Lincoln Electric POWER WAVE 355M, POWER WAVE 405M User Manual

POWER WAVE 355M/405M
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r e m
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d o
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c o
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m
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r e m
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m o d
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a g n a
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m
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d o l o
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m
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L o
r e m
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m
d o l
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L o
r e m
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m
d o l
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m
a g n
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m
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ata
t
L o r
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m
d o
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m
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m m
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m m
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b h
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n a
a l i q
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ata
t
L o r e
m
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d o l
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c o
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t e t u
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s c i n
g
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m
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d o l
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c o
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t e t u
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s c i n
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l i t ,
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a l i q
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ata
t
L o
r e m
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m d
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t a
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n g
L o
r e m
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m
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m
a g
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l i q u
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r
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r
ata
t
L o
r e m
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c o n
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n g
L o
r e m
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m d o
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c o n
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n
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n
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m
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m
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u i
s m o
d t i n
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t u t
y
n i b
h e
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s m o
d t i n
c i d
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t u t
l a o
r e e t
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m
a g n
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m
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m
a g n
a a l i
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m
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ata
t
L o
r e m
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m
d o l
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s i t a
m e t
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c i n
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L o
r e m
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m
d o l
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s i t a
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c o n
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m n
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m n
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u
m m
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m m
y
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d
t i n c
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t
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d
t i n c
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t
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a l i q
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r
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n a
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m e
r
ata
t
L o
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d o
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m e t
c o n
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i n g
L o
r e m
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d o
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m e t
c o n
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r e
m a g
n a
a l
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r
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r e
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n a
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r
ata
t
L o
r e
m
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d o
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s i t
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o
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c i n
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L o
r e
m
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d o
l o r
s i t
a m
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o
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d
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a m
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n
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d
d i
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n o
n
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m
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m
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e u i
s m
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t i
n c
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t
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t i
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t
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n a
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a
m e
r
l a o
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o l
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n a
a l i
q u
a
m e
r
ata
t
L o
r e m
i p
s u m
d
o
l o r
s i t
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c o
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t e t u
e
r a d
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L o
r e m
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d
o
l o r
s i t
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e
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t , e
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m
m
u
m
m
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i s
m
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m
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a
g n
a
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m e
r
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g n
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ata
t
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m
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m
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d i p
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d
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m m
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t i
n c
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t
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t
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t
d o
l o
r e
m a
g
n a
a l i
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t
d o
l o
r e
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g
n a
a l i
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r e m
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m
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r s
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r e m
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m
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r s
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m
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l i t
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l i t
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m m
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m m
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t i n c
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g
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g
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a m
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ata
t
L
o r e
m
i p s
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d o
l o r
s i t
a m e
t c
o n s e
c t e
t u e
r
a d
i p i s
c i n
g
L
o r e
m
i p s
u m
d o
l o r
s i t
a m e
t c
o n s e
c t e
t u e
r
a d
i p i s
c i n
g
e
l i t , e
d d
i a
m n
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l i t , e
d d
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m
m
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m
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m d
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r e m
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p s u
m d
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t c o
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d
i a m
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d
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u
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u
m m
y
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e
u i s m
o
d t i n
c i d u
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t
y
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o
d t i n
c i d u
n t u
t
l a o
r e e
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m
a g n
a a
l i q
u a
m e
r
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l i q
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m e
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ata
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For use with machine code numbers 11141, 11142
Safety Depends on You
Lincoln arc welding and cutting equipment is designed and built with safety in mind. However, your overall safety can be increased by proper installation . . . and thoughtful operation on your part. DO NOT INSTALL,
OPERATE OR REPAIR THIS EQUIPMENT WITHOUT READ­ING THIS MANUAL AND THE SAFETY PRECAUTIONS CON­TAINED THROUGHOUT. And,
most importantly, think before you act and be careful.
SVM181-A
January, 2008
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i i

SAFETY

WARNING
CALIFORNIA PROPOSITION 65 WARNINGS
Diesel engine exhaust and some of its constituents are known to the State of California to cause can­cer, birth defects, and other reproductive harm.
