Box. Note that
this cold feed speed is independent of WFS or run in
speeds. When the cold feed switch is released, the
cold feed value is memorized for the next time cold
feed is activated.
Indicates either WFS or AMPS for the left display,
and VOLTS or TRIM for the right display.
2. Displays:
Two extra bright, 3 1/2 digit, red LED displays. The
values of the active parameters are displayed, as
defined by their associated indicators. The left dis-
play is for WFS or Amps, while the right display is for
voltage or trim.
Gas purge function:
3. Left Encoder-Wire Feed Speed or Output Amps:
When this switch is held in the down position only the
gas solenoid valve is energized.
The left encoder is used to adjust the parameters for
either wire feed speed or output amps, dependent
upon the process and weld mode being used.
Rotating the encoder knob CCW decreases the num-
ber value, while rotating the knob CW increases the
number value. The ranges and limits are as follows:
3. STATUS LIGHT
A two color light that indicates system errors. Normal
operation is a steady green light.
WFS - Low Range: 50 to 800 IPM (1.25 to 19.99 MPM)
High Range: 75 to 1200 IPM (2.0 to 30.5 MPM)
DISPLAY CONTROL PANEL
AMPS - Limited by the power source based on mode
and process.
The Display Control panel is the main input to the
system. From it, the operator can control WFS,
amps, voltage, and trim depending on the active weld
mode. It is also the location of the Status
indicator, a multicolored diagnostic LED (see
Troubleshooting section). Refer to Figure B.3.
4. Right Encoder - Trim or Output Volts:
The right encoder operates in the same manner as
the left except that either output Volts or Trim is
adjusted. The ranges and limits are as follows:
FIGURE B.3 — CONTROL BOX.
1. INDICATOR
LIGHTS
1. INDICATOR
LIGHTS
VOLTS - 00.0 to 99.9 volts, limited by power source
based on mode and process.
2. DISPLAYS
DISPLAY
CONTROL
PANEL
TRIM - 0.50 to 1.50, nominal value is 1.00
3. WFS/
When not welding (no output current flow) the displays
reflect the preset values. During welding (output cur-
rent flowing) the displays depict actual values. These
actual values are held for a period of five seconds after
welding (output current) ceases. This hold feature is
canceled if a trigger pull or encoder adjustment occurs
during the hold time. The actual value displayed is
dependent upon the weld mode and process being
used.
AMPS
ENCODER
WFS
AMPS
VOLTS
TRIM
A
V
T
STATUS
4. VOLTS/
TRIM
ENCODER
BLANK PANEL
5. STATUS
LIGHT
m
WELD MODE
CV/MIG
5. Status light:
GOUGE
6. CV/GOUGE PANEL
A two color light that indicates system errors. Normal
operation is a steady green light.
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B-6
B-6
OPERATION
6. CV/GOUGE PANEL
preprogrammed voltages; for example, to compen-
sate for cable and fixture voltage drops. The preset
voltages can be adjusted on the wire feeder’s voltage
display. When a change is made to the voltage at
one wire feed speed, this change is applied to all
other wire feed speed settings. For example, if the
operator turns up the voltage by 10 percent, the
machine automatically increases the preset voltages
at all the other wire feed speeds by 10 percent. The
preset voltage, programmed at the factory, may be
changed with the wire feeder VOLTS adjustment.
The CV/Gouge Panel provides a fixed toggle switch
selection of two power source modes. The upper
position selects the generic CV/MIG mode from the
power source while the lower position selects the
GOUGE mode.
OPTIONAL PANELS
A number of Optional Features are available for use
with the Power Feed 10. Some Installation informa-
tion is provided in the ACCESSORIES section,
REFER TO THE INSTRUCTIONS THAT COME
WITH EACH KIT FOR DETAILED INFORMATION
REGARDING INSTALLATION.
ARC GOUGING
Arc gouging can be performed by choosing the arc
gouging weld mode. Doing so automatically ener-
gizes the output terminals on the Power Wave, mak-
ing the power source immediately ready to gouge.
The output current is set by the AMPS control on the
Power Weld wire feeder. The VOLTS/TRIM adjust-
ment has no effect in this mode.
BOARD LEVEL ADJUSTMENTS
The control box motherboard provides the capability
to adjust some basic parameters as follows.
The ARC CONTROL adjusts the arc force.
Increasing the ARC CONTROL setting increases the
arc force, making the arc more harsh but less likely
to stick. Decreasing the ARC CONTROL setting
decreases the arc force, making the arc softer and
smoother.
BURNBACK
The BURNBACK trimmer (R5) is provided as a basic
adjustment for burnback time. The range is 0.0 to
0.25 seconds, CCW limit is minimum, CW limit is
maximum. This value is overridden by any option
with the ability to independently adjust burnback.
ELECTRODE ROUTING
ACCELERATION
The electrode supply may be either from reels,
Readi-Reels, spools, or bulk packaged drums or
reels. Observe the following precautions:
See DIP Switch setup in the Installation section.
a. The electrode must be routed to the wire
drive unit so that the bends in the wire are at
a minimum, and also that the force required
to pull the wire from the reel into the wire
drive unit is kept at a minimum.
RUN IN
See DIP Switch setup in the Installation section.
WELD MODE DESCRIPTIONS
b. The electrode is “hot” when the gun trigger is
pressed and must be insulated from the
boom and structure.
CONSTANT VOLTAGE (CV/MIG)
c. If more than one wire feed unit shares the
same boom and are not sharing the some
power source output stud, their wire and
reels must be insulated from each other as
well as insulated from their mounting struc-
ture.
For each wire feed speed, a corresponding voltage is
preprogrammed into the machine through special
softwares at the factory. This preprogrammed volt-
age 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 automatical-
ly changes with it.
In some cases, the operator may want to change the
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B-7
B-7
OPERATION
FIGURE B.4 — READI-REEL MOUNTING.
WIRE SPINDLE PLACEMENT
ADAPTER
2 IN. O.D.
SPINDLE
The reel stand provides two mounting locations for
the 2 inch diameter wire reel spindle to accommo-
date various reel sizes. Each mounting location con-
sists of a tube in the center of the reel stand, and a
locating pin on the right side (viewed from the front)
of the reel stand. The bolt, used with a plain washer
and lock washer, slides through the tube from the left
side of the reel stand. The large plain washer is
placed between the wire spindle hub and the reel
stand. The bolt should be threaded into the wire
spindle such that the locating pin aligns with the
largest of the three holes (the hole that is not
recessed) in the back side of the wire spindle base.
RETAINING
SPRING
RETAINING
COLLAR
BRAKE
HOLDING
PIN
GROOVES
The upper location must be used for 50 to 60 lb
Readi-Reels, spools and coils.
READI-REEL
INSIDE
CAGE
WIRES
RELEASE
BAR
For smaller coils (44 lb, 30 lb, 10 lb, etc.), the spindle
can be placed in either the upper or lower location.
The goal is to make the wire path from the coil to the
incoming wire guide as straight as possible. This will
optimize wire feeding performance.
6. Set one of the Readi-Reel inside cage wires on
the slot in the retaining spring tab.
7. Lower the Readi-Reel to depress the retaining
spring and align the other inside cage wires with
the grooves in the molded adapter.
WIRE REEL LOADING -
READI-REELS, SPOOLS
OR COILS
8. Slide cage all the way onto the adapter until the
retaining spring “pops up” fully.
TO MOUNT A 30 LB (14 KG) READI-
REEL PACKAGE (USING THE MOLDED
PLASTIC K363-P READI-REEL
CAUTION
Check to be sure the retaining spring has fully
returned to the locking position and has SECURELY
locked the Readi-Reel cage in place. Retaining
spring must rest on the cage, not the welding elec-
trode.
ADAPTER) (FIGURE B.4):
The spindle should be located in the LOWER mount-
ing hole.
-----------------------------------------------------------
1. Depress the release bar on the retaining collar
and remove it from the spindle.
9. To remove Readi-Reel from adapter, depress
retaining spring tab with thumb while pulling the
Readi-Reel cage from the molded adapter with
both hands. Do not remove adapter from spindle.
2. Place the adapter on the spindle.
3. Re-install the retaining collar. Make sure that the
release bar “pops up” and that the collar retainers
fully engage the retaining groove on the spindle.
4. Rotate the spindle and adapter so the retaining
spring is at the 12 o'clock position.
5. Position the Readi-Reel so that it will rotate in a
direction when feeding so as to be de-reeled from
the bottom of the coil.
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B-8
B-8
OPERATION
4. Cut and remove only the tie wire holding the free
end of the coil. Hook the free end around the rim
of the reel cover and secure it by wrapping it
around. Cut and remove the remaining tie wires.
TO MOUNT 10 TO 44 LB (4.5 TO 20
KG) SPOOLS [12 IN. (300 MM)
DIAMETER] OR 14 LB (6 KG)
INNERSHIELD COILS (FIGURE B.4):
FIGURE B.5 — K1504-1 COIL REEL.
The spindle should be located in the LOWER
mounting hole.
SPINNER NUT
(For 8 in. (200 mm) spools, a K468 spindle adapter
must first be slipped onto spindle.)
COVER
PLATE
(For 13 to 14 lb (6 kg) Innershield coils, a K435 coil
adapter must be used).
1. Depress the release bar on the retaining collar
and remove it from the spindle.
SLOTS
2. Place the spool on the spindle making certain the
spindle brake pin enters one of the holes in the
back side of the spool. Be certain the wire comes
off the reel in a direction so as to de-reel from the
bottom of the coil.
CARDBOARD
COIL LINER
COIL
3. Re-install the retaining collar. Make sure that the
release bar “pops up” and that the collar retainers
fully engage the retaining groove on the spindle.
TIE WIRE
TO MOUNT A 50 TO 60 LB (22.7 TO
27.2 KG) COIL (USING K1504-1 COIL
REEL) (FIGURE B.5):
SPRING
LOADED ARM
NOTE: (For 50 to 60 lb Readi-Reels a K438
Readi-Reel adapter must be used).
REEL
The spindle must be located in the UPPER mounting
hole.
1. With the K1504-1 coil reel mounted on to the 2 in.
(51 mm) spindle (or with reel laying flat on the
floor) loosen the spinner nut and remove the reel
cover. See Figure B.5.
CAUTION
Always be sure the free end of the coil is securely
held while the tie wires are being cut and until the
wire is feeding through the drive rolls. Failure to do
this will result in “backlashing” of the coil, which may
tangle the wire. A tangled coil will not feed so it must
either be untangled or discarded.
2. Before cutting the tie wires, place the coil of elec-
trode on the reel so it unwinds from the bottom as
the reel rotates. The slots in the cardboard liner
should align over the spring loaded arms.
-----------------------------------------------------------
3. Tighten the spinner nut against the reel cover as
much as possible by hand using the reel cover
spokes for leverage. DO NOT hammer on the
spinner nut arms.
5. Be sure the coil reel is engaged with the spindle
brake pin and the release bar on the retaining col-
lar “pops up” and that the collar retainers fully
engage the retaining groove on the spindle.
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B-9
B-9
OPERATION
7. Install the outer wire guide by sliding over the
locating pins and tightening in place.
FEEDING ELECTRODE AND
BRAKE ADJUSTMENT
8. Engage the upper drive rolls if they are in the
“open” position and close pressure door.
1. Turn the reel or spool until the free end of the
electrode is accessible.
To set drive roll pressure, see Drive Roll Pressure
Setting.
2. While tightly holding the electrode, cut off the bent
end and straighten the first 6 in. (150 mm). Cut
off the first 1 in. (25 mm). (If the electrode is not
properly straightened, it may not feed or may jam
causing a “birdnest”.)
DRIVE ROLL PRESSURE
SETTING
3. Insert the free end through the incoming guide.
The Power Feed 10 pressure is factory pre-set to
about position “2” as shown on the pressure indicator
on the front of the feedplate door. This is an approxi-
mate setting.
4. Press the Cold Feed Switch while pushing the
electrode into the incoming wire guide.
WARNING
The optimum drive roll pressure varies with type of
wire, surface condition, lubrication, and hardness.
Too much pressure could cause “birdnesting”, but
too little pressure could cause wire feed slippage with
load and/or acceleration. The optimum drive roll set-
ting can be determined as follows:
If feeding with the Gun Trigger, the electrode and
wire drive may be electrically “HOT”.
-----------------------------------------------------------
5. Feed the electrode through the gun.
1. Press end of gun against a solid object that is
electrically isolated from the welder output and
press the gun trigger for several seconds.
6. Adjust the brake tension with the thumbscrew on
the spindle hub, until the reel turns freely but with
little or no overrun when wire feeding is stopped.
Do not overtighten.
2. If the wire “birdnests”, jams, or breaks at the drive
roll, the drive roll pressure is too great. Back the
pressure setting out one turn, run new wire
through the gun, and repeat above steps.
DRIVE ROLL KIT INSTALLATION
(KP1505-[])
3. If the only result is drive roll slippage, disengage
the gun, pull the gun cable forward about 6 in.
(150 mm). There should be a slight waviness in
the exposed wire. If there is no waviness, the
pressure is too low. Increase the pressure setting
one turn, reconnect the gun, tighten locking clamp
and repeat the above steps.
1. Turn off welding power source.
2. Pull open pressure door to expose rolls and wire
guides.
3. Remove outer wire guide by turning knurled
thumb screws counterclockwise to unscrew them
from Feedplate.
PROCEDURE FOR SETTING
ANGLE OF FEEDPLATE
4. Remove the drive rolls, if any are installed, by
pulling straight off the shaft. Remove the inner
guide.
1. Loosen the clamping collar screw using a 3/16 in.
Allen wrench. The clamping collar screw is
accessed from the bottom of the feedplate. It is
the screw which is perpendicular to the feeding
direction.
5. Insert the inner wire guide, groove side out, over
the two locating pins in the feedplate.
6. Install each drive roll by pushing over the shaft
until it butts up against the locating shoulder on
the drive roll shaft. (Do not exceed maximum wire
size rating of the wire drive).
2. Rotate feedplate to the desired angle and tighten
clamping collar screw.
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B-10
B-10
OPERATION
and red for about 30 seconds before the wire drive
will automatically reset. At that time, the wire drive
will issue a shutdown over command to the Control
Box that will return the system to normal operation.
The wire drive will force its STATUS light to solid
green.
WIRE FEED OVERLOAD
PROTECTION
The wire drive has solid-state overload protection of
the wire drive motor. If the wire drive motor becomes
overloaded for an extended period of time the wire
drive will issue a shutdown command to the Control
Box and force its STATUS light to blink between
green and red. The Control Box turns off the power
source, wire feed and gas solenoid. The status light
on the wire drive will continue to blink between green
Overloads can result from improper tip size, liner,
drive rolls, or guide tubes, obstructions or bends in
the gun cable, feeding wire that is larger than the
rated capacity of the feeder or any other factors that
would impede normal wire feeding.
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SECTION C-1
SECTION C-1
ACCESSORIES
TABLE OF CONTENTS
-ACCESSORIES SECTION-
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section C
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Power Wave Options and Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Factory Installed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Field Installed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Wire Feeder Options and Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Drive Roll and Guide Tube Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Input Cable Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cable Receptacles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Reel Adapters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Guns and Gun Adapters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Conduit Adapters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Dual Procedure Switch Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Gas and Water Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Chassis Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Description and Installation of Optional Control Box Panels . . . . . . . . . . . . . . . . . . . . . . . . . . .
C-2
C-3
C-3
C-3
C-3
C-3
C-4
C-4
C-6
C-6
C-7
C-8
C-8
C-8
C-9
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C-2
C-2
ACCESSORIES
GENERAL
The following is a list of the accessories that can be
used with the Power Feed 10 wire feeder and the
Power Wave 455. A description of each item is given
later in the section.
TABLE C.1 — POWER FEED 10 AND POWER WAVE 455 ACCESSORIES.
K1570-1
KP1505 Series
K1543
DUAL CYLINDER UNDERCARRIAGE
DRIVE ROLL AND GUIDE TUBE KITS
INPUT CABLE ASSEMBLY (CONTROL CABLE ONLY)
INPUT CABLE ASSEMBLY
K1544
K1548-1
K162h
RECEPTACLE KIT (INPUT AND OUTPUT)
WIRE SPINDLE ADAPTER
K1504-1
K435
COIL ADAPTER
COIL ADAPTER
K363P
READI-REEL ADAPTER
K438
READI-REAL ADAPTER
K489-7
FAST-MATE™ GUN ADAPTERS
K489-2
K466-10
K471-21,-22, -23
K497-20, -21
K613-7
K556 (250XA)
K556 (400XA)
K206
CONNECTOR KIT
MAGNUM 400 WELDING GUNS
MAGNUM 200 WELDING GUNS
MAGNUM 550 WELDING GUN CONNECTOR KIT
LINCOLN FUME EXTRACTION GUNS
K289
K309
K489-2
FAST-MATE™ ADAPTER KIT
LINCOLN INNERSHEILD GUN STANDARD CONNECTION
TWECO™ #2-#4 CONNECTION
TWECO™ #5 CONNECTION
MILLER CONNECTION
K1500-1
K1500-2
K1500-3
K1500-4
K1546-1
K1546-2
K683-1
K683-3
K590-5
K1536-1
K659-1
K1557-1
K1556-1
K1574-1
K1555-1
K1542-5
K1542-6
K1546-7
K1542-8
K1542-9
K1542-11
K1542-12
CONDUIT ADAPTER
CONDUIT ADAPTER
DUAL PROCEDURE SWITCH
DUAL PROCEDURE SWITCH
WATER CONNECTION KIT (FOR DRIVE ONLY)
WATER FLOW SENSOR KIT
GAS GUARD REGULATOR
SWIVEL MOUNT
LIGHT DUTY CASTER KIT
SECURITY DOOR (LARGE)
INSULATED LIFT HOOK
DUAL PROCEDURE PANEL
“M” PANEL
MX PANEL (LARGE)
MSP PANEL (LARGE)
DUAL PROCEDURE / MEMORY PANEL (SMALL)
MX2 PANEL (LARGE)
MSP2 PANEL (LARGE)
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C-3
C-3
ACCESSORIES
POWER WAVE OPTIONS AND
ACCESSORIES
K1570-1 DUAL CYLINDER UNDERCARRIAGE
This is a platform undercarriage for mounting up to
two gas cylinders at the rear of the welder.
The following is a list of available Power Wave
options.
WIRE FEEDER OPTIONS AND
ACCESSORIES
FACTORY INSTALLED
There are no factory installed options available for
the Power Wave machines.
The following is a list of available Wire Feeder
options.
DRIVE ROLL AND GUIDE TUBE KITS
FIELD INSTALLED
The following options/accessories are available for
your Power Wave from your local Lincoln Distributor.
TABLE C.2 — DRIVE ROLL AND GUIDE TUBE KITS.
Wire Size
4-Roll
Drive
(4-Driven)
Solid Steel Electrode
in.
mm
0.6
0.8
0.9
1.0
1.2
1.4
1.6
2.0
2.4
0.023 - 0.025
0.030
0.035
0.040
0.045
0.052
1/16
KP1505 - 030S
KP1505 - 030S
KP1505 - 035S
KP1505 - 045S
KP1505 - 045S
KP1505 - 052S
KP1505 - 1/16S
KP1505 - 5/64
KP1505 - 3/32
5/64
3/32
Cored Electrode
in.
mm
0.8
0.9
1.0
1.2
1.4
1.6
1.7
2.0
2.4
0.030
0.035
0.040
0.045
0.052
1/16
0.068
5/64
3/32
KP1505 - 035C
KP1505 - 035C
KP1505 - 045C
KP1505 - 045C
KP1505 - 052C
KP1505 - 1/16C
KP1505 - 068
KP1505 - 5/64
KP1505 - 3/32
KP1505 - 7/64H
KP1505 - 7/64
KP1505 - 120
7/64 Hard Facing,smooth U groove 2.8
7/64
2.8
3.0
0.120
Aluminum Wire
.035" (0.9 mm) Aluminum
.040" (1.0 mm) Aluminum
3/64" (1.2 mm) Aluminum
1/16" (1.6 mm) Aluminum
3/32” (2.2 mm) Aluminum
KP1507-035A
KP1507-040A
KP1507-3/64A
KP1507-1/16A
KP1507-3/32A
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C-4
C-4
ACCESSORIES
in the bottom of the Control Box cabinet and
store it in the bottom of the Control Box cabinet
for future use, should the Optional Output
Connector be removed.
INPUT CABLE ASSEMBLIES
K1543 (Control Cable Only) - Consists of a 5-con-
ductor control cable with a 5-pin control cable plug,
without electrode cable, and is available in lengths of
10 ft, 15 ft, 20 ft, 50 ft, and 100 ft.
5. Place the Optional Output Connector
(Amphenol) through the hole opened by the pre-
vious step (place from the inside, out). Rotate
the Optional Output Connector so its aligning
key is positioned to the front of the Control Box
cabinet. Fasten the Optional Output Connector
to the bottom wall of the Control Box cabinet with
the four screws provided.
K1544 - Consists of a 5-conductor control cable with
a 5-pin control cable plug and a 3/0 electrode cable.
It is rated at 600 amps, 60% duty cycle and is avail-
able in lengths of 10 ft,15 ft, 20 ft, and 50 ft.
With input power disconnected from the power
source, install the input cable by performing the
following:
6. Secure the choke (large circular component of
the Optional Output Connector) by inserting its
leads into the white nylon clip located near the
Optional Output Connector on the back wall of
the Control Box cabinet. Insert the choke leads
only.
CABLE RECEPTACLES
K1548-1 RECEPTACLE KIT (INPUT AND
OUTPUT)
7. The Optional Output Connector has two internal
connectors, a four pin, and a single lead connec-
tor. Connect the four pin connector to the
unused four pin connector on the main printed
circuit board. Connect the single lead connector
to a similar connector found on a lead nearby
that branches out of the Control Box wiring har-
ness.
This kit contains the contents of both the K1549-1
and K1550-1 kits. Refer to the instructions for each,
below.
RECEPTACLE (OUTPUT)
Optional Output Connector installation into the
Control Box cabinet and/or into the feed head
enclosure.
8. Re-install the lower and middle option panels by
reversing the removal process. While re-
installing the option panels, ensure clearance
between Optional Output Connector compo-
nents, Control Box wiring harness, and option
panel harness (if any).
Control Box Cabinet Procedure
1. Turn off power.
2. Remove the screws from the front of the lower
and middle option panels of the Control Box.
3. Tilt the option panels away from the front open-
ing of the Control Box cabinet. If the option panel
has an electrical connector, disconnect it from
the main printed circuit board (note connection
point for re-connection later). Remove the option
panel and set aside.
4. Remove the plastic plug (black) from the left hole
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C-5
C-5
ACCESSORIES
Feed Head Enclosure Procedure
RECEPTACLE (INPUT)
1. Turn power off.
Power Feed Wire Feeder Optional Input
Connector Installation into the Control Box
Cabinet and Conversion to Fixture Wire Feeder
2. Remove the Feed Head rear access door. The
Feed Head cover can be removed to aid installa-
tion, but is not required.
1. Turn off power.
3. Remove the plastic plug (black) from the hole at
the right rear of the Feed Head and store it in the
left side of the Feed Head rear compartment for
future use, should the Optional Output
Connector be removed.
2. Remove the screws from the front of the lower
and middle option panels of the Control Box cab-
inet.
3. Tilt the option panels away from the front open-
ing of the Control Box cabinet. If the option panel
has an electrical connector, disconnect it from
the main printed circuit board (note connection
point for re-connection later). Remove the option
panel and set aside.
4. Disconnect a printed circuit board connector,
located at the bottom right corner of the printed
circuit board, and position it to the left so as to
provide clear access to the lower right corner of
the Feed Head enclosure.
4. Disconnect the connector located at the back
wall of the Control Box cabinet.
5. Place the Optional Output Connector
(Amphenol) through the hole opened by the two
previous steps (place from the inside, out).
Rotate the Optional Output Connector so its
aligning key is positioned to the top of the Feed
Head enclosure. Fasten the Optional Output
Connector to the back wall of the Control Box
cabinet with the four screws provided.
5. Loosen (do not remove) the four screws located
on the back wall of the Control Box cabinet.
6. Lift Control Box cabinet off of the four screws
loosened above and set on a work surface. Re-
tighten the four screws to secure for future use.
6. Secure the choke (large circular component of
the Optional Output Connector) by inserting its
leads into the white nylon clip located near the
Optional Output Connector on the floor of the
Feed Head. Insert the long choke leads rather
than the short leads that run between the choke
and the Output Connector. Insert the choke
leads only.
7. Remove the plastic plug (black) from the right
hole in the bottom wall of the Control Box cabi-
net and insert it into the hole in the front of the
Feed Head.
8. Place the Optional Input Connector (Amphenol)
through the hole opened by the previous step
(place from the inside, out). Rotate the Optional
Input Connector so it’s aligning key is positioned
to the front of the Control Box cabinet. Fasten the
Optional Input Connector to the bottom wall of
the Control Box cabinet with the four screws pro-
vided and connect the option’s opposite end to
the connector previously disconnected in step 4.
7. The Optional Output Connector has two internal
connectors, a four pin, and a single lead connec-
tor. Connect the four pin connector to the
unused four pin connector on the printed circuit
board. Connect the single lead connector to a
similar connector found on a lead nearby that
branches out of the Feed Head wiring harness.
9. Secure the choke (large circular component of
the Optional Input Connector) by inserting it’s
leads into the white nylon clip located near the
Optional Input Connector on the back wall of the
Control Box cabinet. Insert the choke leads only.
8. Reconnect the printed circuit board connector
that was disconnected earlier.
9. Replace the rear access door and Feed Head
cover if removed.
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10. Install an Optional Output Connector into the
Control Box cabinet, if not already present.
K363P - READI-REEL ADAPTER
Adapts Lincoln Readi-Reel coils of electrode 30 lb
(14 kg) and 22 lb (10 kg) to a 2 in. (51 mm) spindle.
Durable molded plastic one piece construction.
Designed for easy loading; adapter remains on spin-
dle for quick changeover.
11. Mount the Control Box cabinet to the work sta-
tion fixture at this time, if desired. The four holes
in the back wall of the Control Box cabinet can
be used for this purpose.
12. Re-install the lower and middle option panels by
reversing the removal process. While re-
installing the option panels, ensure clearance
between Optional Input Connector components,
Control Box wiring harness, and option panel
wiring harness (if any).
K438 - READI-REEL ADAPTER
Adapts Lincoln Readi-Reel coils of electrode 50 to
60 lb (22.7 to 27.2 kg) to a 2 in. (51 mm) spindle.
GUNS AND GUN ADAPTERS
REEL ADAPTERS
The Power Feed 10 wire feeder is equipped with a
factory installed K1500-2 gun connection kit. This kit
is for guns having a Tweco™ #2-#4 connector. The
Power Feed 10 has been designed to make connect-
ing a variety of guns easy and inexpensive with the
K1500 series of gun connection kits. Gun trigger and
dual procedure lead connections connect to the sin-
gle 5 pin receptacle on the front of the Feed Head
box.
K162H - WIRE SPINDLE ADAPTER
Spindle for boom mounting Readi-Reels and 2 in. (51
mm) I.D. spools with up to 60 lb (27.2 kg) capacity.
User mounted to appropriately prepared boom
framework. Includes an easily adjustable friction
brake for control of overrun (a 2 in. spindle is stan-
dard on Power Feed 10 bench model).
When a 2 in. (51 mm) spindle is used with Readi-
Reels, or coils not on 12 in. (305 mm) O.D. spools,
an adapter is required:
FAST-MATE™ GUNS (INCLUDING THE
MAGNUM 450 WATER COOLED GUN)
A K489-7 adapter will install directly into the wire
drive feedplate, to provide for use of guns with Fast-
Mate™ or European style gun connections. This
K489-7 will handle both standard Fast-Mate™and
Dual Schedule Fast-Mate™ guns.
K1504-1 - COIL ADAPTER
Permits 50 lb to 60 lb (22.7 to 27.2 kg) coils to be
mounted on 2 in. (51 mm) O.D. spindles.
Another way to connect a gun with a Fast-Mate™ or
European style gun connector to the Power Feed 10,
is to use the K489-2 Fast-Mate™ adapter kit.
Installation of this adapter also requires a K1500-1
gun connector.
K435 - COIL ADAPTER
Permits 14 lb (6 kg) Innershield coils to be mounted
on 2 in. (51 mm) O.D. spindles.
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MAGNUM 200/300/400 GUNS
K1500-2 (TWECO™ #2-#4 CONNECTION)
The easiest and least expensive way to use Magnum
200/300/400 guns with the Power Feed 10 wire feed-
er is to order them with the K466-10 connector kit, or
to buy a completely assembled Magnum gun having
the K466-10 connector (such as the K471-21, -22,
and -23 dedicated Magnum 400 guns and the K497-
20 and -21 Magnum 200 guns).
The K1500-2 gun adapter comes factory installed on
the Power Feed 10 wire feeder. Use this adapter for
guns that have a Tweco™ #2-#4 connector. Such
guns include Magnum 200/300/400 guns with K466-
10 connector kit, and completely factory assembled
Magnum guns that are factory equipped with the
K466-10 connector (such as the K497-21 dedicated
Magnum 400).
MAGNUM 550 GUNS
K1500-3 (TWECO™ #5 CONNECTION)
The easiest and least expensive way to use the
Magnum 550 guns with Power Feed 10 wire feeders
is to order the gun with the K613-7 connector kit, and
install a K1500-3 gun connection kit to the wire
feeder.
The K1500-3 gun adapter is for Magnum 550 guns
with a K613-7 connection kit, and any other gun hav-
ing a Tweco™ #5 connector.
K1500-4 (MILLER CONNECTION) for any gun hav-
LINCOLN INNERSHIELD AND SUB ARC GUNS
ing a Miller connector.
All of these guns can be connected to the Power
Feed by using the K1500-1 Adapter Kit.
Install gun adapters per the instructions shipped with
them.
LINCOLN FUME EXTRACTION GUNS
CONDUIT ADAPTERS
The K556 (250XA) and K566 (400XA) guns require
that a K489-2 Fast-Mate™ adapter kit be installed.
Installation of this adapter also requires a K1500-1
gun connector kit.
K1546-1 ADAPTER
For use with Lincoln Magnum conduit (wire sizes
0.023 to 0.052)
The K206, K289, and K309 require only the installa-
tion of a K1500-1 connector in the Power Feed wire
feeder.
Install the K1546-1 gun adapter at the incoming end
of the feed plate, secure with the set screw located at
the back of the feed plate. If a brass fitting is supplied
with the conduit, remove it from the feeder end of the
conduit by unscrewing it. Insert the conduit into the
K1546-1, secure the conduit by fastening it to the
adapter with the supplied knob screw.
NON-LINCOLN GUNS
Most competitive guns can be connected to the
Power Feed by using one of the K1500 series
adapter kits.
K1546-2 ADAPTER
For use with Lincoln Magnum conduit (wire sizes
1/16 to 0.120)
K1500-1 (LINCOLN INNERSHIELD GUN
STANDARD CONNECTION)
Install the K1546-2 gun adapter at the incoming end
of the feed plate; secure with the set screw located at
the back of the feed plate. If a brass fitting is supplied
with the conduit, remove it from the feeder end of the
conduit by unscrewing it. Insert the conduit into the
K1546-2, secure the conduit by fastening it to the
adapter with the supplied knob screw.
Use this kit to connect the following guns: Guns hav-
ing a Lincoln standard innershield gun connector,
Fast-Mate™ guns with K489-2 Fast-Mate™ Adapter
Kit, Magnum 200/300/400 with K466-1 connector kit,
and Magnum 550 guns with the K613-1 gun connec-
tion kit.
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K659-1 GAS GUARD REGULATOR
DUAL PROCEDURE SWITCH OPTIONS
Adjustable flow regulator with removable adjuster key
for CO2 and Argon blend gases. Mounts onto feeder
inlet, and reduces gas waste and arc start “blow” by
reducing surge caused by excess pressure in supply
hose.
K683-3 DUAL PROCEDURE SWITCH
Kit includes gun switch and mountings for Lincoln
Innershield and Magnum guns, with 15 ft (4.5 m)
control cable and 5-pin plug with two leads to con-
nect to gun trigger.
Install the 5/8-18 male outlet of the regulator to the
5/8-18 female gas inlet on the back panel of the wire
drive. Secure fitting with flow adjuster key at top.
Attach gas supply to 5/8-18 female inlet of regulator.
Connect the 5-pin plug of the K683-3 Dual Procedure
Switch to the Power Feed 10 wire feeder trigger/dual
procedure 5-socket receptacle.
The two lead plug cord extending out of the 5-pin
plug of the Dual Procedure Switch is to be connected
to the two trigger leads of the welding gun per
instructions shipped with the kit.
CHASSIS OPTIONS
K1557-1 SWIVEL PLATFORM
The K1557-1 Swivel platform attaches to the power
source. This kit includes a feeder adapter plate that
allows the feeder to rotate on top of the power
source. The feeder can be easily separated from the
swivel mount at any time. This option is compatible
with the K1556-1 Light Duty Caster Kit.
K683-1 DUAL PROCEDURE SWITCH
The K683-3 Dual Procedure Switch is the recom-
mended method of obtaining dual procedure; but if it
is desired to use an existing K683-1 with the Power
Feed 10, it can be done. A K683-1 Dual Procedure
Switch can be used on the Power Feed 10 if a K686-
2 adapter is used. The K682-1 kit includes gun
switch and mountings for Lincoln Innershield and
Magnum guns, with 15 ft (4.5 m) control cable and 3-
pin plug. K686-2 adapter permits 3-pin plug and 5-
pin gun trigger plug to be connected to Power Feed
10 5-pin trigger/dual procedure receptacle.
K1556-1 LIGHT DUTY CASTER KIT
This option provides four casters and all required
hardware to mount it to the Power Feed 10. This
option is compatible with the K1557-1 Swivel
Platform.
K1574-1 SECURITY DOOR (LARGE)
GAS AND WATER KITS
K1574-1 Security Door Installation into the Control
Box cabinet.
K590-5 WATER CONNECTION KIT
(FOR DRIVE ONLY)
1. Turn off power.
Install per the instructions shipped with the kit.
2. Unlatch and swing open the small door. Remove
the two screws from the horizontal hinge rod.
Save the screws.
K1536-1 WATER FLOW SENSOR KIT
Install per the instructions shipped with the kit.
3. While holding the door so it doesn’t fall, slide the
rod out sideways releasing the door.
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4. Position the new door between the panel holes
3. Tilt the new option panel away from the front
opening of the Control Box cabinet. Plug the
electrical connector into the proper connector on
the right side of the main printed circuit board
(10 pin). Make sure the connector latches in
place.
and re-install the rod so the screw holes can be
accessed.
5. Replace the two screws and tighten.
6. Swing the door into the up position. A lock may
be installed through the side holes for security
purposes.
4. Position the new panel, taking care not to dam-
age the switch connections on the back.
5. Align the screw holes, replace the two screws
and tighten.
K1555-1 INSULATED LIFT BAIL
For applications where an insulated lift bail is
required. This kit provides an easily installed, heavy
duty insulated lift eye that mounts to the wire reel
stand mast. See the instructions provided with the kit
for installation.
K1542-6 M PANEL
The M Panel provides a large toggle switch selection
of three power source modes. The upper position
selects the generic CV/MIG mode from the power
source, the middle position selects the CV/FLUX
CORED mode, and the lower position selects the
CC/STICK/GOUGE mode. Arc control is accom-
plished through the use of the ARC CONTROL
potentiometer. The arc control value is actually a trim
with zero being the nominal and the scale ranging
from (-10) to (+10). Preflow, postflow, and spot time
default to zero or off. Run in defaults to the minimum
value, or weld speed depending on the position of its
associated DIP switch. See Installation section for
DIP switch settings. Burnback defaults to the on
board trimmer adjustment.
DESCRIPTION AND INSTALLATION OF
OPTIONAL CONTROL BOX PANELS
K1542-5 DUAL PROCEDURE PANEL
The Dual Procedure Panel provides a fixed large tog-
gle switch or the use of a gun switch for the selection
of either of two procedures. The upper position of the
switch selects PROCEDURE A, while the lower
selects PROCEDURE B. The middle position selects
the GUN switch, in which case the procedure is
determined by the position of the switch located at
the gun.
NOTE: Due to the nature of fixed position switches,
potentiometers, and default values, this option does
not allow the mode, arc control, timers, or burnback
values to be included in dual procedure or memory
information. They are overridden by the fixed values.
NOTE: Due to the nature of fixed position switches,
this option does not allow the indication of a remotely
selected procedure. When in the gun mode there is
no provision to indicate, at the Control Box, which
procedure has been remotely selected (at the gun).
CC/STICK/GOUGE Mode
Installation is as follows:
1. Turn off power.
Selecting the CC/STICK/GOUGE mode on this panel
automatically energizes the output terminals on the
power source, making the power source immediately
ready to weld. In the CC modes, the output current is
set by the AMPS control, and the VOLTS/TRIM
adjustment has no effect in this mode. In this mode,
the ARC CONTROL adjusts the arc force. Increasing
the ARC CONTROL setting increases the arc force,
making the arc more harsh but less likely to stick.
Decreasing the ARC CONTROL setting decreases
the arc force, making the arc softer and smoother.
2. Remove the two screws from the front of the
blank option panel at the location you choose to
install your new option, (middle or top), of the
Control Box cabinet. Save the screws, discard
the old panel or save for future use.
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Constant Voltage (CV/MIG and CV/Flux Cored)
Procedures
Display - Displays the value or status of the active
parameter.
When in this mode, the ARC CONTROL adjusts the
inductance. (This adjustment is often referred to as
“pinch”. Inductance is inversely proportional to
pinch.) Increasing the ARC CONTROL setting
decreases the inductance, which results in the arc
getting colder and pinched tighter. Decreasing the
ARC CONTROL setting increases the inductance,
which results in the arc getting wider (reduced pinch).
Available Modes - CV/MIG
CV/ FLUX CORED
CC/STICK CRISP
CC/STICK SOFT
Due to the nature of the system, the following feature
is required for safety reasons. Upon entering any
constant current (CC) mode, the right encoder,
labeled VOLTS, TRIM, on the Display/Control Panel
acts as a “soft” contactor switch. The encoder knob
must be turned CW at least 45° to activate the output
(turning CCW 45° deactivates the output). This pre-
vents the output from inadvertently becoming “hot”
when scrolling through the weld modes. The excep-
tion to this rule is when the weld mode is entered by
a change in procedure (using a memory panel such
as the K1542-9 Memory/Dual Procedure panel). In
this case, the state of the contactor is recalled as it
was left when the procedure was exited.
Installation is as follows:
1. Turn off power.
2. Remove the two screws from the front of the
blank option panel at the location you choose to
install your new option (bottom) of the Control
Box cabinet. Save the screws, discard the old
panel or save for future use.
3. Tilt the new option panel away from the front
opening of the Control Box cabinet. Plug the
electrical connector into the proper connector on
the right side of the main printed circuit board (12
pin). Make sure the connector latches in place.
In the CC modes, the output current is set by the
AMPS control, and the VOLTS/TRIM adjustment has
no effect in this mode. In this mode, the ARC
CONTROL adjusts the arc force. Increasing the ARC
CONTROL setting increases the arc force, making
the arc more harsh but less likely to stick. Decreasing
the ARC CONTROL setting decreases the arc force,
making the arc softer and smoother.
4. Position the new panel, taking care not to dam-
age the connections on the back.
5. Align the screw holes, replace the two screws
and tighten.
Parameter Ranges
K1542-7 MX PANEL (LARGE PANEL)
PREFLOW -
0.0 to 2.5 seconds (0.1 sec. increments).
RUN IN -
Low Range: 50 to 150 IPM (1.25 to 3.80 MPM).
High Range: 75 to 150 IPM (2.00 to 3.80 MPM).
ARC CONTROL -
The MX Panel provides a selection of four power
source modes. In addition, it provides for the adjust-
ment of the following parameters: PREFLOW, RUN
IN, ARC CONTROL, BURNBACK, POSTFLOW, and
SPOT time.
Trim (-10.0) to (+10.0) , (0) is nominal.
BURNBACK -
0.0 to 0.25 sec. (0.01 sec. increments).
POSTFLOW -
Descriptions
0.0 to 2.5 sec. (0.1 sec. increments).
SPOT -
0 to 25 sec. (0.1 sec. increments).
Indicator Lights - Extra bright red LED’s indicate the
mode and active parameter being displayed.
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Mode Selection
3. Tilt the new option panel away from the front
opening of the Control Box cabinet. Plug the
electrical connector into the proper connector on
the right side of the main printed circuit board
(12 pin). Make sure the connector latches in
place.
