Lincoln Electric SVM112-B Manual do Utilizador

SERVICE MANUAL• World's Leader in Welding and Cutting Products •• Sales and Service through Subsidiaries and Distributors Worldwide •Cleveland, O

Failure to follow these instructions can cause immedi-ate failure of components within the welder.GROUND CONNECTIONSThe frame of the welder must be gr

F-40 F-40AUXILIARY TRANSFORMER #1 SECONDARY AND WIRING HARNESS TEST (continued)FIGURE F.11 - PLUG AND RECEPTACLE INSPECTION POINTS234561TROUBLESHOOTIN

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INPUT POWER AND WIRING HARNESS TESTService and repair should be performed by only Lincoln Electric factory trained personnel.Unauthorized repairs perf

F-44 F-44INPUT POWER AND WIRING HARNESS TESTFIGURE F.13 - INPUT POWER INSPECTION POINTS123TROUBLESHOOTING & REPAIRTEST PROCEDURE1. Remove main in

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INPUT RECTIFIER RESISTANCE TESTService and repair should be performed by only Lincoln Electric factory trained personnel.Unauthorized repairs performe

F-48 F-48INPUT RECTIFIER RESISTANCE TEST (continued)FIGURE F.15 - RECONNECT SWITCH LOCATION123TROUBLESHOOTING & REPAIRTEST PROCEDURE1. Remove mai

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F-50 F-50NOTESPOWER WAVE 450Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to Mast

OUTPUT SHUNT/WELDING FEEDBACK TESTService and repair should be performed by only Lincoln Electric factory trained personnel.Unauthorized repairs perfo

TEST PROCEDURE1. Remove main input supply power to thePower Wave 450. 2. Disconnect the Output leads from themachine. 3. If a wire feeder is conn

F-53 F-53OUTPUT SHUNT/WELDING FEEDBACK TEST (continued)FIGURE F.16 - SHUNT AMPLIFIER BOARD LOCATION1TROUBLESHOOTING & REPAIRTEST PROCEDURE1. Remo

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PIEZO-ELECTRIC ALARM BUZZER TESTService and repair should be performed by only Lincoln Electric factory trained personnel.Unauthorized repairs perform

F-56 F-56PIEZO-ELECTRIC ALARM BUZZER TESTFIGURE F.17 - ALARM BUZZER LOCATION12TROUBLESHOOTING & REPAIRTEST PROCEDURE1. Remove main input supply p

OUTPUT RECTIFIER DIODES TESTService and repair should be performed by only Lincoln Electric factory trained personnel.Unauthorized repairs performed o

F-58 F-58OUTPUT RECTIFIER DIODES TESTFIGURE F.18 - SNUBBER BOARD, OUTPUT TERMINAL LOCATION3412TROUBLESHOOTING & REPAIRTEST PROCEDURE1. Remove mai

FIELD EFFECT TRANSISTOR/SWITCH BOARD TESTORIGBT/SWITCH BOARD TESTService and repair should be performed by only Lincoln Electric factory trained perso

NOTESPOWER WAVE 450Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to Master TOC Re

F-60 F-60FIELD EFFECT TRANSISTOR/SWITCH BOARD TESTFIGURE F.19 – F.E.T. SWITCH BOARD LOCATION1TROUBLESHOOTING & REPAIRTEST PROCEDURE1. Remove main

F-61 F-61FIELD EFFECT TRANSISTOR/SWITCH BOARD TEST (continued)FIGURE F.20 - RESISTOR LOCATIONSTROUBLESHOOTING & REPAIR7. Locate the two sets of t

F-62 F-62FIELD EFFECT TRANSISTOR/SWITCH BOARD TEST (continued)DISCHARGEDISCHARGEDISCHARGEDISCHARGEDISCHARGETROUBLESHOOTING & REPAIR9. Using insul

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Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOCTABLE OF CONTENTS- OPERATION SECTION -Operation...

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F-73 F-73IGBT/SWITCH BOARD TEST (G3165-1)TABLE F.6 – NOTE: This test will NOT determine if an individual IGBT device is open.TROUBLESHOOTING & REP

F-74 F-74IGBT/SWITCH BOARD TEST (Continued)TABLE F.6 (Continued)TROUBLESHOOTING & REPAIRPOWER WAVE 450Return to Section TOC Return to Section TOC

SNUBBER AND BLEEDER RESISTOR TESTService and repair should be performed by only Lincoln Electric factory trained personnel.Unauthorized repairs perfor

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F-79 F-79FIGURE F.25 – SNUBBER AND BLEEDER RESISTOR WIRING DIAGRAM( )( )SWITCHBOARD#340512C4069CC3(405)(12G)(12C)(406)(9G)(9C)R5( )25Ω25W(