The Above For Diesel Engines
ARC WELDING can be hazardous. PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH.
KEEP CHILDREN AWAY. PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING.
Read and understand the following safety highlights. For additional safety information, it is strongly recommended that you pur­chase a copy of “Safety in Welding & Cutting - ANSI Standard Z49.1” from the American Welding Society, P.O. Box 351040, Miami, Florida 33135 or CSA Standard W117.2-1974. A Free copy of “Arc Welding Safety” booklet E205 is available from the Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199.
BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE AND REPAIR PROCEDURES ARE PERFORMED ONLY BY QUALIFIED INDIVIDUALS.
The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm.
The Above For Gasoline Engines
FOR ENGINE powered equipment.
1.a. Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running.
____________________________________________________
1.b.Operate engines in open, well-ventilated areas or vent the engine exhaust fumes outdoors.
____________________________________________________
1.c. Do not add the fuel near an open flame weld­ing arc or when the engine is running. Stop the engine and allow it to cool before refuel­ing to prevent spilled fuel from vaporizing on contact with hot engine parts and igniting. Do not spill fuel when filling tank. If fuel is spilled, wipe it up and do not start engine until fumes have been eliminated.
____________________________________________________
1.d. Keep all equipment safety guards, covers and devices in posi­tion and in good repair.Keep hands, hair, clothing and tools away from V-belts, gears, fans and all other moving parts when starting, operating or repairing equipment.
____________________________________________________
1.e. In some cases it may be necessary to remove safety
guards to perform required maintenance. Remove guards only when necessary and replace them when the maintenance requiring their removal is complete. Always use the greatest care when working near moving parts.
___________________________________________________
1.f. Do not put your hands near the engine fan.Do not attempt to override the governor or idler by pushing on the throttle control rods while the engine is running.
1.h. To avoid scalding, do not remove the radiator pressure cap when the engine is hot.
ELECTRIC AND MAGNETIC FIELDS may be dangerous
2.a. Electric current flowing through any conductor causes localized Electric and Magnetic Fields (EMF). Welding current creates EMF fields around welding cables and welding machines
2.b. EMF fields may interfere with some pacemakers, and welders having a pacemaker should consult their physician before welding.
2.c. Exposure to EMF fields in welding may have other health effects which are now not known.
2.d. All welders should use the following procedures in order to minimize exposure to EMF fields from the welding circuit:
2.d.1.
Route the electrode and work cables together - Secure them with tape when possible.
2.d.2. Never coil the electrode lead around your body.
2.d.3. Do not place your body between the electrode and
work cables. If the electrode cable is on your right side, the work cable should also be on your right side.
___________________________________________________
1.g. To prevent accidentally starting gasoline engines while turning the engine or welding generator during maintenance work, disconnect the spark plug wires, distributor cap or magneto wire as appropriate.
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2.d.4. Connect the work cable to the workpiece as close as possible to the area being welded.
2.d.5. Do not work next to welding power source.
Mar ‘95
ii ii
SAFETY
ELECTRIC SHOCK can kill.
3.a. The electrode and work (or ground) circuits are electrically “hot” when the welder is on. Do not touch these “hot” parts with your bare skin or wet clothing. Wear dry, hole-free gloves to insulate hands.
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.
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:
• Semiautomatic DC Constant Voltage (Wire) Welder.
• DC Manual (Stick) Welder.
• AC Welder with Reduced Voltage Control.
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.
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.
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.
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.
ARC RAYS can burn.
4.a. Use a shield with the proper filter and cover plates to protect your eyes from sparks and the rays of the arc when welding or observing open arc welding. Headshield and filter lens should conform to ANSI Z87. I standards.
4.b. Use suitable clothing made from durable flame-resistant material to protect your skin and that of your helpers from the arc rays.
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.
FUMES AND GASES can be dangerous.