The MODE SELECT switch is a momentary large
three position toggle switch that defaults to the center
(off) position. Moving the switch up advances the
mode indicator in the upward direction, down
advances it in the downward direction. Holding the
switch in either direction will result in the indicator
advancing at a high rate of speed in that direction,
until the switch is released. When the indicator
reaches its upper or lower limit, advancing ceases
until the direction of the switch is changed.
4. Position the new panel, taking care not to dam-
age the connections on the back.
5. Align the screw holes, replace the two screws
and tighten.
Parameter Selection
K1542-8 MSP PANEL (LARGE PANEL)
The PARAMETER SELECT switch is a momentary
large three position toggle switch that defaults to the
center (off) position. Moving the switch up advances
the parameter indicator in the upward direction, down
advances it in the downward direction. Holding the
switch in either direction will result in the indicator
advancing at a high rate of speed in that direction,
until the switch is released. When the indicator
reaches its upper or lower limit, advancing ceases
until the direction of the switch is changed.
The MSP Panel provides a selection of numerous
process specific and generic power source modes. In
addition, it provides for the adjustment of the follow-
ing parameters: PREFLOW, RUN IN, ARC CON-
TROL, BURNBACK, POSTFLOW, and SPOT time.
Only one parameter, as defined by the parameter
indicator, may be displayed and adjusted at a time.
Description
Indicator Lights - Red LED’s indicate the active para-
meter being displayed.
Parameter Adjustment
The value of the active parameter, as defined by the
parameter indicator, is displayed on the parameter
display. The PARAMETER SET switch is a momen-
tary large three position toggle switch that defaults to
the center (off) position. Moving the switch bat up
advances the displayed value in the positive direc-
tion, down advances it in the negative direction.
Holding the switch in either direction will result in the
displayed value advancing at a high rate of speed in
that direction, until the switch is released. When the
indicator reaches its upper or lower limit, advancing
ceases until the direction of the switch is changed.
Display - 3 1/2 digit, red LED display. Displays the
value or status of the active parameter.
Parameter Ranges
WELD MODE -
Adjustable per mode schedule.
PREFLOW -
0.0 to 2.5 seconds (0.1 sec. increments).
RUN IN -
Low Range: 50 to 150 IPM (1.25 to 3.80 MPM).
High Range: 75 to 150 IPM (2.00 to 3.80 MPM).
ARC CONTROL -
Installation is as follows:
1. Turn off power.
Trim (-10.0) to (+10.0) , (0) is nominal.
BURNBACK -
0.0 to 0.25 sec. (0.01 sec. increments).
POSTFLOW -
0.0 to 2.5 sec. (0.1 sec. increments).
SPOT -
2. Remove the two screws from the front of the
blank option panel at the location you choose to
install your new option (bottom) of the Control
Box cabinet. Save the screws, discard the old
panel or save for future use.
0 to 25 sec. (0.1 sec. increments).
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Mode Schedule - Table on the front of the option
used by the operator to correlate the displayed mode
number to an actual power source mode.
that direction, until the switch is released. When the
indicator reaches its upper or lower limit, advancing
ceases until the direction of the switch is changed.
Due to the nature of the system, the following feature
is required for safety reasons. Upon entering any
constant current (CC) mode, the right encoder,
labeled VOLTS, TRIM, on the Display/Control Panel
acts as a “soft” contactor switch. The encoder knob
must be turned CW at least 45° to activate the output
(turning CCW 45° deactivates the output). This pre-
vents the output from inadvertently becoming “hot”
when scrolling through the weld modes. The excep-
tion to this rule is when the weld mode is entered by
a change in procedure (using a memory panel such
as the K1542-9 Memory/Dual Procedure panel). In
this case, the state of the contactor is recalled as it
was left when the procedure was exited.
GMAW 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 proce-
dure. 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.
In the CC modes, the output current is set by the
AMPS control, and the VOLTS/TRIM adjustment has
no effect in this mode. In this mode, the ARC
CONTROL adjusts the arc force. Increasing the ARC
CONTROL setting increases the arc force, making
the arc more harsh but less likely to stick. Decreasing
the ARC CONTROL setting decreases the arc force,
making the arc softer and smoother.
The arc length trim (usually referred to simply as
“trim”) can be adjusted between 0.500 and 1.500 on
the Control Box’s VOLTS/TRIM display. A trim of
1.000 means that no adjustments will be made to the
preset arc lengths. A trim setting less than 1.000
decreases the preset arc lengths. The arc length trim
adjustment is factored in at all wire feed speed set-
tings. Increasing the trim by 10 percent at a given
wire feed speed also increases all the other arc
length trim settings of the procedure by 10 percent.
Parameter Selection
Lincoln Power Wave power sources utilizes a control
scheme known as adaptive control in all pulse
modes. Because the Power Wave utilizes adaptive
control, it can adjust the pulsing parameters based
on changes in the arc due to changes in the electrical
sitckout of the electrode. (Electrical stickout is the
distance from the contact to the workpiece.) The
Power Wave is optimized for use with a 0.75 in. stick-
out. The adaptive behavior is programmed to support
a stickout range from 0.5 in. to 1.25 in. In the low and
high end of the wire feed speed ranges of most
processes, the adaptive behavior may be restricted.
This is a physical restriction due to reaching the edge
of the operating range for the process.
The PARAMETER SELECT switch is a momentary
large three position toggle switch that defaults to the
center (off) position. Moving the switch up advances
the parameter indicator in the upward direction, down
advances it in the downward direction. Holding the
switch in either direction will result in the indicator
advancing at a high rate of speed in that direction,
until the switch is released. When the indicator
reaches its upper or lower limit, advancing ceases
until the direction of the switch is changed.
Parameter Adjustment
The value of the active parameter, as defined by the
parameter indicator, is displayed on the parameter
display. The PARAMETER SET switch is a momen-
tary large three position toggle switch that defaults to
the center (off) position. Moving the switch up
advances the displayed value in the positive direc-
tion, down advances it in the negative direction.
Holding the switch in either direction will result in the
displayed value advancing at a high rate of speed in
The ARC CONTROL adjustment allows the pulse fre-
quency to be varied. Increasing the ARC CONTROL
causes the frequency setting to increase, while
decreasing the ARC CONTROL causes the frequen-
cy to decrease. Varying the ARC CONTROL, and
hence, the pulse frequency, affects the droplet trans-
fer and allows fine-tuning for different welding
positions.
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Installation is as follows:
1. Turn off power.
Dual Procedure Selection
The procedure switch is used to scroll the indicator to
select PROCEDURE A, PROCEDURE B, or the
GUN switch. When the GUN switch is selected, the
procedure is determined by the position of the switch
located at the gun. Under this condition, indicators
will show that the gun switch has been selected and
also which procedure the gun switch is requesting.
2. Remove the two screws from the front of the
blank option panel at the location you choose to
install your new option (bottom) of the Control
Box cabinet. Save the screws, discard the old
panel or save for future use.
3. Tilt the new option panel away from the front
opening of the Control Box cabinet. Plug the
electrical connector into the proper connector on
the right side of the main printed circuit board
(12 pin). Make sure the connector latches in
place.
Memory Selection
RECALL - When a memory key is depressed, its indi-
cator comes on and its contents are copied to the
active procedure. As long as no changes are made
to the contents of that procedure, the memory indica-
tor will be on any time that procedure is active. This
indicates that their contents are the same. Any
change to that procedure will cause the memory indi-
cator to go off, indicating that they are no longer
equal.
4. Position the new panel, taking care not to dam-
age the connections and the printed circuit board
on the back.
5. Align the screw holes, replace the two screws
and tighten.
SAVE - The save mode allows “hard” memories to be
changed. Pressing the SAVE key will light the save
indicator, and enter the save mode. In the save
mode, the indicator for the memory that was the
source of the active procedure’s contents will blink,
whether their contents are still equal or not. This fea-
ture allows the user to choose to save an active pro-
cedure back to its source, or some other location.
K1542-9 DUAL PROCEDURE/MEMORY PANEL
(SMALL PANEL)
The Dual Procedure/Memory panel provides for the
selection of either of two procedures, or a gun switch
for remote selection of the procedure. In addition,
there are six permanent memory storage locations
for saving commonly used procedures. Procedures A
and B are “soft” type memories that record any
changes made to them. The six memory locations
are “hard” or more permanent type memories. Any
changes made must be consciously saved back to
them. Furthermore, each memory contains only one
procedure, therefore any combination of memories
may be recalled to procedure A and B.
To complete the save transaction requires the selec-
tion of one of the memory keys. When the memory
key is pressed in the save mode, it’s contents are
overwritten with the contents of the active procedure.
This means that the contents of the memory location
and the active procedure are now equal, and thereo-
re, by definition, each of their indicators will be lit,
and the save mode will be exited. To exit the save
mode without saving, depress the save key a second
time. This feature allows the operator to determine
the source of the active procedure’s contents without
actually overwriting it.
Descriptions
Indicator Lights - Red LED’s indicate the procedure
and active memory and save mode if applicable.
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C-14
C-14
ACCESSORIES
Installation is as follows:
1. Turn off power.
The value of the active Set Up parameter, as defined
by the Set Up LED, is displayed on the MX2 panel
Set Up display. The value can be modified with the
Set switch. The Set switch is an up/down center-off
momentary toggle switch. Moving the switch bat up
or down adjusts the displayed value in the corre-
sponding direction. Holding the switch in either direc-
tion will cause the display to move quickly in the cor-
responding direction until the switch is released, or
the upper or lower parameter limit is reached.
2. Remove the two screws from the front of the
blank option panel at the location you choose to
install your new option (bottom) of the Control
Box cabinet. Save the screws, discard the old
panel or save for future use.
3. Tilt the new option panel away from the front
opening of the Control Box cabinet. Plug the
electrical connector into the proper connector on
the right side of the main printed circuit board
(10 pin). Make sure the connector latches in
place.
To energize the output studs in either CC/Stick
mode, the right Control/Display panel knob, labeled
Volts/Trim, must be used. The Volts/Trim knob must
be turned clockwise roughly a quarter revolution to
energize the output studs. (The Volts/trim display will
indicate ‘On’ when the studs are energized.)
Similarly, turning the knob a quarter turn counter-
clockwise de-energizes the output studs. If a
CC/Stick weld mode is entered through use of the
Dual Procedure, the studs will be in the same state
as when they were last used. If a CC/Stick weld
mode is entered through a Memory recall, the studs
will be de-energized.
4. Position the new panel, taking care not to dam-
age the connections and the printed circuit board
on the back.
5. Align the screw holes, replace the two screws
and tighten.
K1542-11 MX2 Panel:
K1542-12 MSP2 Panel:
This panel provides a selection of four weld modes:
CV/MIG, CV/Flux Cored, CC/Stick/soft and
CC/Stick/Crisp through a toggle switch and indicator
lights (LEDs). It allows for adjustment of all set up
parameters, Preflow, Run In, Arc Control, Burnback,
Postflow, and Crater, through an up/down toggle
switch, indicator lights and a 3 digit display.
This panel provides a selection of over 25 weld
modes, including CV, pulse, FCAW and CC, through
a toggle switch and indicator lights (LEDs). It allows
for adjustment of all set up parameters, Preflow, Run
In, Arc Control, Burnback, Postflow, and Crater,
through an up/down toggle switch, indicator lights
and a 3 digit display.
Weld modes are selected with the Mode Select
switch, an up/down center-off momentary toggle
switch. Moving the switch bat up or down moves the
Weld Mode LED in the corresponding direction.
Holding the switch in either direction will cause the
indicator to move quickly in the corresponding direc-
tion until the switch is released, or the upper or lower
limit is reached.
To adjust a set up parameter (Weld Mode being one
of those parameters), first select one of the set up
parameters for adjustment, and then adjust the dis-
played value up or down.
Set up parameters are selected with the Select
switch, an up/down center-off momentary toggle
switch. Moving the switch bat up or down moves an
LED in the corresponding direction. Holding the
switch in either direction will cause the indicator to
move quickly in the corresponding direction until the
switch is released, or the upper or lower limit is
reached.
To adjust Set Up parameters, first select the Set Up
parameter for adjustment, and then adjust the dis-
played value up or down.
Set Up parameters are selected with the Select
switch, an up/down center-off momentary toggle
switch. Moving the switch bat up or down moves the
Weld Mode LED in the corresponding direction.
Holding the switch in either direction will cause the
indicator to move quickly in the corresponding direc-
tion until the switch is released, or the upper or lower
limit is reached.
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C-15
C-15
ACCESSORIES
The value of the active set up parameter is shown on
the MSP2 panel digital display. The value can be modi-
fied with the Set switch. The Set switch is an up/down
center-off momentary toggle switch. Moving the switch
bat up or down adjusts the displayed value in the cor-
responding direction. Holding the switch in either direc-
tion will cause the display to move quickly in the corre-
sponding direction until the switch is released, or the
upper or lower parameter limit is reached.
Arc Control - Unitless characteristic, also known as
Inductance or Wave Control. Allows operator to vary
the arc characteristics from “soft” to “harsh” in all weld
modes. Adjustable from -10.0 to 10.0 in increments of
0.1. Off (0.0) is nominal.
Burnback - Time delay after the trigger is released-
during which the power source remains energized but
the Wire Drive stops feeding wire. Adjustable from
0.00 (Off) to 0.25 seconds in 0.01 second increments.
To energize the output studs in either CC/Stick mode,
the right Control/Display panel knob, labeled
Volts/Trim, must be used. The Volts/Trim knob must
be turned clockwise roughly a quarter revolution to
energize the output studs. (The Volts/trim display will
indicate ‘On’ when the studs are energized.)
Similarly, turning the knob a quarter turn counter-
clockwise de-energizes the output studs. If a CC/Stick
weld mode is entered through use of the Dual
Procedure, the studs will be in the same state as
when they were last used. If a CC/Stick weld mode is
entered through a Memory recall, the studs will be de-
energized.
Postflow - Time delay after burnback is complete,
during which shielding gas flows. Adjustable from 0.0
(Off) to 10.0 seconds in 0.1 second increments.
Crater - Used only when welding with the 4-Step trig-
ger mode. Can be set to Off or On. When On,
Adjustments can be made to WFS and Volts/Trim on
the Control/Display panel. These settings are then
used for ‘cratering’ when in the 4-Step trigger mode
(see explanation of 2 Step and 4 Step operation
below). When Off, ‘cratering’ is not possible.
CONTROL BOX -- PC BOARD ADJUSTMENTS
CONTROL BOX PANELS -- SET UP
CONTROLS DESCRIPTION
The Control Box Mother board provides the capability
to adjust some wire feeding parameters as follows:
Certain large option panels can modify the set up
parameters Preflow, Run In, Arc Control, Burnback,
Postflow, and Crater. The meaning of those parame-
ters, and their maximum and minimum values, follows.
Acceleration: The motor acceleration can be varied
in five steps, from slow to fast. See “Setting DIP
Switches in the Control Box” section.
Burnback: For the options which cannot adjust the
Burnback set up parameter (CV/G and M panels) a
PC board adjustment (trimmer R5) is provided. The
range is 0.0 to 0.25 seconds, increasing in the clock-
wise direction. This is ignored by options which have
the ability to adjust Burnback (MX2 and MSP2 pan-
els).
Preflow - Time delay after the trigger is pulled, but
before weld starts, during which shielding gas flows.
Weld start is defined as the time when both the power
source is energized and the Wire Drive begins feeding
wire. Adjustable from 0.0 (Off) to 2.5 seconds in 0.1s
increments.
Run In - Wire feed speed during arc starting. Wire
Drive will feed wire at the Run In speed for one sec-
ond, or until weld current flows. Low speed gear
range: Off (Run In speed equals weld wire feed
speed) or adjustable from 50 to 150 IPM (1.25 to 3.80
MPM). High speed gear range: Off (Run In speed
equals weld wire feed speed) or adjustable from 75 to
150 IPM (2.00 to 3.80 MPM). NOTE: Run In settings
over 150 IPM produce strange display values used for
troubleshooting and service. If encountered, reset Run
In to 150 IPM or less.
Run In: For the options which cannot adjust the Run
In set up parameter (CV/G and M panels) a PC board
DIP switch setting is provided. In one position, the run
in speed will be the minimum Wire Drive WFS. At the
other setting, run in will occur at the same speed as
set on the WFS knob. This DIP switch setting is
ignored by options which have the ability to adjust
Run In (MX2 and MSP2 panels). See “Setting DIP
Switches in the Control Box” section.
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C-16
C-16
ACCESSORIES
operator to adjust his Volts in synergic and non-syn-
ergic CV modes. Procedure B could be set up with
different limits. Limits are absolute -- they will over-
ride values stored in the memories. Note that limits
do not apply to set up parameters, such a Preflow
and Arc Control.
CONTROL BOX -- SETTING OPERATING LIMITS
Upper and lower operating limits can be set for the
WFS/Amps setting and the Volts/Trim setting. Doing
so requires knowledge of how to set the limits, and
access to the PC board in the Control Box.
There are two independent sets of limits, Procedure
A limits and Procedure B limits. If a DP/M door
option is installed, the A and B limits must be set
independently. If there is no DP/M door option, the
Control Box defaults to Procedure A, and only
Procedure A limits can be set.
OPERATION WITH PREVIOUS
SOFTWARE VERSION
The operation of the previous Control Box software
version (S24004-2) is different than described earlier
in this section. The differences are as follows:
With system power on, select the weld mode for
which you want to set limits. If a Dual Procedure
option is installed, select the procedure A. Turn the
system power off. Remove the two screws holding
the Control/Display panel to the Control Box, but do
not unplug it. Tilt the panel down to allow access to
DIP switches S1-1, S2-6 and S2-7. (See “Setting DIP
Switches in the Control Box” section.) Do not allow
the panel to hang by the wiring harness.
• The Memory/Dual Procedure panel is not a valid
option.
• The MX (K1542-1) and MSP (K1542-8) are are
used in place of the MX2 and MSP2 options.
• Limits cannot be set.
The key difference in the MX/MSP panels, compared
to the MX2/MSP2 panels, is the Spot function. In the
old software, a 0.1 to 2.5 second Spot function was
available on these two panels. No Crater function
was available (Crater replaced Spot in the graphics
on these two panels).
Determine if the Wire Drive is set up for low or high
speed. If low speed, S1-1 should be off. If high
speed, set S1-1 to on.
To adjust the lower limit, set S2-6 to on. Turn the
power on and adjust the WFS/Amps and Volts/Trim
knobs to the desired lower limits. Note: You will not
be able to adjust the lower limit outside of the mini-
mum and maximum wire feed speed of the Wire
Drive, nor above the upper limit. Turn the system
power off. Return S2-6 to off.
An upgrade kit is available to change the software
from S24004-2 to the latest version of Control Box
software. Once the upgrade is done, the Dual
Procedure/ Memory panel becomes a valid option,
limits can be set, and Spot is replaced by Crater.
To adjust the upper limit, set S2-7 to on. Turn the
power on and adjust the WFS/Amps and Volts/Trim
knobs to the desired upper limits. Note: You will not
be able to adjust the upper limit outside of the mini-
mum and maximum wire feed speed of the Wire
Drive, nor below the lower limit. Turn the system
power off. Return S2-7 to off.
If a Dual Procedure panel is installed, repeat the
above procedure with the Procedure B selected.
When done, attach the Control/Display panel to the
Control Box. The machine is now ready for normal
operation with the new limits.
CONTROL BOX -- USING OPERATING LIMITS
Once set, limits apply to all weld modes. Limiting
Procedure A to 200 to 300 inches per minute, for
example, limits the ability of the operator to adjust his
WFS in pulse, CV and FCAW weld modes. Limiting
the Volts to 23.0 to 24.5 would limit the ability of the
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SECTION D-1
SECTION D-1
MAINTENANCE
TABLE OF CONTENTS
-MAINTENANCE SECTION-
Maintenance............................................................................................................................................. Section D
Safety Precautions.............................................................................................................................
Routine Maintenance.........................................................................................................................
Power Wave ................................................................................................................................
Wire Feeder.................................................................................................................................
Periodic Maintenance ........................................................................................................................
Wire Drive Motor and Gearbox....................................................................................................
Gun and Cable Maintenance.......................................................................................................
D-2
D-2
D-2
D-2
D-2
D-2
D-2
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D-2
D-2
MAINTENANCE
AVOIDING WIRE FEEDING PROBLEMS
SAFETY PRECAUTIONS
Wire feeding problems can be avoided by observing
the following gun handling and feeder set up proce-
dures:
WARNING
ELECTRIC SHOCK
can kill.
a. Do not kink or pull cable around sharp cor-
ners.
• Do not touch electrically live parts
such as output terminals or internal
wiring.
b. Keep the electrode cable as straight as pos-
sible when welding or loading electrode
through cable.
• Only qualified personnel should
perform maintenance work.
c. Do not allow dolly wheels or trucks to run
over cables.
Observe all additional Safety Guidelines detailed
throughout this manual.
-----------------------------------------------------------
d. Keep cable clean by following maintenance
instructions.
e. Use only clean, rust-free electrode. The
Lincoln electrodes have proper surface lubri-
cation.
ROUTINE MAINTENANCE
f. Replace contact tip when the arc starts to
become unstable or the contact tip end is
fused or deformed.
POWER WAVE
Routine maintenance consists of periodically blowing
out the machine, using a low pressure airstream, to
remove accumulated dust and dirt from the intake
and outlet louvers and the cooling channels in the
machine.
g. Do not use excessive wire spindle brake set-
tings.
h. Use proper drive rolls, wire guides and drive
roll pressure settings.
WIRE FEEDER
PERIODIC MAINTENANCE
DRIVE ROLLS AND GUIDE TUBES
After feeding every coil of wire, inspect the drive roll
section. Clean as necessary. Do not use a solvent
for cleaning the drive rolls because it may wash the
lubricant out of the bearing. The drive rolls and Inner
Wire Guides are stamped with the wire sizes they will
feed. If a wire size other than that stamped on the
roll(s) is to be used, the roll(s) and Inner Wire Guides
must be changed.
WIRE DRIVE MOTOR AND GEARBOX
Every year inspect the gearbox and coat the gear
teeth with grease. Do not use graphite grease.
Refer to the Troubleshooting section for disassem-
bly of Drive Motor and Wire Feed Assembly.
GUN AND CABLE MAINTENANCE
All drive rolls have two identical grooves. The rolls
may be flipped over to use the other groove.
See appropriate Operator’s Manual.
See Procedure to Install Drive Rolls and Wire
Guides in the Operation section for roll changing
instructions.
WIRE REEL MOUNTING - READI-REELS AND
10 THROUGH 30 LB (4.5-14 KG) SPOOLS
No routine maintenance required. Do not lubricate
2 in. (51 mm) spindle.
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SECTION E-1
SECTION E-1
THEORY OF OPERATION
TABLE OF CONTENTS
-THEORY OF OPERATION SECTION-
Theory of Operation ................................................................................................................................. Section E
Modular Inverter Based Welding System...........................................................................................
System Diagram A.............................................................................................................................
System Diagram B.............................................................................................................................
System Diagram C.............................................................................................................................
Power Source General Description....................................................................................................
Input Voltage and Precharge .............................................................................................................
Switch Boards and Main Transformer................................................................................................
Control Board.....................................................................................................................................
Output Rectifier and Choke................................................................................................................
Thermal Protection.............................................................................................................................
Protective Circuits..............................................................................................................................
Over Current Protection.....................................................................................................................
Under/Over Voltage Protection..........................................................................................................
Insulated Gate Bipolar Transistor (IGBT) Operation..........................................................................
Pulse Width Modulation .....................................................................................................................
Minimum Output ..........................................................................................................................
Maximum Output .........................................................................................................................
Control Box (User Interface) ..............................................................................................................
Power Feed 10 Feed Head................................................................................................................
E-2
E-2
E-3
E-4
E-5
E-5
E-6
E-7
E-8
E-9
E-9
E-9
E-9
E-10
E-11
E-11
E-11
E-12
E-13
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E-2
E-2
THEORY OF OPERATION
FIGURE E.1 — SYSTEM DIAGRAM A.
POWER
SOURCE
CONTROL BOX
(USER INTERFACE)
INTERNAL
CONNECTION
WIRE DRIVE
specific requirements and also locate and
identify each piece of equipment for maxi-
mum efficiency and ease of operation.
MODULAR INVERTER
BASED WELDING SYSTEM
The Welding Network is an assembly of
welding equipment joined together by a
common network communication cable.
These individual welding components con-
sist of a power source (Power Wave 455), a
user interface (Power Feed 10 Control Box)
and a modular wire drive (Power Feed 10
Wire Drive). Each discrete element in the
system is designed to “talk” with the other
system components so that all information
is shared and the entire system is in sync.
This communication and shared information
network lays the groundwork for a system
with superior welding performance and
capabilities.
SYSTEM DIAGRAM A
This basic system utilizes two physical
pieces of equipment. Refer to Figure E.1.
The power source (Power Wave 455) and
the combination Control Box and wire drive
(Power Feed 10) are the two circuit ele-
ments. Note the Control Box (user inter-
face) is attached to, and internally connect-
ed to, the wire drive unit.
The communication cable is depicted by the
heavy black connector line. PC board
power, communications and intelligence
between the power source and the combi-
nation wire drive/control box unit are con-
veyed through this cable.
The equipment can be connected together
in a daisy-chain fashion. Lincoln customers
can configure a system to meet their
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E-3
E-3
THEORY OF OPERATION
FIGURE E.2 — SYSTEM DIAGRAM B.
CONTROL
BOX
(USER
INTERFACE)
INTERNAL
CONNECTION
POWER
SOURCE
WIRE DRIVE
The communication cable is depicted by the
heavy black connector line. PC board
power, communications and intelligence
between the wire drive and combination
power source/Control Box unit are con-
veyed through this cable.
SYSTEM DIAGRAM B
This system utilizes two physical pieces of
equipment. Refer to Figure E.2. The combi-
nation Control Box (user interface) and
power source (Power Wave 455) make up
one of the circuit elements. This combina-
tion unit is coupled to the wire drive module
(Power Feed 10). Note the Control Box is
attached to and internally connected to the
power source.
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E-4
E-4
THEORY OF OPERATION
FIGURE E.3 — SYSTEM DIAGRAM C.
CONTROL BOX
(USER
INTERFACE)
WIRE DRIVE
POWER
SOURCE
cables. All PC board power, communica-
tions and intelligence are transmitted via the
two cables.
SYSTEM DIAGRAM C
The power source (Power Wave 455), the
Control Box (user interface) and the wire
drive (Power Feed 10) are the three dis-
crete and physically separate circuit compo-
nents employed in this configuration. Refer
to Figure E.3. The three elements are daisy-
chained together via the communication
This component configuration might be
used if the wire drive unit was mounted on a
boom and the Control Box located remotely
from the power source.
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E-5
E-5
THEORY OF OPERATION
FIGURE E.4 — INPUT VOLTAGE AND RECHARGE.
MAIN
TRANSFORMER
CURRENT
SENSOR
LEFT
SWITCH
BOARD
OUTPUT
TERMINAL
PWM
DRIVE
INPUT
CONTACTOR
INPUT
RECTIFIER
R
E
C
O
N
N
E
C
T
S
W
I
PRIMARY
CURRENT
SENSOR
T
C
H
CAPACITOR
VOLTAGE
FEEDBACK
S
W
I
T
C
H
P
O
W
E
CHOKE
RIGHT
SWITCH
BOARD
R
I
B
O
A
R
D
N
P
U
T
OUTPUT
TERMINAL
CAPACITOR
VOLTAGE
FEEDBACK
CONTROL SIGNALS
PWM
DRIVE
THERMOSTATS
#1
AUX.
TRANS.
RECTIFIER
65VDC
CURRENT FEEDBACK
VOLTAGE FEEDBACK
CONTROL BOARD
AUX.
RECONNECT
#2
AUX.
TRANS.
FAN
MOTOR
POWER
BOARD
40VDC
STATUS
LIGHT
THERMAL
VOLTAGE
LIGHT
SENSE
RECEPTACLE
WIRE FEEDER RS232
RECEPTACLE CONN.
115VAC
RECEPTACLE
voltage developed by the No. 2 auxiliary
transformer is applied to the 115 VAC
receptacle.
POWER SOURCE
GENERAL DESCRIPTION
The Power Wave 455 is an inverter based
welding power source that is designed to be
part of a modular, multi-process welding
system. It is a high performance, digitally
controlled inverter capable of complex,
high-speed waveform control. With the
appropriate modular components it can sup-
port constant current, constant voltage and
pulse welding processes. The output rating
is 450 amps at 38 volts with a 100% duty
cycle.
The 65 VDC produced from the power
board rectifier is utilized by the power board
to provide various DC voltages for the con-
trol board and wire feeder.
The two phases which are connected to the
input board, through the power switch, are
connected to the input rectifier. During
precharge or “soft start” these two phases
are current limited by the input board. This
AC input voltage is rectified, and the resul-
tant DC voltage is applied through the
reconnect switches to the input capacitors
located on the switch boards. The control
board monitors the voltage across the
capacitors. When the capacitors have
charged to an acceptable level, the control
board signals the input board to energize
the main input contactor making all three
phases of input power, without current limit-
ing, available to the input capacitors. At
this point, the Power Wave 455 is in the
“Run Mode” of operation. If the capacitors
become under or overvoltage, the control
board will signal the input board to de-
energize the main input contactor, and the
Power Wave 455 will be disabled.
INPUT VOLTAGE AND
PRECHARGE
The Power Wave 455 can be connected for
a variety of three phase voltages. Refer to
Figure E.4. The initial input power is
applied to the Power Wave 455 through a
line switch located on the front of the
machine. Two phases of the three-phase
input power is applied to the input board
and both auxiliary transformers. The vari-
ous secondary voltages developed by the
#1 auxiliary transformer are applied to the
input board, the power board rectifier and
the fan motor. The 115 VAC secondary
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E-6
E-6
THEORY OF OPERATION
FIGURE E.5 — SWITCH BOARDS AND MAIN TRANSFORMER.
MAIN
TRANSFORMER
CURRENT
SENSOR
LEFT
SWITCH
BOARD
OUTPUT
TERMINAL
PWM
DRIVE
INPUT
CONTACTOR
INPUT
RECTIFIER
R
E
C
O
N
N
E
C
T
S
W
I
PRIMARY
CURRENT
SENSOR
T
C
H
CAPACITOR
VOLTAGE
FEEDBACK
S
W
I
T
C
H
P
O
W
E
CHOKE
RIGHT
SWITCH
BOARD
R
I
B
O
A
R
D
N
P
U
T
OUTPUT
TERMINAL
CAPACITOR
VOLTAGE
FEEDBACK
CONTROL SIGNALS
PWM
DRIVE
THERMOSTATS
#1
AUX.
TRANS.
RECTIFIER
65VDC
CURRENT FEEDBACK
CONTROL BOARD
AUX.
RECONNECT
VOLTAGE FEEDBACK
#2
AUX.
TRANS.
FAN
MOTOR
POWER
BOARD
40VDC
STATUS
LIGHT
THERMAL
VOLTAGE
LIGHT
SENSE
RECEPTACLE
WIRE FEEDER RS232
RECEPTACLE CONN.
115VAC
RECEPTACLE
Each switch board feeds current to a sepa-
rate, oppositely wound primary winding of
the main transformer. The reverse direc-
tions of current flow through the main trans-
former primaries and the offset timing of the
IGBT switch boards induce an AC square
wave output signal at the secondary of the
main transformer. These primary currents
are monitored by the current transformer
(CT). If the primary currents become abnor-
mally high, the control board will shut off the
IGBTs, thus disabling machine output. The
DC current flow through each primary wind-
ing is clamped back to each respective
input capacitor when the IGBTs are turned
off. This is needed due to the inductance of
the transformer primary winding. The firing
of the two switch boards occurs during
halves of a 50 microsecond interval, creat-
ing a constant 20 kHz output.
SWITCH BOARDS AND
MAIN TRANSFORMER
There are two switch boards in the Power
Wave 455, each containing an input capaci-
tor and insulated gate bipolar transistor
(IGBT) switching circuitry. Refer to Figure
E.5. When the machine reconnect switches
are configured for a lower input voltage
(below 300 VAC) the input capacitors are
connected in parallel. When the machine is
configured for higher input voltages (300
VAC and above) the input capacitors are
connected in series.
When the input capacitors are fully charged
they act as power supplies for the IGBT
switching circuit. The Insulated Gate
Bipolar Transistors switch the DC power,
from the input capacitors, “on and off” thus
supplying pulsed DC current to the main
transformer primary windings. See IGBT
Operation Discussion and Diagrams in
this section.
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E-7
E-7
THEORY OF OPERATION
FIGURE E.6 — CONTROL BOARD.
MAIN
TRANSFORMER
CURRENT
SENSOR
LEFT
SWITCH
BOARD
OUTPUT
TERMINAL
PWM
DRIVE
INPUT
CONTACTOR
INPUT
RECTIFIER
R
E
C
O
N
N
E
C
T
S
W
I
PRIMARY
CURRENT
SENSOR
T
C
H
CAPACITOR
VOLTAGE
FEEDBACK
S
W
I
T
C
H
P
O
W
E
CHOKE
RIGHT
SWITCH
BOARD
R
I
B
O
A
R
D
N
P
U
T
OUTPUT
TERMINAL
CAPACITOR
VOLTAGE
FEEDBACK
CONTROL SIGNALS
PWM
DRIVE
THERMOSTATS
#1
AUX.
TRANS.
RECTIFIER
65VDC
CURRENT FEEDBACK
VOLTAGE FEEDBACK
CONTROL BOARD
AUX.
RECONNECT
#2
AUX.
TRANS.
FAN
MOTOR
POWER
BOARD
40VDC
STATUS
LIGHT
THERMAL
VOLTAGE
LIGHT
SENSE
RECEPTACLE
WIRE FEEDER RS232
RECEPTACLE CONN.
115VAC
RECEPTACLE
pulse width modulation (PWM) signal (See
Pulse Width Modulation in this section) is
sent to the switch board IGBTs. In this
manner, the digitally controlled high-speed
welding waveform is created.
CONTROL BOARD
The control board performs the primary
interfacing functions to establish and main-
tain output control of the Power Wave 455.
Refer to Figure E.6. The control board
sends and receives digital command infor-
mation through the wire feeder receptacle
and or the RS232 connector. The software
that is contained within the control board
processes and compares these commands
with the voltage and current feedback infor-
mation it receives from the current sensor
and voltage sensing leads. The appropriate
The control board also monitors the ther-
mostats, main transformer primary current,
and capacitor voltage, and activates either
the thermal light and/or the status light.
Dependent upon the fault situation, the con-
trol board will either disable or reduce
machine output, or de-energize the main
input contactor.
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E-8
E-8
THEORY OF OPERATION
FIGURE E.7 — OUTPUT RECTIFIER AND CHOKE.
MAIN
TRANSFORMER
CURRENT
SENSOR
LEFT
SWITCH
BOARD
OUTPUT
TERMINAL
PWM
DRIVE
INPUT
CONTACTOR
INPUT
RECTIFIER
R
E
C
O
N
N
E
C
T
S
W
I
PRIMARY
CURRENT
SENSOR
T
C
H
CAPACITOR
VOLTAGE
FEEDBACK
S
W
I
T
C
H
P
O
W
E
CHOKE
RIGHT
SWITCH
BOARD
R
I
B
O
A
R
D
N
P
U
T
OUTPUT
TERMINAL
CAPACITOR
VOLTAGE
FEEDBACK
CONTROL SIGNALS
PWM
DRIVE
THERMOSTATS
#1
AUX.
TRANS.
RECTIFIER
65VDC
CURRENT FEEDBACK
VOLTAGE FEEDBACK
CONTROL BOARD
AUX.
RECONNECT
#2
AUX.
TRANS.
FAN
MOTOR
POWER
BOARD
40VDC
STATUS
LIGHT
THERMAL
VOLTAGE
LIGHT
SENSE
RECEPTACLE
WIRE FEEDER RS232
RECEPTACLE CONN.
115VAC
RECEPTACLE
rectifies it to a DC voltage level. Since the
output choke is in series with the negative
leg of the output rectifier and also in series
with the welding load, a filtered DC output is
applied to the machine output terminals.
Refer to Figure E.7.
OUTPUT RECTIFIER
AND CHOKE
The output rectifier receives the AC output
from the main transformer secondary and
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E-9
E-9
THEORY OF OPERATION
THERMAL PROTECTION
OVER CURRENT
PROTECTION
Two normally closed (NC) thermostats pro-
tect the machine from excessive operating
temperatures. These thermostats are wired
in series and are connected to the control
board. One of the thermostats is located on
the heat sink of the output rectifier and the
other is located near the fan. (On later pro-
duction machines this thermostat is located
on the output choke) Excessive tempera-
tures may be caused by a lack of cooling air
or operating the machine beyond its duty
cycle or output rating. If excessive operat-
ing temperatures should occur, the ther-
mostats will prevent output from the
machine. The yellow thermal light, located
on the front of the machine, will be illuminat-
ed. The thermostats are self-resetting once
the machine cools sufficiently. If the ther-
mostat shutdown was caused by excessive
output or duty cycle and the fan is operating
normally, the power switch may be left on
and the reset should occur within a 15-
minute period. If the fan is not turning or
the air intake louvers are obstructed, then
the power must be removed from the
machine, and the fan problem or air
obstruction corrected. On later production
machines (above code 10500) the cooling
fan runs only when necessary. The F.A.N.
(fan as needed) system is controlled by the
control board via a solid state relay.
If the average current exceeds 590 amps,
then the peak current will be limited to 100
amps until the average current decreases to
under 50 amps.
UNDER/OVER VOLTAGE
PROTECTION
A protective circuit is included on the
control board to monitor the voltage across
the input capacitors. In the event that a
capacitor voltage is too high, or too low, the
protection circuit will de-energize the input
contactor. Machine output will be disabled
and the “soft start” mode will be repeated.
The protection circuit will prevent output if
any of the following circumstances occur.
1. Capacitor conditioning is required.
(May be required if machine has been
off for a long period of time and is con-
nected for high input voltage operation.)
2. Voltage across a capacitor exceeds
390 volts. (High line surges or improp-
er input voltage connections.)
3. Voltage across a capacitor is under 70
volts. (Due to improper input voltage
connections.)
PROTECTIVE CIRCUITS
4. Internal component damage.
Protective circuits are designed into the
Power Wave 455 to sense trouble and shut
down the machine before damage occurs to
the machine's internal components.
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E-10
E-10
THEORY OF OPERATION
FIGURE E.8 — IGBT OPERATION.
POSITIVE
VOLTAGE
APPLIED
GATE
GATE
SOURCE
SOURCE
n+
n+
n+
n+
BODY REGION
BODY REGION
P
P
n-
n-
DRAIN DRIFT REGION
DRAIN DRIFT REGION
n+
P+
n+
P+
BUFFER LAYER
INJECTING LAYER
BUFFER LAYER
INJECTING LAYER
DRAIN
DRAIN
A. PASSIVE
B. ACTIVE
connected to the source. The circuit is
turned OFF like a light switch.
INSULATED GATE BIPOLAR
TRANSISTOR (IGBT)
OPERATION
Example B shows the IGBT in an active
mode. When the gate signal , a positive DC
voltage relative to the source, is applied to
the gate terminal of the IGBT, it is capable
of conducting current. A voltage supply con-
nected to the drain terminal will allow the
IGBT to conduct and supply current to the
circuit components coupled to the source.
Current will flow through the conducting
IGBT to downstream components as long
as the positive gate signal is present. This is
similar to turning ON a light switch.
An IGBT is a type of transistor. IGBT are
semiconductors well suited for high frequen-
cy switching and high current applications.
Example A in Figure E.8 shows an IGBT in
passive mode. There is no gate signal, zero
volts relative to the source, and therefore,
no current flow. The drain terminal of the
IGBT may be connected to a voltage sup-
ply; but since there is no conduction, the cir-
cuit will not supply current to components
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E-11
E-11
THEORY OF OPERATION
FIGURE E.9 — TYPICAL IGBT OUTPUTS.
(+)
(-)
1 µsec
48 µsec
1 µsec
50 µsec
MINIMUM OUTPUT
(+)
(-)
24 µsec
2 µsec
24 µsec
50 µsec
MAXIMUM OUTPUT
microsecond. The negative portion is the
other IGBT group . The dwell time (off time)
is 48 microseconds (both IGBT groups off).
Since only two microseconds of the 50-
microsecond time period is devoted to con-
ducting, the output power is minimized.
PULSE WIDTH
MODULATION
1
The term Pulse Width Modulation is used to
describe how much time is devoted to con-
duction in the positive and negative portions
of the cycle. Changing the pulse width is
known as modulation. Pulse Width
Modulation (PWM) is the varying of the
pulse width over the allowed range of a
cycle to affect the output of the machine.