OPERATIONB-2 B-2POWER WAVE 450Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to Ma

F-80 F-80NOTESPOWER WAVE 450Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to Mast

RECONNECT SWITCH TEST 1Service and repair should be performed by only Lincoln Electric factory trained personnel.Unauthorized repairs performed on thi

F-82 F-82RECONNECT SWITCH TEST 1FIGURE F.26 - RECONNECT SWITCH123TROUBLESHOOTING & REPAIRTEST PROCEDURE1. Remove main input supply power to thema

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F-84 F-84FIGURE F.27 – INPUT AND RECONNECT WIRING DIAGRAM6R9UVWGL1L2L3CR1T1T2T3(326) (324)AC1AC2AC3-+POSNEG12A9AC1 C2 C3 C4SWITCHBOARD #1SWITCHBOARD #

RECONNECT SWITCH TEST 2Service and repair should be performed by only Lincoln Electric factory trained personnel.Unauthorized repairs performed on thi

F-86 F-86RECONNECT SWITCH TEST 2 (continued)FIGURE F.28 - RECONNECT SWITCH123TROUBLESHOOTING & REPAIRTEST PROCEDURE1. Remove main input supply po

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F-88 F-88FIGURE F.29 – INPUT AND RECONNECT WIRING DIAGRAM6R9UVWGL1L2L3CR1T1T2T3(326) (324)AC1AC2AC3-+POSNEG12A9AC1 C2 C3 C4SWITCHBOARD #1SWITCHBOARD #

STATIC CAPACITOR BALANCE TESTService and repair should be performed by only Lincoln Electric factory trained personnel.Unauthorized repairs performed

QUICK START REFERENCE FORUSING THE PROCESS SELECTIONOVERLAYRead and understand the “Controls and Settings” and“Operating Overlays” sections of this ma

F-90 F-90STATIC CAPACITOR BALANCE TEST (continued)FIGURE F.30 - BLEEDER RESISTORS R9 AND R10 LOCATION1TROUBLESHOOTING & REPAIRTEST PROCEDURE1. Re

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F-92 F-92Figure F.31 – SNUBBER AND BLEEDER RESISTOR WIRING DIAGRAM( )( )SWITCHBOARD#340512C4069CC3(405)(12G)(12C)(406)(9G)(9C)R5( )25Ω25W(

DYNAMIC CAPACITOR BALANCE TESTService and repair should be performed by only Lincoln Electric factory trained personnel.Unauthorized repairs performed

F-94 F-94DYNAMIC CAPACITOR BALANCE TEST (continued)FIGURE F.32- CONTROL BOARD PLUG LOCATIONSPROTECTION BDGROUND PLANECONTROL BDJ20 J21 J22 J23 J24 J25

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F-96 F-96FIGURE F.33 – INPUT AND RECONNECT WIRING DIAGRAM6R9UVWGL1L2L3CR1T1T2T3(326) (324)AC1AC2AC3-+POSNEG12A9AC1 C2 C3 C4SWITCHBOARD #1SWITCHBOARD #

INTERNAL AND AUXILIARY SUPPLY VOLTAGE TESTService and repair should be performed by only Lincoln Electric factory trained personnel.Unauthorized repai

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GENERAL DESCRIPTIONThe INVERTEC Power Wave power source is a highperformance, digitally controlled inverter weldingpower source capable of complex, hi

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F-101 F-101FIGURE F.34 – INTERNAL AUXILIARY SUPPLY WIRING DIAGRAMP82WF2 RECEPTACLE2536P83WF1 RECEPTACLESQUARE WAVE TIGPROTECTION BD24VTRIG 1J92J9263P8

F-102 F-102NOTESPOWER WAVE 450Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to Ma

MAIN CONTACTOR TESTService and repair should be performed by only Lincoln Electric factory trained personnel.Unauthorized repairs performed on this eq

F-104 F-104MAIN CONTACTOR TEST (continued)FIGURE F.35 - MAIN CONTACTORCR1L1AL1 L2 L3T1 T2 T3L3ATROUBLESHOOTING & REPAIRTEST PROCEDURE1. Remove ma

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F-106 F-106FIGURE F.36 – INPUT AND RECONNECT WIRING DIAGRAM6R9UVWGL1L2L3CR1T1T2T3(326) (324)AC1AC2AC3-+POSNEG12A9AC1 C2 C3 C4SWITCHBOARD #1SWITCHBOARD

SERIAL LOOP WIRING HARNESS TESTService and repair should be performed by only Lincoln Electric factory trained personnel.Unauthorized repairs performe