5.a. Welding may produce fumes and gases hazardous to health. Avoid breathing these fumes and gases.When welding, keep your head out of the fume. Use enough 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.
5. b. The operation of welding fume control equipment is affected by various factors including proper use and positioning of the equipment, maintenance of the equipment and the specific welding procedure and application involved.
Worker exposure level should be checked upon installation and periodically thereafter to be certain it is within applicable OSHA PEL and ACGIH TLV limits.
5.c.
Do not weld in locations near chlorinated hydrocarbon coming from degreasing, cleaning or spraying operations. The heat and rays of the arc can react with solvent vapors form phosgene, a highly toxic gas, and other irritating prod­ucts.
5.d. 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.
vapors
to
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5.e. 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.
5.f. Also see item 1.b.
Aug ‘06
iii iii
SAFETY
WELDING SPARKS can cause fire or explosion.
6.a.
Remove fire hazards from the welding area.
If this is not possible, cover them to prevent
the welding sparks from starting a fire.
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.
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.
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.
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 been “cleaned”. For information, purchase “Recommended Safe Practices for the Containers and Piping That Have Held Hazardous Substances”, AWS F4.1 from the American Welding Society
(see address above).
6.e. Vent hollow castings or containers before heating, cutting or welding. They may explode.
Sparks and spatter are thrown from the welding arc. Wear oil
6.f. 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.
6.g. Connect the work cable to the work as close to the welding area as practical. Work cables connected to the building framework or other locations away from the welding area increase the possibility of the welding current passing through lifting chains, crane cables or other alternate circuits. This can create fire hazards or overheat lifting chains or cables until they fail.
6.h. Also see item 1.c.
Remember that welding sparks and hot
though
they have
Preparation
for Welding and Cutting of
CYLINDER may explode if damaged.
7.a. Use only compressed gas cylinders containing the correct shielding gas for the 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.
7.c. Cylinders should be located:
• Away from areas where they may be struck or subjected to
physical damage.
• 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.
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.
FOR ELECTRICALLY powered equipment.
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.
8.c. Ground the equipment in accordance with the U.S. National Electrical Code and the manufacturer’s recommendations.
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Mar ‘95
iv iv
SAFETY
PRÉCAUTIONS DE SÛRETÉ
Pour votre propre protection lire et observer toutes les instructions et les précautions de sûreté specifiques qui parraissent dans ce manuel aussi bien que les précautions de sûreté générales suiv­antes:
reté Pour Soudage A LʼArc
rotegez-vous contre la secousse électrique:
1. P
a. Les circuits à l’électrode et à la piéce sont sous tension
quand la machine à souder est en marche. Eviter toujours tout contact entre les parties sous tension et la peau nue ou les vétements mouillés. Porter des gants secs et sans trous pour isoler les mains.
b. Faire trés attention de bien s’isoler de la masse quand on
soude dans des endroits humides, ou sur un plancher 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.
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.
e. Ne jamais toucher simultanément les parties sous tension
des porte-électrodes connectés à deux machines à souder parce que la tension entre les deux pinces peut être le total de la tension à vide des deux machines.
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.
2. Dans le cas de travail au dessus du niveau du sol, se protéger contre les chutes dans le cas ou on recoit un choc. Ne jamais enrouler le câble-électrode autour de n’importe quelle partie du corps.
3. Un coup d’arc peut être plus sévère qu’un coup de soliel, donc:
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.
8. S’assurer que la masse est connectée le plus prés possible de la zone de travail qu’il est pratique de le faire. Si on place la masse sur la charpente de la construction ou d’autres endroits éloignés de la zone de travail, on augmente le risque de voir passer le courant de soudage par les chaines de levage, câbles de grue, ou autres circuits. Cela peut provoquer des risques d’incendie ou d’echauffement des chaines et des câbles jusqu’à ce qu’ils se rompent.
9. Assurer une ventilation suffisante dans la zone de soudage. Ceci est particuliérement important pour le soudage de tôles galvanisées plombées, ou cadmiées ou tout autre métal qui produit des fumeés toxiques.