MAXIMUM OUTPUT
By holding the gate signal on for 24
microseconds each, and allowing only two
microseconds 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 that is under the curve indicates that
more power is present.
MINIMUM OUTPUT
By controlling the duration of the gate sig-
nal, the IGBT is turned on and off for differ-
ent durations during the cycle. The top
drawing in Figure E.9 shows the minimum
output signal possible over a 50-microsec-
ond time period.
1
An IGBT group consists of two IGBT
modules feeding one transformer primary
winding.
The positive portion of the signal represents
1
one IGBT group conducting for one
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E-12
E-12
THEORY OF OPERATION
FIGURE E.10 — CONTROL BOX (USER INTERFACE).
DISPLAY AND
ENCODER PANEL
(STANDARD)
STATUS
LED
SMALL
PANEL
OPTIONS
DIP
SWITCHES
USER
INTERFACE
MOTHER-
BOARD
NETWORK
CONNECTOR
(INTERNAL)
LARGE
PANEL
OPTIONS
AMPHENOL-INPUT
NETWORK RECEPTACLE
(OPTIONAL)
AMPHENOL-OUTPUT
NETWORK RECEPTACLE
(OPTIONAL)
In addition to the large and smaller size
options, there is a Display Panel which is
standard on the Control Box unit. The
Display Panel, typically installed in the
upper position of the Control Box assembly,
houses the encoder controls and the STA-
TUS LED. The controls are used to adjust
the wire feed speed, current, voltage and
trim parameters. The STATUS LED is
designed to blink a red and green code if a
fault should occur.
CONTROL BOX
(USER INTERFACE)
The system Control Box is the main entry
point for all system parameters, and from it
the user can control both power source and
wire feeder functions. Refer to Figure E.10.
The user interface motherboard is the heart
of the Control Box. Dependent upon the
option panels and the information received
through the network cable, it directs the
entire system as to the options, wire feed
speed, and weld cycle requirements and
parameters.
The internal Network Connector is used
when the Control Box is mounted on either
the power source or the wire drive units.
See System Diagram A and System
Diagram B in this section.
The options are divided into two physical
size categories. The smaller option, typical-
ly installed in the middle section of the con-
trol box, is dedicated to dual procedure,
head selection, and memory related func-
tions. The larger, or bottom section, is
reserved for control of the setup functions
for the power source (Power Wave 455)
and wire drive (Power Feeder 10) such as
mode, arc control, run in and timer set up.
The optional Network Input and Output
receptacles are utilized when the Control
Box assembly is mounted independently
from both the wire drive and power source.
See System Diagram C in this section.
There are two DIP switch banks located on
the motherboard. They are labeled S1 and
S2 and are used to set display, trigger,
acceleration and run in functions.
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E-13
E-13
THEORY OF OPERATION
FIGURE E.11 — POWER FEED 10 FEED HEAD.
VOLTAGE
SENSE
LEAD #67A
LEAD #67
DRIVE
MOTOR
GEAR BOX
AND
CONDUCTOR
BLOCK
CONTROL BOARD
TACH
TO POWER
FEEDBACK
SOURCE OR
CONTROL
BOX
SHUTDOWN
STATUS LED
DIP SWITCH
GUN TRIGGER AND
DUAL PROCEDURE
RECEPTACLE
INPUT
NETWORK
RECEPTACLE
2-STEP/
4-STEP
NETWORK
CONNECTOR
(INTERNAL)
NETWORK
OUTPUT
GAS
SOLENOID
COLD
INCH/
GAS
RECEPTACLE
(OPTIONAL)
PURGE
the correct commands are transmitted to
POWER FEED 10
FEED HEAD
the feed drive. The feed drive control board
then sends the signals to energize the
active components such as the solenoid
and wire drive motor. The tach feedback
signal is processed on the control board
which regulates the motor armature voltage
so as to maintain the required wire feed
speed.
The Power Feed 10 is a four roll, high per-
formance, digitally controlled, modular wire
feeder that operates on 40 VDC input
power. It is designed to be part of a modu-
lar, multi-process welding system. Refer to
Figure E.11.
When the gun trigger is pulled, the voltage
sense board relays the electrode sense sig-
nal to the input network receptacle for pro-
cessing by the Control Box.
Network communications, intelligence, PC
board input power, and arc voltage feed-
back is received and transmitted through
the input network receptacle. The internal
network connector plug is utilized when the
Control Box is mounted directly to the wire
drive unit. See System Diagram A in this
section. The optional network output recep-
tacle is used when the system components
are connected in a daisy-chain fashion.
The optional shutdown feature can be
implemented as a means of stopping the
wire feeding in the event that the water
cooler (if used) is not turned on.
The STATUS LED is designed to blink a red
and green code if a fault should occur.
The feed drive control board processes the
information it receives from the various user
operated switches such as the gun trigger,
2-step/4-step, and cold inch switches and
sends this information to other system com-
ponents. This information is evaluated and
There is one DIP switch bank located on the
wire drive control board. It is labeled S1
and is used to set gear ratios, arc polarity,
and for network identification purposes.
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E-14
E-14
NOTES
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SECTION F-1
SECTION F-1
TROUBLESHOOTING AND REPAIR
TABLE OF CONTENTS
-TROUBLESHOOTING AND REPAIR SECTION-
Troubleshooting and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section F
How to Use Troubleshooting Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PC Board Troubleshooting Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Power Wave . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Power Feed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Power Wave 455 Control Board LED Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Test Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Input Filter Capacitor Discharge Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Switch Board Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Output Rectifier Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Input Rectifier Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Input Contactor Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Auxiliary Transformer No. 2 Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Auxiliary Transformer No. 1 Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Power Board Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Current Transducer Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Drive Motor Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tach Feedback Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Voltage Sense PC Board Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Dual Encoder PC Board Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Control Cable Continuity Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Component Replacement Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Gas Solenoid Removal and Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Wire Feeder Control Board Removal And Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tach (Hall Effect) Assembly Removal and Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Gear Box and Drive Motor Removal and Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Switch Board and Filter Capacitor Removal and Replacement . . . . . . . . . . . . . . . . . . . . . . . . .
Meter Accuracy Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Control or Power Board Removal and Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Auxiliary Transformer No. 1 Removal and Replacement Procedure . . . . . . . . . . . . . . . . . . . . .
Main Input Contactor Removal and Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Input Rectifier Removal and Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Output Rectifier and Module Removal and Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting Flowcharts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Power Source Error Interpretation Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Performance Troubleshooting Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Functional Troubleshooting Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
F-2
F-3
F-5
F-5
F-13
F-22
F-23
F-23
F-25
F-29
F-31
F-35
F-37
F-39
F-43
F-47
F-51
F-53
F-55
F-57
F-59
F-61
F-61
F-63
F-65
F-67
F-71
F-74
F-75
F-79
F-83
F-87
F-89
F-93
F-93
F-94
F-95
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F-2
F-2
TROUBLESHOOTING AND REPAIR
HOW TO USE TROUBLESHOOTING GUIDE
WARNING
Service and Repair should only be performed by Lincoln Electric Factory Trained
Personnel. Unauthorized repairs performed on this equipment may result in danger to
the technician and machine operator and will invalidate your factory warranty. For your
safety and to avoid electrical shock, please observe all safety notes and precautions
detailed throughout this manual.
---------------------------------------------------------------------------------------------------------
This Troubleshooting Guide is provided to
help you locate and repair possible machine
malfunctions. Simply follow the three-step
procedure listed below.
Step 3. RECOMMENDED COURSE OF
ACTION.
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
(SYMPTOMS)”. This column describes
possible symptoms that the machine may
exhibit. Find the listing that best describes
the symptom that the machine is exhibiting.
Symptoms are grouped into the following
categories: function problems, feeding prob-
lems, and welding problems.
All of the referenced test procedures
referred to in the Troubleshooting Guide are
described in detail at the end of this chap-
ter. Refer to the Troubleshooting and Repair
Table of Contents to locate each specific
Test Procedure. All of the specified test
points, components, terminal strips, etc. can
be found on the referenced electrical wiring
diagrams and schematics. Refer to the
Electrical Diagrams Section Table of
Contents to locate the appropriate diagram.
Step 2. PERFORM EXTERNAL TESTS.
The second column labeled “POSSIBLE
AREAS OF MISADJUSTMENT(S)” lists the
obvious external possibilities that may con-
tribute to the machine symptom. Perform
these tests/checks in the order listed. In
general, these tests can be conducted with-
out removing the case wrap-around cover.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the
tests/repairs safely, contact the Lincoln Electric Service Department for technical
troubleshooting assistance before you proceed. Call 216-383-2531 or 1-800-833-9353.
---------------------------------------------------------------------------------------------------------
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F-3
F-3
TROUBLESHOOTING AND REPAIR
PC BOARD TROUBLESHOOTING PROCEDURES
WARNING
PC board can be
damaged by static
electricity.
ELECTRIC SHOCK
can kill.
- Remove your body’s
static charge before
opening the static-
shielding bag. Wear an
anti-static wrist strap.
For safety, use a 1 Meg
ohm resistive cord con-
nected to a grounded
part of the equipment
frame.
ATTENTION
Static-Sensitive
Devices
Handle only at
Static-Safe
Workstations
Have an electrician install
and service this equipment.
Turn the input power OFF
at the fuse box before
working on equipment. Do
not touch electrically hot
parts.
Reusable
Container
-------------------------------------------------
Do Not Destroy
- If you don’t have a
CAUTION
wrist strap, touch an unpainted, grounded,
part of the equipment frame. Keep touching
the frame to prevent static build-up. Be sure
not to touch any electrically live parts at the
same time.
Sometimes machine failures appear to be
due to PC board failures. These problems
can sometimes be traced to poor electrical
connections. To avoid problems when trou-
bleshooting and replacing PC boards,
please use the following procedure:
- Tools which come in contact with the PC
board must be either conductive, anti-static
or static-dissipative.
-------------------------------------------------
- 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 cannot
be installed immediately, put it back in the
static-shielding bag.
1. Determine to the best of your technical
ability that the PC board is the most
likely component causing the failure
symptom.
2. Check for loose connections at the PC
board to assure that the PC board is
properly connected.
- If the PC board uses protective shorting
jumpers, don’t remove them until installation
is complete.
3. If the problem persists, replace the sus-
pect PC board using standard practices
to avoid static electrical damage and
electrical shock. Read the warning
inside the static resistant bag and per-
form the following procedures:
- If you return a PC board to the Lincoln
Electric Company for credit, it must be in
the static-shielding bag. This will prevent
further damage and allow proper failure
analysis.
POWER WAVE 455/POWER FEED 10
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F-4
F-4
TROUBLESHOOTING AND REPAIR
4. Test the machine to determine if the
failure symptom has been corrected by
the replacement PC board.
harness, junction blocks, and termi-
nal strips.
b. If the original problem is recreated
by the substitution of the original
board, then the PC board was the
problem. Reinstall the replacement
PC board and test the machine.
NOTE: It is desirable to have a spare
(known good) PC board available for PC
board troubleshooting.
NOTE: Allow the machine to heat up so
that all electrical components can reach
their operating temperature.
6. Always indicate that this procedure was
followed when warranty reports are to
be submitted.
5. Remove the replacement PC board and
substitute it with the original PC board
to recreate the original problem.
NOTE: Following this procedure and writing
on the warranty report, “INSTALLED AND
SWITCHED PC BOARDS TO VERIFY
PROBLEM,” will help avoid denial of legiti-
mate PC board warranty claims.
NOTE: Do not substitute boards that show
physical damage.
a. If the original problem does not reap-
pear by substituting the original
board, then the PC board was not
the problem. Continue to look for
bad connections in the control wiring
POWER WAVE 455/POWER FEED 10
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F-5
F-5
TROUBLESHOOTING AND REPAIR
TROUBLESHOOTING GUIDE
POWER WAVE
Observe all Safety Guidelines detailed throughout this manual.
PROBLEMS
(SYMPTOMS)
POSSIBLE AREAS OF
MISADJUSTMENT(S)
RECOMMENDED
COURSE OF ACTION
OUTPUT PROBLEMS
Major physical or electrical dam- 1. Contact your local authorized 1. Contact the Lincoln Electric
age is evident when the sheet
metal cover(s) are removed.
Lincoln Electric Field Service
Facility for technical assistance.
Service Department, 216-383-
2531 or 1-800-833-9353
(WELD).
The machine is dead -- no output -- 1. Make certain the input power 1. Check the input power switch
no fan -- no LEDs.
switch SW1 is in the ON posi-
tion.
(SW1) for proper operation.
Also check the associated leads
for loose or faulty connections.
See wiring diagram.
2. Check the main input fuses. If
open, replace.
2. Check CB4 for proper operation.
3. Check the 6 amp circuit breaker
(CB4). Reset if tripped.
3. Perform the T1 Auxiliary
Transformer Test.
4. Make certain the reconnect
panel is configured correctly for 4. Perform the Power Board Test.
the applied input voltage.
The main input fuses (or breaker) 1. Make certain the fuses or break- 1. Check the reconnect switches
repeatedly fail.
ers are properly sized.
and associated wiring. See
wiring diagram.
2. Make certain the reconnect
panel is configured properly for 2. Perform the Input Rectifier
the applied input voltage. Test.
3. The welding procedure may be 3. Perform the Switch Board
drawing too much input current
or the duty cycle may be too
high. Reduce the welding cur-
rent and/or reduce the duty
cycle.
Test.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric
Service Department for technical troubleshooting assistance before you proceed. Call 216-383-2531 or 1-800-833-9353.
-----------------------------------------------------------------------------------------------------------------------------
POWER WAVE 455/POWER FEED 10
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F-6
F-6
TROUBLESHOOTING AND REPAIR
POWER WAVE
Observe all Safety Guidelines detailed throughout this manual.
PROBLEMS
(SYMPTOMS)
POSSIBLE AREAS OF
MISADJUSTMENT(S)
RECOMMENDED
COURSE OF ACTION
OUTPUT PROBLEMS (Continued)
The Power Wave has no output -- 1. Turn the input power OFF 1. Perform the T1 Auxiliary
the fan is running -- a “clicking”
immediately.
Transformer Test.
sound may be heard coming from
the machine. The main contactor 2. Make certain the reconnect 2. Perform the Main Contactor
CR1 is not “pulling in”. If the
STATUS LED is not steady green,
see LED Code Table.
panel is configured correctly for
the applied input voltage.
Test.
3. Perform the Input Rectifier
3. If the machine is connected for
380 VAC or higher and has not
Test.
been used for a long period of 4. Perform the Switch Board
time, the capacitors may require
“conditioning”. Let the Power
Test.
Wave 455 run at an idle state 5. The power board rectifier may
for 30 minutes.
be faulty. Check or replace.
Also check associated wiring.
See wiring diagram.
6. Perform the Power Board Test.
7. The input voltage board may be
faulty.
8. The control board may be faulty.
The fan runs slow or intermittently 1. Make certain the reconnect 1. Perform the T1 Auxiliary
-- low or no weld output.
panel is configured correctly.
Transformer Test.
2. The power board rectifier may
be faulty. Check or replace.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric
Service Department for technical troubleshooting assistance before you proceed. Call 216-383-2531 or 1-800-833-9353.
-----------------------------------------------------------------------------------------------------------------------------
POWER WAVE 455/POWER FEED 10
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F-7
F-7
TROUBLESHOOTING AND REPAIR
POWER WAVE
Observe all Safety Guidelines detailed throughout this manual.
PROBLEMS
(SYMPTOMS)
POSSIBLE AREAS OF
MISADJUSTMENT(S)
RECOMMENDED
COURSE OF ACTION
OUTPUT PROBLEMS (Continued)
The thermal LED is lit. The 1. Welding application may exceed 1. One of the thermostats may be
machine regularly overheats.
recommended duty cycle.
faulty. Check or replace. See
wiring diagram.
2. Dirt and dust may have clogged
the cooling channels inside the
machine. Refer to the Mainte-
nance Section of this manual.
3. Air intake and exhaust louvers
may be blocked due to inade-
quate
clearance
around
machine.
4. Make sure the fan is functioning
correctly.
The Auxiliary Receptacle is “dead”. 1. Check the 10 amp circuit break- 1. Check the receptacle and asso-
The 115 VAC is missing.
er (CB2) located on the case
front. Reset if necessary.
ciated wiring for loose or faulty
connections. See wiring dia-
gram. (Plugs P80 and P81)
2. Check the 10 amp circuit break-
er (CB3) located in the recon- 2. Perform the Auxiliary Transfor-
nect area. Reset if necessary. mer T2 Test.
The Power Wave 455 won’t pro- 1. The input voltage may be too 1. Perform the Output Rectifier
duce full output.
low, limiting the output capability
of the Power Wave 455. Make
Test.
certain the input voltage is prop- 2. Perform the Power Board Test.
er for the machine and recon-
nect panel configuration.
3. Compare the display voltage
reading with an actual voltage
reading at the output terminals.
If the discrepancy is greater
than two volts the control board
may be faulty.
2. Make sure all three phases of
input power are being applied to
the machine.
4. Perform the Current Trans-
ducer Test.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric
Service Department for technical troubleshooting assistance before you proceed. Call 216-383-2531 or 1-800-833-9353.
-----------------------------------------------------------------------------------------------------------------------------
POWER WAVE 455/POWER FEED 10
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F-8
F-8
TROUBLESHOOTING AND REPAIR
POWER WAVE
Observe all Safety Guidelines detailed throughout this manual.
PROBLEMS
(SYMPTOMS)
POSSIBLE AREAS OF
MISADJUSTMENT(S)
RECOMMENDED
COURSE OF ACTION
WELDING PROBLEMS
For no apparent reason, the weld- 1. Check for proper wire feed 1. If zero arc voltage is displayed
ing characteristics have changed.
speed setting. In the MIG/MAG
and FCAW modes, check for
proper voltage settings. In the
MIG/MAG pulse modes, check
the arc length trim setting.
These controls are on the
Control Box (user interface).
on the Control Box while weld-
ing, the voltage sense leads
may be broken. Check lead #67
at the wire drive. See wiring
diagram. Also check leads
#202 (Neg. output terminal) and
#206 (Pos. output terminal).
See Power Wave 455 wiring
diagram. If external voltage
sensing is utilized, check the
#21 lead between the 4-pin
receptacle on the Power Wave
455 and the workpeice.
2. Check for proper shielding gas
and gas flow.
3. Check for loose or faulty weld-
ing cables and connections.
2. Perform the Output Rectifier
Test.
3. The control board may be faulty.
4. Perform the Current Trans-
ducer Test.
The machine often “noodle welds” 1. The machine may be trying to 1. Perform the Current Trans-
with a particular procedure.
deliver too much power. When
the average output current
ducer Test.
exceeds a maximum limit, the 2. The control board may be faulty.
machine will “phase back” to
protect itself. Adjust the proce-
dure or reduce the load to lower
the current draw from the Power
Wave 455 machine.
Power Wave 455 - When the
average output current exceeds
570 amps, the output current is
phased back to 100 amps.
The arc burns back to the tip.
1. The voltage settings may be too 1. Perform the Voltage Sense PC
high for the procedure.
Board Test.
2. The voltage sensing lead or con-
nection may be faulty. See the
Power Feed 10 Wiring Diagram
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric
Service Department for technical troubleshooting assistance before you proceed. Call 216-383-2531 or 1-800-833-9353.
-----------------------------------------------------------------------------------------------------------------------------
POWER WAVE 455/POWER FEED 10
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F-9
F-9
TROUBLESHOOTING AND REPAIR
POWER WAVE
Observe all Safety Guidelines detailed throughout this manual.
PROBLEMS
(SYMPTOMS)
POSSIBLE AREAS OF
MISADJUSTMENT(S)
RECOMMENDED
COURSE OF ACTION
FUNCTION PROBLEMS
The wire feeder won’t work. No 1. Make certain the Power Wave 1. Check for 40 VDC on pin “D” (+)
lights. Apparently the wire feeder
is not being powered-up.
455 is turned on.
and pin “E” (-) at the Power
Wave 455 wire feeder recepta-
cle. See wiring diagram.
2. Check circuit breaker CB1 locat-
ed on the case front of the
Power Wave 455. Reset if nec-
essary.
If 40 volts DC is not present at
the Power Wave wire feeder
receptacle, perform the Power
Board Test.
3. Check the 6 amp circuit breaker
(CB4) located on the reconnect
panel. Reset if necessary.
2. Check the power board rectifier.
See wiring diagram.
4. Check the control cable
between the power source and 3. Perform the T1 Auxiliary
the wire feeder. Transformer Test.
Check for loose or broken con- 4. If the 40 volts DC is present at
nections. Check continuity on
all five leads from one end to
the other.
the Power Wave wire feeder
receptacle, the problem is in
the control cable or the
wire drive/control box. See
Wire Drive/Control Box
Troubleshooting.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric
Service Department for technical troubleshooting assistance before you proceed. Call 216-383-2531 or 1-800-833-9353.
-----------------------------------------------------------------------------------------------------------------------------
POWER WAVE 455/POWER FEED 10
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F-10
F-10
TROUBLESHOOTING AND REPAIR
POWER WAVE 455 STATUS LED CHART
STATUS LED
CONDITION
POSSIBLE FAULT(S)
LED is solid green (not blinking)
LED is solid red
System operating normally.
-- Indicates that nothing is connected to the wire feeder receptacle.
Connect a control cable to the Power Wave 455 wire feeder receptacle.
The other end of the control cable must be connected to either a
Control Box or wire drive unit.
-- The control cable may be faulty. Check continuity on all five leads from
end to end in the control cable.
-- The wire drive and/or Control Box may not be properly configured or
connected together. See Installation section of Power Feed 10
Instruction Manual.
-- If the wire drive unit and Control Box are properly configured, consult
the Status LED Error Code Table.
LED is solid red (not blinking)
LED is blinking red and green
-- The Power Wave 455 cannot communicate with the wire drive unit
and/or the Control Box due to a problem within the Power Wave 455.
Consult the three column Troubleshooting Guide.
-- The welding software may be corrupt. Contact the Lincoln Electric
Service Department.
-- If the Thermal LED is also lit, consult the Power Wave three column
Troubleshooting Guide “Thermal LED is lit”.
-- The input voltage is too high or too low. Make certain the input voltage
is proper according to the rating plate located on the rear of the Power
Wave 455.
-- The Power Wave 455 is having trouble communicating with the wire
drive or control box. Turn the Power Wave 455 off. Disconnect the
control cable from the wire feeder receptacle on the power source.
Turn the Power Wave 455 on. If the status LED then blinks green, the
problem is external to the power source. If the LED is still blinking red
and green, consult Status LED Error Code Table.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric
Service Department for technical troubleshooting assistance before you proceed. Call 216-383-2531 or 1-800-833-9353.
-----------------------------------------------------------------------------------------------------------------------------
POWER WAVE 455/POWER FEED 10
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F-11
F-11
TROUBLESHOOTING AND REPAIR
STATUS LED ERROR CODE TABLE
NOTE: The error code signal sequence is always preceeded by a 2 second green light. If more than one error
code is present, a 4 second off signal will separate the individual error code signals. Note that the [2 sec.green]
is only displayed at the beginning of the entire code sequence, not between codes if more than one error code is
present.
Example: (Code. #11 “one long red” followed by “one short red”) followed by (Code. #21 “two long reds”
followed by “one short red”).
[2 sec.green] [1.2 sec.red] [1.6 sec.off] [0.4 sec.red] [4.0 sec.off] [1.2 sec.red] [0.4 sec.off]
[1.2 sec.red] [1.6 sec.off] [0.4 sec.red]
DIGITAL COMMUNICATION ERROR CODE LED
ERRORS
SEQUENCE
#11 CAN bus off (Excessive [2 sec.green] [1.2 sec.red] [1.6 sec.off] [0.4 sec.red]
number of communication errors).
#12 Ul time out (Loss of communi- [2 sec.green] [1.2 sec.red] [1.6 sec.off] [0.4 sec.red] [0.4 sec.off]
cation to control box).
[0.4 sec.red]
WELDING FILE ERRORS
#21 Unprogrammed mode
#22 Empty weld table
ERROR CODE LED SEQUENCE
[2 sec.green] [1.2 sec.red] [0.4 sec.off] [1.2 sec.red] [1.6 sec.off]
[0.4 sec.red]
[2 sec.green] [1.2 sec.red] [0.4 sec.off] [1.2 sec.red] [1.6 sec.off]
[0.4 sec.red] [0.4 sec.off] [0.4 sec.red]
#23 Weld table check sum (table is [2 sec.green] [1.2 sec.red] [0.4 sec.off] [1.2 sec.red] [1.6 sec.off]
corrupt)
[0.4 sec.red] [0.4 sec.off] [0.4 sec.red] [0.4 sec.off] [0.4 sec.red]
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric
Service Department for technical troubleshooting assistance before you proceed. Call 216-383-2531 or 1-800-833-9353.
-----------------------------------------------------------------------------------------------------------------------------
POWER WAVE 455/POWER FEED 10
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F-12
F-12
TROUBLESHOOTING AND REPAIR
STATUS LED ERROR CODE TABLE (Continued)
POWER SOURCE
ERRORS
ERROR CODE
LED SEQUENCE
#31 Primary over current
[2 sec.green] [1.2 sec.red] [0.4 sec.off] [1.2 sec.red] [0.4 sec.off]
[1.2 sec.red] [1.6 sec.off] [0.4 sec.red]
#32 Capacitor “A” under voltage
#33 Capacitor “B” under voltage
[2 sec.green] [1.2 sec.red] [0.4 sec.off] [1.2 sec.red] [0.4 sec.off]
[1.2 sec.red] [1.6 sec.off] [0.4 sec.red] [0.4 sec.off] [0.4 sec.red]
[2 sec.green] [1.2 sec.red] [0.4 sec.off] [1.2 sec.red] [0.4 sec.off]
[1.2 sec.red] [1.6 sec.off] [0.4 sec.red] [0.4 sec.off] [0.4 sec.red]
[0.4 sec.off] [0.4 sec.red]
#34 Capacitor “A” over voltage
#35 Capacitor “B” over voltage
#36 Thermal overload
[2 sec.green] [1.2 sec.red] [0.4 sec.off] [1.2 sec.red] [0.4 sec.off]
[1.2 sec.red] [1.6 sec.off] [0.4 sec.red] [0.4 sec.off] [0.4 sec.red]
[0.4 sec.off] [0.4 sec.red] [0.4 sec.off] [0.4 sec.red]
[2 sec.green] [1.2 sec.red] [0.4 sec.off] [1.2 sec.red] [0.4 sec.off]
[1.2 sec.red] [1.6 sec.off] [0.4 sec.red] [0.4 sec.off] [0.4 sec.red]
[0.4 sec.off] [0.4 sec.red] [0.4 sec.off] [0.4 sec.red] [0.4 sec.off]
[0.4 sec.red]
[2 sec.green] [1.2 sec.red] [0.4 sec.off] [1.2 sec.red] [0.4 sec.off]
[1.2 sec.red] [1.6 sec.off] [0.4 sec.red] [0.4 sec.off] [0.4 sec.red]
[0.4 sec.off] [0.4 sec.red] [0.4 sec.off] [0.4 sec.red] [0.4 sec.off]
[0.4 sec.red] [0.4 sec.off] [0.4 sec.red]
#37 Machine failed soft start
[2 sec.green] [1.2 sec.red] [0.4 sec.off] [1.2 sec.red] [0.4 sec.off]
[1.2 sec.red] [1.6 sec.off] [0.4 sec.red] [0.4 sec.off] [0.4 sec.red]
[0.4 sec.off] [0.4 sec.red] [0.4 sec.off] [0.4 sec.red] [0.4 sec.off]
[0.4 sec.red] [0.4 sec.off] [0.4 sec.red] [0.4 sec.off] [0.4 sec.red]
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric
Service Department for technical troubleshooting assistance before you proceed. Call 216-383-2531 or 1-800-833-9353.
-----------------------------------------------------------------------------------------------------------------------------
POWER WAVE 455/POWER FEED 10
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F-13
F-13
TROUBLESHOOTING AND REPAIR
POWER FEED
Observe all Safety Guidelines detailed throughout this manual.
PROBLEMS
(SYMPTOMS)
POSSIBLE AREAS OF
MISADJUSTMENT(S)
RECOMMENDED
COURSE OF ACTION
FUNCTION PROBLEMS
Major physical or electrical dam- 1. Contact your local authorized 1. Contact the Lincoln Electric
age is evident when the sheet
metal cover(s) are removed.
Lincoln Electric Field Service
Facility for technical assistance.
Service Department, 216-383-
2531 or 1-800-833-9353
(WELD).
No wire feed, solenoid or arc volt- 1. The gun trigger may be faulty. 1. Check the continuity of leads
age. The STATUS LEDs are
steady green.
Check or replace.
#556 and #557 from the gun
trigger receptacle to plug J5
pins #11 and #12. See wire
drive wiring diagram.
2. Make certain the Control Box is
configured for a wire feeding
mode.
2. The wire drive control board
may be faulty.
3. Check option panel connec-
tions and switch(s) for proper
operation.
3. The Control Box control board
may be faulty.
No control of wire feed speed. All 1. Check for a mechanical restric- 1. Perform the Tach Feedback
STATUS LEDs are steady green.
The preset wire feed speed is
adjustable on the Control Box.
tion in the wire feed path.
Test.
2. The wire drive control board
may be faulty.
No welding arc voltage when the 1. The power source may unable 1. Make certain the Power Wave
gun trigger is activated. The wire
feeds normally and the gas sole-
noid functions properly. The
STATUS LEDs are steady green
on the wire drive unit and the
Contol Box.
to produce welding output due
to a thermal fault or other mal-
function. Check STATUS LED
on Power Wave 455 machine. 2. The wire drive control board
See Power Wave 455
455 power source is function-
ing correctly.
may be faulty.
Troubleshooting.
3. The Control Box control board
may be faulty.
The wire feed speed does not 1. The run in and weld wire feed 1. Perform the Current Trans-
change when welding current is
established. The WFS stays at the
run-in speed. The STATUS LEDs
are steady green.
speeds may be set to the same
value. Set run in speed to a
value that gives best starting 2. If the run in wire feed speed
ducer Test.
results.
cannot be adjusted, perform the
Tach Feedback Test and also
the Drive Motor Test.
3. The wire drive control board
may be faulty.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric
Service Department for technical troubleshooting assistance before you proceed. Call 216-383-2531 or 1-800-833-9353.
-----------------------------------------------------------------------------------------------------------------------------
POWER WAVE 455/POWER FEED 10
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F-14
F-14
TROUBLESHOOTING AND REPAIR
POWER FEED
Observe all Safety Guidelines detailed throughout this manual.
PROBLEMS
(SYMPTOMS)
POSSIBLE AREAS OF
MISADJUSTMENT(S)
RECOMMENDED
COURSE OF ACTION
FUNCTION PROBLEMS (Continued)
The purge switch on the wire drive 1. Make certain the COLD 1. If the COLD INCH/GAS PURGE
unit does not activate the gas sole-
noid, but gun trigger closure in the
MIG or Pulse modes does acitvate
INCH/GAS PURGE switch is
operating properly.
switch is operating correctly and
the associated leads are OK,
the wire drive control board may
be faulty.
the solenoid. The LEDs are steady 2. Check for loose or faulty leads
green on the power source,
Control Box and wire drive unit.
between COLD INCH/GAS
PURGE switch and the wire
drive control board. See wiring
diagram.
The COLD INCH/GAS PURGE 1. Make certain the COLD 1. If the COLD INCH/GAS PURGE
switch does not turn on the wire
drive motor but gun trigger closure
in the MIG or Pulse modes does
INCH/GAS PURGE switch is
operating properly.
switch is operating correctly and
the associated leads are OK,
the wire drive control board may
be faulty.
activate the wire drive motor. The 2. Check for loose or faulty leads
LEDs are steady green on the
power source, Control Box and
wire drive unit.
between the COLD INCH/GAS
PURGE switch and the wire
drive control board. See wiring
diagram.
The voltmeter on the Control Box 1. Make sure the DIP switches are 1. Check leads #512B and #511
does not function properly even
though the STATUS LEDS are
steady green.
configured correctly for the weld-
ing polarity being used. See
Setting DIP Switches in the
Wire Drive in the Installation
section of this manual.
from plug J4 on the wire drive
control board to the voltage
sense PC board.
2. Perform the Voltage Sense
Board Test.
2. Check the #67 lead on the wire
drive unit. Make sure it is con-
nected to the motor gear box
and also the voltage sense PC
board.
3. The display board may be
faulty.
4. The wire drive control board
may be faulty.
3. Check the work sensing leads
on the Power Wave 455 power
source. Check leads #202
(Neg. output terminal) and #206
(Pos. output terminal). See
Power Wave 455 wiring dia-
gram. If external voltage sens-
ing is utilized, check the #21
lead between the 4-pin recepta-
cle on the front of the Power
Wave 455 and the workpiece.
5. The Control Box control board
may be faulty.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric
Service Department for technical troubleshooting assistance before you proceed. Call 216-383-2531 or 1-800-833-9353.
-----------------------------------------------------------------------------------------------------------------------------
POWER WAVE 455/POWER FEED 10
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F-15
F-15
TROUBLESHOOTING AND REPAIR
POWER FEED
Observe all Safety Guidelines detailed throughout this manual.
PROBLEMS
(SYMPTOMS)
POSSIBLE AREAS OF
MISADJUSTMENT(S)
RECOMMENDED
COURSE OF ACTION
FUNCTION PROBLEMS (Continued)
The ammeter on the Control Box 1. Make sure the DIP switches are 1. Perform the Current Trans-
does not function properly even
though the STATUS LEDs are
steady green.
configured correctly for the
welding process and polarity
being used. See Setting DIP 2. The display board, located in
ducer Test.
Switches in the Wire Drive in
the Installation section of this
manual.
the control box, may be faulty.
3. The control board, located in the
power source, may be faulty.
2. Check the following connections
on the Power Wave 455
machine. Check for loose or
faulty connections between plug
J90 at the current transducer
and plug J21 on the Power
Wave 455 control board.
The display and/or indicator LEDs 1. Check for loose or faulty con- 1. Check suspected potentiometer
do not change when their corre-
sponding switches and or knobs
are activated or turned.
nections between the encoder
panel and the Control Box con-
trol board.
and/or switches for correct
resistances and operation.
2. Perform the Encoder PC Board
2. Check for loose or faulty con-
nections between the appropri-
Test.
ate switches and the Control 3. The Control Box control board
Box control board. may be faulty.
The mode and/or settings change 1. Contact the Lincoln Electric ser-
while welding under normal condi-
tions.
vice dept. for possible software
updates 1-800-833-9353.
(Please ref. your current soft-
ware number.)
The feeder resets when the gun 1. The auxiliary reconnect (Lead 1. Perform the Power Board Test.
trigger is activated. The LEDs blink
and the displays are intermittent.
“A”) may not be configured cor-
rectly. See Figure A.2. in the 2. Perform
the
Auxiliary
Installation Section of this man-
ual.
Transformer Test #1.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric
Service Department for technical troubleshooting assistance before you proceed. Call 216-383-2531 or 1-800-833-9353.
-----------------------------------------------------------------------------------------------------------------------------
POWER WAVE 455/POWER FEED 10
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F-16
F-16
TROUBLESHOOTING AND REPAIR
POWER FEED
Observe all Safety Guidelines detailed throughout this manual.
PROBLEMS
(SYMPTOMS)
POSSIBLE AREAS OF
MISADJUSTMENT(S)
RECOMMENDED
COURSE OF ACTION
FUNCTION PROBLEMS (Continued)
The displays are blank (not lit). The 1. Check for loose or faulty con- 1. Check for 12 VDC at plug J1 pin
wire feeds when the gun trigger is
activated.
nections at plug J1 on the dis-
play board, to plug J4 on the
Control Box control board.
7 (lead #512+) to plug J1 pin 8
(lead #500-) on the display
board. If the 12 VDC is present,
then the display board may be
faulty.
2. If the 12 VDC is low or not pre-
sent, check for loose or faulty
connections on leads #512 and
#500.
3. The Control Box control board
may be faulty.
The dual procedure is not function- 1. Make certain the the bat switch 1. The remote Dual Procedure
al when using the remote Dual
Prodedure switch. The STATUS
LEDs are steady green on the
power source, Control Box and
wire drive units.
on the Dual Procedure Panel is
in the middle position. This
enables the gun remote dual
procedure switch.
switch may be faulty. Check
switch and associated leads.
2. The local dual procedure switch
may be faulty.
Remove power to the machine.
Disconnect plug J5 from the
Control Box control board.
Check for continuity (less than
one ohm) between pins 1 and 7
when the Dual Procedure switch
is in position “A”. Next check for
continuity (less than one ohm)
between pins 1 and 8 when the
Dual Procedure switch is in the
“B” position. If either of these
continuity tests fail, replace the
switch. When the switch is in
the center postion there should
not be any continuity between
pins.
3. The Control Box control board
may be faulty.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric
Service Department for technical troubleshooting assistance before you proceed. Call 216-383-2531 or 1-800-833-9353.
-----------------------------------------------------------------------------------------------------------------------------
POWER WAVE 455/POWER FEED 10
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F-17
F-17
TROUBLESHOOTING AND REPAIR
POWER FEED
Observe all Safety Guidelines detailed throughout this manual.
PROBLEMS
(SYMPTOMS)
POSSIBLE AREAS OF
MISADJUSTMENT(S)
RECOMMENDED
COURSE OF ACTION
FUNCTION PROBLEMS (Continued)
The Dual Procedure is not func- 1. Check the leads and plug J5 1. The local dual procedure switch
tioning when using the local Dual
Procedure switch on the Control
Box. The STATUS LEDs are
steady green on the power source,
Control Box and wire drive units.
between the switch and the
Control Box control board for
loose or faulty connections.
See wiring diagram.
may be faulty.
Remove power to the machine.
Disconnect plug J5 from the
Control Box control board.
Check for continuity (less than
one ohm) between pins 1 and 7
when the Dual Procedure switch
is in position “A”. Next check for
continuity (less than one ohm)
between pins 1 and 8 when the
Dual Procedure switch is in the
“B” position. If either of these
continuity tests fail, replace the
switch. When the switch is in
the center position, there should
not be any continuity between
pins.
2. The Control Box control board
may be faulty.
The wire feed speed is consistent 1. The DIP switch on the wire drive 1. The wire drive control board
and adjustable, but runs at the
wrong speed.
unit may not be set for the cor-
rect gear ratio. See the Instal-
lation section of this manual.
may be faulty.
The unit shuts off while welding or 1. The shut down circuit in the 1. Disconnect any shutdown
attempting to weld. The STATUS
LED is alternating between red and
green every second. The unit tries
to recover after 30 seconds and
may repeat sequence.
wire drive unit may be electrical-
ly “open”. Make sure leads
#570 and #571 are connected
together.
device from leads #570 and
#571 (0.25 in. insulated tab ter-
minals). Connect leads #570
and #571 together. If the feeder
STATUS LED is now steady
green, the problem is in the
external shutdown circuit.
2. The drive motor may be over
loaded due to a mechanial
restriction in the wire feeding
path. See Operation section of 2. If there are no restrictions in the
this manual.
wire feeding path, the drive
motor or gear box may be faulty.
3. The wire drive control board
may be faulty.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric
Service Department for technical troubleshooting assistance before you proceed. Call 216-383-2531 or 1-800-833-9353.
-----------------------------------------------------------------------------------------------------------------------------
POWER WAVE 455/POWER FEED 10
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F-18
F-18
TROUBLESHOOTING AND REPAIR
POWER FEED
Observe all Safety Guidelines detailed throughout this manual.
PROBLEMS
(SYMPTOMS)
POSSIBLE AREAS OF
MISADJUSTMENT(S)
RECOMMENDED
COURSE OF ACTION
FUNCTION PROBLEMS (Continued)
When the gun trigger is activated, 1. Check plug J3 on the wire drive 1. Perform the Drive Motor Test.
the drive rolls do not turn. The arc
voltage is present and the solenoid
is energized. The STATUS LEDs
are steady green.
control board, and leads #550
and #551 for loose or faulty con- 2. The wire drive control board
nections. See wiring diagram.
may be faulty.
The wire is feeding rough or not 1. The drive roll pressure may be 1. Contact the Lincoln Electric
feeding, but the drive rolls are
turning.
incorrect. Set drive roll pres-
sure. See Operation section in
this manual.
Service Department, 216-383-
2531 or 1-800-833-9353
(WELD).
2. Check for dirty or rusty elec-
trode wire.
3. Make sure the drive rolls and
wire guides are positioned and
installed correctly. See Opera-
tion section of this manual.