F-108 F-108SERIAL LOOP WIRING HARNESS TEST (continued)FIGURE F.37 - WIRE FEEDER AMPHENOL LOCATIONS1TROUBLESHOOTING & REPAIRTEST PROCEDURE1. Remov

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CONTROLS AND SETTINGSAll operator controls and adjustments are located onthe case front of the Power Wave. Refer to Figure B.1and corresponding expla

F-110 F-110FIGURE F.38 – SERIAL LOOP WIRING DIAGRAM40mA current supplyJ22J26J26J27J27J28J28J2253414144(263)(264)(111A)(112A)(117A)(118A)(5R)(5W)5J4440

WIRE FEEDER 1 TRIGGER CIRCUIT TESTService and repair should be performed by only Lincoln Electric factory trained personnel.Unauthorized repairs perfo

F-112 F-112WIRE FEEDER 1 TRIGGER CIRCUIT TEST (continued)FIGURE F.39 - DISPLAY BOARD PLUG LOCATIONSJ17 J16 J15 J14 J13 J12 J11 J10TROUBLESHOOTING &

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F-114 F-114FIGURE F.40 – TRIGGER CIRCUIT WIRING DIAGRAM(2)(4)8-pinAmphenols14-pinAmphenols(2)(4)CDCDCDCDFEDCBAR(2)(4)(75)(76)(77)ARemote Control KitK9

WIRE FEEDER 2 TRIGGER CIRCUIT TESTService and repair should be performed by only Lincoln Electric factory trained personnel.Unauthorized repairs perfo

F-116 F-116WIRE FEEDER 2 TRIGGER CIRCUIT TEST (continued)FIGURE F.41 - DISPLAY BOARD PLUG LOCATIONSJ17 J16 J15 J14 J13 J12 J11 J10TROUBLESHOOTING &

F-117 F-117WIRE FEEDER 2 TRIGGER CIRCUIT TEST (continued)TROUBLESHOOTING & REPAIR11. Remove plug J30 from the protectionboard. See Figure F.1 fo

F-118 F-118FIGURE F.42 – TRIGGER CIRCUIT WIRING DIAGRAM(2)(4)8-pinAmphenols14-pinAmphenols(2)(4)CDCDCDCDFEDCBAR(2)(4)(75)(76)(77)ARemote Control KitK9

TRIGGER CIRCUIT AND WIRING HARNESS TESTService and repair should be performed by only Lincoln Electric factory trained personnel.Unauthorized repairs

OPERATING OVERLAYSOVERVIEWThe Power Wave is controlled by a panel of keys (key-pad) located on the front of the machine. The opera-tor can access con

F-120 F-120TRIGGER CIRCUIT AND WIRING HARNESS TEST (continued)FIGURE F.43 - PROTECTION BOARD PLUG/HEADER LOCATIONS31161141616114161 1 114444114 7 2PRO

F-121 F-121FIGURE F.44AUXILIARY TRANSFORMER #1 SECONDARY CIRCUIT WIRING DIAGRAM2536WUNR5AC.B.33 32A333334*33642V24V115VCOMMONAUXILIARYTRANSFORMER 1PRO

F-122 F-122NOTESPOWER WAVE 450Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to Ma

INTERNAL REMOTE CONTROL TESTService and repair should be performed by only Lincoln Electric factory trained personnel.Unauthorized repairs performed o

F-124 F-124INTERNAL REMOTE CONTROL TEST (continued)FIGURE F.45 - DISPLAY BOARD PLUG LOCATIONSJ17 J16 J15 J14 J13 J12 J11 J10TROUBLESHOOTING & REPA

F-125 F-125INTERNAL REMOTE CONTROL TEST (continued)TROUBLESHOOTING & REPAIRELECTRIC SHOCKcan kill.With input power ON, thereare high voltages insi

F-126 F-126FIGURE F.46 – TRIGGER CIRCUIT WIRING DIAGRAM(2)(4)8-pinAmphenols14-pinAmphenols(2)(4)CDCDCDCDFEDCBAR(2)(4)(75)(76)(77)ARemote Control KitK9

K941-1 REMOTE CONTROL KIT TESTService and repair should be performed by only Lincoln Electric factory trained personnel.Unauthorized repairs performed

F-128 F-128K941-1 REMOTE CONTROL KIT TEST (continued)FIGURE F.47 - 6-PIN AMPHENOL LOCATION12TROUBLESHOOTING & REPAIRTEST PROCEDURE1. Remove the R

F-129 F-129FIGURE F.48 – TRIGGER CIRCUIT WIRING DIAGRAM(2)(4)8-pinAmphenols14-pinAmphenols(2)(4)CDCDCDCDFEDCBAR(2)(4)(75)(76)(77)ARemote Control KitK9