10. Ne pas souder en présence de vapeurs de chlore provenant d’opérations de dégraissage, nettoyage ou pistolage. La chaleur ou les rayons de l’arc peuvent réagir avec les vapeurs du solvant pour produire du phosgéne (gas fortement toxique) ou autres produits irritants.
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.
PRÉCAUTIONS DE SÛRETÉ POUR LES MACHINES À SOUDER À TRANSFORMATEUR ET À REDRESSEUR
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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.
b. Porter des vêtements convenables afin de protéger la peau
de soudeur et des aides contre le rayonnement de l‘arc.
c. Protéger l’autre personnel travaillant à proximité au
soudage à l’aide d’écrans appropriés et non-inflammables.
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.
5. Toujours porter des lunettes de sécurité dans la zone de soudage. Utiliser des lunettes avec écrans lateraux dans les zones où l’on pique le laitier.
1. Relier à la terre le chassis du poste conformement au code de l’électricité et aux recommendations du fabricant. Le dispositif de montage ou la piece à souder doit être branché à une bonne mise à la terre.
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. Garder tous les couvercles et dispositifs de sûreté à leur place.
Mar ‘93
v v
SAFETY
Electromagnetic Compatibility (EMC)
Conformance Products displaying the CE mark are in conformity with European Community Council Directive of 3 May 1989 on the approximation of the laws of the Member States relating to electromagnetic compatibility (89/336/EEC). It was manufactured in conformity with a national standard that implements a harmonized standard: EN 60974-10 Electromagnetic Compatibility (EMC) Product Standard for Arc Welding Equipment. It is for use with other Lincoln Electric equipment. It is designed for industrial and professional use.
Introduction All electrical equipment generates small amounts of electromagnetic emission. Electrical emission may be transmitted through power lines or radiated through space, similar to a radio transmitter. When emissions are received by other equipment, electrical interference may result. Electrical emissions may affect many kinds of electrical equipment; other nearby welding equipment, radio and TV reception, numerical controlled machines, telephone systems, computers, etc. Be aware that interference may result and extra precautions may be required when a welding power source is used in a domestic establishment.
Installation and Use The user is responsible for installing and using the welding equipment according to the manufacturer’s instructions. If electromagnetic disturbances are detected then it shall be the responsibility of the user of the welding equipment to resolve the situation with the technical assistance of the manufacturer. In some cases this remedial action may be as simple as earthing (grounding) the welding circuit, see Note. In other cases it could involve construction an electromagnetic screen enclosing the power source and the work complete with associated input filters. In all cases electromagnetic disturbances must be reduced to the point where they are no longer troublesome.
Note: The welding circuit may or may not be earthed for safety reasons according to national
codes. Changing the earthing arrangements should only be authorized by a person who is competent to access whether the changes will increase the risk of injury, e.g., by allowing parallel welding current return paths which may damage the earth circuits of other equip­ment.
Assessment of Area Before installing welding equipment the user shall make an assessment of potential electromagnetic prob­lems in the surrounding area. The following shall be taken into account:
a) other supply cables, control cables, signaling and telephone cables; above, below and adjacent to the
welding equipment;
b) radio and television transmitters and receivers;
c) computer and other control equipment;
d) safety critical equipment, e.g., guarding of industrial equipment;
e) the health of the people around, e.g., the use of pacemakers and hearing aids;
f) equipment used for calibration or measurement
g) the immunity of other equipment in the environment. The user shall ensure that other equipment being
used in the environment is compatible. This may require additional protection measures;
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h) the time of day that welding or other activities are to be carried out.
L10093 3-1-96H
vi vi
SAFETY
Electromagnetic Compatibility (EMC)
The size of the surrounding area to be considered will depend on the structure of the building and other activities that are taking place. The surrounding area may extend beyond the boundaries of the premises.