4. Check for mechanical restric-
tions in the wire feeding path.
When in CC modes with the 1. Rotate Volts/Trim encoder knob 1. Check option panel installation
optional “MX” or “MSP” panels, the
output does not energize.
at least 45° clockwise. This is
normal. See Accessories sec-
tion for detailed operation.
for loose or faulty connections.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric
Service Department for technical troubleshooting assistance before you proceed. Call 216-383-2531 or 1-800-833-9353.
-----------------------------------------------------------------------------------------------------------------------------
POWER WAVE 455/POWER FEED 10
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F-19
F-19
TROUBLESHOOTING AND REPAIR
POWER FEED
Observe all Safety Guidelines detailed throughout this manual.
PROBLEMS
(SYMPTOMS)
POSSIBLE AREAS OF
MISADJUSTMENT(S)
RECOMMENDED
COURSE OF ACTION
WELDING PROBLEMS
The gun tip seizes in diffuser.
1. The tip may be overheating due 1. Contact the Lincoln Electric
to prolonged or excessive high
current and /or duty cycle. Do
not exceed the current and duty
cycle rating of the gun.
Service Department, 216-383-
2531 or 1-800-833-9353
(WELD).
2. A light application of high tem-
perature antiseize lubricant
(such as Graphite Grease) may
be applied to tip threads.
Poor arc striking with sticking or 1. Make sure the weld procedures 1. Contact the Lincoln Electric
“blast-offs”. The weld bead may
be narrow and ropy with weld
porosity.
are correct for the process being
used. Check gas, wire feed,
speed and arc voltage.
Service Department, 216-383-
2531 or 1-800-833-9353
(WELD).
2. Remove the gun liner and check
the rubber seal for any sign of
deterioration or damage. Be
sure the set screw in the con-
nector block is in place and
tightened against the liner
bushing.
3. Check the welding cables for
loose or faulty connections.
The arc is variable and/or hunting. 1. Check the contact tip. It may be 1. Contact the Lincoln Electric
The power source, Control Box
and drive units seem to be operat-
ing properly.
worn or the wrong size for the
electrode wire being used.
Service Department, 216-383-
2531 or 1-800-833-9353
(WELD).
2. Check for loose or faulty weld-
ing cables and connections.
3. Make sure the weld procedures
are correct for the process being
used. Check gas, wire feed
speed and arc voltage.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric
Service Department for technical troubleshooting assistance before you proceed. Call 216-383-2531 or 1-800-833-9353.
-----------------------------------------------------------------------------------------------------------------------------
POWER WAVE 455/POWER FEED 10
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F-20
F-20
TROUBLESHOOTING AND REPAIR
POWER FEED ERROR CODE CHART
DISPLAYED
CODE
POSSIBLE CAUSE
(FAULT)
RECOMMENDED
COURSE OF ACTION
CONTROL BOX/WIRE DRIVE ERROR CODE CHART
Err 011
More than one control box has the Make sure the group DIP switch
same group number.
setting is unique for each Control
Box. See Installation section of
this manual.
Err 003
There are too many objects in the A given group can support a max-
group.
imun of seven objects. Remove
any objects over seven either by
changing the group DIP switch set-
tings or physically disconnecting
the “extra” objects. See Instal-
lation section of this manual.
Err 004
More than one object of the same Adjust the DIP switch setting to
equipment type with the same make either the group number or
group number and feed head num- the feed head number unique for all
ber.
objects of the same equipment
type. See Installation section of
this manual.
Err 005
Err 006
A wire drive unit has its DIP switch- The appropriate wire drive numbers
es set to zero. It is in a group that are 1 through 7. Check the DIP
has more than one object.
switch setting chart in the Instal-
lation section of this manual.
The unit did not receive a recogni- Check to see if the STATUS LED on
tion command from the power the Power Wave 455 is not steady
source.
green. If it is not steady green, refer
to the Power Wave 455 Status
LED Chart and Code Table. Check
the control cables for loose or faulty
connections. Also check the conti-
nuity of all five leads from one end
to the other. The control board in the
PW 455 may be faulty.
Err 020
An attempt was made to reprogram
the Control Box or the wire drive Check for potential electrical high
unit, but the program did not verify. frequency noise in the surrounding
area. Remove any potential HF
noise and program the unit again.
If the Err 020 still occurs, either
replace the EEPROM chip(s) in the
board being programmed or
replace the entire PC board being
programmed.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric
Service Department for technical troubleshooting assistance before you proceed. Call 216-383-2531 or 1-800-833-9353.
-----------------------------------------------------------------------------------------------------------------------------
POWER WAVE 455/POWER FEED 10
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F-21
POWER FEED ERROR CODE CHART
F-21
TROUBLESHOOTING AND REPAIR
Observe all Safety Guidelines detailed throughout this manual.
PROBLEMS
(SYMPTOMS)
POSSIBLE AREAS OF
MISADJUSTMENT(S)
RECOMMENDED
COURSE OF ACTION
CONTROL BOX/WIRE DRIVE ERROR CODE CHART (Continued)
Err 100
Err 200
Err 201
For some reason the Power Wave See Err 006 in this chart.
455 issued a shutdown command.
No response from the Power Wave See Err 006 in this chart.
455.
No response from either the If this condition occurs while weld-
Control Box or wire feed unit.
ing, the status LED should be flash-
ing red on the problem unit.
Otherwise, check for any units that
are flashing green. This indicates
that the particular unit has not been
recognized and there is a power
source problem. See Power Wave
455 Troubleshooting. If the STA-
TUS LED is either flashing red or
steady red, there may be a fault in
the control cable(s).
Err 210
EEPROM error
The parameter(s) recalled at power
up was out of range. Rotate
Encoder Knob to reset. Check all
settings before proceeding to weld.
If this condition persists, replace
the Control Box control board.
Err 211
A microprocessor RAM error Remove the input power. Wait five
occurred in the Control Box.
seconds. Turn power on. If Err
211 is displayed again, the Control
Box control board may be faulty.
- - - (three dashes)
Appears on the control box display. This is an indication that constant
current such as STICK or GOUGE
mode has been selected. Turning
the right encoder clockwise when in
this state will activate output from
the Power Wave 455. Turning the
right encoder counterclockwise will
deactivate output.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric
Service Department for technical troubleshooting assistance before you proceed. Call 216-383-2531 or 1-800-833-9353.
-----------------------------------------------------------------------------------------------------------------------------
POWER WAVE 455/POWER FEED 10
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F-22
F-22
NOTES
PW 455 CONTROL BOARD LED DEFINITIONS
LED COLOR AND NUMBER
CIRCUIT INDICATORS
-15 VDC Supply
Green LED 1
Green LED 3
Green LED 4
Red LED 5
+15 VDC Supply
+5 VDC Supply
On when jumper removed from J26
+5 VDC Communication Supply
Fault Error Indicator
Green 6 LED
Red LED 7
Green LED 8
+5 VDC RS232 Supply
NOTE: The only LED that changes state when the machine is running is
LED 7 (Fault Indicator). The rest are either on or off depending upon the
power supply or jumper status.
POWER WAVE 455/POWER FEED 10
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F-23
F-23
TROUBLESHOOTING AND REPAIR
TEST PROCEDURES
INPUT FILTER CAPACITOR DISCHARGE PROCEDURE
WARNING
Service and repair should only be performed by Lincoln Electric factory trained
personnel. Unauthorized repairs performed on this equipment may result in dan-
ger to the technician or machine operator and will invalidate your factory warran-
ty. For your safety and to avoid electrical shock, please observe all safety notes
and precautions detailed throughout this manual.
If for any reason you do not understand the test procedures or are unable to per-
form the test/repairs safely, contact the Lincoln Electric service department for
technical troubleshooting assistance before you proceed. Call 216-383-2531 or
1-800-833-9353(WELD).
------------------------------------------------------------------------------------------------
TEST DESCRIPTION
This “safety” procedure should be performed before any internal maintenance or repair
procedures are attempted on the Power Wave 455. Capacitance normally discharges
within 2 minutes of removing input power. This procedure is used to check that the
capacitors have properly discharged.
This procedure takes approximately 9 minutes to perform.
MATERIALS NEEDED
3/8 in. nutdriver
Volt-Ohmmeter
25-1000 ohms @ 25 watts (minimum) resistor
Electrically insulated gloves and pliers
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F-24
F-24
TROUBLESHOOTING AND REPAIR
INPUT FILTER CAPACITOR DISCHARGE PROCEDURE (continued)
FIGURE F.1 — CAPACITOR DISCHARGE PROCEDURE.
SWITCH
BOARD
CAPACITOR
TERMINALS
6. Using the high wattage resistor (25-
1000 ohms @ 25 watts (minimum),
electrically insulated gloves and pliers,
connect the resistor across the two
capacitor terminals. Hold the resistor in
place for 10 seconds. DO NOT
TOUCH THE CAPACITOR TERMI-
NALS WITH YOUR BARE HANDS.
NEVER USE A SHORTING STRAP
FOR THIS PROCEDURE.
TEST PROCEDURE
1. Remove input power to the Power
Wave 455.
2. Using the 3/8 in. nutdriver, remove the
left and right case sides.
3. Be careful not to make contact with the
capacitor terminals that are located in
the bottom center of the left and right
side switch boards. See Figure F.1.
7. Repeat procedure for the other
capacitor.
4. Carefully check for a DC voltage at the
capacitor terminals on both boards.
Note the polarity is marked on the PC
board and also lead #19 is positive.
8. Recheck the voltage across the capaci-
tor terminals. The voltage should be
zero. If any voltage remains, repeat the
discharge procedure.
5. If any voltage is present, proceed to
Step #6. If no voltage is present, the
capacitors are discharged.
NOTE: Voltage present after the discharge
has been performed is an abnormal condi-
tion and may indicate a switch board
problem.
POWER WAVE 455/POWER FEED 10
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F-25
F-25
TROUBLESHOOTING AND REPAIR
SWITCH BOARD TEST
WARNING
Service and repair should only be performed by Lincoln Electric factory trained
personnel. Unauthorized repairs performed on this equipment may result in dan-
ger to the technician or machine operator and will invalidate your factory warran-
ty. For your safety and to avoid electrical shock, please observe all safety notes
and precautions detailed throughout this manual.
If for any reason you do not understand the test procedures or are unable to per-
form the test/repairs safely, contact the Lincoln Electric service department for
technical troubleshooting assistance before you proceed. Call 216-383-2531 or
1-800-833-9353(WELD).
------------------------------------------------------------------------------------------------
TEST DESCRIPTION
This test will help determine if the “power section” of the switch boards are functioning
correctly. This test will NOT indicate if the entire PC board is functional. This resis-
tance test is preferable to a voltage test with the machine energized because these
boards can be damaged easily. In addition, it is dangerous to work on these boards
with the machine energized.
This procedure takes approximately 20 minutes to perform.
MATERIALS NEEDED
3/8 in. nutdriver
3/8 in. wrench
Analog Volt-Ohmmeter
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F-26
F-26
TROUBLESHOOTING AND REPAIR
SWITCH BOARD TEST (continued)
FIGURE F.2 — RECONNECT SWITCHES.
19C
19D
RECONNECT
SWITCHES
4. Locate label and remove leads 19C
and 19D from the reconnect switches
with the 3/8 in. wrench. Note lead
placement for reassembly. Clear leads.
Refer to Figure F.2.
TEST PROCEDURE
1. Remove input power to the Power
Wave 455.
2. Using the 3/8 in. nutdriver, remove the
case top and sides.
5. Using the Analog ohmmeter, perform
the resistance tests detailed in Table
F.1. Refer to Figure F.3 for the test
points.
3. Perform the Capacitor Discharge
Procedure.
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F-27
F-27
TROUBLESHOOTING AND REPAIR
SWITCH BOARD TEST (continued)
FIGURE F.3 — SWITCH BOARD TEST POINTS.
SWITCH
BOARD
-20+19
11/12
OR
15/16
13/14
OR
17/18
6. If any test fails replace both switch
8. Reconnect leads 19C and 19D to the
reconnect switches. Ensure that the
leads are installed in the same location
they were removed from.
boards. See Switch Board Removal
and Replacement.
7. If the switch board resistance tests are
OK, check the molex pin connections
and associated wiring from the switch
boards to the control board. See wiring
diagram.
9. Install the right and left case sides
using the 3/8 in. nutdriver.
TABLE F.1 — SWITCH BOARD RESISTANCE TEST.
APPLY POSITIVE TEST
PROBE TO TERMINAL
APPLY NEGATIVE TEST
PROBE TO TERMINAL
NORMAL
RESISTANCE READING
+19
+19
11/12 OR 15/16
13/14 OR 17/18
- 20
Greater than 1000 ohms
Greater than 1000 ohms
Greater than 1000 ohms
Greater than 1000 ohms
Less than 100 ohms
Less than 100 ohms
Less than 100 ohms
Less than 100 ohms
11/12 OR 15/16
13/14 OR 17/18
- 20
- 20
11/12 OR 15/16
13/14 OR 17/18
+19
- 20
11/12 OR 15/16
13/14 OR 17/18
+19
POWER WAVE 455/POWER FEED 10
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F-28
F-28
NOTES
POWER WAVE 455/POWER FEED 10
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F-29
F-29
TROUBLESHOOTING AND REPAIR
OUTPUT RECTIFIER TEST
WARNING
Service and repair should only be performed by Lincoln Electric factory trained
personnel. Unauthorized repairs performed on this equipment may result in dan-
ger to the technician or machine operator and will invalidate your factory warran-
ty. For your safety and to avoid electrical shock, please observe all safety notes
and precautions detailed throughout this manual.
If for any reason you do not understand the test procedures or are unable to per-
form the test/repairs safely, contact the Lincoln Electric service department for
technical troubleshooting assistance before you proceed. Call 216-383-2531 or
1-800-833-9353(WELD).
------------------------------------------------------------------------------------------------
TEST DESCRIPTION
The test will help determine if any of the output rectifiers are shorted.
This procedure takes approximately 10 minutes to perform.
MATERIALS NEEDED
Analog Volt-Ohmmeter
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F-30
F-30
TROUBLESHOOTING AND REPAIR
OUTPUT RECTIFIER TEST (continued)
FIGURE F.4 — OUTPUT RECTIFIER TEST.
NEGATIVE (-)
OUTPUT
TERMINAL
POSITIVE (+)
OUTPUT
TERMINAL
TEST PROCEDURE
3. With the analog ohmmeter, measure
the resistance between the positive and
negative output terminals. Refer to
Figure F.4. IMPORTANT: The positive
(+) meter probe must be attached to the
positive (+) output terminal and the
negative (-) meter probe must be
attached to the negative (-) output ter-
minal.
1. Remove main input supply power to the
Power Wave 455.
NOTE: Later code machines have a 50
ohm resistor across the welding output ter-
minals. It will be necessary to remove the
case sides and Perform the Input Filter
Capacitor Discharge Procedure. Remove
and insulate one of the resistor leads (#
202A or #206A) from the appropriate weld-
ing output terminal. See the wiring diagram.
4. If the reading is more than 200 ohms,
the output rectifier modules are not
shorted. If the reading is less than 200
ohms, one or more of the rectifier mod-
ules are shorted. Refer to the Output
Rectifier Module Replacement
Procedure.
2. Remove any output load that may be
connected to the Power Wave 455.
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F-31
F-31
TROUBLESHOOTING AND REPAIR
INPUT RECTIFIER TEST
WARNING
Service and repair should only be performed by Lincoln Electric factory trained
personnel. Unauthorized repairs performed on this equipment may result in dan-
ger to the technician or machine operator and will invalidate your factory warran-
ty. For your safety and to avoid electrical shock, please observe all safety notes
and precautions detailed throughout this manual.
If for any reason you do not understand the test procedures or are unable to per-
form the test/repairs safely, contact the Lincoln Electric service department for
technical troubleshooting assistance before you proceed. Call 216-383-2531 or
1-800-833-9353(WELD).
------------------------------------------------------------------------------------------------
TEST DESCRIPTION
This test will help determine if the input rectifier has “shorted” or “open” diodes.
This procedure takes approximately 15 minutes to perform.
MATERIALS NEEDED
Analog Volt-Ohmmeter
Phillips head screwdriver
Wiring diagram
3/8 in. nutdriver
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F-32
F-32
TROUBLESHOOTING AND REPAIR
INPUT RECTIFIER TEST (continued)
FIGURE F.5 — INPUT RECTIFIER TEST.
INPUT
RECTIFIER
C
NEG (-)
B
A
POS (+)
NOTE: Some RTV sealant may have to be
removed from the input rectifier terminals.
The RTV should be replaced when test is
complete.
TEST PROCEDURE
1. Remove input power to the Power
Wave 455.
5. With the Phillips head screwdriver
remove the positive and negative leads
from the rectifier.
2. Using the 3/8 in. nutdriver, remove the
case top.
3. Perform the Capacitor Discharge
6. Use the analog ohmmeter to perform
Procedure.
the tests detailed in Table F.2.
4. Locate the Input Rectifier and lead
locations. Refer to Figure F.5.
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F-33
F-33
TROUBLESHOOTING AND REPAIR
INPUT RECTIFIER TEST (continued)
TABLE F.2 — INPUT RECTIFIER TEST POINTS AND ACCEPTABLE READINGS.
TEST POINT TERMINALS
ANALOG METER X10 RANGE
Acceptable Meter Readings
+ Probe
- Probe
A
B
C
NEG
NEG
NEG
Greater than 1000 ohms
Greater than 1000 ohms
Greater than 1000 ohms
A
B
C
POS
POS
POS
Less than 100 ohms
Less than 100 ohms
Less than 100 ohms
NEG
NEG
NEG
A
B
C
Less than 100 ohms
Less than 100 ohms
Less than 100 ohms
POS
POS
POS
A
B
C
Greater than 1000 ohms
Greater than 1000 ohms
Greater than 1000 ohms
7. If the input rectifier does not meet the
acceptable readings outlined in the
table, the component may be faulty.
Replace.
9. If the input rectifier is good, be sure to
reconnect the positive and negative
leads to the correct terminals and
torque to 31 in/lbs. See wiring diagram.
NOTE: Before replacing the input rectifier,
perform the Switch Board Test and the
Input Contactor Test.
10. Replace any RTV sealant previously
removed.
11. Install the case top.
8. When installing a new input rectifier,
see Input Rectifier Removal and
Replacement procedure.
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F-34
F-34
NOTES
POWER WAVE 455/POWER FEED 10
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F-35
F-35
TROUBLESHOOTING AND REPAIR
INPUT CONTACTOR TEST
WARNING
Service and repair should only be performed by Lincoln Electric factory trained
personnel. Unauthorized repairs performed on this equipment may result in dan-
ger to the technician or machine operator and will invalidate your factory warran-
ty. For your safety and to avoid electrical shock, please observe all safety notes
and precautions detailed throughout this manual.
If for any reason you do not understand the test procedures or are unable to per-
form the test/repairs safely, contact the Lincoln Electric service department for
technical troubleshooting assistance before you proceed. Call 216-383-2531 or
1-800-833-9353(WELD).
------------------------------------------------------------------------------------------------
TEST DESCRIPTION
This test will help determine if the input contactor is functional and if the contacts are
functioning correctly.
This procedure takes approximately 17 minutes to perform.
MATERIALS NEEDED
3/8 in. nutdriver
Volt-Ohmmeter
External 24 VAC supply
POWER WAVE 455/POWER FEED 10
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F-36
F-36
TROUBLESHOOTING AND REPAIR
INPUT CONTACTOR TEST (continued)
FIGURE F.6 — INPUT CONTACTOR COIL.
INPUT
CONTACTOR
X4/X4A
601/601A
FIGURE F.7 — INPUT CONTACTOR
TEST POINTS.
TEST PROCEDURE
1. Remove input power to the Power
Wave 455.
L3
T3
2. Using the 3/8 in. nutdriver, remove the
input access panel and case top.
L2
L1
T2
T1
3. Locate, mark, and remove the four
leads (601, 601A, X4 and X4A) that are
connected to the input contactor coil.
Refer to Figure F.6.
6. When the contactor is NOT activated,
the resistance should be infinite or very
high across the contacts. If the resis-
tance is low, the input contactor is
faulty.
4. Using the external 24 VAC supply,
apply 24 VAC to the terminals of the
input contactor coil. If the contactor
does NOT activate, the input contactor
is faulty. Replace.
7. Reconnect the four leads (601, 601A,
X4, and X4A) to the input contactor coil.
5. With the input contactor activated,
check the continuity across the three
sets of contacts. (Zero ohms or very
low resistance is normal). Refer to
Figure F.7. If the resistance is high, the
input contactor is faulty. Replace the
input contactor.
8. Install the input access door and case
top using the 3/8 in. nutdriver.
POWER WAVE 455/POWER FEED 10
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F-37
F-37
TROUBLESHOOTING AND REPAIR
AUXILIARY TRANSFORMER NO. 2 TEST
WARNING
Service and repair should only be performed by Lincoln Electric factory trained
personnel. Unauthorized repairs performed on this equipment may result in dan-
ger to the technician or machine operator and will invalidate your factory warran-
ty. For your safety and to avoid electrical shock, please observe all safety notes
and precautions detailed throughout this manual.
If for any reason you do not understand the test procedures or are unable to per-
form the test/repairs safely, contact the Lincoln Electric service department for
technical troubleshooting assistance before you proceed. Call 216-383-2531 or
1-800-833-9353(WELD).
------------------------------------------------------------------------------------------------
TEST DESCRIPTION
This test will determine if the correct voltage is being applied to the primary of Auxiliary
Transformer No. 2 and also if the correct voltage is being induced on the secondary
winding of the transformer.
This procedure takes approximately 10 minutes to perform.
MATERIALS NEEDED
Volt-Ohmmeter (Multimeter)
3/8 in. nutdriver
Wiring diagram
POWER WAVE 455/POWER FEED 10
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F-38
F-38
TROUBLESHOOTING AND REPAIR
AUXILIARY TRANSFORMER NO. 2 TEST (continued)
FIGURE F.8 — AUXILIARY TRANSFORMER NO. 2 TEST.
4
6
1
3
2
P80
1
4
P81
8. If 115 VAC is not present between pins
#1 and #4, check the associated leads
and plugs for loose or faulty connec-
tions.
TEST PROCEDURE
1. Remove the main input supply power to
the Power Wave 455 machine.
2. Remove any load that may be connect-
ed to the 115 VAC receptacle.
WARNING
High voltage is present at plug P80.
3. Using the 3/8 in. nutdriver, remove the
left and right case sides.
9. Carefully test for the correct AC input
voltage applied to the primary windings
at plug P80. See wiring diagram.
4. Perform the Capacitor Discharge
Procedure.
10. If the correct AC input voltage is
applied to the primary of the Auxiliary
Transformer No. 2 and the secondary
voltage is NOT correct, the transformer
may be faulty. Replace.
5. Locate plugs P80 and P81 at the
Auxiliary Transformer No. 2. Refer to
Figure F.8.
6. Carefully apply the correct input power
and check for 115 VAC at plug P81
pins #1 and #4.
11. Install the left and right case sides
using the 3/8 in. nutdriver.
7. If 115 VAC is present, the Auxiliary
Transformer No. 2 is good.
POWER WAVE 455/POWER FEED 10
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F-39
F-39
TROUBLESHOOTING AND REPAIR
AUXILIARY TRANSFORMER NO. 1 TEST
WARNING
Service and repair should only be performed by Lincoln Electric factory trained
personnel. Unauthorized repairs performed on this equipment may result in dan-
ger to the technician or machine operator and will invalidate your factory warran-
ty. For your safety and to avoid electrical shock, please observe all safety notes
and precautions detailed throughout this manual.
If for any reason you do not understand the test procedures or are unable to per-
form the test/repairs safely, contact the Lincoln Electric service department for
technical troubleshooting assistance before you proceed. Call 216-383-2531 or
1-800-833-9353(WELD).
------------------------------------------------------------------------------------------------
TEST DESCRIPTION
This test will determine if the correct voltage is being applied to the primary of Auxiliary
Transformer No. 1 and also if the correct voltage is being induced on the secondary
windings of the transformer.
This procedure takes approximately 16 minutes to perform.
MATERIALS NEEDED
Volt-Ohmmeter (Multimeter)
3/8 in. nutdriver
Wiring diagram
POWER WAVE 455/POWER FEED 10
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F-40
F-40
TROUBLESHOOTING AND REPAIR
AUXILIARY TRANSFORMER NO. 1 TEST (continued)
FIGURE F.9 — AUXILIARY TRANSFORMER NO. 1 TEST.
POWER BOARD
RECTIFIER BRIDGE
MAIN
CONTACTOR
X1
X4
X2
X3
X5
FAN MOTOR
LEADS
4. Locate secondary leads X1 and X2 (at
power board rectifier bridge). Refer to
Figure F.9.
TEST PROCEDURE
1. Remove the main input supply power to
the Power Wave 455 machine.
5. Locate secondary leads X3 and X5 (fan
motor leads).
2. Using the 3/8 in. nutdriver, remove the
case sides and top.
6. Locate secondary lead X4 (at main
contactor).
3. Perform the Capacitor Discharge
Procedure.
POWER WAVE 455/POWER FEED 10
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F-41
F-41
TROUBLESHOOTING AND REPAIR
AUXILIARY TRANSFORMER NO. 1 TEST (continued)
TABLE F.3 — SECONDARY VOLTAGES.
NORMAL EXPECTED
LEAD IDENTIFICATION
VOLTAGE
X1 to X2
52 VAC
X3 to X5
X3 to X4
115 VAC
24 VAC
7. Carefully apply the correct input voltage
to the Power Wave 455 and check for
the correct secondary voltages per
Table F.3.
WARNING
High voltage is present at primary of
Auxiliary Transformer.
NOTE: The secondary voltages will vary if
the input line voltage varies.
9. If the correct input voltage is applied to
the primary, and the secondary volt-
age(s) are not correct, the T1 trans-
former may be faulty.
8. If the correct secondary voltages are
present, the T1 auxiliary transformer is
functioning properly. If any of the sec-
ondary voltages are missing or low,
check to make certain the primary is
configured correctly for the input volt-
age applied. See wiring diagram.
10. Install the case sides and top using the
3/8 in. nutdriver.
POWER WAVE 455/POWER FEED 10
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F-42
F-42
NOTES
POWER WAVE 455/POWER FEED 10
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F-43
F-43
TROUBLESHOOTING AND REPAIR
POWER BOARD TEST
WARNING
Service and repair should only be performed by Lincoln Electric factory trained
personnel. Unauthorized repairs performed on this equipment may result in dan-
ger to the technician or machine operator and will invalidate your factory warran-
ty. For your safety and to avoid electrical shock, please observe all safety notes
and precautions detailed throughout this manual.
If for any reason you do not understand the test procedures or are unable to per-
form the test/repairs safely, contact the Lincoln Electric service department for
technical troubleshooting assistance before you proceed. Call 216-383-2531 or
1-800-833-9353(WELD).
------------------------------------------------------------------------------------------------
TEST DESCRIPTION
This test will help determine if the power board is receiving the correct voltages and
also if the power board is regulating and producing the correct DC voltages.
This procedure takes approximately 20 minutes to perform.
MATERIALS NEEDED
3/8 in. nutdriver
Volt-Ohmmeter
Wiring diagram
POWER WAVE 455/POWER FEED 10
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F-44
F-44
TROUBLESHOOTING AND REPAIR
POWER BOARD TEST (continued)
FIGURE F.10 — POWER BOARD TEST.
50
51
WT
BK
B2
B1
2
1 2 3 4 5
1
4
3
6
6
J31
J32
11
12
910
5
7 8
6. Carefully test for the correct voltages at
the power board as per Table F.4.
TEST PROCEDURE
1. Remove input power to the Power
Wave 455.
NOTE: Capacitor C3 (25000 mfd/100 V)
may hold a charge. Do not come in con-
tact with the capacitor terminals.
2. Using the 3/8 in. nutdriver, remove the
case sides and top.
7. If the 65 VDC is low or not present at
plug J32, check the rectifier bridge and
C3 filter capacitor. See wiring diagram.
Also perform the T1 Auxiliary
Transformer Test.
3. Perform the Capacitor Discharge
Procedure.
4. Locate the power board and plugs J31
and J32. Also locate leads #51 (black)
and #50 (white). Do not remove plugs
or leads from the power board. Refer
to Figure F.10.
8. If any of the DC voltages are low, or not
present, at plug J31, the power board
may be faulty.
9. Install the case sides and top using the
3/8 in. nutdriver.
5. Carefully apply the correct input voltage
to the Power Wave 455.
POWER WAVE 455/POWER FEED 10
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F-45
F-45
TROUBLESHOOTING AND REPAIR
POWER BOARD TEST (continued)
TABLE F.4 — POWER BOARD VOLTAGE CHECKS.
NORMAL
LEAD NO.
ACCEPTABLE
VOLTAGE
CHECK POINT
TEST
CONNECTOR
OR
LOCATION
DESCRIPTION
PLUG PIN NO.
IDENTITY
READING
POWER PC
BOARD
CONNECTOR
PLUG J32
CHECK 65 VDC
SUPPLY FROM
POWER BOARD
RECTIFIER
1 & 2(+)
4 & 5(-)
POS(+)
NEG(-)
73 VDC
POS
BRIDGE
NEG
POWER PC
BOARD
CONNECTOR
PLUG J31
CHECK +15
VDC SUPPLY
FROM POWER
PC BOARD
2(+)
4(-)
225(+)
222(-)
15 VDC
5 VDC
15 VDC
5 VDC
5 VDC
225
222
POWER PC
BOARD
CONNECTOR
PLUG J31
CHECK +5 VDC
SUPPLY FROM
POWER PC
BOARD
7(+)
4(-)
221(+)
222(-)
222
221
POWER PC
BOARD
CONNECTOR
PLUG J31
CHECK -15 VDC
SUPPLY FROM
POWER PC
BOARD
4(+)
3(-)
222(+)
223(-)
223 222
POWER PC
BOARD
CONNECTOR
PLUG J31
CHECK +5 VDC
“CAN” SUPPLY
FROM POWER
PC BOARD
11(+)
12(-)
274(+)
273(-)
274 273
POWER PC
BOARD
CHECK +5 VDC
“RS232”
6(+)
5(-)
226(+)
228(-)
CONNECTOR
PLUG J31
SUPPLY FROM
POWER PC
BOARD
228 226
POWER PC
BOARD SPADE
TERMINALS
CHECK +40
VDC WIRE
FEEDER SUPPLY
FROM POWER PC
BOARD
#50 TERMINAL
TO
#51 TERMINAL
WHITE (+)
BLACK (-)
40 VDC
POWER WAVE 455/POWER FEED 10
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F-46
F-46
NOTES
POWER WAVE 455/POWER FEED 10
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F-47
F-47
TROUBLESHOOTING AND REPAIR
CURRENT TRANSDUCER TEST
WARNING
Service and repair should only be performed by Lincoln Electric factory trained
personnel. Unauthorized repairs performed on this equipment may result in dan-
ger to the technician or machine operator and will invalidate your factory warran-
ty. For your safety and to avoid electrical shock, please observe all safety notes
and precautions detailed throughout this manual.
If for any reason you do not understand the test procedures or are unable to per-
form the test/repairs safely, contact the Lincoln Electric service department for
technical troubleshooting assistance before you proceed. Call 216-383-2531 or
1-800-833-9353(WELD).
------------------------------------------------------------------------------------------------
TEST DESCRIPTION
This test will help determine if the current transducer and associated wiring is function-
ing correctly.
This procedure takes approximately 25 minutes to perform.
MATERIALS NEEDED
3/8 in. nutdriver
Volt-Ohmmeter
POWER WAVE 455/POWER FEED 10
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F-48
F-48
TROUBLESHOOTING AND REPAIR
CURRENT TRANSDUCER TEST (continued)
FIGURE F.11 — CURRENT TRANSDUCER TEST.
NOTE: On later codes
the transducer is located
on left side of the
machine near the output
choke.
1234
CURRENT
TRANSDUCER
P90
7. Check for the correct DC supply volt-
ages to the current transducer at plug
P90.
TEST PROCEDURE
1. Remove input power to the Power
Wave 455.
A. Pin 1 (lead 212+) to pin 4 (lead
216-) should read +15 VDC.
2. Using the 3/8 in. nutdriver remove the
right side case cover.
B. Pin 2 (lead 213-) to pin 4 (lead
216+) should read -15 VDC.
3. Perform the Capacitor Discharge
Procedure.
8. If either of the supply voltages are low
or missing, check the associated leads
between the current transducer and the
control board. If the leads are OK and
the DC supply voltages are not present,
the control board may be faulty.
4. Locate the current transducer at the
lower right front of the machine.
5. Apply the correct input power to the
Power Wave 455.
6. Locate plug P90 at the current trans-
ducer. Do not remove the plug. Refer
to Figure F.11.
POWER WAVE 455/POWER FEED 10
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F-49
F-49
TROUBLESHOOTING AND REPAIR
CURRENT TRANSDUCER TEST (continued)
TABLE F.5 — CURRENT FEEDBACK AT VARIOUS OUTPUT LOADS.
EXPECTED TRANSDUCER FEEDBACK
VOLTAGE
OUTPUT LOAD CURRENT
500
450
400
350
300
250
200
150
100
4.0
3.6
3.2
2.8
2.4
2.0
1.6
1.2
0.8
9. Check the feedback voltage from the
current transducer. With the Power
Wave system in a constant current
mode and the machine loaded to 250
amps, the current feedback voltage can
be read at plug P90.
11. If the correct supply voltages are
applied to the current transducer, and
with the machine loaded, the feedback
voltage is missing or not correct, the
current transducer may be faulty. Also
make certain that lead #211 has conti-
nuity (zero ohms) between the current
transducer and the control board. See
wiring diagram.
A. Pin 3 (lead 211) to pin 4 (lead
216) should read 2.0 VDC (machine
loaded to 250 amps).
12. Install the right side case cover using
the 3/8 in. nutdriver.
10. If for any reason the machine cannot be
loaded to 250 amps, Table F.5 shows
what feedback voltage is produced at
various current loads.
POWER WAVE 455/POWER FEED 10
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F-50
F-50
NOTES
POWER WAVE 455/POWER FEED 10
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F-51
F-51
TROUBLESHOOTING AND REPAIR
DRIVE MOTOR TEST
WARNING
Service and repair should only be performed by Lincoln Electric factory trained
personnel. Unauthorized repairs performed on this equipment may result in dan-
ger to the technician or machine operator and will invalidate your factory warran-
ty. For your safety and to avoid electrical shock, please observe all safety notes
and precautions detailed throughout this manual.
If for any reason you do not understand the test procedures or are unable to per-
form the test/repairs safely, contact the Lincoln Electric service department for
technical troubleshooting assistance before you proceed. Call 216-383-2531 or
1-800-833-9353(WELD).
------------------------------------------------------------------------------------------------
TEST DESCRIPTION
This test will help determine if the wire drive motor is receiving the correct voltage, and
if it is capable of running properly.
This procedure takes approximately 12 minutes to perform.
MATERIALS NEEDED
3/8 in. nutdriver
Volt-Ohmmeter
POWER WAVE 455/POWER FEED 10
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F-52
F-52
TROUBLESHOOTING AND REPAIR
DRIVE MOTOR TEST (continued)
FIGURE F.12 — DRIVE MOTOR TEST.
#551
J3
#550
4
6
1
3
#550 (-)
BLACK
#551 (+)
WHITE
5. If the correct voltages are NOT present
at the motor leads, check the associat-
ed leads between the motor and plug
J3 on the control board. If the leads
are OK, the control board may be
faulty.
PROCEDURE
1. Remove input power to wire feed unit.
2. Using the 3/8 in. nutdriver, remove the
cover from the wire feeder.
6. If the correct voltages are present at
the motor armature leads and the motor
does not run and vary speed with
changes in armature voltage, the motor
or gear box may be faulty. See Gear
Box and Drive Motor Removal and
Replacement.
3. Locate the two quick connectors in the
two motor armature leads. Refer to
Figure F.12. Do NOT disconnect the
leads.
4. Apply the correct input power (from the
Power Wave 455 control cable) to the
wire feeder. Activate the gun trigger
and with the motor running check at the
quick connectors [#551 White (+) to
#550 Black (-)] for approximately 1
VDC to 32 VDC dependent upon motor
speed. The motor speed should vary
with changes in motor armature
voltage.
7. Install the wire feeder cover using the
3/8 in. nutdriver.
POWER WAVE 455/POWER FEED 10
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F-53
F-53
TROUBLESHOOTING AND REPAIR
TACH FEEDBACK TEST
WARNING
Service and repair should only be performed by Lincoln Electric factory trained
personnel. Unauthorized repairs performed on this equipment may result in dan-
ger to the technician or machine operator and will invalidate your factory warran-
ty. For your safety and to avoid electrical shock, please observe all safety notes
and precautions detailed throughout this manual.
If for any reason you do not understand the test procedures or are unable to per-
form the test/repairs safely, contact the Lincoln Electric service department for
technical troubleshooting assistance before you proceed. Call 216-383-2531 or
1-800-833-9353(WELD).
------------------------------------------------------------------------------------------------
TEST DESCRIPTION
This test will determine if the tach unit is receiving the correct supply voltage from the
control board, and also if the tach unit is sending feedback information to the control
board.
This procedure takes approximately 7 minutes to perform.
MATERIALS NEEDED
3/8 in. nutdriver
Volt-Ohmmeter
POWER WAVE 455/POWER FEED 10
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F-54
F-54
TROUBLESHOOTING AND REPAIR
TACH FEEDBACK TEST (continued)
FIGURE F.13 — TACH FEEDBACK TEST.
#1
#3
RED
BLACK
#2
(BLUE)
J4
WIRE FEED
CONTROL BOARD
5. With the gun trigger activated and the
motor running, check the feedback volt-
age at plug J4 pin #2 (blue wire) posi-
tive to pin #3 (black wire) negative.
Normal feedback voltage is approxi-
mately 5 VDC. If the correct supply volt-
age is present and the feedback volt-
age is missing, the tach unit may be
faulty. With the motor NOT running,
the feedback voltage may be either 0 or
10 VDC depending upon where the
motor stopped.
TEST PROCEDURE
1. Remove input power from the wire
feeder unit.
2. Using the 3/8 in. nutdriver, remove the
cover from the wire feeder.
3. Locate plug J4 on the control board.
Refer to Figure F.13. Do NOT remove
the plug from the control board.
4. Apply the correct input power (from the
Power Wave 455 control cable) to the
wire feeder unit and check for approxi-
mately 12 VDC from pin #1 (red wire)
positive to pin #3 (black wire) negative.
This is the supply voltage from the con-
trol board to the tach feedback unit. If
the 12 VDC is missing or not correct,
the wire feeder control board may be
faulty. Also check for loose or faulty
wires and connections.
6. Remove input power from the wire
feeder unit.
7. Install the wire feeder cover with the 3/8
in. nutdriver.
POWER WAVE 455/POWER FEED 10
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F-55
F-55
TROUBLESHOOTING AND REPAIR
VOLTAGE SENSE PC BOARD TEST
WARNING
Service and repair should only be performed by Lincoln Electric factory trained
personnel. Unauthorized repairs performed on this equipment may result in dan-
ger to the technician or machine operator and will invalidate your factory warran-
ty. For your safety and to avoid electrical shock, please observe all safety notes
and precautions detailed throughout this manual.
If for any reason you do not understand the test procedures or are unable to per-
form the test/repairs safely, contact the Lincoln Electric service department for
technical troubleshooting assistance before you proceed. Call 216-383-2531 or
1-800-833-9353(WELD).
------------------------------------------------------------------------------------------------
TEST DESCRIPTION
This test will help determine if the voltage sensing board is receiving the correct activa-
tion signal from the control board and also if the voltage sensing board is processing
arc voltage sensing information.
This procedure takes approximately 13 minutes to perform.
MATERIALS NEEDED
3/8 in. nutdriver
Volt-Ohmmeter
POWER WAVE 455/POWER FEED 10
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F-56
F-56
TROUBLESHOOTING AND REPAIR
VOLTAGE SENSE PC BOARD TEST (continued)
FIGURE F.14 — VOLTAGE SENSING BOARD TEST.
J2
1 2 3
1
2
J1
4
6
5
NOTE: Inspect the molex
plug connector pins on the
Voltage Sense Board. If
any of them are gold plat-
ed the P.C. board should
be replaced
5. With the gun trigger activated and arc
voltage present at the conductor block,
check for arc voltage from plug J1 pin 3
(lead 67) to the workpiece. If actual
arc voltage is NOT present, check the
continuity of lead 67 from the conductor
block to plug J1 pin 3 on the voltage
sense PC board.