OVERLAY TYPES Four types of overlays can be used with the PowerWave.1. Process Overlays. These overlays are used tocreate, save and recall specific we

F-130 F-130NOTESPOWER WAVE 450Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to Ma

K941-1 REMOTE CONTROL KIT TRIGGER CIRCUIT TESTService and repair should be performed by only Lincoln Electric factory trained personnel.Unauthorized r

F-132 F-132K941-1 REMOTE CONTROL KIT TRIGGER CIRCUIT TEST (continued)FIGURE F.49 - DISPLAY BOARD PLUG LOCATIONSJ17 J16 J15 J14 J13 J12 J11 J10TROUBLES

F-133 F-133K941-1 REMOTE CONTROL KIT TRIGGER CIRCUIT TEST (continued)TROUBLESHOOTING & REPAIR11. Remove plug J30 from the protectionboard. See F

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LCD DISPLAY TESTService and repair should be performed by only Lincoln Electric factory trained personnel.Unauthorized repairs performed on this equip

F-136 F-136LCD DISPLAY TEST (continued)FIGURE F.51 - DISPLAY BOARD PLUG LOCATIONSJ17 J16 J15 J14 J13 J12 J11 J10TROUBLESHOOTING & REPAIRTEST PROCE

F-137 F-137LCD DISPLAY TEST (continued)TROUBLESHOOTING & REPAIRELECTRIC SHOCKcan kill.With input power ON, thereare high voltages inside themachin

F-138 F-138FIGURE F.52 – INTERNAL AUXILIARY SUPPLY WIRING DIAGRAMP82WF2 RECEPTACLE2536P83WF1 RECEPTACLESQUARE WAVE TIGPROTECTION BD24VTRIG 1J92J9263P8

CALIBRATION PROCEDURESPOWER WAVE PC BOARDREPLACEMENT CALIBRATION PROCEDURESIf the display board is replaced, the display sensor cal-ibration and a vol

Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOCFOR ENGINEpowered equipment.1.a. Turn the engine off before trouble

1. LCD DISPLAY WINDOW: Power up the machinewith this overlay in place. When the Power Waveis turned on, the following message appears onthe display f

F-140 F-140NOTESPOWER WAVE 450Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to Ma

SENSOR CALIBRATION TEST (FOR DISPLAY BOARD)Service and repair should be performed by only Lincoln Electric factory trained personnel.Unauthorized repa

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QUICK VOLTAGE CALIBRATIONService and repair should be performed by only Lincoln Electric factory trained personnel.Unauthorized repairs performed on t

F-144 F-144QUICK VOLTAGE CALIBRATION (continued)FIGURE F.54 - TEST AND CALIBRATION OVERLAYTROUBLESHOOTING & REPAIRPROCEDURE1. Before changing or

FULL VOLTAGE CALIBRATIONService and repair should be performed by only Lincoln Electric factory trained personnel.Unauthorized repairs performed on th

F-146 F-146FULL VOLTAGE CALIBRATION(continued)FIGURE F.55 - TEST AND CALIBRATION OVERLAYTROUBLESHOOTING & REPAIRPROCEDURE1. The voltage calibrati

FULL VOLTAGE CALIBRATION USING A WELDING ARCService and repair should be performed by only Lincoln Electric factory trained personnel.Unauthorized rep

F-148 F-148FULL VOLTAGE CALIBRATION(continued)FIGURE F.55a - TEST AND CALIBRATION OVERLAYTROUBLESHOOTING & REPAIRPROCEDURE1. The voltage calibrat

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3. ELECTRODE CLASS UP/DOWN: Use the ELEC-TRODE CLASS UP or DOWN keys to select fromthe material types available for the selectedprocess. Press the EL

F-150 F-150NOTESPOWER WAVE 450Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to Ma

CURRENT CALIBRATIONService and repair should be performed by only Lincoln Electric factory trained personnel.Unauthorized repairs performed on this eq

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F-154 F-154NOTESPOWER WAVE 450Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to Ma

T1 AUXILIARY TRANSFORMER REMOVAL AND REPLACEMENTService and repair should be performed by only Lincoln Electric factory trained personnel.Unauthorized

F-156 F-156T1 AUXILIARY TRANSFORMER REMOVAL AND REPLACEMENT (continued)FIGURE F.59 - T1 AUXILIARY TRANSFORMER LOCATION12TROUBLESHOOTING & REPAIRPR

WATER COOLER REMOVAL AND REPLACEMENTFor later model coolers (Inlet & Outlet on lower left of machine back) Refer to IM645-AService and repair shou