Methods of Reducing Emissions
Mains Supply Welding equipment should be connected to the mains supply according to the manufacturer’s recommenda­tions. If interference occurs, it may be necessary to take additional precautions such as filtering of the mains supply. Consideration should be given to shielding the supply cable of permanently installed welding equipment, in metallic conduit or equivalent. Shielding should be electrically continuous throughout its length. The shielding should be connected to the welding power source so that good electrical contact is maintained between the conduit and the welding power source enclosure.
Maintenance of the Welding Equipment The welding equipment should be routinely maintained according to the manufacturer’s recommendations. All access and service doors and covers should be closed and properly fastened when the welding equip­ment is in operation. The welding equipment should not be modified in any way except for those changes and adjustments covered in the manufacturers instructions. In particular, the spark gaps of arc striking and stabilizing devices should be adjusted and maintained according to the manufacturer’s recommendations.
Welding Cables The welding cables should be kept as short as possible and should be positioned close together, running at or close to floor level.
Equipotential Bonding Bonding of all metallic components in the welding installation and adjacent to it should be considered. However, metallic components bonded to the work piece will increase the risk that the operator could receive a shock by touching these metallic components and the electrode at the same time. The operator should be insulated from all such bonded metallic components.
Earthing of the Workpiece Where the workpiece is not bonded to earth for electrical safety, not connected to earth because of its size and position, e.g., ships hull or building steelwork, a connection bonding the workpiece to earth may reduce emissions in some, but not all instances. Care should be taken to prevent the earthing of the workpiece increasing the risk of injury to users, or damage to other electrical equipment. Where necessary, the con­nection of the workpiece to earth should be made by a direct connection to the workpiece, but in some countries where direct connection is not permitted, the bonding should be achieved by suitable capacitance, selected according to national regulations.
Screening and Shielding Selective screening and shielding of other cables and equipment in the surrounding area may alleviate problems of interference. Screening of the entire welding installation may be considered for special applica-
1
tions.
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1
Portions of the preceding text are contained in EN 60974-10: “Electromagnetic Compatibility (EMC) product standard for arc welding equipment.”
L10093 3-1-96H
I I
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- MASTER TABLE OF CONTENTS FOR ALL SECTIONS -
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age
P
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .i-vi
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section A
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section B
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section C
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section D
Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section E
Troubleshooting and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section F
Electrical Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section G
Parts Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .P-418 Series
POWER WAVE 355M/405M
A-1 A-1
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-1
Technical Specifications 355M . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-2
Technical Specifications 405M . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-3
Safety Precautions .....................................................................................................................................A-4
Stacking......................................................................................................................................................A-4
Tilting ..........................................................................................................................................................A-4
Input Grounding Connections ....................................................................................................................A-4
Power Cord Connection.............................................................................................................................A-4
Output Cables, Connections and Limitations ............................................................................................A-5
TABLE OF CONTENTS - INSTALLATION SECTION
Negative Electrode Polarity ........................................................................................................................A-5
Voltage Sensing..........................................................................................................................................A-5
Power Wave to Semi-Automatic Wire Feeder ...........................................................................................A-6
System Description ....................................................................................................................................A-7
System Set-up ...........................................................................................................................................A-8
Multiple Group System...............................................................................................................................A-9
Single Group Multi-Head System ............................................................................................................A-10
Welding with Multiple Power Waves ........................................................................................................A-11
Control Cable Specifications....................................................................................................................A-11
I/0 Receptacle Specifications ..................................................................................................................A-13
Dip Switch Settings and Locations..........................................................................................................A-13
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POWER WAVE 355M/405M
A-2 A-2
INSTALLATION
TECHNICAL SPECIFICATIONS -
POWER WAVE 355
INPUT AC VOLTAGE & DC OUTPUT
Product Ordering Input AC Rated DC Output Output Weight Dimensions
Name Information Voltage Amps/Volts/Duty Cycle Range with Cord HxWxD
(continuous)
Power
Wave
355
* Overall Length Including Handle, 21.6” (549mm) without handle.