TEST PROCEDURE
1. Remove input power from the wire feed
unit.
2. Using the 3/8 in. nutdriver, remove the
cover from the wire feeder.
3. Locate the voltage sense PC board and
plugs J1 and J2. Do not remove the
plugs from the voltage sense PC board.
Refer to Figure F.14.
6. If the actual arc voltage IS present at
plug J1 pin 3 (lead 67), then check for
arc voltage from plug J2 pin 1 (lead
67A) to the workpiece. See wiring dia-
gram.
4. Apply the correct input power (from the
Power Wave 455 control cable) to the
wire feeder. With the gun trigger acti-
vated, check for approximately 12 VDC
at plug J1 pin 1 (+) to pin 4 (-). If the 12
VDC is NOT present, the control board
may be faulty. Also check for loose or
faulty wires and connections between
the control board (plug J6) and plug J1
on the voltage sense PC board.
7. If the 12 VDC IS present in Step #4 and
the arc voltage IS present in Step #5
but the arc voltage is NOT present in
Step #6 (lead 67A), the voltage sense
PC board may be faulty.
8. Remove all input power from the wire
feeder unit.
9. Install the wire feeder cover with the 3/8
in. nutdriver.
POWER WAVE 455/POWER FEED 10
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F-57
F-57
TROUBLESHOOTING AND REPAIR
DUAL ENCODER PC BOARD TEST
WARNING
Service and repair should only be performed by Lincoln Electric factory trained
personnel. Unauthorized repairs performed on this equipment may result in dan-
ger to the technician or machine operator and will invalidate your factory warran-
ty. For your safety and to avoid electrical shock, please observe all safety notes
and precautions detailed throughout this manual.
If for any reason you do not understand the test procedures or are unable to per-
form the test/repairs safely, contact the Lincoln Electric service department for
technical troubleshooting assistance before you proceed. Call 216-383-2531 or
1-800-833-9353(WELD).
------------------------------------------------------------------------------------------------
TEST DESCRIPTION
This test will help determine if the encoder PC board is functioning properly.
This procedure takes approximately 20 minutes to perform.
MATERIALS NEEDED
Phillips head screwdriver
Volt-Ohmmeter (Analog Recommended)
POWER WAVE 455/POWER FEED 10
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F-58
F-58
TROUBLESHOOTING AND REPAIR
DUAL ENCODER PC BOARD TEST (continued)
FIGURE F.15 — DUAL ENCODER TEST.
CONTROL
BOARD
DISPLAY
BOARD
1
2
3
4
5
6
7
8
9
10
11
12
13
14
1234 5678
J1
6. While rotating the wire feed speed
(WFS) control check for a “pulsing” 0
to 5 VDC signal at plug J1 pin 5 + (lead
553) to J1 pin 1 - (lead 500C). Also
check for a “pulsing” 0 to 5 VDC signal
from plug J1 pin 6 + (lead 554) to J1 pin
1 - (lead 500C).
TEST PROCEDURE
1. Remove input power from control box
assembly.
2. Using the Phillips head screwdriver,
remove the display/encoder assembly
panel from the Control Box. Refer to
Figure F.15.
7. While rotating the volts/trim control
check for a “pulsing” 0 to 5 VDC signal
at plug J1 pin 3 + (lead 555) to J1 pin 1-
(lead 500C). Also check for a “pulsing”
0 to 5 VDC signal at plug J1 pin 4 +
(lead 556) to J1 pin 1 - (lead 500C).
NOTE: The panel assembly cannot be
removed completely without removing the
lead plug from the control board. DO NOT
remove the lead plug.
3. Locate the dual encoder PC board and
plug J1. Also locate plug J4 on the
control board.
8. If the 12 VDC supply in Step 5 is pre-
sent and any of the 0 to 5 VDC “puls-
ing”* signals are missing, the encoder
PC board may be faulty.
4. Apply the correct input power (from the
Power Wave 455 control cable) to the
Control Box.
*“Pulsing” means that as the control is
rotated the signal will fluctuate from 0
to 5 VDC.
5. Check for approximately 12 VDC from
plug J1 pin 2+ (lead 512C) to plug J1
pin 1 - (lead 500C). This is the supply
voltage from the control board to the
encoder board. If this voltage is miss-
ing, check the continuity of the leads
between the control board (J4) and the
encoder board (J1). See wiring dia-
gram. The control board may be faulty.
9. Remove input power to the control box
assembly.
10. Install the display/encoder assembly
panel into the Control Box.
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F-59
F-59
TROUBLESHOOTING AND REPAIR
CONTROL CABLE CONTINUITY TEST
WARNING
Service and repair should only be performed by Lincoln Electric factory trained
personnel. Unauthorized repairs performed on this equipment may result in dan-
ger to the technician or machine operator and will invalidate your factory warran-
ty. For your safety and to avoid electrical shock, please observe all safety notes
and precautions detailed throughout this manual.
If for any reason you do not understand the test procedures or are unable to per-
form the test/repairs safely, contact the Lincoln Electric service department for
technical troubleshooting assistance before you proceed. Call 216-383-2531 or
1-800-833-9353(WELD).
------------------------------------------------------------------------------------------------
TEST DESCRIPTION
This test will help determine if the control cable is functional.
This procedure takes approximately 6 minutes to perform.
MATERIALS NEEDED
Volt-Ohmmeter
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F-60
F-60
TROUBLESHOOTING AND REPAIR
CONTROL CABLE CONTINUITY TEST (continued)
FIGURE F.16 — CABLE CONTINUITY TEST.
WIRE FEEDER END
POWER SOURCE END
E
E
A
D
D
A
C
C
B
B
TABLE F.6 CONTROL CABLE PIN AND LEAD DESIGNATIONS.
FIVE PIN AMPHENOL AT
POWER SOURCE END
FIVE PIN AMPHENOL AT
WIRE FEEDER/CONTROL BOX END
A
B
C
D
E
A
B
C
D
E
feeder/Control Box end. Refer to Figure
F.16 and Table F-6.
TEST PROCEDURE
1. Disconnect the input power to the
Power Wave 455 machine.
4. If any conductor resistance measures
greater than 1.0 ohm, the cable is
faulty and should be replaced. If the
resistance between any two conductors
or any conductor and the amphenol
body is less than 0.5M ohms, the cable
is faulty and should be replaced.
2. Disconnect the control cable amphe-
nols from the power source and the
wire feeder.
3. Using the ohmmeter measure the resis-
tance of the individual control cable
leads from the amphenol on the power
source end to the amphenol on the wire
5. Connect the control cable amphenols to
the wire feeder and power source.
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F-61
F-61
TROUBLESHOOTING AND REPAIR
COMPONENT REPLACEMENT PROCEDURES
GAS SOLENOID REMOVAL AND REPLACEMENT
WARNING
Service and repair should only be performed by Lincoln Electric factory trained
personnel. Unauthorized repairs performed on this equipment may result in dan-
ger to the technician or machine operator and will invalidate your factory warran-
ty. For your safety and to avoid electrical shock, please observe all safety notes
and precautions detailed throughout this manual.
If for any reason you do not understand the test procedures or are unable to per-
form the test/repairs safely, contact the Lincoln Electric service department for
technical troubleshooting assistance before you proceed. Call 216-383-2531 or
1-800-833-9353(WELD).
------------------------------------------------------------------------------------------------
DESCRIPTION
This will aid the technician in the removal and replacement of the gas solenoid.
This procedure takes approximately 12 minutes to perform.
MATERIALS NEEDED
3/8 in. nutdriver
Needlenose pliers
5/16 in. nutdriver
3/4 in. wrench
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F-62
F-62
TROUBLESHOOTING AND REPAIR
GAS SOLENOID REMOVAL AND REPLACEMENT (continued)
FIGURE F.17 — GAS SOLENOID REMOVAL AND REPLACEMENT.
MOUNTING
SCREW
BRASS
FITTING
GAS
SOLENOID
GAS
HOSE
HOSE
FITTING
PROCEDURE
INSTALLATION
1. Remove input power to the wire feeder.
1. If a new solenoid is to be installed, it
may be necessary to remove the hose
fitting from the “old” solenoid and install
it into the new solenoid using the 1/2 in.
wrench.
2. Using the 3/8 in. nutdriver, remove the
cover from the wire feeder.
3. Locate the gas solenoid on the rear
panel of the wire feeder. Refer to
Figure F.17.
2. Place the gas solenoid into the wire
feeder and secure it to the rear case
panel using the two 5/16 in. mounting
screws.
4. Using the 3/4 in. wrench, remove the
external brass fitting.
3. Install the gas hose onto the solenoid.
5. Carefully remove the two leads from
the solenoid.
4. Connect the two electrical leads to the
gas solenoid.
6. Remove the gas hose from the sole-
noid.
5. Install the external brass fitting onto the
gas solenoid using the 3/4 in. wrench.
7. Using the 5/16 in. nutdriver, remove the
two screws mounting the solenoid to
the rear case panel.
6. Install the wire feeder cover with the 3/8
in. nutdriver.
8. Carefully remove the gas solenoid from
the wire feeder.
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F-63
F-63
TROUBLESHOOTING AND REPAIR
WIRE FEEDER CONTROL BOARD REMOVAL
AND REPLACEMENT
WARNING
Service and repair should only be performed by Lincoln Electric factory trained
personnel. Unauthorized repairs performed on this equipment may result in dan-
ger to the technician or machine operator and will invalidate your factory warran-
ty. For your safety and to avoid electrical shock, please observe all safety notes
and precautions detailed throughout this manual.
If for any reason you do not understand the test procedures or are unable to per-
form the test/repairs safely, contact the Lincoln Electric service department for
technical troubleshooting assistance before you proceed. Call 216-383-2531 or
1-800-833-9353(WELD).
------------------------------------------------------------------------------------------------
DESCRIPTION
This will aid the technician in the removal and replacement of the control board.
This procedure takes approximately 7 minutes to complete.
MATERIALS NEEDED
3/8 in. nutdriver
Pliers
Anti-static wrist strap
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F-64
F-64
TROUBLESHOOTING AND REPAIR
WIRE FEEDER CONTROL BOARD REMOVAL AND REPLACEMENT (continued)
FIGURE F.18 — WIRE FEEDER CONTROL BOARD REMOVAL AND REPLACEMENT.
LOCKING
TAB
WIRE FEEDER
CONTROL BOARD
PROCEDURE
INSTALLATION
1. Remove input power to the wire feeder.
NOTE: Press the PC board onto the support
by pressing near the mounting hole you are
securing. Pressing near the center of the
PC board could damage the circuitry within
the board.
2. Using the 3/8 in. nutdriver, remove the
cover from the wire feeder.
3. Observe static precautions detailed
in PC Board Troubleshooting
Procedures at the beginning of this
section.
1. Align the holes on the PC board with
the supports attached to the wire feeder
and press the PC board until it is held
securely in place.
4. Disconnect the molex type plugs from
the control board. Refer to Figure F.18.
2. Connect the molex type plugs to the
control board.
5. Disengage the PC board supports by
squeezing each support in turn with a
pair of pliers and gently pulling out on
the board next to the support. When all
five supports have been disconnected,
carefully remove the control PC board
from the wire feeder.
3. Install the wire feeder cover using the
3/8 in. nutdriver.
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F-65
F-65
TROUBLESHOOTING AND REPAIR
TACH (HALL EFFECT) ASSEMBLY REMOVAL
AND REPLACEMENT
WARNING
Service and repair should only be performed by Lincoln Electric factory trained
personnel. Unauthorized repairs performed on this equipment may result in dan-
ger to the technician or machine operator and will invalidate your factory warran-
ty. For your safety and to avoid electrical shock, please observe all safety notes
and precautions detailed throughout this manual.
If for any reason you do not understand the test procedures or are unable to per-
form the test/repairs safely, contact the Lincoln Electric service department for
technical troubleshooting assistance before you proceed. Call 216-383-2531 or
1-800-833-9353(WELD).
------------------------------------------------------------------------------------------------
DESCRIPTION
The procedure will aid the technician in the removal and replacement of the tach
assembly from the gear box.
This procedure takes approximately 10 minutes to perform.
MATERIALS NEEDED
3/8 in. nutdriver
9/16 in. wrench
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F-66
F-66
TROUBLESHOOTING AND REPAIR
TACH (HALL EFFECT) ASSEMBLY REMOVAL AND REPLACEMENT (continued)
FIGURE F.19 — TACH REMOVAL AND REPLACEMENT.
LOCK
NUT
HALL
EFFECT
DEVICE
TACH
ASSEMBLY
REMOVAL PROCEDURE
REPLACEMENT PROCEDURE
1. Remove input power to the wire feeder.
1. Carefully screw the Hall Effect device
into the gear box assembly until it gen-
tly “bottoms out” on the rotary magnet
inside.
2. Using the 3/8 in. nutdriver, remove the
case cover.
3. Locate the tach assembly on the top of
the gear box. Refer to Figure F.19.
2. Unscrew the Hall Effect device 1/2 turn
from the rotary magnet. Tighten the
locking nut to 8 in/lbs.
4. Locate and remove plug J4 from the
control board.
3. Thread the J4 leads through the vertical
baffle and install cable ties where
appropriate.
5. Thread plug J4 and associated leads
through the vertical baffle. Cut any
necessary cable ties.
4. Connect plug J4 into the control board.
6. Using the 9/16 in. wrench, loosen the
locking nut on the Hall Effect device.
5. Install the wire feeder cover using the
3/8 in. nutdriver.
7. Carefully unscrew the Hall Effect device
from the gear box assembly.
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F-67
F-67
TROUBLESHOOTING AND REPAIR
GEAR BOX AND DRIVE MOTOR REMOVAL
AND REPLACEMENT
WARNING
Service and repair should only be performed by Lincoln Electric factory trained
personnel. Unauthorized repairs performed on this equipment may result in dan-
ger to the technician or machine operator and will invalidate your factory warran-
ty. For your safety and to avoid electrical shock, please observe all safety notes
and precautions detailed throughout this manual.
If for any reason you do not understand the test procedures or are unable to per-
form the test/repairs safely, contact the Lincoln Electric service department for
technical troubleshooting assistance before you proceed. Call 216-383-2531 or
1-800-833-9353(WELD).
------------------------------------------------------------------------------------------------
DESCRIPTION
This test will aid the technican in the removal and replacement of the wire feed drive
motor.
Removal and installation of the gearbox and drive motor assembly
takes approximately 20 minutes to perform. Removal and installation
of the drive motor takes approximately 10 minutes. Removal and
installation of the gearbox takes approximately 4 minutes to complete.
MATERIALS NEEDED
3/8 in. nutdriver
Slot head screwdriver
Phillips head screwdriver
7/16 in. socket wrench with extension
Needlenose pliers
5/16 in. wrench
3/16 in. Allen wrench
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F-68
F-68
TROUBLESHOOTING AND REPAIR
GEAR BOX AND DRIVE MOTOR REMOVAL AND REPLACEMENT (continued)
FIGURE F.20 — GEAR BOX AND DRIVE MOTOR REMOVAL AND REPLACEMENT.
J4
DRIVE
MOTOR
MOUNTING BOLT
INSPECTION COVER
GEAR BOX
WIRE
DRIVE
ASSEMBLY
#551
(BLACK)
#550
(WHITE)
INSULATION
GAS
FITTING
4. Thread plug J4 and associated leads
through the vertical baffle. Cut any
necessary cable ties.
PROCEDURE
1. Remove the input power to the wire
drive unit.
5. Locate and disconnect the motor leads
(#551 and #550) at the quick connects.
Cut any necessary cable ties.
2. Using the 3/8 in. nutdriver, remove the
case cover.
6. Using the Phillips head screwdriver,
remove the #67 lead from the conduc-
tor block.
3. Locate and remove plug J4 from the
control board. Refer to Figure F.20.
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F-69
F-69
TROUBLESHOOTING AND REPAIR
GEAR BOX AND DRIVE MOTOR REMOVAL AND REPLACEMENT (continued)
7. Using the needlenose pliers, discon-
nect the gas hose from the brass gun
connector block.
2. Tighten the two Allen type screws at
the bottom of the wire drive unit using
the 3/16 in. Allen wrench.
8. Using the 7/16 in. socket wrench,
remove the four mounting bolts, lock
washers, and flat washers from the
glastic base insulator.
3. Attach lead #67 to the conductor block.
4. Carefully slide the drive motor into the
gear box assembly. Be sure to position
the motor leads so that they can be
properly connected.
9. Carefully slide and remove the entire
gear box, drive motor, and wire drive
assembly from the wire feeder
case. Note insulation placement for
reassembly.
5. Install the slot head screws that mount
the “top” of the drive motor to the gear
box.
6. Install the mounting screw located
inside the gearbox using the 5/16 in.
wrench.
TO REMOVE THE DRIVE MOTOR
FROM THE GEAR BOX:
10. Using the slot head screwdriver,
remove the gear box inspection cover
nearest to the drive motor.
7. Install the gear box inspection cover
and secure it with slot head screws.
8. Properly place insulation in the bottom
of the wire feeder case.
11. Using the 5/16 in. wrench, remove the
motor mounting screw located inside
the gear box.
9. Place the entire gear box, drive motor
and wire drive assembly into the wire
feeder case, aligning the holes in the
glastic base insulator with the mounting
holes in the case.
12. Using the slot head screwdriver,
remove the two screws mounting the
“top” of the motor to the gear box.
13. Carefully remove the motor from the
gear box assembly. Note motor lead
placement for reassembly.
10. Mount the gear box and drive motor
assembly to the wire feeder case using
the four mounting bolts, lock washers
and flat washers.
TO REMOVE THE WIRE DRIVE
ASSEMBLY FROM THE GEAR BOX:
11. Connect the gas hose to the brass gun
connector block.
14. Using the 3/16 in. Allen wrench, loosen
the two Allen type screws at the bottom
of the wire drive unit.
12. Connect drive motor leads #550 and
#551 to their quick disconnects.
13. Thread plug J4 and associated leads
through the vertical baffle and attach it
to the control board. Install cable ties
as necessary.
15. Remove lead #67 from the conductor
block.
16. Carefully slide and remove the wire
drive assembly from the gear box
assembly.
14. Install the wire feeder cover using the
3/8 in. nutdriver.
REPLACEMENT PROCEDURES
1. Carefully slide the wire drive assembly
and gear box together.
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F-70
F-70
NOTES
POWER WAVE 455/POWER FEED 10
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F-71
F-71
TROUBLESHOOTING AND REPAIR
SWITCH BOARD AND FILTER CAPACITOR REMOVAL
AND REPLACEMENT
WARNING
Service and repair should only be performed by Lincoln Electric factory trained
personnel. Unauthorized repairs performed on this equipment may result in dan-
ger to the technician or machine operator and will invalidate your factory warran-
ty. For your safety and to avoid electrical shock, please observe all safety notes
and precautions detailed throughout this manual.
If for any reason you do not understand the test procedures or are unable to per-
form the test/repairs safely, contact the Lincoln Electric service department for
technical troubleshooting assistance before you proceed. Call 216-383-2531 or
1-800-833-9353(WELD).
------------------------------------------------------------------------------------------------
DESCRIPTION
This procedure will aid the technician in the removal and replacement of the switch
board(s) and/or filter capacitor(s).
This procedure takes approximately 25 minutes to perform.
MATERIALS NEEDED
3/8 in. nutdriver
7/16 in. wrench
3/16 in. Allen wrench
Slot head screwdriver
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F-72
F-72
TROUBLESHOOTING AND REPAIR
SWITCH BOARD AND FILTER CAPACITOR REMOVAL
AND REPLACEMENT (continued)
FIGURE F.21 — SWITCH BOARD AND FILTER CAPACITOR REMOVAL AND REPLACEMENT.
MOUNTING
SCREW (4X)
MOLEX PLUG
SWITCH
BOARD
11/12
OR
15/16
19+
20-
NYLON
SCREW
(2X)
13/14
OR
17/18
4. Remove the molex plug from the top of
REMOVAL PROCEDURE
the switch board. Refer to Figure F.21.
NOTE: Observe all static electricity precau-
tions.
5. Using the 7/16 in. wrench, remove
leads 11/12 or 15/16 from the switch
board.
1. Remove input power to the Power
Wave 455.
6. Using the 7/16 in. wrench, remove
leads 13/14 or 17/18 from the switch
board.
2. Using the 3/8 in. nutdriver, remove the
case top and sides.
7. Using the 7/16 in. wrench, remove
leads 19+ and 20- from the switch
board capacitor connection bolts.
3. Perform the Capacitor Discharge
Procedure.
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F-73
F-73
TROUBLESHOOTING AND REPAIR
SWITCH BOARD AND FILTER CAPACITOR REMOVAL
AND REPLACEMENT (continued)
8. With the slot head screwdriver, remove
the two nylon mounting screws at the
bottom of the switch board. Note
placement of the shake-proof washers
and fiber spacers.
5. Mount the new switch board and tight-
en the four cap head screws in the fol-
lowing manner.
• Tighten all until snug.
9. Using the 3/16 in. Allen wrench, care-
fully remove the four cap screws that
mount the switch board to the heatsink.
• Tighten all from 24 to 28 in/lbs.
• Tighten all from 40 to 48 in/lbs.
10. Carefully remove the switch board from
the heatsink.
6. Make sure the capacitor is positioned
correctly. Connect leads 19+ and 20-
to the correct terminals. Tighten to
55 in/lbs.
11. If the filter capacitor is to be removed,
carefully slide it out of the mounting
bracket.
7. Position and mount the two nylon
screws, fiber spacers, and washers.
Torque from 4 to 8 in/lbs.
REPLACEMENT PROCEDURE
8. Connect leads 11/12 or 15/16 to the
correct terminal.
1. If the filter capacitor is to be replaced,
carefully slide the new capacitor into
the mounting bracket. Position the
capacitor so the correct polarity termi-
nal is lined up with the correct hole on
the switch board.
9. Connect leads 13/14 or 17/18 to the
correct terminal.
10. Connect the molex plug to the top of
the switch board.
2. All heatsink and IGBT mounting sur-
faces must be clean.
11. Install the case top and sides using the
3/8 in. nutdriver.
3. Apply a thin coat of thermal compound
(Penetrox A13) 0.005 in. to 0.010 in. to
the mating surfaces. Do not apply
around mounting holes.
4. Apply a thin coat of Penetrox A13 to the
capacitor terminals. Be careful not to
apply compound to screw threads or
threaded area of terminals.
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F-74
F-74
TROUBLESHOOTING AND REPAIR
POWER WAVE 455 / PF-10 METER ACCURACY CHECK
WARNING
Service and repair should only be performed by Lincoln Electric factory trained
personnel. Unauthorized repairs performed on this equipment may result in dan-
ger to the technician or machine operator and will invalidate your factory warran-
ty. For your safety and to avoid electrical shock, please observe all safety notes
and precautions detailed throughout this manual.
If for any reason you do not understand the test procedures or are unable to per-
form the test/repairs safely, contact the Lincoln Electric service department for
technical troubleshooting assistance before you proceed. Call 216-383-2531 or
1-800-833-9353(WELD).
------------------------------------------------------------------------------------------------
DESCRIPTION
This procedure will aid the technician in checking and calibrating meter displays.
This procedure takes approximately 30 minutes to perform.
MATERIAL NEEDED
DC ammeter and meter grade shunt, +/- 1% accuracy
DC voltmeter, +/- 1% accuracy
Resistive load bank
DSP, STT or other PF-10 option panel with mode light and set switch
PW-455 and PF-10 Operator’s manual for reference
METER ACCURACY CHECK
8. At conclusion of test, turn the power off
and set the DIP switch to its original posi-
tion.
1. With power off, locate DIP switch bank
S2 on the PF-10 Control PC board.
(There are 8 switches, number 1 on the
left, through number 8).
PROCEDURE TO REPAIR IF
METERS ARE OUT OF RANGE
2. Set switch 8 to the up position.
3. Connect a resistive load between the out-
put block of the PF-10 and the work ter-
minal of the PW-455 machine.
If the measured voltage is not within the
acceptable range, the Control PC board
must be replaced. The Control PC board
can not be calibrated.
4. Turn machine on.
5. Using the Set Control on the PF-10, set
the display to mode 200. Turn the right
knob of the PF-10 to energize the output.
6. Adjust the resistive load and the left knob
of the PF-10 to achieve 300A at 32v. The
left knob will adjust the output current.
Amps and volts will be displayed on the
PF-10 meters.
7. After the load condition is set, accuracy is
measured by comparing the meter of the
PF-10 to the master meter. At 300A,
amperage must agree within +/-10A. At
32V, voltage must agree within +/- 1V.
If the measured current is not within the
acceptable current range, adjust trimmer
R126 on the Control PC board. R126 is
located on the upper left corner of the
Control PC board. If the display is still in
error, either the Control PC board or LEM
(Current Transducer) may be faulty.
Perform the Current Transducer Test.
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F-75
F-75
TROUBLESHOOTING AND REPAIR
CONTROL OR POWER BOARD REMOVAL AND REPLACEMENT
WARNING
Service and repair should only be performed by Lincoln Electric factory trained
personnel. Unauthorized repairs performed on this equipment may result in dan-
ger to the technician or machine operator and will invalidate your factory warran-
ty. For your safety and to avoid electrical shock, please observe all safety notes
and precautions detailed throughout this manual.
If for any reason you do not understand the test procedures or are unable to per-
form the test/repairs safely, contact the Lincoln Electric service department for
technical troubleshooting assistance before you proceed. Call 216-383-2531 or
1-800-833-9353(WELD).
------------------------------------------------------------------------------------------------
DESCRIPTION
This procedure will aid the technician in the removal and replacement of either the
power board or the control board.
This procedure takes approximately 15 minutes to perform.
MATERIAL NEEDED
3/8 in. nutdriver
Phillips head screwdriver
Anti-static wrist strap
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F-76
F-76
TROUBLESHOOTING AND REPAIR
CONTROL OR POWER BOARD REMOVAL AND REPLACEMENT (continued)
FIGURE F.22 — CONTROL OR POWER BOARD REMOVAL AND REPLACEMENT.
COMPARTMENT
COVER
CONTROL
BOARD
POWER
BOARD
6. Remove the eight molex plugs from the
control board.
REMOVAL PROCEDURE
1. Remove input power to the Power
Wave 455.
7. Remove the two molex plugs and white
and black wires with quick connects
from the power PC board.
2. Using the 3/8 in. nutdriver, remove the
case top and sides.
8. Using the 3/8 in. nutdriver, remove the
two screws holding the rear of the
Control Box in place.
3. Perform the Capacitor Discharge
Procedure.
9. Clear the lead harnesses from the left
and right sides and carefully remove
the power and control PC board
assembly.
4. Observe all static electricity precau-
tions.
5. Using the 3/8 in. nutdriver, remove the
PC board compartment cover. Refer to
Figure F.22.
10. Using the Phillips head screwdriver,
remove either the power or the control
board from the PC board assembly.
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F-77
F-77
TROUBLESHOOTING AND REPAIR
CONTROL OR POWER BOARD REMOVAL AND REPLACEMENT (continued)
4. Connect two molex plugs and black
and white wires with quick disconnects
to the power PC board.
INSTALLATION PROCEDURE
1. Install either the power or control board
to the PC board assembly and secure it
in place using the Phillips head mount-
ing screws.
5. Connect the eight molex plugs to the
control PC board.
6. Install the PC board compartment cover
using the 3/8 in. nutdriver.
2. Carefully slide the power and control
PC board assembly into place, making
sure to clear the lead harnesses on the
right and left side of the PC board com-
partment.
7. Install the case top and sides using the
3/8 in. nutdriver.
3. Secure the rear of the control box in
place using two screws and the 3/8 in.
nutdriver.
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F-78
F-78
NOTES
POWER WAVE 455/POWER FEED 10
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F-79
F-79
TROUBLESHOOTING AND REPAIR
AUXILIARY TRANSFORMER NO. 1 REMOVAL AND
REPLACEMENT PROCEDURE
WARNING
Service and repair should only be performed by Lincoln Electric factory trained
personnel. Unauthorized repairs performed on this equipment may result in dan-
ger to the technician or machine operator and will invalidate your factory warran-
ty. For your safety and to avoid electrical shock, please observe all safety notes
and precautions detailed throughout this manual.
If for any reason you do not understand the test procedures or are unable to per-
form the test/repairs safely, contact the Lincoln Electric service department for
technical troubleshooting assistance before you proceed. Call 216-383-2531 or
1-800-833-9353(WELD).
------------------------------------------------------------------------------------------------
DESCRIPTION
This procedure will aid the technician in the removal and replacement of auxiliary
transformer No. 1.
This procedure takes approximately 25 minutes to perform.
MATERIALS NEEDED
3/8 in. nutdriver
Wire cutters
Wire splicer or soldering equipment
POWER WAVE 455/POWER FEED 10
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F-80
F-80
TROUBLESHOOTING AND REPAIR
AUXILIARY TRANSFORMER NO. 1 REMOVAL AND
REPLACEMENT PROCEDURE (continued)
FIGURE F.23 — AUXILIARY TRANSFORMER NO. 1 REMOVAL AND REPLACEMENT PROCEDURE.
RECONNECT
H1
TERMINALS
POWER BOARD
RECTIFIER BRIDGE
H2
H3
H4
H5
CB4
X1
MAIN
CONNECTOR
X4
X2
X3
X5
FAN
MOTOR
LEADS
MOUNTING
SCREW
(2X)
5. Remove leads X1 and X2 from the
power board rectifier bridge. Refer to
Figure F.23.
REMOVAL PROCEDURE
1. Remove input power to the Power
Wave 455.
6. Cut X3 and X5 from the fan motor
leads. Leave enough lead length to
splice in the new transformer leads.
2. Using the 3/8 in. nutdriver, remove the
case top, sides and input access panel.
7. Remove lead X4 from the main contac-
tor coil terminal.
3. Perform the Capacitor Discharge
Procedure.
4. Using the 3/8 in. nutdriver, remove the
case back.
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F-81
F-81
TROUBLESHOOTING AND REPAIR
AUXILIARY TRANSFORMER NO. 1 REMOVAL AND
REPLACEMENT PROCEDURE (continued)
8. Cut the X3 lead that is connected to the
input board. Leave enough lead length
to splice in the new transformer lead.
and the machine base using the 3/8 in.
nutdriver.
3. Install the primary leads H2, H3, H4,
and H5 to the reconnect terminals on
the reconnect panel.
9. Locate, label, and remove primary lead
H1 from circuit breaker CB4.
10. Label and remove primary leads H2,
H3, H4, and H5 from the reconnect ter-
minals on the reconnect panel. Note
lead placement for reassembly.
4. Connect primary lead H1 to circuit
breaker CB4.
5. Splice the new transformer lead with
the X3 lead connected to the input
board.
11. Using the 3/8 in. nutdriver, remove the
two mounting screws that hold the
transformer to the fan baffle and the
machine base.
6. Connect lead X4 to the main contactor
coil terminal.
7. Splice the new transformer fan leads to
the fan motor leads X3 and X5.
12. Cut any necessary cable ties and clear
the leads.
8. Connect leads X1 and X2 to the power
board rectifier bridge.
13. Carefully remove the transformer from
the Power Wave 455.
9. Reposition any wire leads and install
wire ties as necessary.
REPLACEMENT PROCEDURE
10. Install the case back using the 3/8 in.
nutdriver.
1. Carefully place the transformer into the
Power Wave 455.
11. Install the case top, sides, and input
access panel using the 3/8 in. nutdriver.
2. Install the two mounting screws that
hold the transformer to the fan baffle
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F-82
NOTES
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F-83
F-83
TROUBLESHOOTING AND REPAIR
MAIN INPUT CONTACTOR REMOVAL AND REPLACEMENT
WARNING
Service and repair should only be performed by Lincoln Electric factory trained
personnel. Unauthorized repairs performed on this equipment may result in dan-
ger to the technician or machine operator and will invalidate your factory warran-
ty. For your safety and to avoid electrical shock, please observe all safety notes
and precautions detailed throughout this manual.
If for any reason you do not understand the test procedures or are unable to per-
form the test/repairs safely, contact the Lincoln Electric service department for
technical troubleshooting assistance before you proceed. Call 216-383-2531 or
1-800-833-9353(WELD).
------------------------------------------------------------------------------------------------
DESCRIPTION
This procedure will aid the technician in the removal and replacement of the input con-
tactor.
This procedure takes approximately 15 minutes to perform.
MATERIALS NEEDED
3/8 in. nutdriver
5/16 in. nutdriver
Slot head screwdriver
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F-84
F-84
TROUBLESHOOTING AND REPAIR
MAIN INPUT CONTACTOR REMOVAL AND REPLACEMENT (continued)
FIGURE F.24 — MAIN INPUT CONTACTOR REMOVAL AND REPLACEMENT.
MOUNTING
SCREW (3X)
X4/X4A
601/601A
L3
L2
L1
T3
T2
T1
remove the small T2 lead. Label leads
for reassembly.
REMOVAL PROCEDURE
1. Remove input power to the Power
Wave 455.
6. Remove the two small leads T1 and T3
from the quick disconnect terminals.
2. Using the 3/8 in. nutdriver, remove the
case top, sides, and input access
panel.
7. Remove leads 601, 601A, and X4, X4A
from the contactor coil terminals.
8. Remove leads L1A and L3A from the
contactor line side quick-disconnect ter-
minals.
3. Perform the Capacitor Discharge
Procedure.
4. Using the slot head screwdriver,
remove the three input lines (L1, L2,
and L3) from the main contactor. Refer
to Figure F.24.
9. Using the 5/16 in. nutdriver, remove the
three mounting screws holding the
input contactor to the metal housing
bracket.
5. Using the slot head screwdriver,
remove the three heavy leads (T1, T2,
and T3) from the input contactor. Also
10. Carefully remove the input contactor.
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F-85
F-85
TROUBLESHOOTING AND REPAIR
MAIN INPUT CONTACTOR REMOVAL AND REPLACEMENT (continued)
5. Install the two small leads T1 and T3 to
the quick-disconnect terminals.
REPLACEMENT PROCEDURE
1. Carefully place the input contactor into
position.
6. Install the three input lines (L1, L2 and
L3) to the main contactor using the slot
head screwdriver.
2. Install the three mounting screws that
hold the input contactor to the metal
housing bracket using the 5/16 in.
nutdriver.
7. Install the three heavy leads (T1, T2
and T3) from the input contactor using
the slot head screwdriver.
3. Connect leads L1A and L3A to the
contactor line side quick-disconnect
terminals.
8. Install the small T2 lead to the input
contactor.
9. Install the case top, sides, and input
access panel using the 3/8 in. nutdriver.
4. Install leads 601, 601A, and X4, X4A
to the contactor coil terminals.
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F-86
F-86
NOTES
POWER WAVE 455/POWER FEED 10
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F-87
F-87
TROUBLESHOOTING AND REPAIR
INPUT RECTIFIER REMOVAL AND REPLACEMENT
WARNING
Service and repair should only be performed by Lincoln Electric factory trained
personnel. Unauthorized repairs performed on this equipment may result in dan-
ger to the technician or machine operator and will invalidate your factory warran-
ty. For your safety and to avoid electrical shock, please observe all safety notes
and precautions detailed throughout this manual.
If for any reason you do not understand the test procedures or are unable to per-
form the test/repairs safely, contact the Lincoln Electric service department for
technical troubleshooting assistance before you proceed. Call 216-383-2531 or
1-800-833-9353(WELD).
------------------------------------------------------------------------------------------------
DESCRIPTION
This procedure will aid the technician in the removal and replacement of the input recti-
fier module.
This procedure takes approximately 15 minutes to perform.
MATERIALS NEEDED
3/8 in. nutdriver
3/16 in. Allen wrench
Phillips head screwdriver
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F-88
TROUBLESHOOTING AND REPAIR
INPUT RECTIFIER REMOVAL AND REPLACEMENT (continued)
FIGURE F.25 — INPUT RECTIFIER REMOVAL AND REPLACEMENT.
INPUT
RECTIFIER
A
B
C
NEG (-)
POS (+)
7. Carefully remove the module.
REMOVAL PROCEDURE
1. Remove input power to the Power
REPLACEMENT PROCEDURE
Wave 455.
1. Clean heatsink surfaces.
2. Using the 3/8 in. nutdriver, remove the
case top, sides, and input access
panel.
2. Apply an even coating of joint com-
pound (Penetrox A-13) to both the
heatsink and module mounting sur-
faces. The joint compound should be
0.002 in/0.005 in. thick per surface.
3. Perform the Capacitor Discharge
Procedure.
4. Locate and remove the RTV sealant
from the input rectifier connection termi-
nals. Refer to Figure F.25.
3. Mount the module to the heat sink and
evenly torque the mounting screws
(with washers) to 44 in/lbs.
5. Label leads and using the Phillips head
screwdriver carefully remove the five
leads from the input rectifier terminals.
Note placement for reassembly.
4. Assembly the leads to the correct mod-
ule terminals and torque to 26 in/lbs.
5. Apply RTV sealant to the rectifier con-
nection terminals.
6. Using the 3/16 in. Allen wrench,
remove the two mounting screws and
washers from the rectifier module.
6. Install the case top, sides, and input
access panel using the 3/8 in. nutdriver.
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F-89
F-89
TROUBLESHOOTING AND REPAIR
OUTPUT RECTIFIER AND MODULE REMOVAL
AND REPLACEMENT
WARNING
Service and repair should only be performed by Lincoln Electric factory trained
personnel. Unauthorized repairs performed on this equipment may result in dan-
ger to the technician or machine operator and will invalidate your factory warran-
ty. For your safety and to avoid electrical shock, please observe all safety notes
and precautions detailed throughout this manual.
If for any reason you do not understand the test procedures or are unable to per-
form the test/repairs safely, contact the Lincoln Electric service department for
technical troubleshooting assistance before you proceed. Call 216-383-2531 or
1-800-833-9353(WELD).
------------------------------------------------------------------------------------------------
DESCRIPTION
This procedure will aid the technician in the removal and replacement of the output rec-
tifier assembly and individual rectifier module replacement.
This procedure takes approximately 35 minutes to remove and replace
the output rectifier and 5 minutes to remove and replace the rectifier
module.
MATERIALS NEEDED
3/8 in. nutdriver
7/16 in. wrench
9/16 in. wrench
9/64 in. Allen wrench
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F-90
TROUBLESHOOTING AND REPAIR
OUTPUT RECTIFIER AND MODULE REMOVAL AND REPLACEMENT (continued)
FIGURE F.26 — OUTPUT RECTIFIER AND MODULE REMOVAL AND REPLACEMENT.
TRANSFORMER
LEADS
RECTIFIER
MODULE
POSITIVE
OUTPUT
LEAD
THERMOSTAT
HEATSINK
MOUNT
BOLTS (4X)
HEATSINK
5. Using the 7/16 in. wrench, remove the
eight transformer leads from the rectifi-
er modules. Label the leads and take
note of lead placement for reassembly.
Note that each screw has two flat
washers and one lock washer.
RECTIFIER ASSEMBLY
REMOVAL PROCEDURE
1. Remove input power to the Power
Wave 455.
2. Using the 3/8 in. nutdriver, remove the
case top and sides.
6. Remove leads #220 and #290 from the
rectifier thermostat.
3. Perform the Capacitor Discharge
7. Using the 7/16 in. wrench, remove the
four nuts and associated washers from
the heatsink mounting bolts. The heat-
sink assembly can be removed by care-
fully sliding the assembly forward and
removing the mounting bolts.
Procedure.
4. Using the 9/16 in. wrench, remove the
positive output lead from the rectifier
heatsink. Refer to Figure F.26.
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F-91
F-91
TROUBLESHOOTING AND REPAIR
OUTPUT RECTIFIER AND MODULE REMOVAL AND REPLACEMENT (continued)
RECTIFIER MODULE REMOVAL
AND REPLACEMENT
PROCEDURE
RECTIFIER ASSEMBLY
REPLACEMENT PROCEDURE
1. Position the assembly in place with the
mounting bolts.
1. Using the 9/64 in. Allen wrench,
remove the cap screw from the center
of the rectifier module that is to be
replaced.
2. Assemble the nuts and associated
washers to the mounting bolts.
3. Using the 7/16 in. wrench, tighten the
four nuts on the mounting bolts.
2. Using the 7/16 in. wrench, remove the
two mounting bolts and associated
washers from the rectifier module to be
replaced.
4. Replace leads #220 and #290 to the
thermostat.
3. Remove the faulty module.
5. Connect the eight transformer leads to
the correct rectifier modules. Tighten
the screws (with two flat washers and
one lock washer) to between 30 and 40
in/lbs. Do not stress the terminals
when making these connections.