F-158 F-158WATER COOLER REMOVAL AND REPLACEMENT (continued)FIGURE F.60 - WATER COOLER LOCATION132TROUBLESHOOTING & REPAIRPROCEDURENOTE: These inst

F-159 F-159WATER COOLER REMOVAL AND REPLACEMENT (continued)TROUBLESHOOTING & REPAIR10. With the 9/16" open end wrench, removethe circuit bre

10. RECALL FROM MEMORY KEY: This key is usedto recall an existing procedure from memory. Youcan recall and use any of the previously createdwelding p

F-160 F-160NOTESPOWER WAVE 450Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to Ma

WATER COOLER DISASSEMBLYService and repair should be performed by only Lincoln Electric factory trained personnel.Unauthorized repairs performed on th

F-162 F-162WATER COOLER DISASSEMBLY (continued)FIGURE F.61 - WATER COOLER DISASSEMBLY (EARLY MODEL)123TROUBLESHOOTING & REPAIRPROCEDURE1. Remove

F-163 F-163WATER COOLER DISASSEMBLY (continued)TROUBLESHOOTING & REPAIRReservoir RemovalA. After you have completed the capacitordischarge proced

F-164 F-164NOTESPOWER WAVE 450Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to Ma

T2 AUXILIARY TRANSFORMER REMOVAL AND REPLACEMENTService and repair should be performed by only Lincoln Electric factory trained personnel.Unauthorized

F-166 F-166T2 AUXILIARY TRANSFORMER REMOVAL AND REPLACEMENT (continued)FIGURE F.62 - T2 AUXILIARY TRANSFORMER LOCATION123TROUBLESHOOTING & REPAIRP

FAN MOTOR REMOVAL AND REPLACEMENTService and repair should be performed by only Lincoln Electric factory trained personnel.Unauthorized repairs perfor

F-168 F-168FAN MOTOR REMOVAL AND REPLACEMENT (continued)FIGURE F.63 - FAN MOTOR LOCATION123TROUBLESHOOTING & REPAIRPROCEDURE1. Remove main input

F-169 F-169FAN MOTOR REMOVAL AND REPLACEMENT (continued)FIGURE F.64 - MACHINE BACK SECURED TO LIFT BAIL.12TROUBLESHOOTING & REPAIR11. With the 3/

1. LCD DISPLAY WINDOW: Power up the machinewith this overlay in place. When the Power Waveis turned on, the following message appears in thedisplay w

F-170 F-170NOTESPOWER WAVE 450Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to Ma

INPUT RECTIFIER REMOVAL AND REPLACEMENTService and repair should be performed by only Lincoln Electric factory trained personnel.Unauthorized repairs

F-172 F-172INPUT RECTIFIER REMOVAL AND REPLACEMENT (continued)FIGURE F.65 - INPUT RECTIFIER LOCATIONCR1123456TROUBLESHOOTING & REPAIRPROCEDURE1.

F-173 F-173INPUT RECTIFIER REMOVAL AND REPLACEMENT (continued)TROUBLESHOOTING & REPAIR10. With the 5 mm Allen wrench and the 10mm open end wrench

F-174 F-174NOTESPOWER WAVE 450Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to Ma

PRINTED CIRCUIT BOARD REMOVAL AND REPLACEMENT(CONTROL BOARD, POWER BOARD,AND PROTECTION BOARD)Service and repair should be performed by only Lincoln E

F-176 F-176PRINTED CIRCUIT BOARD REMOVAL AND REPLACEMENT(CONTROL BOARD, POWER BOARD, AND PROTECTION BOARD) (continued)FIGURE F.66 - PC BOARD REMOVAL13

F-177 F-177PRINTED CIRCUIT BOARD REMOVAL AND REPLACEMENT(CONTROL BOARD, POWER BOARD, AND PROTECTION BOARD) (continued)TROUBLESHOOTING & REPAIRBe s

F-178 F-178NOTESPOWER WAVE 450Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to Ma

DISPLAY BOARD REMOVAL AND REPLACEMENTService and repair should be performed by only Lincoln Electric factory trained personnel.Unauthorized repairs pe

1. LCD DISPLAY WINDOW: Power up the machinewith this overlay in place. When the Power Wave isturned on, the following message appears in thedisplay wi

F-180 F-180DISPLAY BOARD REMOVAL AND REPLACEMENT (continued)FIGURE F.68 - DISPLAY BOARD REMOVAL34521TROUBLESHOOTING & REPAIRNOTE: Before changing

F-181 F-181DISPLAY BOARD REMOVAL AND REPLACEMENT (continued)TROUBLESHOOTING & REPAIR8. Carefully remove the key pad ribbon con-nector from the ri

F-182 F-182NOTESPOWER WAVE 450Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to Ma