K2152-1
200-208 220-240 380-415 440-480
575
60/50 HZ
350A / 34V / 60%
1 & 3 Phase
300A / 32V / 100%
1 & 3 Phase
AMPS
5-425
(81.5 lbs.)
(37.0 kg.)
14.8” x 13.3” x
27.8”*
(373 x 338 x
706*)mm *Includes
Handles
POWER WAVE 355 INPUT CURRENT
Recommended Fuse Sizes Base On The U.S. National Electrical Code And Maximum Machine Outputs
Input 50/60 Hz Output Recommended
Voltage
200
208 230 380
400
415 460 575
Phases
1
1 1 1
1
1 1 1
300Amps @
32Volts(100%)
Not
Recommended
76 69
Not
Recommended
Not
Recommended
41 36 31
350Amps @
34Volts(60%)
Not
Recommended
94 85
Not
Recommended
Not
Recommended
64 42 37
Line Cord
AWG
2 4
---
6 8 8
Fuse size
---
125A 125A
---
---
80A 70A 50A
Notes
Note 1
Note 2 Note 2 Note 1
Note 1
Note 2
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200 208 230 380 400 415 460 575
Note 1. Not rated is indicated by 4-x’s in the box on the rating plate. Note 2. When operating on these inputs, the line cord should be changed to an input conductor of 6 AWG or larger.
3 3 3 3 3 3 3 3
41 39 36 23 22 22 19 16
50 50 42 28 27 26 23 18
6 6 8 8 8 8 8 8
80A 80A 70A 50A 50A 50A 50A 35A
Note 2 Note 2
OUTPUT CABLES, CONNECTIONS AND LIMITATIONS
Select The output cable size based upon the following chart.* Cable sizes for Combined Length of Electrode and Work Cable (Copper) 75C rated:
DUTY CYCLE
100%
60%
CURRENT
300 350
LENGTH UP 200FT.(61m)
1/0 1/0
200-250 FT. (61-76m)
1/0 2/0
*Lincoln Electric recommends using a minimum of 2/0 welding cable for pulse welding.
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POWER WAVE 355M/405M
A-3 A-3
INSTALLATION
TECHNICAL SPECIFICATIONS -
POWER WAVE 405
INPUT AC VOLTAGE & DC OUTPUT
Product Ordering Input AC Rated DC Output Output Weight Dimensions
Name Information Voltage Amps/Volts/Duty Cycle Range with Cord HxWxD
(continuous)
335500AA // 3344VV // 6600%%
PPoowweerr 220000--220088 // 33 PPhhaassee 2277..88**
WWaavvee KK 22115522--22 222200--224400// 332200AA // 3333VV // 6600%% AAMMPPSS 8866..55llbbss ((337733xx331188xx
440055 338800--441155// 11 PPhhaassee 55--442255 ((3377..44 kkgg)) 770066**))mmmm
33//5500//6600
6600//5500 HHzz227755AA // 3311VV //110000%%
11 PPhhaassee
330000AA // 3322VV // 110000%% ** IInncclluuddeess
33 PPhhaassee hhaannddlleess
* Overall Length Including Handle, 21.6” (549mm) without handle.
1144..77xx1122..55xx
POWER WAVE 405 INPUT CURRENT
Recommended Fuse Sizes Based On The U.S. National Electrical Code And Maximum Machine Outputs
Input 50/60 Hz Output Recommended
Voltage Phases 300Amps@ 350Amps@ Line Cord Size Fuse Size Notes
32Volts(100%) 34Volts(60%) Size mm 200 3 41 48 16 80A Note 2 220 3 37 48 16 80A Note 2 380 3 23 28 10 50A 400 3 22 27 10 50A 415 3 22 26 10 50A
2
Voltage Phases 275Amps@ 320Amps@ Line Cord Fuse Size Notes
31Volts(100%) 33Volts(60%) Size mm 200 1 Not Recommended Not Recommended --- ----- Note 1 220 1 64 82 20 125A Note 2 380 1 44 55 16 80A Note 2 400 1 40 50 10 80A 415 1 38 48 10 80A