4. This module requires special mounting
considerations to prevent warping of
the base plate. The heatsink surfaces
must be clean and flat. Apply a thin,
even coating of thermal compound,
(Penetrox A13) 0.004 to 0.010 inches
thick. Keep the compound away from
the area of the mounting holes.
6. Apply a thin coat of Penetrox A13 to the
heatsink where the positive output lead
attaches.
5. Press the new module firmly against
the heatsink while aligning the mount-
ing holes. Start all three screws two to
three turns by hand.
7. Attach the positive output lead to the
heatsink using the 9/16 in. wrench.
8. Install the case top and sides using the
3/8 in. nutdriver.
6. Tighten each of the outer screws to
between 5 and 10 in/lbs.
7. Tighten the center screw to between 12
and 18 in/lbs.
8. Tighten each of the outer screws again,
this time to between 30 and 40 in/lbs.
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F-92
F-92
NOTES
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F-93
F-93
TROUBLESHOOTING AND REPAIR
FLOWCHART - POWER SOURCE ERROR INTERPRETATION GUIDE
Start
Power Source Error Interpretation Guide
(Semi Automatic PW-455, PW455/STT)
(For Codes 10555 and Below)
If the PS Status light is flashing any combination of red and green,
errors are present in the PW-455.
Error Code interpretation through the Status light is detailed in the
Service Manual. Individual code digits are flashed in red with a long
pause between digits. If more than one code is present, the codes
will be separated by a green light.
Perform the Contactor Test.
Perform the Switch
Perform Input Board Test.
Y
Pass
Codes 32, 33, 34,
and 35?
Board Test on both
sides.
UI previously recognized by the system is no
longer communicating, but power appears to
Perform the Input Rectifier Test.
be present at the UI. Check for intermittent
UI Display and
Status light on?
Fail
Y
Y
Code 12?
N
connections in the communication path
(pins A and B in the control cable, wires 541
N
and 542 in both the UI and FH).
N
Replace as Necessary.
Replacement board(s) must have
identical part number (including the
"dash number").
Weld Table Error is present.
UI previously recognized by the system is no
longer communicating, and no power appears to
be present at the UI. Check for intermittent
connections in the +40 VDC path (pins D and E
in the control cable, wires 540 and 500 in both
the UI and FH).
Reload known good Weld Software.
Codes 21,
22, or 23?
Y
Check the "All Modes" dipswitch in the UI, typically
SW2-8 (refer to dipswitch settings specified for the
software version loaded in the UI).
Both Switch boards are reporting an undervoltage error.
Check Input Voltage.
N
Perform the Input Board Test.
The current transformer (CT)
Check for proper reconnect position.
Code 32 and
33?
Y
feedback signal to the control
board is too high. Look for a
short in the transformer or
primary side of the machine.
Perform Output
Pass
Rectifier Test
Y
Code 31?
N
Look for faulty undervoltage connections from the Switch board(s) to the
Control board (+5VDC = normal, 0VDC = fault).
N
Fail
If the symptom is intermittent, Check the operation of the main contactor.
Replace Output
Rectifier Modules as
Required
Both Switch boards are reporting an overvoltage error.
Check the Input Voltage.
Y
Code 34 and
35?
Check for proper reconnect position.
Any of the following
codes:
32, 33, 34, or 35?
Look for faulty overvoltage connections from the Switch
board(s) to the Control board
(+5VDC = normal, 0VDC = fault).
N
N
Thermal Error (generally accompanied by a thermal error light):
N
Machine configured
for 230V?
Check continuity of thermostat circuit. Thermostats are connected
in series, so open circuit reading indicates tripped thermostat or
faulty connection
Y
Y
Code 36?
N
Perform the Switch Board
Code 32 and
34?
Y
Pass
Check operation of the cooling fan.
Test on Side "A" (left side
facing the front of
machine)
Invalid error combination. Check for
faulty overvoltage and undervoltage
connections from the Switch
Check for excessive dirt build up in heatsink fins etc.
N
Fail
board(s) to the Control board
(+5VDC = normal, 0VDC = fault).
Check main capacitor for a short circuit
condition.
Soft Start failure.
Replace the Switch Board
Replacement board(s) must have
identical part number (including
the "dash number").
Generally accompanied by under and over voltage errors
(32-35), because the system is unable to charge the
main capacitors to an acceptable voltage level.
Check for faulty overvoltacge and
undervoltage connections from the Switch
board(s) to the Control board
Y
Code 37?
N
(+5VDC = normal, 0VDC = fault).
Follow the branch for under and over voltage errors
(32-35) to test the Input Bd., Switch Bd., and main
contactor operation.
Perform the Switch Board
Test on Side "B" (right
side facing the front of
Code 33 and
35?
N
Y
Pass
Error codes that contain three or four digits are defined as fatal errors. These codes
generally indicate internal errors on the PS Control Board. If cycling the input power on
the machine does not clear the error, try reloading the operating system. If this fails,
replace the control board.
machine)
Fail
Y
Other Codes?
N
EXCEPTION:
Reoccuring fatal errorscan sometimes be caused by overloading the system. As an
example this could occur in earlier versions of PS software when rapidly changing from
one head to the another on a multi-head system (i.e. PF10x2). Adding a minimum (0.1
seconds) of preflow time to each head or upgrading the operating system shoudl
generally solve the problem.
Replace the Switch
BoardReplacement board(s)
must have identical part number
(including the "dash number").
Key:
PS = PowerSource
UI = UserInterface (Control
Box)
Finish
FH = Feed Head
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TROUBLESHOOTING AND REPAIR
FLOWCHART - PERFORMANCE TROUBLESHOOTING GUIDE
Performance Test Configuration (USE STD
STUD)**
GMAW (.045 Steel - 3/8" Plate)
Mode = 5
WFS =400 ipm
Voltage = 28V
Gas =90/10 ArCO2
Arc Control= 0
** Configuration may be altered based on available
materials. A spray procedure was selected for
Performance Troubleshooting Guide
(Semi Automatic PW-455, PW455/STT)
(For Codes 10555 and Below)
Alternate CV Configuration:
Grid Load (300A / 30V)
Mode = 201
Voltage = 30V
Arc Control = 0
Note: Mode 201 requires an
electrode sense lead (67).
Alternate CC Configuration:
Grid Load (300A / 30V)
Mode = 200
Current = 300
Arc Control = 0
Turn On
Y
A NOTE ON VOLTAGE SENSING:
All CV and Pulse modes utilize the electrode sense lead (lead #67) built into the control cable.
As with any sense lead it's performance is only as good as the worst connection.
For diagnostic purposes, an external sense lead can be used to bypass the entire electrode
sense network. This can be accomplished by removing the front cover of the PW-455, and
connecting a lead (20 AWG minimum) from pin 5 of the exposed 6 pin UI molex connector (P6),
to the feedplate on the feeder.
See Functional
Troubleshooting
Guide
All Status Lights green?
UI functional with no
errors displayed? FH
functional?
N
Y
as defined
actual voltage
Under load
previously:
**Note: The accuracy of measuring equipment
plays a significant role.Generally speaking,
meters of reasonable accuracy should give
readings within the stated limits. The intent
here is to establish proper performance, not
absolute accuracy.
Activate output (trigger the welding
output).
Key:
Check for
Control PC
at the PS
Bd., from P20-8
P20-4 if using
Matches Display
Value +/- 1V
to P20-2
a remote work
sense lead)
PS = PowerSource
UI = UserInterface (Control
Box)
(P20-8 to
Using the appropiate measuring
equipment, compare the Actual Current,
Voltage, and WFS to the readings
displayed on the UI
Increase or Decrease the
output settings as
required to achieve a
stable output.
FH = Feed Head
The Power Source Control PC Board is interpreting voltage correctly, but
there is a bad or incorrect connection in the feedback path.
Does not match
Display Value +/- 1V
Y
Check to make sure the weld polarity matches the Electrode Sense
Polarity dipswitch in the FH (SW-7). The default setting is electrode
positive.
Perform tachometer test.
Correct FH
Dipswitch
setting.
Do you get output
from the machine
(can you weld)?
Repair / replace as
necessary.
N
Check connections in the entire electrode sense path (wire #67) from the
2 pin output connector on the Voltage Sense PC Board, through the FH
wiring harness, control cable(s), UI wiring harness (if system is
configured with the UI between the FH and PS), and up to P20-8 on the
Control PC Board inside of the PS.
Y
N
Y
Check for proper Drive Roll tension.
Does FH gear ratio
dipswitch setting match
pinion gear size?
Motor running full
speed regardless of
WFS setting?
Check the work sense path (wire #202) from P20-2 on the PS Control PC
Board to the Work Stud, or (wire #21) from P20-4 to the remote work
sense lead depending on the configuration.
Actual vs Displayed
WFS:
+/-10 ipm?**
Check for proper Drive Rolls.
N
N
Y
Verify software is correct version
(PF-10 vs.PF-11).
OK
Y
ALL VOLTAGE MEASUREMENTS SHOULD BE MADE
AT THE SOURCE OF THE VOLTAGE FEEDBACK.
The source of voltage feedback is mode dependent. Mode
200 senses voltage from the output studs of the machine.
Modes 5 and 201 sense from the Conductor Block on the
feeder to the negative stud of the machine, unless the
Voltage Sense Plug (P26) is removed from the Control PC
Bd., inwhich case the remote work sense plug is used
instead of the negative stud.
The PS Control PC Board is NOT interpreting voltage correctly.
Test being
performed in Mode
200?
Actual vs Displayed
Voltage:
+/-1 Volt?**
On "-3" and higher vintage PS Control PC Boards the Voltage
feedback can be calibrated. Perform the "Voltage Calibration
Procedure".
Perform the Voltage
Sense PC Board Test.
N
N
Y
If unable to calibrate, replace the Control PC Board. Please note the
statement regarding test meter accuracy, and follow all applicable
board replacement procedures when replacing this board.
Y
The PS Control PC Board is NOT interpreting current correctly.
Check the connections at P21 on the Control PC Board. Particularly the
signal pins (1 and 6).
Under load as defined
previously: Check for actual
voltage at the PS Control PC
Bd., from P20-6 to P20-2.
Perform the PS
Current Transducer
Test
Matches Display
Value +/- 1V
Actual vs Displayed
Current:
+/- 10 Amps?**
Depending on the magnitude of the descrepency, the current feedback
can be calibrated. Perform the "Current Calibration Procedure".
N
Pass
If unable to calibrate, and the connections are OK, replace the Control PC
Board. Please note the statement regarding test meter accuracy, and
follow all applicable board replacement procedures when replacing this
board.
Fail
Y
Does not match
Display Value +/- 1V
Replace the current
Transducer.
The Power Source Control PC Board is interpreting voltage
correctly, but there is a bad connection in the feedback path.
STT Performance Test Configuration (USE STT STUD)**
GMAW (.045 Steel - 1/4" Plate)
Mode = 117
WFS =170 ipm
Trim = 1.00
Gas =CO2
Arc Control= 0
** Configuration may be altered based on available
materials, but basic waveshape should remain the same.
!!CANNOT BE TESTED WITH STATIC GRID LOAD!!
Check connections in the electrode sense path (wire #206) from
P20-6 on the Control PC Board to the electrode(+) stud inside of
the PS.
Using the Arc Scope function in
Wave Designer / Wave Surfer, or
an oscilloscope equiped with a
current probe, capture an STT
waveform, and compare it to the
sample STT waveform (shown at
right).
Y
STT Machine?
Check the work sense path (wire #202) from P20-2 on the Control
PC Board to the Work Stud.
N
Are the wave shapes
similar, and does current
drop in the middle of the
pulse as indicated?
The STT portion of the system
is operating properly
The PS Control PC Board is NOT interpreting voltage correctly.
Y
On "-3" and higher vintage PS Control PC Boards the Voltage
feedback can be calibrated. Perform the "Voltage Calibration
Procedure".
N
The STT Chopper PC Board appears to be shorted, and therefore,
the resulting current waveform does not drop in the middle of the
pulse as indicated in the Sample STT Waveform
The STT Chopper PC Board appears to be "open".
The system is monitoring and
controlling WFS, Voltage,
and Current correctly.
If unable to calibrate, replace the Control PC Board. Please note the
statement regarding test meter accuracy, and follow all applicable
board replacement procedures when replacing this board.
Check for 18Vac at J10 pins 1 & 4 on the STT Chopper Board.
Does the machine
noodle weld ( low output)?
N
Y
Performance checks OK.
Disconnect J10 from the STT Chopper PC Board, and make
another test weld. If the same symptoms result, perform the STT
chopper PCBD test. If the machine noodle welds, the problem is
related to the control signal from the Control PC Board.
Check for loose or broken connections. Inspect the PC board for physical
damage
Perform the STT Chopper Board Test.
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F-95
F-95
TROUBLESHOOTING AND REPAIR
FLOWCHART - FUNCTIONAL TROUBLESHOOTING GUIDE
Functional Troubleshooting Guide
(Semi Automatic PW-455, PW455/STT)
(For Codes 10555 and Below)
See UI Error
Chart for
additional error
codes.
N
N
Error 006?
Y
Error 100?
Y
Turn On
Condition of
Status Light?
Main UI Display
panel on?
UI Status
on?
N
Y
Other
Status Light on the PS
on?
N
At this point, voltage is being supplied to the UI Control
Board, and the on board supply is properly converting it to
12Vdc. This has been verified by the condition of the Status
light and by measurement at the display.
Y
Solid Green
N
Y
Errors on UI
Display?
Y
Verify 12 VDC is being
supplied to UI Display
PCBD (J1 pin 7 to 8)
Because the Status light indicates a healthy condition, the
Communication Fault.
Go To PS
Error
Interpretation
Guide.
Y
problem is most likely in the harness from the Display to
the UI Control board or in the Display board itself. Check the
harness, and run the Display Panel Check.
Solid
Red
Flashing
Red and Green
Check Wiring and
Linc-Net Cables for
open circuit
Condition of
Status light
N
N
PS Status
on?
There is a remote possibility that the Communications
Hardware on the UI Control board is not functioning
properly.
N
Flashing Green
Select a CV
Mode
Check connections from UI Control Board to
Display panel. If the display and Status light are
still not functioning, remove P4 from the UI
Control Board.
Check for 12 VDC at J4 pins 1 to 4 , and J4
pins 3 to 8 on the UI Control board. If voltage is
not present, replace UI Control Board
Y
System is stuck in Remapping loop.
Most likely cause is the loss of the
+5Vcan Supply. Check J27 on PS
Control Board, check Power Board,
Etc.
Can you adjust
WFS and Voltage?
N
At this point, voltage is being supplied to the UI Control
Board, and the on board supply is properly converting it to
12Vdc, which has been verified at the display.
Y
Y
Check Status Light and harness
N
The Status light is not functioning, so the most likely
problem is that the UI Control board is "lost".Try reloading
the UI Software. If problem still exists, Replace the Control
board.
Verify all connections to the PS Control Board
Errors on UI
Display?
Does Wire feed when
you pull the trigger?
Check For
40VDC at UI
Control Board
N
N
Verify 12 VDC is being
supplied to UI Display
PCBD (J1 pin 7 to 8)
5 Green LED's lit on
the PS Control
Board?
OK
Y
Y
Perform Power Board test to verify correct
voltage levels
Y
There is a remote possibility that a multiple fault exists in
the harness from the Display to the UI Control board, or in
any combination of the following: The harness, the Display
board, and the Status light.
Not OK
Reload the PS Software. If Problem still
exists, replace PS Control Board.
N
Y
Is there OCV from the
brass block to the work stud
with the trigger pulled
Check PS breaker (CB1), Linc-Net
cables, wiring in UI and PS.
Errors on UI
Display?
N
+40 VDC section of Power Board
may be malfunctioning, Perform
Power Board test
N
Y
UNHEALTHY STATUS LIGHT WITH BLANK DISPLAY:
Look for open
circuit in the
PS secondary
Improper system configuration (dipswitch settings) can result in
mapping errors that cause PS to continuously issue a system reset
command. The result is the UI gets stuck in a reset loop, usually
accompanied by a blank display with a green and/or red flashing
status light. Correct the system configuration.
System is functional. If
performance problems
exist see System
Performance
Troubleshooting guide
Verify no Limits are set.
Check the connections on wires 541 & 542, and pins A & B in the
Linc-Net control cable.
Check/repair harness between:
Check Harness for UI Control Board
to the Dislay Panel (specifically the
wires to the Encoder Board.
The Power Board and the Control Board.
- AND/OR -
The Power Board and the wire feeder
receptacle (S1), including the output
circuit breaker (CB1).
Run Power
Board Test
UI software may be corrupt. Reload UI soft ware
Pass
Run The Dual Encoder PC Board
Test
Fail
FH does not appear to have power.
Replace the
Power Board.
Was 60-80 VDC at Power
Board input connector
Y
N
FH Status On?
Y
Check +40 VDC connections on
pins "D" & "E" of the Linc Net
receptacle in the FH.
N
Be sure the trigger is engaged long enough to overcome any set preflow
delay, or turn the preflow timer off.
Check/repair harness
between the Power
Board and the Capacitor.
The FH has detected no activity from the
communication network.
Voltage at the Power
Board Capacitor?
Y
FH Status
Green
Condition?
Red
Check trigger circuit operation from the gun to the FH Control Board.
Check the connections on wires 541 & 542, and pins
A & B in the Linc-Net control cable.
N
Perform the Drive Motor Test to verify motor voltage is present when the
trigger is pulled.
Flashing
Check for 60 to 80 VDC at the
Output of the rectifier. If present,
check harness from rectifier to
Capacitor. If not replace rectifier
FH Status
Condition?
Voltage at the input to
the Rectifier?
Flashing Red
Flashing Green
Y
Flashing
Red and Green
N
Check the continuity of the Shutdown circuit in the FH (wires
570 & 571). If the path between these wires is interrupted the
FH will not operate and the Status light will flash red while all
other nodes appear normal.
Check the system configuration.
If the FH is not recognized as part of a valid group, or if
improper dipswitch settings result in a duplicate or invalid
network assignment, a mapping error will be generated.
FH has a motor
overcurrent/overtemperature
error.
Key:
A rapidly flashing red Status light indicates the node needs to be
reprogrammed.
PS = PowerSource
UI = UserInterface (Control
Box)
Input power does not appear to be
supplied to aux. transformers
Check input power, check reconnect,
check Breakers, check Line Switch, etc.
FH = Feed Head
POWER WAVE 455/POWER FEED 10
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G-1
G-1
ELECTRICAL DIAGRAMS
TABLE OF CONTENTS
-ELECTRICAL DIAGRAMS SECTION-
ELECTRICAL DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION G
POWER WAVE 455 WIRING DIAGRAM - CODE 10372 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-2
POWER WAVE 455 WIRING DIAGRAM - CODE 10555 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-3
POWER WAVE 455 WIRING DIAGRAM - CODE 10553 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-4
POWER FEED 10 MACHINE SCHEMATIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-7
POWER WAVE 455 POWER PC BOARD SCHEMATIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-14
POWER FEED 10 CONTROL PC BOARD SCHEMATIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-19
POWER FEED 10 DISPLAY PC BOARD SCHEMATIC. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-20
POWER FEED 10 ENCODER PC BOARD SCHEMATIC. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-21
POWER FEED 10 VOLTAGE SENSE PC BOARD SCHEMATIC. . . . . . . . . . . . . . . . . . . . . . . . . G-22
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NOTES
POWER WAVE 455/POWER FEED 10
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G-2
G-2
ELECTRICAL DIAGRAMS
Power Wave 455 Wiring Diagram - Code 10372
LEFT SIDE OF MACHINE
CB3
CONTROL BOARD
10A CIRCUIT
BREAKER
TO SW1
612B
TO
1
2
TP3
202
21A
206
67A
202
TO J20
TO CB4
612A
3
4
5
6
7
8
-
AUXILIARY TRANSFORMER #1
TO
WORK
POWER BD. RECTIFIER
W
H5
X1
X2
X3
X3
C1
TO
S2
H5A
H4A
H3A
H2A
H1A
TO P80
(440-460)
.05/600V
H5
H4
U
(51V)
W
TO CB1
POWER BOARD
H4
TP1
L2
J20
9
S1
TO
(380-415)
WORK
ELECTRODE
AUX #2
10
11
12
13
14
15
16
H3
TO
CR1
FAN
J60
J61
TO CB3
612A
CB4
(220-230)
H2
H3
H2
N
(24V)
R
RECONNECT PANEL
TO
X4
X5
CB4
6A CIRCUIT
BREAKER
(200-208)
J27
P6
53A
53
54
54A
67A
67B
52
52A
51
H1
612
POWER BOARD
A
B
(115V)
S1
WIRE
FEEDER
RECEPTACLE
H1
CB1
J20
H1
50
51
50WT
TO
S1
CB1
TO AUX #1
51BK
C
D
E
1
2
3
211
212
213
214
4
J21
TO
CT
P90
5
6
7
8
51A
216
218
1
2
1
2
3
4
5
6
53A
225
P6
223
222
228
226
221
3
4
5
6
7
8
MAIN CHOKE
L1
54A
51A
67B
52A
TO
S1
1
221
222
223
224
225
226
2B
228
2W
220
USER
TO
2
3
4
5
6
7
8
9
10
INTERFACE
J31
THERMAL
TO
J22
J27
J31
LED
MAIN TRANSFORMER
LEFT SIDE
THIS AREA VIEWED FROM REAR OF MACHINE
S2
RECT.
1
2
3
4
J22
TO
J20
THERM.
9
VOLTAGE
SENSE
N.B.
TO CURRENT
TRANSFORMER
10
11
12
TO J23
21A
RECONNECT SWITCH
274
273
RECEPTACLE
16
TO SWITCH BD #2
RECONNECT PANEL
19D
TO SWITCH BD #1
19C
1
231
232
233
234
235
503
406
238
239
405
604
1
2
3
4
5
TO SW1
2
3
4
5
6
SECONDARY
(TOP
PRIMARY
(TOP
253
254
OUTPUT RECT
S3
RS232
CONNECTOR
N.C.
POS
TO INPUT RECT
LEFT)
LEFT)
TO
TO AUX #1
H2
200-208V
D4
TO
J25
J40
J50
J60
220-230V
380-415V
440-460V
6
7
TO SWITCH BD #2
18
7
F4
F4
251
H3
H4
H5
J23
'A'
8
J40
1
2
3
4
5
6
POS
POS
TO SWITCH BD #1
20C
9
TO SWITCH BD #2
20D
10
11
12
13
14
20
TO
C3
TO CURRENT
TRANSFORMER
12
J32
NEG
NEG
.022
800V
2.7
10W
SWITCH BOARD #1
404
506
403
NEG
TO INPUT RECT
+
CB1
10A CIRCUIT
BREAKER
52
50
TO
L2
POWER
BOARD
1
N.D.
C4
SECONDARY
(BOTTOM
LEFT)
PRIMARY
(BOTTOM
LEFT)
1W
1B
2
3
4
5
TO
STATUS
LED
2.7
TO AUX #1
X3
X5
11 12
14
13
.022
10W
TO CURRENT
TRANSFORMER
800V
20C
19C
TO MAIN TRANS
D3
TO SWITCH
BD #1
TO
WORK
ELECTRODE
6
FAN
J24
F3
F3
TP3
7
14
TO RECONNECT
TO J21
8
11 12
16
15
9
10
11
12
214
CURRENT
TRANSFORMER
TO CURRENT
TRANSFORMER
15
TO
CB2
10A CIRCUIT
BREAKER
31
33
TO
S4
J81
J22
1
2
251
218
220
INPUT BOARD
224
TO
S3
RECT.
THERM.
J25
3
253
254
SECONDARY
(BOTTOM
RIGHT)
PRIMARY
(BOTTOM
RIGHT)
1
2
601
X3
4
224A
290
1
2
3
4
5
6
7
TO FAN THERM
D2
238
604
232
3
4
5
6
7
8
S4
TO SWITCH
BD #2
TO
J23
110V RECEPTACLE
J60
F2
F2
CR1
17
AUX #1
31
32
TO
TO
J81
CB2
RECONNECT
SWITCH
231
J26
8
9
.022
800V
2.7
10W
TO J23
TO CURRENT
TRANSFORMER
10
11
12
13
14
15
16
POWER BD RECTIFIER
NEG
POS
INPUT
POS
11
N.D.
RECTIFIER
TO
1
2
3
4
5
6
7
8
9
10
AUX. #1
TP5
T1
T2
AC
X2
C3
AC
NEG
POS
AC1
SECONDARY
(TOP
PRIMARY
(TOP
NEG
X1
1
2
3
4
5
6
54
TO
J61
RIGHT)
RIGHT)
AC3
AC2
612
H1D
T3
CR1
SW1
CB4
TO
S1
J31
D1
TO SWITCH
BD #1
273
274
53
J50
J27
J28
F1
F1
13
SWITCH BOARD #2
1
2
3
4
5
6
.022
800V
2.7
10W
TO J61
+
RIGHT SIDE
TO
NEG
NEG
N.A.
FAN THERM
TO J60
1B
2B
1W
2W
C5
J32
POWER
BD.
T3
T2
T1
STATUS LED (R/G)
TO J24
C3
POS
POS
TO
15 16
17
18
601
RECT
TO CURRENT
TRANSFORMER
RECT.
N.D.
POS
THERM
20D
19D
N.A.
601A
X4A
CR1
290
THERMAL LED (Y)
TO J22
TO MAIN TRANS
X4
TO AUX #1
FAN THERM
L2
L1
L3
TO RECONNECT SWITCH
224A
TO SW1
L3A
TO SW1
L1A
TO J21
T0
RECT
THERM
206
TO J20
TP2
C2
W
H5
32
33
1
6
3
2
4
1
H5A
H4A
H3A
H2A
W
V
U
(440-460)
.05/600V
R
H4
TO
4
TO SUPPLY LINES
S4
(380-415)
H3
(115V)
CB2
P81
TO AUX #1
CB3
(220-230)
H2
AUXILIARY
TRANSFORMER
#2
P90
(200-208)
H1
TO TP3
G
+
H1A
TO RECONNECT PANEL
TO
A
SYSTEM GROUND PER
A
CURRENT
TRANSDUCER
NOTES:
ELECTRODE
NATIONAL ELECTRICAL CODE.
TO J61
H1D
N.A. PIN NEAREST THE FLAT EDGE OF LED LENS (CATHODE)
ALIGNS WITH BLACK LEAD OF LED SOCKET.
J27,J28
J32,J40
J50,J81
(TOP)
RIGHT SIDE OF MACHINE
TO CB3
612B
J25
1
J21,J60
1
J22,J61
N.B. PLACE SWITCH IN APPROPRIATE POSITION FOR INPUT VOLTAGE.
CONNECTION SHOWN IS FOR 380-460V OPERATION.
ELECTRICAL SYMBOLS PER E1537
J20,J26
J24,J31
1
J23
2
4
1
3
1
6
5
6
1
7
1
9
8
2
4
4
8
LEAD COLOR CODING
LOAD
LINE
SW1
B=BLACK
G=GREEN
N=BROWN
R=RED
U=BLUE
W=WHITE
COMPONENT VALUES:
N.C. PLACE "A" LEAD ON APPROPRIATE CONNECTION FOR INPUT VOLTAGE.
CONNECTION SHOWN IS FOR 440-460V OPERATION.
POWER
TO CONTACTOR
L1A
CAPACITORS=MFD/VOLTS
RESISTORS=OHMS/WATTS
3
4
6
5
10
7
12
8
14
16
3
1
N.D. MAY NOT APPEAR ON ALL MACHINES.
CONNECTOR CAVITY NUMBERING SEQUENCE
(VIEWED FROM COMPONENT SIDE OF BOARD)
TO CONTACTOR
L3A
3-19-99D
G3051
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The wiring diagram specific to your code is pasted inside one of the enclosure panels of your machine.
POWER WAVE 455/POWER FEED 10
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G-3
G-3
ELECTRICAL DIAGRAMS
Power Wave 455 Wiring Diagram - Code 10555
LEFT SIDE OF MACHINE
TO J20
202
CONTROL BOARD
TO SW1
612B
TO
S1
S2
WORK
TO
3W
3R
CB3
TO TP3
1
2
3
4
5
6
7
J24
202
21A
206
67A
10A CIRCUIT
BREAKER
202A
TO R1
TO CB4
612A
4
-
+
3
2
-
ELECTRODE
AUXILIARY TRANSFORMER #1
WORK
C1
W
SOLID
STATE
RELAY
H5
X1
H5A
H4A
H1A
TO AUX #2
(440-460)
TO POWER BD. RECTIFIER
H5
H4
U
TO RECT THERM
8
9
.05/600V
H4
X2
J20
224A
(51V)
TO
TO
CURRENT
TRANSFORMER
(380-415)
TO
TP1
1
10
11
12
13
14
15
16
1
2
3
L2 CB1
CHOKE
THERM.
AUX #2
CB4
RECONNECT PANEL
MAIN CHOKE
L1
POWER BD
X3
X3
TO J61
CB3
612A
612
W
N
H3
TO
CR1
J60
H3A
H2A
291
(220-230)
H3
444
X3A
TO AUX#1
TP4
53A
TO
H2
(200-208)
H1
CB4
6A CIRCUIT
BREAKER
X4
X5
A
B
53
54
(24V)
H2
H1
J27
P6
J20
R
TO FAN
L7
S1
WIRE
H1
TO J21A
54A
67A
(115V)
216
4
TO AUX #1
211
P91
CURRENT
TRANSDUCER
C
D
E
211
213
212
N.D.
3
2
1
212
213
214
FEEDER
RECEPTACLE
67B
52
52A
51
51A
+
TO SOLID STATE RELAY
444
TO FAN
X3A
POWER BOARD
4
5
6
X5
J21A
TO AUX#1
50WT
50
51
TO
P91
TO
L2
CB1
FAN
216
218
TO SOLID STATE RELAY
7
8
1
2
3
51BK
1
2
3
4
5
6
53A
P6
54A
51A
67B
52A
USER
TO
S1
THIS AREA VIEWED FROM REAR OF MACHINE
1
2
3
4
5
6
7
8
INTERFACE
225
223
222
228
226
4
5
6
TO
J22
J27
N.B.
J21B
RECONNECT SWITCH
MAIN TRANSFORMER
LEFT SIDE
S2
1
7
8
2
3
4
TO SWITCH BD #2
VOLTAGE
SENSE
TO
J20
RECONNECT PANEL
J31
TO CURRENT
21A
TO J23
19D
221
TO SWITCH BD #1
19C
1
2
3
4
221
222
223
224
225
226
2B
228
2W
220
TRANSFORMER
TO SW1
RECEPTACLE
TO
J31
THERMAL
LED
RECT.
THERM.
16
9
N.C.
10
11
12
POS
1
2
3
4
5
6
7
274
273
TO INPUT RECT
TO AUX #1
H2
200-208V
220-230V
380-415V
440-460V
OUTPUT RECT
5
6
253
254
J22
SECONDARY
(TOP
LEFT)
PRIMARY
(TOP
LEFT)
7
8
9
H3
H4
H5
'A'
S3
1
2
3
4
5
6
POS
POS
TO
TO SWITCH BD #1
D4
RS232
TO SWITCH BD #2
20C
TO SWITCH
BD #2
J25
CONNECTOR
20D
10
F4
F4
251
TO
C3
J32
18
NEG
NEG
J40
231
232
233
234
235
503
406
238
239
405
604
404
1
2
3
4
5
6
NEG
20
TO CURRENT
TO
TO INPUT RECT
TRANSFORMER
J40
J50
J60
.022
800V
SWITCH BOARD #1
2.7
10W
12
+
52
50
TO
L2
CB1
10A CIRCUIT
BREAKER
7
8
9
J23
N.D.
C4
POWER BD
PRIMARY
(BOTTOM
LEFT)
SECONDARY
(BOTTOM
LEFT)
.022
800V
D3
2.7
10W
10
11
12
13
14
11
12
14
13
TO CURRENT
TRANSFORMER
20C
19C
TO MAIN TRANS
TO SWITCH
506
403
TO
WORK
BD #1
F3
F3
TP3
14
ELECTRODE
1
2
3
4
5
16 11 12
15
TO RECONNECT SWITCH
TO L7
1W
1B
214
TO J22
224
CURRENT
TO CURRENT
220
TRANSFORMER
218
TRANSFORMER
RECT.
THERM.
291
6
7
15
TO
J24
INPUT BOARD
STATUS LED
SOLID STATE RELAY
224A
8
9
10
11
12
1
2
601
X3
S4
TO
CHOKE
THERM
3W
110V RECEPTACLE
SECONDARY
(BOTTOM
RIGHT)
PRIMARY
(BOTTOM
RIGHT)
.022
800V
D2
2.7
10W
TO
CR1
J23
3
238
604
232
4
POWER BD RECTIFIER
3R
31
J60
32
5
6
7
8
TO SWITCH
1
2
3
251
POS
AUX #1
BD #2
F2
F2
N.D.
TO
17
TO
J25
TO
S3
253
254
J81
CB2
RECONNECT
SWITCH
231
4
AC
X2
AC
TO
C3
AUX. #1
TO CURRENT
TRANSFORMER
11
1
2
3
4
5
6
7
TO J23
NEG
X1
NEG
POS
INPUT
TP7
202A
206A
RECTIFIER
1
2
3
4
5
6
7
8
9
10
PRIMARY
(TOP
RIGHT)
SECONDARY
(TOP
RIGHT)
TO
WORK
ELECTRODE
T1
N.D.
NEG
POS
AC1
50
R1
NEG
NEG
NEG
J26
8
T2
9
D1
TO
TO SWITCH
BD #1
10
11
12
13
14
C3
POS
POS
POS
CR1
SW1
CB4
J61
AC3
AC2
F1
F1
612
H1D
T3
TO
J32
13
J50
CB2
10A CIRCUIT
BREAKER
31
33
POWER BD RECT
TO
S4
J81
15
16
.022
800V
2.7
10W
SWITCH BOARD #2
1
54
RIGHT SIDE
TO J61
+
2
3
4
5
6
N.D.
TO
S1
J31
273
274
53
J27
J28
C5
1W
2W
1B
N.A.
T3
T2
T1
TO J60
STATUS LED (R/G)
TO J24
15 16
17
601
18
TO CURRENT
TRANSFORMER
20D 19D
2B
1
N.A.
CR1
2
3
4
THERMAL LED (Y)
TO J22
TO MAIN TRANS
X4
TO AUX #1
L3
L2
L1
5
6
TO RECONNECT SWITCH
H5
TO J20
206
TO SW1
L3A
TO SW1
L1A
W
1
32
33
6
H5A
H4A
H3A
H2A
H1A
W
V
(440-460)
U
C2
R
(115V)
H4
4
P81
3
TO SUPPLY LINES
TO
S4
CB2
.05/600V
(380-415)
TO
CB3
AUX #1
TP2
H3
2
4
1
(220-230)
H2
TO R1
(200-208)
G
206A
+
H1
TO TP3
TO RECONNECT PANEL
TO
A
SYSTEM GROUND PER
A
NOTES:
N.A.
AUXILIARY TRANSFORMER #2
ELECTRODE
NATIONAL ELECTRICAL CODE.
TO J61
H1D
PIN NEAREST THE FLAT EDGE OF LED LENS (CATHODE)
ALIGNS WITH BLACK LEAD OF LED SOCKET.
J27,J28
J32,J40
J50,J81
J21A,J21B
J60
RIGHT SIDE OF MACHINE
(TOP)
TO CB3
612B
ELECTRICAL SYMBOLS PER E1537
LEAD COLOR CODING
B=BLACK
G=GREEN
N=BROWN
R=RED
J24,J31
J23
N.B. PLACE SWITCH IN APPROPRIATE POSITION FOR INPUT VOLTAGE.
CONNECTION SHOWN IS FOR 380-460V OPERATION.
J22,J61
J25
J20,J26
2
4
6
2
4
1
1
3
1
1
6
5
1
1
7
1
8
4
LOAD
LINE
COMPONENT VALUES:
SW1
N.C. PLACE "A" LEAD ON APPROPRIATE CONNECTION FOR INPUT VOLTAGE.
CONNECTION SHOWN IS FOR 440-460V OPERATION.
CAPACITORS=MFD/VOLTS
RESISTORS=OHMS/WATTS
TO CONTACTOR
L1A
POWER
16
8
3
4
5
10
8
6
7
12
9
14
1
3
N.D MAY NOT APPEAR ON ALL MACHINES.
U=BLUE
W=WHITE
CONNECTOR CAVITY NUMBERING SEQUENCE
(VIEWED FROM COMPONENT SIDE OF BOARD)
TO CONTACTOR
L3A
3-19-99D
G3051-1
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 455/POWER FEED 10
Download from Www.Somanuals.com. All Manuals Search And Download.
G-4
G-4
ELECTRICAL DIAGRAMS
Power Wave 455 Wiring Diagram - Code 10553
LEFT SIDE OF MACHINE
CONTROL BOARD
CB3
10A CIRCUIT
BREAKER
AUXILIARY TRANSFORMER #1
SOLID
STATE
RELAY
WORK
L2
CB4
6A CIRCUIT
BREAKER
MAIN CHOKE
L1
S1
WIRE
FEEDER
RECEPTACLE
L7
N.D.
P91
CURRENT
TRANSDUCER
+
FAN
POWER BOARD
THIS AREA VIEWED FROM REAR OF MACHINE
N.B.
RECONNECT SWITCH
MAIN TRANSFORMER
LEFT SIDE
S2
VOLTAGE
SENSE
RECONNECT PANEL
TO BOTTOM RIGHT PRI
TO SWITCH BD #2
17A
18
TO SW1
RECEPTACLE
18A
N.C.
TO TOP LEFT PRI
TO AUX #1
SECONDARY
(TOP
LEFT)
TO BOTTOM RIGHT PRI
PRIMARY
(TOP
LEFT)
OUTPUT RECT
TO SWITCH BD #2
17
17B
S3
RS232
440-460V
550-575V
'A'
18B
H5
H6
TO TOP LEFT PRI
CONNECTOR
TO TOP RIGHT PRI
13A
TO SWITCH BD #1
14
14A
SWITCH BOARD #1
TO BOTTOM LEFT PRI
.022
800V
2.7
10W
CB1
TO TOP RIGHT PRI
13B
10A CIRCUIT
BREAKER
TO SWITCH BD #1
13
N.D.
SECONDARY
(BOTTOM
LEFT)
PRIMARY
(BOTTOM
LEFT)
14B
.022
800V
2.7
10W
TO BOTTOM LEFT PRI
S4
110V RECEPTACLE
INPUT BOARD
PRIMARY
(BOTTOM
RIGHT)
31
32
SECONDARY
(BOTTOM
RIGHT)
TO
.022
800V
2.7
10W
J81
CB2
N.D.
TO SWITCH
BD #1
TO SWITCH
BD #2
CB2
10A CIRCUIT
BREAKER
POWER BD RECTIFIER
NEG
POS
INPUT
RECTIFIER
N.D.
NEG
POS
AC1
PRIMARY
(TOP
RIGHT)
SECONDARY
(TOP
RIGHT)
AC3
AC2
SWITCH BOARD #2
.022
800V
2.7
10W
RIGHT SIDE
TO J61
N.D.
T3
T2
T1
TO J60
601
CR1
X4
TO AUX #1
L2
L1
L3
TO SW1
L3A
TO SW1
L1A
W
V
U
TO SUPPLY LINES
N.B. PLACE SWITCH IN APPROPRIATE POSITION FOR INPUT
VOLTAGE. CONNECTION SHOWN IS FOR 550-575V OPERATION.
G
N.C. PLACE "A" LEAD ON APPROPRIATE CONNECTION FOR INPUT
VOLTAGE. CONNECTION SHOWN IS FOR 550-575V OPERATION.
TO
A
SYSTEM GROUND PER
NATIONAL ELECTRICAL CODE.
AUXILIARY TRANSFORMER #2
ELECTRODE
(TOP)
N.D. MAY NOT APPEAR ON ALL MACHINES.
RIGHT SIDE OF MACHINE
SW1
POWER
3-19-99D
G3051-2
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The wiring diagram specific to your code is pasted inside one of the enclosure panels of your machine.
POWER WAVE 455/POWER FEED 10
Download from Www.Somanuals.com. All Manuals Search And Download.
G-5
G-5
ELECTRICAL DIAGRAMS
Power Feed 10 Control Box Wiring Diagram
1
2
512B
565
564
500F
566
567
568
569
USER
UPPER
OPTION
N.E.
INTERFACE
MOTHER
BOARD
(J1)
N.F.
3
1
8
4
1
6
5
(J5)
N.A.
5
DISPLAY
P.C. BOARD
6
1
2
3
4
5
6
7 8
10
7
S1
8
1 2 3 4 5 6 7 8
ON
9
10
OFF
512
551
512C
500
552
550
1
2
S2
1 2 3 4 5 6 7 8
ON
3
4
OFF
(J1)
N.F.