MAIN INPUT CONTACTOR (CR1) REMOVALAND REPLACEMENTService and repair should be performed by only Lincoln Electric factory trained personnel.Unauthorize

F-184 F-184MAIN INPUT CONTACTOR (CR1) REMOVAL AND REPLACEMENT (continued)FIGURE F.69 - MAIN CONTACTORCR1L1AL1 L2 L3T1 T2 T3324326T1T3L3ATROUBLESHOOTIN

F-185 F-185MAIN INPUT CONTACTOR (CR1) REMOVAL AND REPLACEMENT (continued)TROUBLESHOOTING & REPAIR9. With the slot head screw driver, removethe tw

F-186 F-186NOTESPOWER WAVE 450Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to Ma

OUTPUT RECTIFIER BRIDGE REMOVALAND REPLACEMENTService and repair should be performed by only Lincoln Electric factory trained personnel.Unauthorized r

F-188 F-188OUTPUT RECTIFIER BRIDGE REMOVAL AND REPLACEMENT (continued)FIGURE F.70 - OUTPUT RECTIFIER BRIDGE LOCATION1TROUBLESHOOTING & REPAIRPROCE

F-189 F-189OUTPUT RECTIFIER BRIDGE REMOVAL AND REPLACEMENT (continued)TROUBLESHOOTING & REPAIR9. Cut all necessary cable ties on the rightside of

When a pair of welding procedures are recalledfrom memory, the display window will show theprocedure description, wire feed speed, and thepreset volta

F-190 F-190OUTPUT RECTIFIER BRIDGE REMOVAL AND REPLACEMENT (continued)TROUBLESHOOTING & REPAIR13. For reassembly, attach the glastic insulat-ed a

FET MODULE REMOVAL AND REPLACEMENTService and repair should be performed by only Lincoln Electric factory trained personnel.Unauthorized repairs perfo

F-192 F-192FET MODULE REMOVAL AND REPLACEMENT (continued)FIGURE F.73 - FET MODULE LOCATION1432TROUBLESHOOTING & REPAIRPROCEDURE1. Remove main inp

F-193 F-193FET MODULE REMOVAL AND REPLACEMENT (continued)FIGURE F.74 - LIFT BAFFLE/BAIL REMOVALTROUBLESHOOTING & REPAIR9. With the wire cutters,

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F-195 F-195FET MODULE REMOVAL AND REPLACEMENT (continued)TROUBLESHOOTING & REPAIR30. Install the water cooler assembly. Refer tothe Water Cooler

F-196 F-196NOTESPOWER WAVE 450Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to Ma

MAIN TRANSFORMER REMOVAL AND REPLACEMENTService and repair should be performed by only Lincoln Electric factory trained personnel.Unauthorized repairs

F-198 F-198MAIN TRANSFORMER/CHOKE REMOVAL AND REPLACEMENT (continued)FIGURE F.75 - MAIN TRANSFORMER LOCATION1TROUBLESHOOTING & REPAIRPROCEDURE1.

TROUBLESHOOTING & REPAIRF-199 F-199POWER WAVE 450Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to

1. LCD DISPLAY WINDOW: Power up the machinewith this overlay in place. When the Power Wave isturned on, the following message appears in thedisplay wi

SETUP THE POWER WAVE FORPRETEST1. Turn the input power switch to the OFF position.2. Unplug P73. See wiring diagram.3. Install the L9660-255 Calib

MAKE SURE FILTER CAPACITORS ARE DISCHARGED1. Construct a 115VAC pretest power supplyas per Figure F.78 using the following:Switch (SPST)Fuse (5 amp

Connect the pretest power supply to plug P70 asper Figure F.78. See wiring diagram.ARC START PW450 WITH WIREFEEDERThe arc start may be initiated by a

ARC START FOR PW450 ROBOTIC1. Construct and connect an arc start circuit asper Figure F.79. 2. Install leads and an arc start switch into plugJ103 p

TROUBLESHOOTING & REPAIRF-204 F-204POWER WAVE 450Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to

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TROUBLESHOOTING & REPAIRF-206 F-206POWER WAVE 450Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to

TROUBLESHOOTING & REPAIRF-207 F-207POWER WAVE 450Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to

TROUBLESHOOTING & REPAIRF-208 F-208POWER WAVE 450Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to

Electrical Diagrams Section...Section GWiring Diagram ...