1. Not rated is indicated by 4-x's in the box on the rating plate
2. When operating on these inputs, the line cord should be changed to an input conductor of 6 AWG or larger.
2
OUTPUT CABLES, CONNECTIONS AND LIMITATIONS
Select the output cable size based upon the following chart. Cable sizes for Combined Length of Electrode and Work Cable (Copper) 75C rated:
DUTY CYCLE CURRENT LENGTH UP 61m (200 FT) 61-76m (200-250 FT)
100% 275 1/0 1/0
60% 350 1/0 2/0
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POWER WAVE 355M/405M
A-4 A-4
W
A R N I N G
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y n i b h e u i s
m o d t i n c i d u n t u t
e l i t , e d d i a m
n o n u m m
y n i b h e u i s
m o d t i n c i d u n t u t
l a o r
e e t d o l o r e m
a g n a a l i q
u a m e r a t
l a o r
e e t d o l o r e m
a g n a a l i q
u a m e r a t
INSTALLATION
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC
SAFETY PRECAUTIONS
WARNING
ELECTRIC SHOCK can kill.
• TURN THE INPUT POWER OFF AT THE DISCONNECT SWITCH BEFORE ATTEMPTING TO CONNECT OR DIS-
CONNECT INPUT POWER LINES, OUTPUT CABLES, OR CONTROL CABLES.
• Only qualified personnel should perform this installation.
• Connect the green/yellow lead of the power cord to ground per U.S.National Electrical Code.
----------------------------------------------------------------------
SELECT SUITABLE LOCATION
In order to assure long life and reliable operation, the owner of this machine should follow these sim­ple preventative measures:
• The machine must be located where there is free cir­culation of clean back, out the sides and bottom will not be restricted.
• Dirt and dust that can be drawn into the machine should be kept to a minimum. Failure to observe these precautions can result in excessive operating temperatures and nuisance shutdown.
• Keep machine dry. Shelter from rain and snow. Do not
place on wet ground or in puddles.
air such that air movement in the
CAUTION
• DO NOT MOUNT OVER COMBUSTIBLE SURFACES.
Where there is a combustible surface directly under stationary or fixed electrical equipment, that surface shall be covered with a steel plate at least .06”(1.6mm) thick, which shall extend not less than 5.90”(150mm) beyond the equipment on all sides.
STACKING
POWER WAVE 355M/405M cannot
TILTING
Place the machine directly on a secure, level surface or on a recommended undercarriage. The machine may topple over if this procedure is not followed.
INPUT AND GROUNDING CONNECTIONS
• Only a qualified electrician should connect the
POWER WAVE 355M/405M. Installation should be made in accordance with the appropriate National Electrical Code, all local codes and the information detailed below.
• When received directly from the factory, multiple volt­age machines are internally connected for the highest voltage. Always double-check connections before powering up the machine.
• Initial 200VAC - 415VAC and 575VAC operation will
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC
require an Input voltage panel setup.
be stacked.
• Open the access panel on the rear of the machine.
• For 200 or 230: Position the large switch to 200-
230. For higher voltages: Position the large switch to 380-575.
• Move the "A" lead to the appropriate terminal.
POWER CORD CONNECTION
A power cord is provided and wired into the machine. Follow the power cord connection instructions.
Incorrect connection may result in equipment
damage.
Single Phase Input (PW 355M)
Connect green lead to ground per National Electrical Code. Connect black and white leads to power. Wrap red lead with tape to provide 600V insulation.
Three Phase Input (PW 355M)
Connect green lead to ground per National Electric Code. Connect black, red and white leads to power.
Lead Color Single Phase Three Phase
Green
Black
White
Red
Single Phase Input (PW 405M)
Connect green/yellow lead to ground per National Electrical Code. Connect blue and brown leads to power. Wrap black lead with tape to provide 600V insulation.
Three Phase Input (PW 405M)
Connect green/yellow lead to ground per National Electric Code. Connect black, blue and brown leads to power.