5
1
8
6
1
7
DUAL
ENCODER
P.C. BOARD
(J4)
N.A.
7
RED/GREEN
STATUS LED
N.C.
1
2
3
4
5
6
7 8
8
500C
554
553
556
555
B
8
14
9
10
11
12
13
14
B W
W
1
2
512A
558
LOWER
OPTION
N.E.
3
557
4
500D
559
5
1
6
(J3)
6
560
N.A.
7
511
7
12
8
561
9
562
1
3
6
3
6
1
4
(P7)
N.B.
N.D.
10
11
12
563
(J7 ON WIRE DRIVE OR ON INPUT RECEPTACLE SHOWN)
N.B.
500E
4
1
2
3
4
5
6
541
541A
541A
1 2
(J2)
542A
500A
540A
400A
542A
500A
67
R.F.
(USED FOR
BENCH SET
UP)
N.A.
542
500
TOROID
3 4
1 2
NOTES:
N.A. CAVITY NUMBERING SEQUENCE AS VIEWED FROM COMPONENT SIDE OF PC BOARD.
N.B. CAVITY NUMBERING SEQUENCE AS VIEWED FROM LEAD SIDE OF CONNECTOR.
N.C. PIN NEAREST THE FLAT EDGE OF LED LENS (CATHODE) ALIGNS WITH BLACK
LEAD OF LED SOCKET.
541D
542D
500D
540D
540A
540
(J1)
N.A.
R.F.
TOROID
(J8)
3 4
67
67
LINC-NET
INPUT
N.D. TO FEEDER HEAD OR OPTIONAL INPUT LINC-NET RECEPTACLE.
N.E. THE OPTION INSTALLED MAY NOT HAVE ALL OF THE SHOWN WIRES. SEE THE
OPTION'S WIRING DIAGRAM FOR ADDITIONAL INFORMATION.
RECEPTACLE
(OPTIONAL FOR
BOOM SET UP)
(J6)
N.F. CAVITY NUMBERING SEQUENCE AS VIEWED FROM EDGE OF PC BOARD, COMPONENT
SIDE DOWN.
LINC-NET
OUTPUT
RECEPTACLE
(OPTIONAL)
TOP
PANEL
MIDDLE
PANEL
BOTTOM
PANEL
N.G. MAY NOT BE PRESENT ON CODE 10494 OR PRIOR MACHINES.
400D
400B
400C
ELECTRICAL SYMBOLS PER E1537.
= CHASSIS CONNECTION
LEAD COLOR CODING
B - BLACK
CONTROL BOX
W - WHITE
N.G.
9-11-98D
L10586
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The wiring diagram specific to your code is pasted inside one of the enclosure panels of your machine.
POWER WAVE 455/POWER FEED 10
Download from Www.Somanuals.com. All Manuals Search And Download.
G-6
G-6
ELECTRICAL DIAGRAMS
Power Feed 10 Wire Drive Wiring Diagram
VOLTAGE SENSING
TO USER
CONNECTION
W
B
551
550
GUN
INTERFACE
IF USED
COLD INCH/
GAS PURGE
2 STEP/
4 STEP
RECEPTACLE
R.F.
TOROID
3
1
4
DUAL
(J7)
559
512
512A
558
PROCEDURE
N.B.
512A
560
TRIGGER
P.M.
6
B
U
R
A
C
D
E
B
1
2
3
4
5
6
N.D.
N.D.
N.E.
(J8)
N.E.
R.F.
MOTOR/GEARBOX
(J1)
B
RED/GREEN
STATUS LED
N.C.
TOROID
W
512B
67A
511
400
554
555
512
558
559
560
570
B
571
W
67
67
CONTROL
P.C. BOARD
(J2)
N.A. CAVITY NUMBERING SEQUENCE AS VIEWED FROM COMPONENT SIDE OF PC BOARD.
N.B. CAVITY NUMBERING SEQUENCE AS VIEWED FROM LEAD SIDE OF CONNECTOR.
N.C. PIN NEAREST THE FLAT EDGE OF LED LENS (CATHODE) ALIGNS WITH BLACK
LEAD OF LED SOCKET.
1
7
6
(J5)
N.A.
VOLTAGE SENSE
SELECT P.C. BOARD
S1
1 2 3 4 5 6 7 8
ON
12
1
3
1
2
OFF
N.D. TOGGLE SWITCHES SHOWN FROM CONNECTION SIDE OF SWITCH.
SHUT
DOWN N.E. MAY NOT BE PRESENT ON CODES 10494 AND PRIOR MACHINES.
4
6
556
557
(J2)
(J1)
ELECTRICAL SYMBOLS PER E1537.
R
U
B
1 2
LEAD COLOR CODING
B - BLACK
(J4)
N.A.
= CHASSIS CONNECTION
R - RED
3 4
U - BLUE
W - WHITE
512B
511
(J6)
1
N.A. 2
550
1
3
(J3)
N.A.
552
551
4
6
553
541D
542D
500D
540D
1 2
RECTIFIER
BRIDGE
(J2)
N.A.
AC
+
3 4
540C
540A
541A
541
AC
-
540B
542A
542
540B
540
500A
500
540C
1
5
(J1)
N.A.
R.F.
R.F.
TOROID
TOROID
6
10
67
67
(J6)
(J9)
LINC-NET
INPUT
RECEPTACLE
LINC-NET
OUTPUT
552 553
RECEPTACLE
(OPTIONAL)
GAS
SOLENOID
9-11-98D
L10587
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The wiring diagram specific to your code is pasted inside one of the enclosure panels of your machine.
POWER WAVE 455/POWER FEED 10
Download from Www.Somanuals.com. All Manuals Search And Download.
G-7
G-7
ELECTRICAL DIAGRAMS
POWER FEED 10 MACHINE SCHEMATIC
J8 OPTIONAL
INPUT RECEPTACLE.
IF CONFIGURED AS BOOM, CONNECTS VIA
ARCLINK CABLE FROM WIRE DRIVE (J9)
OR POWER WAVE 455.
J9 OPTIONAL
OUTPUT
J6 INPUT
RECEPTACLE
WIRE DRIVE CONTROL PCB
67
RECEPTACLE
L1
(BOOM)
L7
L1
541
542
541
542
3J1
5J1
COMMUNICATION
-
A
B
C
D
E
COMMUNICATION
COMMUNICATION
-
67
541D
542D
541D
A
541
542
67
541
542
J6 OPTIONAL
OUTPUT
RECEPTACLE
1J2
2J2
A
B
C
D
E
1J7
3J7
COMMUNICATION
COMMUNICATION
-
OR
L1
L8
L1
COMMUNICATION
ELECTRODE
+
+
542D
B
(BENCH)
67
+
VOLTAGE SENSE
C
67
541D
542D
540D
500D
ELECTRODE
C
L2
L2
L9
L2
L2
VOLTAGE SENSE
540
500
540
500
L7
L8
7J1
9J1
+40 VDC
+40 VDC
540D
500D
540D
D
540
500
540
500
4J2
3J2
+40 VDC
6J7
4J7
541A
542A
500A
67
541D
542D
540D
500D
1J2
2J2
3J2
1J1
2J1
4J1
3J1
COMMUNICATION
-
1P7
3P7
4P7
5P7
6P7
A
B
D
E
COMMUNICATION
COMMUNICATION
+40 VDC
-
COMMUNICATION
-
L10
0
VDC
0
VDC
500D
0
VDC
E
COMMUNICATION
+
COMMUNICATION
+40 VDC
+
+
L9
DISPLAY
P.C. BOARD
+40 VDC
1
OR
8
L10
BLOCKING
RECTIFIER
540B
540C
0
VDC
0
VDC
541A
542A
500A
541A
6J1
+40 VDC
2J1
4J1
8J1
COMMUNICATION
COMMUNICATION
-
1J7
3J7
4J7
5J7
6J7
540A
4J2
0
VDC
WIRE DRIVE PCB
CIRCUIT SUPPLY
542A
500A
67
10J1
+
+40 VDC
INTERNAL HARNESS AND
CONTROL BOX
CONNECTOR USED ONLY IF UNIT
USER INTERFACE PCB
R
512
551
512C
500
552
550
CONFIGURED AS
A
BENCH FEEDER.
1J4
+12 VDC
1J4
2J4
*
SERIAL
PERIPHERAL
INTERFACE
+12 VDC
MOSI
+12 VDC
-
-
-
-
-
-
540A
540A
1J1
0
VDC
*
MOTOR
TACH
U
B
2J4
3J4
TACH SIGNAL INPUT
3J4
4J4
0
VDC
SCK
DUAL
0
VDC
5J4
*
ENCODER
B
STATUS LED
(HIGH FOR GREEN)
1
8
8J5
6J4
P.C. BOARD
*
LATCH
CATHODE
B
7J4
-
RED/GREEN
STATUS
LED
500C
554
553
556
555
B
CATHODE
8J4
0
VDC
-
-
570
571
W
STATUS LED
(HIGH FOR RED)
7J5
9J5
SIGNAL COMMON
CONTROL SIGNAL
9J4
ENCODER 1, SIG.
ENCODER 1, SIG.
ENCODER 2, SIG.
ENCODER 2, SIG.
B
A
10J5
RED/GREEN
STATUS
LED
SHUT
DOWN
10J4
11J4
12J4
13J4
14J4
-
W
B
A
-
OPEN
=
FAULT
-
STATUS LED (HIGH FOR GREEN)
STATUS LED (HIGH FOR RED)
-
ELECTRODE VOLTAGE SENSE
FROM ADDITIONAL WIRE DRIVE
THRU CONTROL BOX WHEN
552
553
W
-
3J3
6J3
+40 VDC
GUN
RECEPTACLE
GUN
GAS
SOLENOID
CONTROLS
CONFIGURED AS
A
BENCH FEEDER
WITH J9 OPTIONAL OUTPUT
RECEPTACLE.
(P11) (J11)
L3
L4
L5
L6
DUAL
PROCESS
PWM
CONTROL
555
554
556
557
DUAL PROCESS,
OPEN PROCESS
2J5
1J5
D
=
A
UPPER OPTION PANELS.
512B
565
564
500F
566
567
568
569
1J5
2J5
3J5
4J5
5J5
6J5
7J5
8J5
9J5
10J5
+12 VDC
-
-
SOME OPTIONS DO NOT HAVE ALL WIRES SHOWN.
E
A
C
SIGNAL COMMON
TRIGGER
*
MOSI
MISO
GUN TRIGGER,
11J5
12J5
*
-
DUAL PROCEDURE PANEL KIT
CLOSE
=
FEED HOT WIRE
L11
0
VDC
SCK
-
551
550
551
550
+
PWM
W
B
4J3
1J3
DUAL PROCEDURE
/
MENORY PANEL KIT
SIGNAL COMMON
CONTROL
*
-
*
LATCH
-
MOTOR
L12
PROC.
PROC.
A
-
-
-
-
FEEDER
CONTROLS
-
PWM
B
CONTROL
2/4 STEP
512A
VOLTAGE SENSE
SELECT PCB
560
TRIGGER ACTION SELECT,
6J5
5J5
3J5
4J5
OPEN
=
2
STEP
512B
511
559
512
558
1J6
2J6
1J1
+12 VDC
PURGE SIGNAL
+12 VDC
(SOLID STATE)
512A
COLD INCH
LOWER OPTION PANELS.
512A
558
CR1
/
1J3
2J3
+12 VDC
-
SOME OPTIONS DO NOT HAVE ALL WIRES SHOWN.
PURGE
VOLTAGE SENSE
SELECT SIGNAL
*
MOSI
MISO
-
4J1
COLD INCH SIGNAL
557
3J3
*
-
CV/GOUGE PANEL (STD)
"M" PANEL KIT
67
67
500D
559
2J2
1J2
4J3
J6 INPUT
0
VDC
SCK
-
RECEPTACLE
5J3
*
-
CR1
560
"MSTT" PANEL KIT
"MX2" PANEL KIT
"MSP2" PANEL KIT
6J3
*
LATCH
-
67A
ELECTRODE VOLTAGE
SENSE TO WELDER
511
561
3J1
7J3
C
POT SUPPLY
POT WIPER
MODE
-
ELECTRODE CABLE
8J3
-
562
WIRE DRIVE
ASSEMBLY
9J3
1
-
-
67
563
10J3
11J3
12J3
MODE
3
-
-
500E
POT COMMON
J9 OPTIONAL
OUTPUT
RECEPTACLE
ELECTRODE VOLTAGE
SENSE FROM
ADDITIONAL WIRE DRIVE
67
67
67
C
NOTES:
OPTIONAL OUTPUT RECEPTACLE IS REFERENCED (J9) ON WIRE DRIVE AND
(J8) ON USER INTERFACE CONTROL BOX.
WIRE COLOR CODE
B = BLACK
U = BLUE
R = RED
W = WHITE
8-14-98F
G3602
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
POWER WAVE 455/POWER FEED 10
Download from Www.Somanuals.com. All Manuals Search And Download.
G-8
G-8
Enhanced Diagram
ELECTRICAL DIAGRAMS
POWER WAVE 455 MACHINE SCHEMATIC - CODE 10372
3 1 8 G 1
N.A.
RECONNECT
SWITCH
INPUT
RECTIFIER
SWITCH BOARD #1 (LEFT)
380-460V
208-230V
19C
19D
CR1
AC3
POS
L1
T1
19A
N.A.
U
S5 RS232
CONNECTOR
CONTROL BOARD
AC2
NEG
CURRENT
TRANSDUCER
L2
L3
T2
T3
V
211
212
213
216
253
1J21
2J21
3J21
6J21
CURRENT FEEDBACK
3J25
4J25
2
3
RS232 RECEIVE
20C
20D
2.7
10W
.022u
800V
AC1
NEG
MAIN TRANSFORMER T1
254
20A
+15V
RS232 TRANSMIT
W
G
13
14
-15V
4
5
F
ELECTRODE
+
CR1
C4
3400uF
450V
2.7
10W
.022u
800V
A
CONTROL BOARD COMMON
S
601
403
406
404
233
405
C2/TP2
3J40
6J40
4J40
1J40
5J40
320V
160J
6
7
.05uF
600V
601A
ON
X4A
X4
2.7
10W
SW1
251
.022u
800V
1J25
RS232 COMMON
POWER
F
OUTPUT DIODES
D1-D4
612B
TP3
150V
80J
OFF
B
20
N.A.
S
H1D
206
202
2.7
10W
6J20
2J20
.022u
800V
+ELECTRODE VOLTAGE SENSE
INPUT BOARD
12
11
A
PRIMARY
CURRENT
SENSE
1J60
+13V
2J60
X3
S2 VOLTAGE SENSE
RECEPTACLE
-
ELECTRODE VOLTAGE SENSE
5J60
232
ELECTRODE
-
1
2
N.A.
MAIN CONTACTOR CONTROL
MAIN CHOKE L1
C1/TP1
SWITCH BOARD#2 (RIGHT)
320V
160J
.05uF
600V
T3
T1
8J61
10J61
2J61
4J60
21A
3
4J20
WORK VOLTAGE SENSE
612
6J61
4
+13V
15
604
T2
S
214
218
4J21
8J21
PRIMARY CURRENT SENSE
PRIMARY CURRENT SENSE
PRECHARGE RELAY
C
2B
7J22
9J22
F
THERMAL LED
THERMAL LED
17
4J61
YELLOW
THERMAL
LED
S
16
18
2W
D
3J60
8J60
238
231
C5
3400uF
F
SINGLE
PHASE
DETECT
503
506
235
234
239
450V
6J23
13J23
5J23
4J23
9J23
503
506
235
234
239
IGBT DRIVE (+)
IGBT DRIVE (-)
3J50
15
16
6J50
4J50
1J50
5J50
CAPACITOR C5 OVERVOLTAGE (LOW=RUN)
CAPACITOR C5 UNDERVOLTAGE (LOW=RUN)
CONTROL BOARD COMMON
AUX. RECONNECT
A
403
406
404
233
405
14J23
7J23
IGBT DRIVE (+)
H2
H3
200-208V
220-230V
380-415V
IGBT DRIVE (-)
H4
12J23
3J23
CAPACITOR C4 OVERVOLTAGE (LOW=RUN)
CAPACITOR C4 UNDERVOLTAGE (LOW=RUN)
CONTROL BOARD COMMON
H5
440-460V
10J23
224A
224
220
4J22
THERMOSTAT (CLOSE TO 10J22 TO RUN)
THERMOSTAT (CLOSE TO 4J22 TO RUN)
290
10J22
OUTPUT RECTIFIER
THERMOSTAT
X4A
601A
1W
1B
270 OHM,5W
2J24
4J24
STATUS LED (HI FOR RED)
RED/GREEN
STATUS
LED
FAN THERMOSTAT
STATUS LED (HI FOR GREEN)
238
604
231
232
8J23
11J23
1J23
2J23
+13V
PRECHARGE CONTROL
PHASE DETECT (5V=RUN)
MAIN CONTACTOR CONTROL
N.A.
POWER BOARD
AUXILIARY
TRANSFORMER T1
S1 WIRE FEEDER
RECEPTACLE
X4
0V
H5
H5A
H4A
(440-460)
H4
(380-415)
53
54
8J31
5J27
1J27
8J20
TESTVa
NOT USED
ARCLINK
-
A
B
C
D
E
ARCLINK
ARCLINK
-
612
24V
X3
1J31
Vcc(+15)
NOT USED
225
ARCLINK
+
+
H3
(220-230)
H2
(200-208)
H1
FAN
1J32
2J32
4J32
5J32
POS
POS
H3A
115V
225
221
222
223
274
273
226
228
67A
52
X5
X1
2J31
5J22
1J22
2J22
3j22
+15Va
+15V
FEEDER VOLTAGE SENSE
ELECTRODE SENSE
+40VDC
POS
CB4
6A
221
222
223
274
273
226
228
H2A
H1
65VDC
C3
7J31
+5Va
+5V
52V
WELD AND
CURRENT
CONTROL
25000uF/100V
NEG
NEG
NEG
X2
51
4J31
3J31
GND
a
CONTROL BOARD COMMON
-15V
0VDC
TRANSFORMER T2
H5
-15Va
+5Vc
P80
6
H5A
H4A
(440-460)
CB2
10A
11J31
12J31
6J31
4J27
3J27
6J22
8J22
+5V ARCLINK +5V
ARCLINK COMMON
RS232 +5V
H4
CAN
3
612B
612A
P81
4
(380-415)
c
31
33
L2
R
H3
2
H3A
H2A
H1A
(115V)
W
+5Ve
(220-230)
1
RS232
H2
4
(200-208)
5J31
e
RS232 COMMON
CB3
10A
32
H1
1
51
50
51BK
50WT
0VDC FEEDER
S4
RECEPTACLE
+40VDC FEEDER
CB1 10A
ELECTRICAL SYMBOLS PER E1537
NOTES
:
N.A. PC BOARD COMPONENTS SHOWN FOR REFERENCE
ONLY. ALL COMPONENTS ARE NOT SHOWN.
UNLESS OTHERWISE SPECIFIED TOLERANCE
ON HOLE SIZES PER E2056
THIS SHEET CONTAINS PROPRIETARY INFORMATION
EQUIP.
INVERTER WELDERS
THE LINCOLN ELECTRIC CO.
OWNED BY
AND IS
XA
TYPE
THE LINCOLN ELECTRIC CO.
ON
ON
2
3
PLACE DECIMALS IS .02
PLACE DECIMALS IS .002
CLEVELAND, OHIO U.S.A.
NOT TO BE REPRODUCED, DISCLOSED OR USED
WITHOUT THE EXPRESS PERMISSION OF
11-14-97A
3-19-99D
MACHINE SCHEMATIC
SUBJECT
ON ALL ANGLES IS .5 OF
MATERIAL TOLERANCE (" ") TO AGREE
A
DEGREE
SCALE
NONE
t
SHT.
NO.
THE LINCOLN ELECTRIC CO.
BK/JLV
3-22-96
REF.
3181
DR
DATE
CHK
SUP'S'D'G
WITH PUBLISHED STANDARDS.
G
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
POWER WAVE 455/POWER FEED 10
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G-9
G-9
ELECTRICAL DIAGRAMS
POWER WAVE 455 MACHINE SCHEMATIC - CODE 10555
3 1 8 G 1 - 1
N.A.
INPUT
LINE
FILTER
INPUT
RECTIFIER
SWITCH BOARD #1 (LEFT)
CR1
AC3
POS
L1
T1
N.A.
POS
U
L1B
S5 RS232
CONNECTOR
CONTROL BOARD
AC2
AC1
NEG
NEG
L2
L3
T2
T3
V
253
2
RS232 RECEIVE
3J25
4J25
.022u
800V
2.7
10W
254
3
NEG
MAIN TRANSFORMER T1
F
RS232 TRANSMIT
W
13
14
L3B
4
5
6
ELECTRODE
+
CR1
C4
+
.022u
800V
2.7
10W
(CAP "A")
3400uF
450V
A
SWITCH
LEAD
FILTER
S
601
C2/TP2
403
406
404
233
405
3J40
6J40
4J40
1J40
5J40
206A
320V
160J
.05uF
600V
.022u
800V
2.7
10W
251
7
1J25
RS232 COMMON
F
X4
OUTPUT DIODES
D1-D4
TP3
150V
80J
R1
50
G
B
20
S
206
202
.022u
800V
2.7
10W
6J20
2J20
+ELECTRODE VOLTAGE SENSE
12
11
CURRENT
TRANSDUCER
202A
PRIMARY
CURRENT
SENSE
+
ON
S2 VOLTAGE SENSE
RECEPTACLE
-
ELECTRODE VOLTAGE SENSE
SW1
POWER
ELECTRODE
612B
-
OFF
N.A.
MAIN CHOKE L1
1
2
N.A.
C
C1/TP1
H1D
SWITCH BOARD#2 (RIGHT)
320V
160J
INPUT BOARD
L4
.05uF
600V
216
211
213
6J21
1J21
3J21
CONTROL BOARD COMMON
CURRENT FEEDBACK
-15V
21A
3
P91
4J20
WORK VOLTAGE SENSE
H4B
2J60
1J60
+13V
X3
4
232
5J60
15
S
212
214
2J21
4J21
MAIN CONTACTOR CONTROL
+15
C
D
2B
7J22
9J22
F
THERMAL LED
THERMAL LED
PRIMARY CURRENT SENSE
17
T3
T1
8J61
10J61
2J61
YELLOW
THERMAL
LED
218
S
8J21
PRIMARY CURRENT SENSE
16
18
2W
612
6J61
L7
C5
+
F
+13V
(CAP "B")
3400uF
450V
503
506
6J23
604
T2
IGBT DRIVE (+)
IGBT DRIVE (-)
4J60
4J61
503
3J50
PRECHARGE RELAY
13J23
5J23
15
16
506
235
234
239
235
234
239
6J50
4J50
CAPACITOR C5 OVERVOLTAGE (LOW=RUN)
CAPACITOR C5 UNDERVOLTAGE (LOW=RUN)
4J23
9J23
3J60
8J60
238
231
SINGLE
PHASE
DETECT
CONTROL BOARD COMMON
1J50
5J50
403
406
404
14J23
7J23
IGBT DRIVE (+)
IGBT DRIVE (-)
12J23
3J23
CAPACITOR C4 OVERVOLTAGE (LOW=RUN)
233
405
CAPACITOR C4 UNDERVOLTAGE (LOW=RUN)
CONTROL BOARD COMMON
10J23
224
220
224A
291
SOLID
STATE
RELAY
4J22
THERMOSTAT
(NORMALLY CLOSED)
THERMOSTAT
10J22
X3A
3R
+
-
CHOKE
THERMOSTAT
OUTPUT RECTIFIER
THERMOSTAT
3R
1W
1B
TP4
444
2J24
4J24
12J24
10J24
STATUS LED (HI FOR RED)
FAN CONTROL (+)
FAN CONTROL (-)
RED/GREEN
STATUS
LED
3W
3W
STATUS LED (HI FOR GREEN)
238
604
231
232
8J23
11J23
1J23
2J23
+13V
PRECHARGE CONTROL
N.A.
PHASE DETECT (5V=RUN)
MAIN CONTACTOR CONTROL
POWER BOARD
N.B.
AUXILIARY
TRANSFORMER T1
S1 WIRE FEEDER
RECEPTACLE
L4
H5
X4
0V
(440-460)
H5A
53
54
H4
(380-415)
444
TESTVa
8J31
1J31
5J27
ARCLINK
ARCLINK
-
A
ARCLINK
ARCLINK
-
NOT USED
H4B
H4A
H3A
24V
X3A
X3
612
FAN
1J27
8J20
Vcc(+15)
+15Va
+5Va
NOT USED
225
+
B
C
+
H3
(220-230)
POS
1J32
115V
225
221
222
223
274
273
226
228
67A
52
X5
X1
2J31
5J22
1J22
2J22
+15V
FEEDER VOLTAGE SENSE
ELECTRODE SENSE
+40VDC
H2
POS
POS
2J32
4J32
5J32
(200-208)
CB4
6A
221
222
223
H2A
H1
65VDC
C3
25000uF/100V
7J31
4J31
+5V
D
E
52V
WELD AND
CURRENT
CONTROL
H1
X2
NEG
NEG
NEG
51
GND
a
0VDC
CONTROL BOARD COMMON
-15V
TRANSFORMER T2
P80
3J31
3j22
4J27
3J27
6J22
-15Va
+5Vc
H5
6
H5A
274
273
226
228
11J31
12J31
+5V ARCLINK +5V
ARCLINK COMMON
RS232 +5V
(440-460)
H4
CB2
5A
N.B.
CAN
H4A
H3A
3
612B
612A
(380-415)
P81
6
c
+5Ve
e
351
352
B
L4
H3
2
(220-230)
(115V)
B
6J31
5J31
1
RS232
H2
4
(200-208)
H2A
H1A
8J22
RS232 COMMON
CB3
10A
350
H1
1
L2
51
50
S4
220V
RECEPTACLE
51BK
50WT
0VDC FEEDER
+40VDC FEEDER
CB1 10A
NOTES
:
ELECTRICAL SYMBOLS PER E1537
N.A. PC BOARD COMPONENTS SHOWN FOR REFERENCE
ONLY. ALL COMPONENTS ARE NOT SHOWN.
N.B. L4 IS WOUND ON ONE COMMON CORE.
Ch'ge. Sht. No.
XB-UF
UNLESS OTHERWISE SPECIFIED TOLERANCE
MANUFACTURING TOLERANCE PER E2056
THIS SHEET CONTAINS PROPRIETARY INFORMATION
EQUIP.
INVERTER WELDERS
THE LINCOLN ELECTRIC CO.
OWNED BY
AND IS
TYPE
THE LINCOLN ELECTRIC CO.
ON
ON
2
3
PLACE DECIMALS IS
PLACE DECIMALS IS
.02
.002
12-4-98
CLEVELAND, OHIO U.S.A.
NOT TO BE REPRODUCED, DISCLOSED OR USED
WITHOUT THE EXPRESS PERMISSION OF
MACHINE SCHEMATIC
SUBJECT
3-19-99D
ON ALL ANGLES IS
.5 OF
A
DEGREE
SCALE
NONE
SHT.
MATERIAL TOLERANCE (" ") TO AGREE
t
THE LINCOLN ELECTRIC CO.
G3181
JLV
11-7-97
B.S.
REF.
3181-1
DR
DATE
CHK
SUP'S'D'G
WITH PUBLISHED STANDARDS.
NO.
G
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
POWER WAVE 455/POWER FEED 10
Download from Www.Somanuals.com. All Manuals Search And Download.
G-10
G-10
ELECTRICAL DIAGRAMS
POWER WAVE 455 MACHINE SCHEMATIC - CODE 10553
3 1 8 G 1 - 2
N.A.
INPUT
RECTIFIER
SWITCH BOARD #1 (LEFT)
CR1
N.A.
S5 RS232
CONNECTOR
CONTROL BOARD
N.C.
+
N.A.
INPUT BOARD
+
S2 VOLTAGE SENSE
RECEPTACLE
N.A.
SWITCH BOARD#2 (RIGHT)
+
AUX. RECONNECT
SOLID
STATE
RELAY
N.A.
POWER BOARD
N.B.
S1 WIRE FEEDER
RECEPTACLE
N.B.
(115V)
1
H1
H1A
1
NOTES
:
N.A. PC BOARD COMPONENTS SHOWN FOR REFERENCE ONLY.
ALL COMPONENTS ARE NOT SHOWN.
N.B. L2 IS WOUND ON ONE COMMON CORE.
Ch'ge. Sht. No.
XA
N.C. T1 PRIMARY CONNECTIONS SHOWN FOR REFERENCE ONLY.
SEE WIRING DIAGRAM FOR 460/575 SWITCHING.
UNLESS OTHERWISE SPECIFIED TOLERANCE
MANUFACTURING TOLERANCE PER E2056
THIS SHEET CONTAINS PROPRIETARY INFORMATION
EQUIP.
TYPE
INVERTER WELDERS
THE LINCOLN ELECTRIC CO.
CLEVELAND, OHIO U.S.A.
OWNED BY
AND IS
THE LINCOLN ELECTRIC CO.
ON
ON
2
3
PLACE DECIMALS IS
PLACE DECIMALS IS
.02
.002
12-18-98A
3-19-99D
NOT TO BE REPRODUCED, DISCLOSED OR USED
WITHOUT THE EXPRESS PERMISSION OF
MACHINE SCHEMATIC
SUBJECT
ON ALL ANGLES IS
.5 OF
A
DEGREE
SCALE
NONE
SHT.
MATERIAL TOLERANCE (" ") TO AGREE
WITH PUBLISHED STANDARDS.
THE LINCOLN ELECTRIC CO.
G3181-1
JLJ
11-4-98
K.J.
REF.
3181-2
DR
DATE
CHK
SUP'S'D'G
NO.
G
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
POWER WAVE 455/POWER FEED 10
Download from Www.Somanuals.com. All Manuals Search And Download.
G-11
G-11
ELECTRICAL DIAGRAMS
POWER WAVE 455 CONTROL PC BOARD SCHEMATIC (1 of 3)
NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your factory warranty. Individual Printed Circuit Board Components are not available from Lincoln Electric. This information is pro-
vided for reference only. Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician. Improper PC board repairs could result in damage to the
machine.
POWER WAVE 455/POWER FEED 10
Download from Www.Somanuals.com. All Manuals Search And Download.
G-12
G-12
ELECTRICAL DIAGRAMS
POWER WAVE 455 CONTROL PC BOARD SCHEMATIC (2 of 3)
NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your factory warranty. Individual Printed Circuit Board Components are not available from Lincoln Electric. This information is pro-
vided for reference only. Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician. Improper PC board repairs could result in damage to the
machine.
POWER WAVE 455/POWER FEED 10
Download from Www.Somanuals.com. All Manuals Search And Download.
G-13
G-13
ELECTRICAL DIAGRAMS
POWER WAVE 455 CONTROL PC BOARD SCHEMATIC (3 of 3)
NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your factory warranty. Individual Printed Circuit Board Components are not available from Lincoln Electric. This information is pro-
vided for reference only. Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician. Improper PC board repairs could result in damage to the
machine.
POWER WAVE 455/POWER FEED 10
Download from Www.Somanuals.com. All Manuals Search And Download.
G-14
G-14
ELECTRICAL DIAGRAMS
POWER WAVE 455 POWER PC BOARD SCHEMATIC
3 0 2 G 6
4.7
10W
L7
INVERTER POWER SUPPLIES
R39
+40Vwf
GND
a
VOLTAGE
USE
TRANS
T1
BRD
C12
.0047
400V
SEC.
A
D20
50
"WT"
B1
+5Va
+15Va
-15Va
+40Vf
WELD
WELD
WELD
&
&
&
CURRENT CONTROL
CURRENT CONTROL
CURRENT CONTROL
T1
.47mH
15A
600V
8t
B
CTRL
100
100
To
TP1
50V
15J
10W
10W
C4
33
100V
WIRE FEEDER
WIRE FEEDER POWER
Wire
8t
C
D21
100
100
comF
T1
T1
AMPH.
CTRL
10W
Feeder
10W
15A
600V
51
"BK"
B2
c
e
+5Vc
+5Ve
CAN
comF
RS 232
9
J31
J31
10
1
Vcc(+15)
J31
J31
Test Points
8
TESTVa
WELD
&
CURRENT CONTROL
R33
+15Va
D4
20
5W
500mA
C15
.001
J32
65 Vdc +/- 20%
1
400V
3A
L3
D6
D9
J32
600V
2
2
X3
IN
OUT
1mH
3A
J31
1500
5W
1500
5W
1500
5W
1500
5W
DZ4
43V
1W
600V
C13
2.21K
C25
2.21K
GND
SEC.
12
C26
0.1
50V
0.1
D2
Vcc(+15)
+5Va
4.7
D5
50V
TESTVa
46VAC
35V
500mA
C7
.47
630Vdc
T1
2t
TP2
1N4007
D3
3A
Rect.& Filtered
L5
D7
D8
C16
600V
320V
160J
DZ5
43V
1W
1N4007
4.7
13
7
X1
DZ1
17V
5W
C36
50
25V
35V
IN
OUT
1mH
J32
J32
3A
600V
R14
+40Vwf
J31
OVER/DOUBLE VOLTAGE
PROTECTION CIRCUIT
C3
C6
4
2t
4.7
1.00K
0.1
243
270
5W
C10
0.1
50V
35V
50V
ADJ
R11
5
14
1.50K
1.50K
2t
C2
0.1
50V
C5
C19
-15Va
4.7
0.1
4
15
D10
1N4936
1N4936
GND
35V
50V
comF
D26
1.0A
30V
J31
J31
L4
a
2t
D11
SWITCH_GND
DZ6
3.3V
1W
C20
0.1
50V
X7
IN
OUT
16
1mH
D22
4.7
3
Vcc(+15)
10W
C31
.0022
400V
D14
1.0A
30V
To
C35
0.1
50V
D
R49
10.0
Q3
38A
250V
Control
Board
Vin
+
Vc
OUT
GND
G
+5Vc
D1
R47
10.0
S
125mA
X6
CAN
D15
1.0A
30V
R48
10.0
DZ2
16V
1W
Vcc(+15)
INV IN
N.I. IN
T1
7
L8
SEC.
1N4936
D18
17
X2
11
7t
T1
C21
1.8
20V
IN
OUT
1mH
C18
C22
1.8
20V
2t
J31
J31
0.1
R38
475
6
5
PRI.
50V
1N4936
C34
4.7
35V
GND
C14
D17
D16
C1
18
C11
0.1
C33
0.1
50V
681
681
0.1
35V
7t
1N4936
1000
50V
50V
X4
1
16
15
14
13
12
11
SHUT
Vin
CLIM
4
2
3
4
5
6
7
8
12
Vref
I-
R21
Vcc(+15)
1.50K
1N4936
D19
OUTB
Vc
4.7
c
I+
10W
D24
1.0A
30V
PWM
C32
0.1
50V
V+
GND
OUTA
SYNC
RT
R20
Vin
+
Vc
OUT
GND
INV IN
C30
.0022
400V
3.32K
V-
10.0
D
S
100p
100V
10
C23
22p
100V
R45
COMP
CT
Q2
38A
250V
C28
9
G
X5
D25
1.0A
30V
+5Ve
R46
SG3846
D23
10.0
30mA
RS232
N.I. IN
12.1K
R32
133K
82.5K
R44
DZ3
16V
1W
22.1K
C27
10.0
68.1K
R35
475
820p
50V
L6
15.0K
SEC.
10
D13
X8
6
T1
IN
OUT
C17
2700p
50V
1mH
1N4936
8t
J31
GND
150
11
C8
4.7
35V
D12
1N4936
C9
0.1
50V
C24
0.1
50V
PRI. CURRENT
FEEDBACK
.1
.1
+40Vwf
R30
750
R31
C29
0.1
50V
7W
7W
15.0K
5
J31
VOLTAGE
FEEDBACK
PRIMARY SWITCHING CIRCUIT
2.21K
e
SWITCH_GND
NOTES
:
N.A. SINCE COMPONENTS OR CIRCUITRY ON
WITHOUT AFFECTING THE INTERCHANGEABILITY OF COMPLETE BOARD, THIS DIAGRAM MAY
A
PRINTED CIRCUIT BOARD MAY CHANGE
A
GENERAL INFORMATION
LAST NO. USED
NOT SHOW THE EXACT COMPONENTS OR CIRCUITRY OF CONTROLS HAVING
NUMBER.
A
COMMON CODE
R- 55
C- 36
D- 26
X-
8
T-
1
ELECTRICAL SYMBOLS PER E1537
Q-
3
TP-
L-
2
CAPACITORS
RESISTORS
DIODES
=
MFD
(
.022/50V
1/4W
UNLESS OTHERWISE SPECIFIED)
UNLESS OTHERWISE SPECIFIED)
DZ-
6
8
LABELS
SUPPLY
=
Ohms
(
=
1A, 400V
(UNLESS OTHERWISE SPECIFIED)
VOLTAGE NET
POWER SUPPLY SOURCE POINT
COMMON CONNECTION
FRAME CONNECTION
EARTH GROUND CONNECTION
FILE: G3026_2E1
EQUIP.
TYPE
Ch'ge.Sht.No.
INVERTER WELDERS
THE LINCOLN ELECTRIC CO.
CLEVELAND, OHIO U.S.A.
XC-RW
11-14-97A
12-4-98A
SCHEMATIC, POWER PCB
SUBJECT
NONE
SCALE
DATE
SHT.
KJ
LC
2-21-97
CHK.
SUP'S'D'G.
DR.
NO.
G 3026
NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your factory warranty. Individual Printed Circuit Board Components are not available from Lincoln Electric. This information is pro-
vided for reference only. Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician. Improper PC board repairs could result in damage to the
machine.
POWER WAVE 455/POWER FEED 10
Download from Www.Somanuals.com. All Manuals Search And Download.
G-15
G-15
ELECTRICAL DIAGRAMS
POWER WAVE 455 INPUT PC BOARD SCHEMATIC
M
1 7 9 2 1
PRE-CHARGE CONNECTIONS
CONTACTOR OUTPUT
J60
2
10
2
4
J61
3
4
CONTACTOR
J61
J61
CR1
COIL CONNECT
TP1
TP3
J60
1
660V
250J
660V
250J
TP2
J60
5
CONTACTOR CONTROL
+13V FROM CONTROL BOARD
PRE-CHARGE CONTROL
R9
R8
3
4
660V
250J
5
6
CR2
CR2
100
10W
100
10W
J61
+13V
CR1
R2
R1
6
100
10W
100
10W
J60
3
VAC
Input
TP4
660V
250J
J61
CR2
R7
R10
8
100
10W
100
10W
J60
4
R6
R3
100
10W
100
10W
+13V
475
1
5
4
D2
1A
D3
D1
OCI1
CNY17-3V
1500V
J60
2
6
SINGLE PHASE DETECT
8
CENTER LEG TO OUTSIDE LEG OF INPUT
C1
.022
50V
GENERAL INFORMATION
ELECTRICAL SYMBOLS PER E1537
LAST NO. USED
UNUSED PINS
R- 25
OCI-
CR-
TP-
1
C-
D-
1
2
J61
J60
6
CAPACITORS
RESISTORS
DIODES
=
MFD
(
.022/50V
1/4W
UNLESS OTHERWISE SPECIFIED)
UNLESS OTHERWISE SPECIFIED)
3
4
LABELS
=
Ohms
(
1
NOTES :
=
1A, 400V
(UNLESS OTHERWISE SPECIFIED)
SUPPLY
VOLTAGE NET
J61
J60
7
N.A. SINCE COMPONENTS OR CIRCUITRY ON
A
PRINTED CIRCUIT BOARD MAY CHANGE
POWER SUPPLY SOURCE POINT
COMMON CONNECTION
3
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.
J61
FRAME CONNECTION
5
J61
EARTH GROUND CONNECTION
THIS SHEET CONTAINS PROPRIETARY INFORMATION OWNED BY
THE LINCOLN ELECTRIC CO.
FILENAME: M17921_3DA
AND IS NOT TO BE REPRODUCED, DISCLOSED OR USED WITHOUT THE EXPRESS PERMISSION OF
THE LINCOLN ELECTRIC CO.
7
UNLESS OTHERWISE SPECIFIED TOLERANCE
ON HOLES SIZES PER E-2056
Ch'ge.Sht.No.
J61
EQUIP.
TYPE
INVERTER WELDERS
SCHEMATIC, INPUT PCB
THE LINCOLN ELECTRIC CO.
CLEVELAND, OHIO U.S.A.