1. LCD DISPLAY WINDOW: Power up the machinewith this overlay in place. When the Power Wave isturned on, the following message appears in thedisplay w

ELECTRICAL DIAGRAMSG-2POWER WAVE 450WIRING DIAGRAM - POWER WAVE 450KEYPADRS232CONNECTOR1234567820LCDDISPLAYRECEPTACLE5ACIRCUITBREAKER+-+-+-+-CURRENTTR

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ELECTRICAL DIAGRAMSG-7POWER WAVE 450SCHEMATIC - CONTROL PC BOARD #45.11KR20610.0R225221KR219CNY17-3OCI44216510KR257221KR254CNY17-3OCI842165D42150R256J

NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your fa

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ELECTRICAL DIAGRAMSG-10POWER WAVE 450SCHEMATIC - DISPLAY PC BOARD (SHEET 2)PRESSURE50V150pC716.81KR103TO REMOTE 10K POTENTIOMETERS22.1KR10240V600mAQ9+

NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your fa

Use the LIMIT UP and LIMIT DOWN keys tochange the maximum wire feed speed to thedesired value.Press the SET LIMIT key again. The new maximumand old mi

ELECTRICAL DIAGRAMSG-12POWER WAVE 450SCHEMATIC - POWER PRINTED CIRCUIT BOARDGNDINOUTX9301R1921mHL1161A100VQ111GNDINOUTX10-8Vbe1W5.1VDZ1151N4936D43CURR

NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your fa

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to Master TOC Return to Master TOC

NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your fa

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NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your fa

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to Master TOC Return to Master TOC

NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your fa

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NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your fa

1. LCD DISPLAY WINDOW: Power up the machinewith this overlay in place. When the Power Waveis turned on, the following message appears in thedisplay w

ELECTRICAL DIAGRAMSG-22POWER WAVE 450SCHEMATIC-SWITCH PRINTED CIRCUIT BOARD600mA40VQ8600mA40VQ91/2W1R281W10VDZ10100V1AQ101N4936D1050V2700pC815.0KR321W

NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your fa

ELECTRICAL DIAGRAMSG-24 G-24POWER WAVE 450Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC

SVM ERROR REPORTING FORMWe need to know if there are errors in our manuals. We also value any suggestions as toadditional tests or procedures that wo

Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOCiiSAFETYiiARC RAYS can burn.4.a. Use a shield with the proper filte

When the “WATER COOLER PRESSURE” lightturns on, release the key. If this key has beenpressed for 30 seconds and the ‘WATER COOLERPRESSURE’ light stil

Use the ELECTRODE SENSE LEAD KEY to selecteither the - output terminal or the electrode sense (67)lead for the positive voltage reference.The work sen

OVERVIEW OF WELDING PROCEDURESFLUX CORED ARC WELDING (FCAW)AND GMAW PROCEDURESFor each wire feed speed, a corresponding voltagehas been preprogrammed

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In Pulse processes:The wave control adjustment allows the frequency set-ting to vary. Increasing the wave control allows the fre-quency setting to inc

OVERLOAD PROTECTIONTHERMAL PROTECTIONThe Power Wave has thermostatic protection fromexcessive duty cycles, overloads, loss of cooling, andhigh ambient

NOTESPOWER WAVE 450Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to Master TOC Re

Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOCTABLE OF CONTENTS- ACCESSORIES -Accessories...

OPTIONS/ACCESSORIES•Synergic 7 wire feeder (K632-1) standard speed,or (K632-2) high speed• MAGNUM 400 gun (K471-2) or 550 gun (K598)• Internal water c

ACCESSORIESC-3 C-3POWER WAVE 450Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to

Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOCFOR ELECTRICALLYpowered equipment.8.a. Turn off input power using t

G3503-[ ] COOLER PERIODIC MAINTENANCE1. Preparation:• Always switch off the Power Wave machinepower.• Always disconnect the Power Wave machinefrom ser

C-5 C-5ACCESSORIESg. Install new pump and v-band clamp:• Do not apply any lubricant to pump’sdrive coupling.• Pump body is properly oriented with itss

C-6 C-6NOTESPOWER WAVE 450Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to Master

D-1 D-1TABLE OF CONTENTS-MAINTENANCE-POWER WAVE 450Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOCMaintenance ...

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6. Locate the #9 and #12 terminals, identified by the“Discharge” labels, on each of the four SwitchBoards. See Figure D.2.7. Using insulated, needle

PREVENTIVE MAINTENANCEPerform the following preventive maintenance proce-dures at least once every six months. It is good prac-tice to keep a prevent

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Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOCTABLE OF CONTENTS-THEORY OF OPERATION-Theory of Operation ...

Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOCivSAFETYivPRÉCAUTIONS DE SÛRETÉPour votre propre protection lire et

CONTROLBOARDDISPLAYBOARDPROTECTIONBOARDAUX.TRANSPOWERBOARDCTCONTACTORINPUTINPUTRECTIFIERANDRECONNECTSWITCHBOARDFETASSEMBLYSWITCHBOARDFETASSEMBLYMAINTR

PRECHARGE (SOFT START)The Protection Board contains a “soft Start” circuit,which is powered by the Auxiliary Transformer. Duringprecharge or “soft st

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THERMAL PROTECTIONTwo normally closed (NC) thermostats protect themachine from excessive operating temperatures.These thermostats are wired in series

An FET is a type of transistor. FETs are semi-conductors well suited for high-frequencyswitching.Drawing A above shows an FET in a passivemode. Ther

MASTER TABLE OF CONTENTS FOR ALL SECTIONSv vPOWER WAVE 450PageSafety...

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Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOCTABLE OF CONTENTS-TROUBLESHOOTING & REPAIR SECTION-Troubleshoot

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ELECTRIC SHOCK can kill.Have an electrician install and ser-vice this equipment. Turn themachine OFF before working onequipment. Do not touch electr

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TROUBLESHOOTING & REPAIRF-8 F-8POWER WAVE 450TROUBLESHOOTING GUIDE Observe Safety Guidelinesdetailed in the beginning of this manual.CAUTIONIf for

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Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOCTABLE OF CONTENTS- INSTALLATION SECTION -Section A-1 Section A-1POW

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TROUBLESHOOTING & REPAIRF-11 F-11POWER WAVE 450TROUBLESHOOTING GUIDE Observe Safety Guidelinesdetailed in the beginning of this manual.CAUTIONIf f

TROUBLESHOOTING & REPAIRF-12 F-12POWER WAVE 450TROUBLESHOOTING GUIDE Observe Safety Guidelinesdetailed in the beginning of this manual.CAUTIONIf f

TROUBLESHOOTING & REPAIRF-13 F-13POWER WAVE 450TROUBLESHOOTING GUIDE Observe Safety Guidelinesdetailed in the beginning of this manual.CAUTIONIf f

TROUBLESHOOTING & REPAIRF-14 F-14POWER WAVE 450TROUBLESHOOTING GUIDE Observe Safety Guidelinesdetailed in the beginning of this manual.CAUTIONIf f

TROUBLESHOOTING & REPAIRF-15 F-15POWER WAVE 450TROUBLESHOOTING GUIDE Observe Safety Guidelinesdetailed in the beginning of this manual.CAUTIONIf f

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Input Voltages:200 230 400 460 575Input Currents@ 500A/40 VDC 87 76 44 38 32@ 450A/38 VDC 75 65 38 32 28Duty CycleAmps Volts at Rated Amperes60% Duty

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CAPACITOR DISCHARGE PROCEDUREService and repair should be performed by only Lincoln Electric factory trained personnel.Unauthorized repairs performed

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F-26 F-26CAPACITOR DISCHARGE PROCEDURE (continued)FIGURE F.4 - RESISTOR WITH LEADS CONNECTED.TROUBLESHOOTING & REPAIR11. Check the voltage across

AUXILIARY TRANSFORMER TEST #1Service and repair should be performed by only Lincoln Electric factory trained personnel.Unauthorized repairs performed

F-28 F-28AUXILIARY TRANSFORMER TEST #1 (continued)FIGURE F.5 - TRANSFORMER T1 AND T2 LOCATION3241TROUBLESHOOTING & REPAIRTEST PROCEDURE1. Remove

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Read this entire installation section before youstart installation.SAFETY PRECAUTIONSELECTRIC SHOCK can kill.• Only qualified personnel shouldperform

POWER WAVE 450FIGURE F.6 – INPUT AND AUXILIARY CIRCUIT WIRING DIAGRAMTROUBLESHOOTING & REPAIRF-30 F-30(L1A)(L3A)4231F1FUSEPOWERSWITCHSWI(321B)(HIB

AUXILIARY TRANSFORMER TEST #2Service and repair should be performed by only Lincoln Electric factory trained personnel.Unauthorized repairs performed

F-32 F-32AUXILIARY TRANSFORMER TEST #2 (continued)FIGURE F.7 - TRANSFORMER T1 AND T2 LOCATION312TROUBLESHOOTING & REPAIRTEST PROCEDURE1. Remove m

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AUXILIARY TRANSFORMER PRIMARY WIRING HARNESS TESTService and repair should be performed by only Lincoln Electric factory trained personnel.Unauthorize

F-36 F-36AUXILIARY TRANSFORMER PRIMARY WIRING HARNESS TEST (continued)FIGURE F.9 - RECONNECT PANEL/TERMINAL STRIP LOCATION1324TROUBLESHOOTING & RE

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POWER WAVE 450AUXILIARY TRANSFORMER #1 SECONDARYAND WIRING HARNESS TESTService and repair should be performed by only Lincoln Electric factory trained