XB-RW
ON
ON
2
3
PLACE DECIMALS IS
PLACE DECIMALS IS
+
+
.O2
.OO2
9
11-14-97
2-27-98L
12-4-98A
SUBJECT
ON ALL ANGLES IS
+
.5 OF
A
DEGREE
NONE
SCALE
MATERIAL TOLERANCE ("t") TO AGREE
WITH PUBLISHED STANDARDS
SHT.
JLV
17921
5-17-96
DATE
CHK.
SUP'S'D'G.
M
DR.
NO.
NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your factory warranty. Individual Printed Circuit Board Components are not available from Lincoln Electric. This information is pro-
vided for reference only. Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician. Improper PC board repairs could result in damage to the
machine.
POWER WAVE 455/POWER FEED 10
Download from Www.Somanuals.com. All Manuals Search And Download.
G-16
G-16
ELECTRICAL DIAGRAMS
POWER WAVE 455 SWITCH PC BOARD SCHEMATIC - CODE 10372 & 10555
RECONNECT
B
R34
10.0
R43
10.0
4
7
10
13
16
DZ4
C1 C2 C3 C4 C5
6.2V
1W
5
8
G1
W1
R42
10.0
0.01
G2
G3
G4
G5
A2
DZ5
15V
1W
C8
11
1.00K
1.00K
1.00K
1.00K
D3
.01
R41
10.0
C7
.0047
50V
14
1A
1000V
2000V
17
R40
10.0
E1 E2 E3
3
E4
12
E5
DZ6
6
9
15
15V
1W
R39
10.0
13/14 OR 17/18
2500
5W
TRANSFORMER
PRIMARY
2
19
C1
A1
C2
BLEEDER
C9
.0047
1000V
A2
A2
RESISTORS
T1
1
1
18
2500
5W
3
19
150K
J9
GATE
4
3
6
DRIVE
J9
PWM
5
C12
C13
C14
C15
2500
5W
+15V
FILTER
CAPACITOR
2
19
2
.22
.22
.22
.22
GATE
1000V
1000V
1000V
1000V
C1
A1
C2
C10
.0047
1000V
6
A1
15.0K
A2
D2
2500
5W
1
18
150K
20
R24
A
R26
10.0
+15V
11/12 OR 15/16
332K
10
R20
TRANSFORMER
PRIMARY
DZ3
4
7
10
13
16
8
10.0
X2
C11
6.2V
1W
C1 C2 C3 C4 C5
5
8
2.8K
9
G1
W2
0.01
R19
10.0
+
1
G2
G3
G4
G5
C1
.01
2000V
DZ1
15V
1W
C6
27
35V
A1
11
D1
1A
1000V
X1
8
1.00K
1.00K
1.00K
1.00K
R18
10.0
REF
14
C3
.0047
50V
TL431
-
6
17
6.19K
18.2K
R17
10.0
DZ2
E1 E2 E3
3
E4
12
E5
6
9
15
15V
1W
562
R16
10.0
RECONNECT
C
+15V
+15V
OVERVOLTAGE
PROTECTION
10K
5
DZ7
5.1V
1W
7
X2
6
J9
1
R3
R5
1.82K
J9
221
1.21K
TO CONTROL BD.
(VOLTAGE PROTECTION)
(Pre-charge Shut-off)
4
R21
5
1
3.32K
221
OCI1
CNY17-3V
1
5
OCI2
CNY17-3V
10K
4
6
2
TO CONTROL BD.
(VOLTAGE PROTECTION)
(Trigger Loop)
2
6
4
C2
.022
50V
J9
2
267K
C4
.022
50V
681K
J9
5
3
2
1
+15V
4
X2
C5
X2
12
LM224
14
X2
11
13
NOTE: 203,206 BOLT ON WITH FILTER CAPS
NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your factory warranty. Individual Printed Circuit Board Components are not available from Lincoln Electric. This information is pro-
vided for reference only. Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician. Improper PC board repairs could result in damage to the
machine.
POWER WAVE 455/POWER FEED 10
Download from Www.Somanuals.com. All Manuals Search And Download.
G-17
G-17
ELECTRICAL DIAGRAMS
POWER WAVE 455 SWITCH PC BOARD SCHEMATIC - CODE 10553
RECONNECT
B
R34
10.0
R43
10.0
DZ4
6.2V
C1 C2 C3 C4 C5
G1
R42
10.0
C8
1W
G2
G3
G4
G5
.047
A2
DZ5
15V
1W
1600V
D3
1A
1000V
R41
10.0
1.00K
1.00K
1.00K
1.00K
C7
2500
5W
R40
10.0
E1 E2 E3
E4
E5
DZ6
.0047
50V
15V
1W
R39
10.0
13/14 OR 17/18
2500
5W
C1
TRANSFORMER
PRIMARY
C9
.0047
1000V
221K
221K
T1
1
BLEEDER
RESISTORS
3
A2
J9
GATE
4
2500
5W
3
6
A1
19
DRIVE
J9
PWM
5
2
GATE
+15V
C1
6
2500
5W
CAPACITOR
20
FILTER
C10
.0047
1000V
A1
15.0K
D2
A1
2500
5W
A
R26
10.0
R24
11/12 OR 15/16
+15V
332K
R20
TRANSFORMER
PRIMARY
DZ3
10
10.0
6.2V
1W
C1 C2 C3 C4 C5
8
G1
X2
R19
10.0
C1
.047
1600V
2.8K
9
G2
G3
G4
G5
1.50K
6.19K
DZ1
15V
1W
A1
+
1
D1
1A
1000V
1.00K
1.00K
1.00K
C6
1.00K
R18
10.0
X1
8
27
35V
REF
C3
.0047
50V
TL431
-
R17
10.0
6
DZ2
E1 E2 E3
E4
E5
15V
1W
562
16.5K
R16
10.0
RECONNECT
C
+15V
+15V
OVERVOLTAGE
PROTECTION
10K
DZ7
5.1V
1W
5
6
7
X2
J9
1
R3
R5
1.82K
J9
221
1.21K
TO CONTROL BD.
(VOLTAGE PROTECTION)
(Pre-charge Shut-off)
4
R21
5
1
3.32K
221
OCI1
CNY17-3V
1
5
OCI2
CNY17-3V
10K
4
6
2
TO CONTROL BD.
(VOLTAGE PROTECTION)
(Trigger Loop)
2
6
4
C2
.022
50V
J9
2
267K
C4
.022
50V
681K
J9
5
3
2
1
+15V
4
X2
C5
X2
12
LM224
14
X2
11
13
NOTE: 203,206 BOLT ON WITH FILTER CAPS
NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your factory warranty. Individual Printed Circuit Board Components are not available from Lincoln Electric. This information is pro-
vided for reference only. Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician. Improper PC board repairs could result in damage to the
machine.
POWER WAVE 455/POWER FEED 10
Download from Www.Somanuals.com. All Manuals Search And Download.
G-18
G-18
ELECTRICAL DIAGRAMS
POWER FEED 10 MOTHER CONTROL PC BOARD SCHEMATIC
3 1 4 G 2
+5VN
+5V
STD
DISPLAY
512
512
540
+12.8 VDC
ENCODER SUPPLY
+12.8 VDC
+5V
1
J4
J4
J4
J4
3
7
8
MOSI
SCK
D9
D10
D11
B
MOSI
SCK
1
2
+5VN
2
X5
R25
475
J4
A
MOLATCH
LOLATCH
S1LATCH
16
1
9
8
X11
A
Vcc
/YO
/Y1
14
5
1
X5
R26
475
RESET
1
VCC
RESET
+5V
PA4
PA5
X26
Vdd
J4
2
3
4
6
5
7
15
14
13
12
11
+5V
B
2
3
4
5
6
7
13
12
11
10
9
DATA
1
2
D2
X17
RES
LATCH
C23
0.1
50V
500N
C
6
DATA
2
R27
475
CLOCK
1
S-8054HN
J4
/G2A
G1
/Y2
D1
SET
Q1
1
CLOCK
2
C24
ENCODER
1
J4
500D
Vss
C25
/Y3
/Y4
A
SET
2
11
10
B
D12
D13
D14
4
9
R1
X6
/SS
/G2B
/Y7
GND
/Q1
Q2
J4
2.67K
10
/Y5
/Y6
8
B
GND
N.C.
J4
500D
13
12
A
8
9
10
R2
X6
54HC74
500D
500N
+5VN
74AC138
500N
512
2.67K
500N
D3
+5VN
D4
+12.8 VDC
C17
C18
MEMORY/DP
OPTION
D6
556
R3
R28
10K
16
14
2
S0
Vcc
I0a
I1a
ENCODER
2
J4
500N
500N
+5V
D5
D7
1
6
+5V
S1
J1AMISO
J5
C
1
MISO
9
8
17
18
45
7
X9
B
Vss
/RESET
/XIRQ
PE1
MOMISO
7
5
11
X6
Za
X22
MOMISO
LOMISO
S1MISO
MISO
MOSI
SCK
D15
D16
D17
D18
+5V
3
3
2
4
5
6
R29
+5V
MODA
MODB
AS
2.67K
9
4
XTAL
MISO
Zb
I2a
I3a
I0b
I1b
J5
D
J4
5
6
475
A
1
3
12
R4
X6
D
/Ea
/Eb
I3b
GND
3
4
2
X5
R30
475
EXTAL
XTAL
MISO
MOSI
SCK
/SS
2.67K
15
13
10
11
12
J5
8
E
C
C19
5
6
C20
D8
5
22
23
24
25
31
19
35
38
39
36
9
X5
R31
475
R//W
PE7
PE2
PE3
PE4
PE5
PE6
PA1
8
500D
I2b
J5
1
20
19
18
17
16
15
14
13
12
11
OSC1
OSC2
PB5
PB4
PB3
PB2
PB1
/RESET
/IRQ
PA0
PA1
50
+5V
MOSI
74AC153
MOLATCH
LATCH
2
3
4
5
6
7
8
6
47
49
44
46
48
33
34
32
30
29
52
51
R32
475
PE2
SCK
500N
+5V
J5
BURNBACK
TRIMMER
500N
PE3
/SS
4
X10
PE4
PA3
/IRQ
A15
PA3
J5
CW
D19
D20
D21
D22
PA2
PA3
PA4
PA5
PA6
PA7
PE4
C21
0.1
50V
J1AMISO
SCK
A15
/IRQ
500N
500N
A12
PB0
Vdd
500D
MOSI
PA0
PA2
PA4
PA5
VRH
VRL
PE0
PA6
PD1
PD0
PA7
A13
A11
9
500D
A14
A14
10
+5V
1.82K
Vss
24
7
+5V
PA6
PA4
PA5
AD0
AD1
AD2
AD3
AD4
AD5
AD6
AD7
A8
A/D0
X7
Vcc
AS
PROC.
PROC.
A
B
MC68HC705J1
7
R33
C44
1.0
10
11
8
22
18
R14
A/D1
A/D2
A/D3
A/D4
A/D5
A/D6
A/D7
A8
J5
DIP SWITCH
1
PE0
1.00K
9
35V
E
8
R34
3.32K
R35
J5
12
13
14
15
16
42
41
40
10
11
13
14
15
21
23
X6
C22
SCK
4.75K
R/W
N/C
N/C
N/C
CE
4
3
4.32K
F
9
43
28
21
1
PE0
PA6
PD1
J5
C26
0.1
50V
3
X6
S1LATCH
500D
500D
2
1
10
E
4
J5
20
27
16
2
PA7
PD0
PA7
A13
X8
DATA
NC
A12
A11
500N
DECODE INFO
500N
DS2501
GND
37
26
20
19
5
A9
A9
+5VN
512
17
A15
A14
A13
Vdd
A10
A10
/WC
SEL
+12.8 VDC
LOWER
OPTION
16
MC68HC11E1
12
1
6
SS/PL
CLK1
E
Vcc
GND
HIGH
1
1
1
1
1
0
X68C64
2
3
4
5
6
7
15
R60
CLK2
500D
LOW
CAN
500D
1
14
13
12
11
10K
D
C
X13
J3
16
15
14
13
12
11
10
9
F
0
1
0
LOMISO
X5
MISO
MOSI
D23
D24
D25
D26
3
R61
475
B
G
-1
-2
-3
-4
-5
-6
-7
-8
S1
S1
S1
S1
S1
S1
S1
S1
J3
H
A
F
11
10
16
2
1
2
3
4
5
6
7
8
10
1
R62
475
/QH
GND
SA
A13
A
Vcc
1
X16
24
4
7
+5V
Vcc
AD0
AD1
AD2
AD3
AD4
AD5
AD6
AD7
P1.0
P1.1
A/D0
A/D1
A/D2
A/D3
A/D4
A/D5
A/D6
A/D7
A8
Vcc
AS
J3
X12
8
9
2
3
11
6
4
5
15
14
7
QH
A14
A15
B
/YO
/Y1
13
3
8
22
18
S1MISO
X23
E
P2.4
SCK
13
12
74HC165
5
X5
R63
475
C
5
6
7
2
9
AS
E
J3
500D
11
9
10
/Y4
G1
/Y7
LOLATCH
43
42
41
40
39
38
37
36
35
34
33
32
31
17
16
15
22
10
11
13
14
15
21
23
X24
E
R/W
N/C
N/C
N/C
CE
LATCH
6
12
13
10
R64
475
500D
/Y3
/Y2
1
R/W
J3
/G2A
/G2B
GND
27
3
CLK OUT
/RESET
/INT
4
XTAL
/IRQ
+5V
/Y5
/Y6
J3
29
24
4
D27
D28
D29
D30
PA3
8
9
8
C47
22p
100V
16
2
X24
DIP SWITCH
2
500D
74AC138
500N
8
/CS
A12
A11
500N
130
8.0MHz
28
9
20
19
5
Y1
READY
/DSACKO
XTAL1
XTAL2
TX1
A9
512
+5V
17
C48
22p
100V
P1.2
P1.3
P1.4
P1.5
P1.6
P1.7
P2.0
P2.1
P2.2
RX0
TX0
Vss1
A10
/WC
SEL
ISO +5
+12.8 VDC
12
PE2
18
19
25
10
11
6
500D
GND
R65
3.32K
X68C64
500D
POT SUPPLY
POT WIPER
MODE
7
R67
C31
+5V
P2.7
J3
0.1
16.5K
50V
P2.6
8
4.75K
J3
21
14
RX1
16
500N
1
1
SS/PL
CLK1
E
Vcc
500N
9
R68
P2.3
J3
2
3
4
5
6
7
15
CLK2
D
30
20
1.82K
OCI1
MODE1
Vss2
MODE
3
6
5
7
8
R95
2
3
10
14
13
12
11
R69
R70
X14
PE3
J3
1
2
3
4
5
6
7
8
4.75K
3.32K
4.32K
C29
0.1
50V
C
F
POT COMMON
500N
44
12
26
23
MODE0
P2.5
Q1
2N4403
11
C32
0.1
50V
B
G
J3
-1
-2
-3
-4
-5
-6
-7
-8
S2
S2
S2
S2
S2
S2
S2
S2
NC
NC
1
H
A
AN82527
12
4
J3
16
15
14
13
12
11
10
9
10
/QH
GND
SA
QH
8
9
500D
74HC165
ISO COM
500D
500N
500D
+5V
DATA BUS
500N
ISO +5
500D
1
BUS
BUS
BUS
BUS
L
J1
DZ2
6.2V
1W
13
5
12
X24
X24
X24
540
+40 VDC
1
ISO +5
+5V
SWITCHING
POWER SUPPLY
L
J2
485
8
1
POWER BUS
RO
DE
DI
VCC
A
ISO +5
6
4
D36
6
7
5
3
4
2
ISO COM
J1
J1
DZ3
6.2V
1W
2
2
4
OCI2
B
H
H
D33
8
7
6
5
2
3
8
16
9
VCC
D37
1N5402
/RE
GND
1N4936
J2
3
C30
0.1
50V
4
X1
X20
X1
R76
10.0
R77
10.0
X10
C12
0.1
50V
C10
0.1
50V
IN
OUT
C1
X12
J2
0.1
C33
.022
200V
2
NC
NC
4
9
C34
Q2
2N4403
50V
74AC138
MC68HC705J1
10
ISO COM
1
4.7
GND
C35
485
GND
T1
B
512
512
1
2
35V
18
T1
A
X24
10
5
8
+12.8 VDC
+12.8 VDC
15V
500D
ISO COM
4
GREEN
DIAGNOSTIC
LED
RED
DIAGNOSTIC
LED
ISO COM
500D
500D
D32
1N4936
ISO COM
+5V
512
+12.8 VDC
BLACK
WHITE
D31
13
14
1N4936
J4
J4
Q5
+5V
+5VN
Q4
D35
14
14
24
26
14
16
16
16
16
24
Vcc
1
14
PD0
R86
3.32K
PD1
R88
3.32K
Vdd
Vcc
2N4401
2N4401
D
S
Vcc
X7
Q3
X5
X6
X11
C9
X9
18A
C50
C49
0.1
C51
0.1
C52
0.1
50V
G
X23
7
8
4
5
6
C5
0.1
C6
0.1
50V
C7
0.1
C11
C13
0.1
C14
0.1
50V
C16
VCC
OUT
VFB
X16
X26
X22
X13
X14
X24
R84
26.7
200V
0.1
500D
HEXINV
HEXINV
0.1
0.1
0.1
500D
2
50V
50V
50V
VREF
RT/CT
GND
D34
X68C64
Vss
X68C64
Vss
74AC04
50V
50V
50V
50V
50V
50V
MC68HC11E1
54HC74
7
74AC138
8
74AC153
8
74HC165
8
74HC165
8
AN82527
23 20
Vss2
1
COMP
CS
X19
GND
IN
OUT
Vss
1
Vss1
DZ1
16V
1W
3
4A
200V
7
7
12
12
7
C36
33
100V
C43
18
15V
C37
X18
C40
2700p
50V
20
50V
C
6
7
GENERAL INFORMATION
ELECTRICAL SYMBOLS PER E1537
CAPACITORS
RESISTORS
DIODES
LAST NO. USED
T1
R- 96
C- 52
D- 37
C38
0.1
50V
500D
=
MFD
(
.022/50V
1/4W
UNLESS OTHERWISE SPECIFIED)
UNLESS OTHERWISE SPECIFIED)
S1
S2
R81
332
NOTES
:
LABELS
SUPPLY
=
Ohms
(
C42
3300
50V
=
1A, 400V
(UNLESS OTHERWISE SPECIFIED)
MOLEX CONNECTORS
N.A. SINCE COMPONENTS OR CIRCUITRY ON
A
PRINTED CIRCUIT BOARD MAY CHANGE
VOLTAGE NET
1
2
3
4
5
6
7
8
1
2
3
4
5
6
7
8
C41
2700p
50V
WITHOUT AFFECTING THE INTERCHANGEABILITY OF COMPLETE BOARD, THIS DIAGRAM MAY
A
C39
2700p
50V
.5
POWER SUPPLY SOURCE POINT
COMMON CONNECTION
1
NOT SHOW THE EXACT COMPONENTS OR CIRCUITRY OF CONTROLS HAVING
NUMBER.
A
COMMON CODE
5
1
2
5W
J1,J2
J5
J1
3
3
FRAME CONNECTION
THIS SHEET CONTAINS PROPRIETARY INFORMATION OWNED BY
THE LINCOLN ELECTRIC CO.
EARTH GROUND CONNECTION
J2
FILENAME: G3142_1BA
3
4
AND IS NOT TO BE REPRODUCED, DISCLOSED OR USED WITHOUT THE EXPRESS PERMISSION OF
THE LINCOLN ELECTRIC CO.
6
10
EQUIP.
TYPE
Ch'ge.Sht.No.
SWG USER INTERFACE
MOTHER BD. SCHEMATIC
1
7
1
UNLESS OTHERWISE SPECIFIED TOLERANCE
ON HOLES SIZES PER E-2056
6
THE LINCOLN ELECTRIC CO.
CLEVELAND, OHIO U.S.A.
J4
J5
XB
ON
ON
2
3
PLACE DECIMALS IS
PLACE DECIMALS IS
+
+
.O2
.OO2
SUBJECT
10-17-97A
NONE
SCALE
ON ALL ANGLES IS
+
.5 OF
A
DEGREE
500P
500D
500N
SHT.
MATERIAL TOLERANCE ("t") TO AGREE
WITH PUBLISHED STANDARDS
BS
8
G 3142
7
12
TF
2/15/96
CHK.
SUP'S'D'G.
DR.
DATE
NO.
14
NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your factory warranty. Individual Printed Circuit Board Components are not available from Lincoln Electric. This information is pro-
vided for reference only. Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician. Improper PC board repairs could result in damage to the
machine.
POWER WAVE 455/POWER FEED 10
Download from Www.Somanuals.com. All Manuals Search And Download.
G-19
G-19
ELECTRICAL DIAGRAMS
POWER FEED 10 CONTROL PC BOARD SCHEMATIC
3 1 4 G 4
540
4
505
505
512
512
J3
540
505
505
MOTOR
CIRCUITRY
D2
D
S
TRIGGER
1N4936
M
D1
Q3
70A
60V
D16
G
1N4936
DIP1
S1 -H
S1 -E
J5
9
8
5
Vdd
7
2
3
4
5
1
11
R4
AHI
BHB
BHO
AHS
AHO
Vdd
6
7
R79
825
C16
X6
X20
RES
3.32K
16
11
10
X7
TR
C7
.33
200V
ON
A
BHI
BLI
1
R37
C46
1
0.1
J5
S-8054HN
3
4
15.0
X9
OFF
J3
100
12
C1
50V
C8
MO
C17
A
D17
Vss
R39
C9
0.1
ALI
12
50V
12
R80
DEL
Vss
AHB
DIS
D
S
6
D3
1N4936
1.30K
15
14
13
C2
BHS
BLO
ALO
Q4
500
G
70A
60V
9
8
3W
0.05
R6
D4
4A
200V
R41
150
500
C18
1.0
35V
1.00K
3W
500
HIP4082IP
0.05
500
uCOMPUTER
505
512
505
DUAL PROC.
B
500
500
505
J5
J5
1
17
18
45
7
Vss
/RESET
/XIRQ
PE1
1
D18
D19
R7
2.21K
505
3
MODA
MODB
AS
505
2
2
R8
3.32K
DIP2
R48
4
5
4
S1 -D
S1 -A
EXTAL
XTAL
PA6
PE0
PD2
PA2
PA3
/IRQ
A15
13
16
4
5.62K
X7
DP
C3
B
2
5
8
E
R82
825
MO
_
6
28
43
22
32
31
19
35
38
39
36
9
R/W
X3
C47
DIP3
DIP2
CU
A
505
50
47
49
44
46
48
33
34
30
29
27
52
51
25
24
23
20
21
PE7
PE2
PE3
PE4
PE5
PE6
PA1
1
8
PD2
NULL
INPUT
INPUT
NULL
DIP1
A1FN
8
500
7
1
2
3
TA
V
CC
X7
C
14
R83
X5
6
5
GS
OUT
NC
R49
CI
D22
1.30K
9
4
V
EE
1.00K
OP27
GP
505
CU
500
ST
512
505
SHUT DOWN
D6
C20
A12
TR
505
330p
50V
DP
PA0
PA4
PA5
PA7
VRH
VRL
PD5
PD4
PD3
PD0
PD1
A13
A11
C21
1.0
D23
500
J5
J5
C19
PA4
7
9
C22
A14
35V
R84
2.21K
D20
D21
24
7
AD0
AD1
A/D0
A/D1
A/D2
A/D3
A/D4
A/D5
A/D6
A/D7
A8
Vcc
AS
X1
10
11
8
22
18
ID
R85
10
11
9
AD2
AD3
AD4
AD5
AD6
AD7
A8
E
_
3.32K
X7
SD
B
500
13
12
13
14
15
16
42
41
40
10
11
13
14
15
21
23
R/W
512
512
C12
DIP3
C50
SD
1
1.0
S1
N/C
N/C
N/C
CE
-C
14
15
505
3
2
35V
3
DL2
TACH
CIRCUITRY
R90
500
4
DL1
825
1
C51
J4
16
2
C23
0.1
50V
500
PD0
RED
D25
S1 -B
A12
A11
505
15.0K
R55
ISO +5
37
26
20
19
5
R91
A9
A9
TACH.
TA
X9
2
6
5
C
J4
J4
1.30K
17
Vdd
A10
A10
/WC
SEL
BLUE
MC68HC11
COLD INCH
ON
12
6
GND
D24
500
3
C24
X68C64
500
47p
J5
BLACK
500
4
5
R10
CI
100V
505
3.32K
500
OFF
500
DATA BUS
1
4
C4
C5
C6
Vcc
P2.4
AS
AD0
AD1
AD2
AD3
AD4
AD5
AD6
AD7
/INT
/CS
P1.2
P1.3
P1.4
P1.5
P1.6
P1.7
P2.0
P2.1
P2.2
RX0
TX0
Vss1
13
3
X21
OCI1
6
7
8
2
3
1
J5
BUS
BUS
BUS
L
L
L
DECODE INFO
5
6
7
2
1.00K
J2
485
DZ1
6.2V
1W
1
8
6
C14
ON
RO
DE
DI
VCC
A
2
43
42
41
40
39
24
8
E
A15
A14
A13
Q1
2N4403
0.1
3
4
2
J1
50V
GAS PURGE
R/W
R27
PD0
3
NC
NC
7
5
500
B
27
CLK OUT
/RESET
P1.0
1
X
1
X
MEM
CAN
3.74K
5
4
1
J1
PD2
C11
/RE
GND
29
38
X8
R12
GP
ISO COM
C52
S1 -G
0
0
2
ISO COM
BUS
H
10
3.32K
7
22p
500
37
J2
P1.1
100V
DZ2
ISO COM
28
9
130
8.0MHz
READY
/DSACKO
XTAL1
XTAL2
TX1
6.2V
1W
4
5
Y1
505
BUS
BUS
H
H
ISO +5
512
36
35
34
33
32
31
17
16
15
22
J1
J1
500
512
C53
22p
100V
16
18
19
25
10
11
3
2
1
C
Vcc
/YO
/Y1
500
505
X2
15
14
7
B
J5
J5
A
505
3
6
4
STEP
ON
505
DIAGNOSTIC
LED #1
11
6
4
5
500
P2.7
/Y4
G1
/Y7
540
12
13
10
4.75K
P2.6
/Y3
/Y2
GAS
SOLENOID
8
21
14
R14
ST
RX1
/G2A
/G2B
GND
J5
Q5
OCI2
3.32K
8
7
6
5
2
3
4.75K
P2.3
/Y5
/Y6
3
6
8
J3
J3
30
20
9
MODE1
Vss2
R94
4.75K
DL1
R59
C15
2N4401
500
74AC138
0.1
3.32K
D8
50V
GAS
SOLENOID
DRIVER
44
12
26
23
ID
MODE0
P2.5
X10
NC
NC
Q2
2N4403
1
4
DATA
NC
OFF
500
AN82527
DS2501
GND
OUT
500
ISO COM
512
500
500
X11
GS
500
IN
SWITCH
GND
DIAGNOSTIC
LED #2
POWER BUS
10
540
SWITCHING
POWER SUPPLY
500
J5
+40 VDC
D11
512
Q6
J1
DL2
R61
2N4401
1N4936
D10
CIRCUIT
FEED
3.32K
10
VOLTAGE
SENSE
T1
ISO +5
1
9
8
11
10
13
12
1
2
X9
F
X9
X9
D
X9
A
X22
E
J6
J6
IN
OUT
5
10
C26
500
ISOLATED
LEAD
20t
C28
16t
9
C27
4.7
GND
18
1
500
500
500
500
J2
J1
J1
J1
35V
15V
505
512
2
CONTROL
4
+40V
+40V
+40V
+40V
D9
1N4936
ISO +5
Q10
2N4401
512
ISO COM
1
PA4
R96
3.32K
+12.8 VDC
D12
7
12
3
1N4936
1
14
24
16
26
8
Vcc
Vdd
VCC
6
7
100K
Vcc
X1
X9
C40
C48
0.1
50V
C42
0.1
50V
C43
0.1
50V
C44
C45
X21
X3
X6
X7
X5
C49
0.1
C38
0.1
50V
C39
0.1
50V
0.1
X2
D14
0.1
0.1
D
S
X8
7
6
HEXINV
50V
VCC
OUT
R67
26.7
50V
50V
Q9
X68C64
Vss
OP27
4
HIP4082IP
LM2901
12
50V
AN82527
23 20
74AC138
8
MC68HC11
8
4
5
2
18A
VREF
VFB
G
485
C29
2200
63V
D13
200V
1
6
RT/CT
GND
COMP
Vss1
Vss2
Vss
GND
1N4936
7
12
1
5
505
500
3
CS
X24
IN
OUT
X23
DZ3
16V
1W
+5 VDC
C33
2700p
50V
C35
4.7
35V
T1
ISO COM
GND
8
C31
0.1
50V
-10VDC
1
C36
500
500
NOTES
:
18
25t
15V
N.A. SINCE COMPONENTS OR CIRCUITRY ON
A
PRINTED CIRCUIT BOARD MAY CHANGE
WITHOUT AFFECTING THE INTERCHANGEABILITY OF COMPLETE BOARD, THIS DIAGRAM MAY
NOT SHOW THE EXACT COMPONENTS OR CIRCUITRY OF CONTROLS HAVING
NUMBER.
C30
A
R73
332
1
7
6
6
4.7
1
2
3
1
A
1
COMMON CODE
5
1
2
35V
GENERAL INFORMATION
LAST NO. USED
S-
1
J3
J4
J5
J2
J1
20t
C37
1.8
20V
N.B. A, B, C, POSITIONS ARE FOR THE SETTING OF THE GROUP ID.
R- 97
C- 53
D- 25
X- 24
Q- 10
T-
Y-
1
1
C32
.0047
50V
ELECTRICAL SYMBOLS PER E1537
500
S1
1.0
THE
H
POSITION IS FOR SELECTING BETWEEN HIGH
&
LOW SPEED.
LOW MOTOR SPEED.)
(SEE THE OPERATING NAMUAL FOR ADDITIONAL INFORMATION.)
C34
2700p
50V
CAPACITORS
RESISTORS
DIODES
=
MFD
(
.022/50V
1/4W
UNLESS OTHERWISE SPECIFIED)
UNLESS OTHERWISE SPECIFIED)
(SWITCHES ARE SHOWN WITH GROUP ID
=
0
&
1W
DZ-
3
OCI-
2
7
12
3
4
LABELS
SUPPLY
=
Ohms
(
4
6
2
3
4
5
6
7
8
6
3
4
10
=
1A, 400V
(UNLESS OTHERWISE SPECIFIED)
-10VDC
VOLTAGE NET
=
SWITCH NOT USED
MOLEX CONNECTORS
POWER SUPPLY SOURCE POINT
COMMON CONNECTION
D15
1N4936
J2
3
GND
FRAME CONNECTION
J1
J1
EARTH GROUND CONNECTION
FILENAME: G3144_1BA
500
8
9
GND
GND
EQUIP.
TYPE
Ch'ge.Sht.No.
WIRE FEEDER
UNLESS OTHERWISE SPECIFIED TOLERANCE
ON HOLES SIZES PER E-2056
THE LINCOLN ELECTRIC CO.
CLEVELAND, OHIO U.S.A.
XB
ON
ON
2
3
PLACE DECIMALS IS
PLACE DECIMALS IS
+
+
.O2
.OO2
CONTROL P.C. BOARD SCHEMATIC
SUBJECT
10-17-97A
NONE
1-8-96
SCALE
DATE
ON ALL ANGLES IS
+
.5 OF
A
DEGREE
SHT.
BS
MATERIAL TOLERANCE ("t") TO AGREE
WITH PUBLISHED STANDARDS
G 3144
TF
CHK.
SUP'S'D'G.
DR.
NO.
NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your factory warranty. Individual Printed Circuit Board Components are not available from Lincoln Electric. This information is pro-
vided for reference only. Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician. Improper PC board repairs could result in damage to the
machine.
POWER WAVE 455/POWER FEED 10
Download from Www.Somanuals.com. All Manuals Search And Download.
G-20
G-20
ELECTRICAL DIAGRAMS
POWER FEED 10 DISPLAY PC BOARD SCHEMATIC
16
7
6
5
4
2
a
BANK4
BANK3
Vdd
X3
2
8
4
7
3
8
15
3
b
c
3
8
3
8
1
1
1
1
C
B
2
4
5
6
7
9
2
4
5
6
7
9
2
4
5
6
7
9
13
9
3
5
6
9
BANK2
BANK1
d
WFS
LED1
AMPS
LED2
e
h
DP
A
17
12
11
19
14
BANK5
DATA IN
CLOCK
/ENABLE
DATA OUT
DISP3
DISP2
DISP1
Vss
D
10
DISP4
10
10
20
1
g
10
18
f
8
Rx
MC14489
500
J1
LATCH
13
12
1
2
4
R10
475
X5
X5
1
C9
.0047
50V
2
500
J1
SCK
11
10
5
R9
X5
475
1
C8
.0047
50V
2
16
7
6
5
4
2
a
BANK4
BANK3
Vdd
X4
2
8
4
7
3
8
15
3
b
c
3
8
3
8
1
1
1
1
C
B
2
4
5
6
7
9
500
2
4
5
6
7
9
2
4
5
6
7
9
13
9
3
5
6
9
J1
BANK2
BANK1
BANK5
VOLTS
LED3
TRIM
LED4
d
MOSI
9
8
6
R8
X5
e
h
DP
A
475
17
12
10
11
19
14
1
C7
.0047
50V
DISP7
DISP6
DISP5
DATA IN
/ENABLE
CLOCK
Vss
D
10
DISP8
2
10
10
20
1
g
500
f
18
8
DATA OUT
Rx
MC14489
500
+5VA
D1
3
Vdd
14
X5
J1
X1
X4
7
5
3
6
4
R1
R2
R13
C3
0.1
50V
C4
0.1
50V
512
X5
X5
IN
OUT
7805
10.0
10.0
10.0
HEXINV
MC14489
C1
GND
C2
18
15V
4.7
Vss
14
35V
7
J1
500
8
500
+5VB
500
D2
3
Vdd
X2
7805
X3
R3
R4
R14
C10
0.1
50V
IN
OUT
10.0
10.0
10.0
MC14489
C5
GND
C6
18
15V
4.7
Vss
14
35V
500
NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your factory warranty. Individual Printed Circuit Board Components are not available from Lincoln Electric. This information is pro-
vided for reference only. Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician. Improper PC board repairs could result in damage to the
machine.
POWER WAVE 455/POWER FEED 10
Download from Www.Somanuals.com. All Manuals Search And Download.
G-21
G-21
ELECTRICAL DIAGRAMS
POWER FEED 10 ENCODER PC BOARD SCHEMATIC
2 2 9 2 0
S
+5VDC
D9
J1
J1
7
2
X1
R5
R6
IN
OUT
10.0
10.0
GND
C2
18
C1
D1
D2
D4
4.7
1
35V
15V
475
R2
+
X
J1
J1
4
2
3
5
6
A1
Y
-
R1
475
D3
OPTICAL
ROTARY
ENCODER
L1
J1
J1
1
.33mH
8
+5VDC
D5
D7
D6
D8
1
475
R4
+
X
J1
J1
4
2
3
3
4
A2
Y
-
R3
475
OPTICAL
ROTARY
ENCODER
THIS SHEET CONTAINS PROPRIETARY INFORMATION OWNED BY
NOTES :
THE LINCOLN ELECTRIC CO.
AND IS NOT TO BE REPRODUCED, DISCLOSED OR USED WITHOUT THE EXPRESS PERMISSION OF
LABELS
THE LINCOLN ELECTRIC CO.
FILENAME: S22920_2BB
GENERAL INFORMATION
N.A.
SINCE COMPONENTS OR CIRCUITRY ON
CIRCUIT BOARD MAY CHANGE
A PRINTED
ELECTRICAL SYMBOLS PER E1537
FRAME CONNECTION
WITHOUT AFFECTING
SUPPLY
VOLTAGE NET
MFD
CAPACITORS =
(
.022/50V
1/4W UNLESS OTHERWISE SPECIFIED)
(UNLESS OTHERWISE SPECIFIED)
UNLESS OTHERWISE SPECIFIED)
THE INTERCHANGEABILITY
OF A COMPLETE
SHOW THE EXACT COMPONENTS
CONTROLS HAVING A COMMON CODE NUMBER.
BOARD.
POWER SUPPLY SOURCE POINT
COMMON CONNECTION
RESISTORS = Ohms (
THIS DIAGRAM MAY NOT
EARTH GROUND CONNECTION
OR CIRCUITRY OF
DIODES =
1A, 400V
EQUIP.
TYPE
Ch'ge.Sht.No.
UNLESS OTHERWISE SPECIFIED TOLERANCE
ON HOLES SIZES PER E-2056
ON 2 PLACE DECIMALS IS + .O2
ON 3 PLACE DECIMALS IS + .OO2
ON ALL ANGLES IS + .5 OF A DEGREE
MATERIAL TOLERANCE ("t") TO AGREE
WITH PUBLISHED STANDARDS
USER INTERFACE
THE LINCOLN ELECTRIC CO.
CLEVELAND, OHIO U.S.A.
NONE
XA
DUAL ENCDR PCB SCHEM.
SUBJECT
10-17-97
3-27-98D
SCALE
3-11-96
SHT.
22920
JRF
DR.
DATE
CHK.
SUP'S'D'G.
NO.
S
NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your factory warranty. Individual Printed Circuit Board Components are not available from Lincoln Electric. This information is pro-
vided for reference only. Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician. Improper PC board repairs could result in damage to the
machine.
POWER WAVE 455/POWER FEED 10
Download from Www.Somanuals.com. All Manuals Search And Download.
G-22
G-22
ELECTRICAL DIAGRAMS
POWER FEED 10 VOLTAGE SENSE PC BOARD SCHEMATIC
2 3 9 1 8
S
TP1
J1
5
FRAME
320V
160J
TP2
TO HEAD P.C.B.
320V
160J
J1
1
R1
475
L1
R3
J1
3
BRASS BLOCK
.33mH
2
6
OCI1
+
t
D1
56
S
4
J2
5
1
J1
4
#67 LEAD NETWORK
1
R2
J2
475
2
J1
6
2
6
OCI2
S
4
5
J1
2
1
THIS SHEET CONTAINS PROPRIETARY INFORMATION OWNED BY
NOTES :
THE LINCOLN ELECTRIC CO.
GENERAL INFORMATION
AND IS NOT TO BE REPRODUCED, DISCLOSED OR USED WITHOUT THE EXPRESS PERMISSION OF
LABELS
THE LINCOLN ELECTRIC CO.
FILENAME: S23918_3CA
N.A.
SINCE COMPONENTS OR CIRCUITRY ON
CIRCUIT BOARD MAY CHANGE
A PRINTED
ELECTRICAL SYMBOLS PER E1537
FRAME CONNECTION
WITHOUT AFFECTING
SUPPLY
VOLTAGE NET
MFD
CAPACITORS =
(
.022/50V
1/4W UNLESS OTHERWISE SPECIFIED)
(UNLESS OTHERWISE SPECIFIED)
UNLESS OTHERWISE SPECIFIED)
THE INTERCHANGEABILITY
OF A COMPLETE
SHOW THE EXACT COMPONENTS
CONTROLS HAVING A COMMON CODE NUMBER.
BOARD.
POWER SUPPLY SOURCE POINT
COMMON CONNECTION
RESISTORS = Ohms (
THIS DIAGRAM MAY NOT
EARTH GROUND CONNECTION
OR CIRCUITRY OF
DIODES =
1A, 400V
EQUIP.
Ch'ge.Sht.No.
UNLESS OTHERWISE SPECIFIED TOLERANCE
ON HOLES SIZES PER E-2056
ON 2 PLACE DECIMALS IS + .O2
ON 3 PLACE DECIMALS IS + .OO2
ON ALL ANGLES IS + .5 OF A DEGREE
MATERIAL TOLERANCE ("t") TO AGREE
WITH PUBLISHED STANDARDS
SWG VOLTAGE SENSE SELECT
SCHEMATIC
THE LINCOLN ELECTRIC CO.
CLEVELAND, OHIO U.S.A.
NONE
6/9/98
TYPE
XA
10-17-97
10-9-98D
SUBJECT
SCALE
DATE
SHT.
MAB
DR.
CHK.
SUP'S'D'G.
NO.
S
23918
NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your factory warranty. Individual Printed Circuit Board Components are not available from Lincoln Electric. This information is pro-
vided for reference only. Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician. Improper PC board repairs could result in damage to the
machine.
POWER WAVE 455/POWER FEED 10
Download from Www.Somanuals.com. All Manuals Search And Download.
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