POWER WAVE 355M/405M
Machine
PW 355 PW 405
CAUTION
Connect to
ground per NEC
Power Lead Power Lead
Tape, provide
600V insulation
Cord Length
10 Feet
5 Meters
Connect to
ground per NEC
Power Lead Power Lead
Power Lead
A-5 A-5
3
.44
21.60
2
7.82
5.50
10.00
M
OUNTING HOLE LOCATIONS
M19527
1/4-20 NUT (4 PLACES)
N
OTE: MOUNTING SCREWS CA
4/01
N NOT PROTR
UDE MORE THAN
0.5 IN
C
HES INSIDE THE MACHINE.
11.8
4
3.50
INSTALLATION
UNDERCARRIAGE MOUNTINGS
OUTPUT CABLES, CONNECTIONS AND LIMITATIONS
Connect a work lead of sufficient size and length between the proper output terminal on the power source and the work. Be sure the connection to the work makes tight metal-to-metal electrical contact. 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 and do not coil excess cable.
When using inverter type power sources like the Power Waves, use the largest welding (electrode and work) 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, leading to poor weld­ing characteristics, if undersized welding cables are used.
-----------------------------------------------------------------------­Most welding applications run with the electrode being positive (+). For those applications, connect the elec­trode cable between the wire feeder and the positive (+) output Twist-Mate terminal on the power source. Connect the other end of the electrode cable to the wire drive feed plate. The electrode cable lug must be against the feed plate. Be sure the connection to the feed plate makes tight metal-to-metal electrical con­tact. The electrode cable should be sized according to the specifications given in the output cable connections section. Connect a work lead from the negative (-) power source output Twist-Mate terminal to the work piece. The work piece connection must be firm and secure, especially if pulse welding is planned.
CAUTION
CAUTION
Excessive voltage drops caused by poor work piece connections often result in unsatisfactory welding performance.
-----------------------------------------------------------------------
NEGATIVE ELECTRODE POLARITY
When negative electrode polarity is required, such as in some Innershield applications, reverse the output connections at the power source (electrode cable to the negative (-) Twist-Mate terminal, and work cable to the positive (+) Twist-Mate terminal.
When operating with electrode polarity negative the "Electrode Sense Polarity" DIP switch must be set to the "Negative" position on the Wire Drive Feed Head PC Board. The default setting of the switch is positive electrode polarity. Consult the Power Feed instruction manual for further details.
VOLTAGE SENSING
The best arc performance occurs when the PowerWaves have accurate data about the arc condi­tions. Depending upon the process, inductance within the electrode and work lead cables can influence the voltage apparent at the studs of the welder. Voltage sense leads improve the accuracy of the arc conditions and can have a dramatic effect on performance. Sense Lead Kits (K940-10, -25 or -50) are available for this purpose.
CAUTION
If the voltage sensing is enabled but the sense leads are missing, improperly connected, or if the electrode polarity switch is improperly configured, extremely high welding outputs may occur.
-----------------------------------------------------------------------­The ELECTRODE sense lead (67) is built into the con­trol cable, and is automatically enabled for all semi­automatic processes. The WORK sense lead (21) con­nects to the Power Wave at the four pin connector. By default the WORK voltage is monitored at the output stud in the POWER WAVE 355/405. For more informa­tion on the WORK sense lead (21), see"Work Voltage Sensing” in the following paragraph.
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC
For additional Safety information regarding the elec­trode and work cable set-up, See the standard "SAFE­TY INFORMATION" located in the front of the Instruction Manuals.
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POWER WAVE 355M/405M
A-6 A-6
INSTALLATION
Enable the voltage sense leads as follows:
TABLE A.1
Process Electrode Voltage Work Voltage
Sensing 67 lead * Sensing 21 lead
GMAW 67 lead required 21 lead optional GMAW-P FCAW 67 lead required 21 lead optional GTAW GMAW
SAW 67 lead required 21 lead optional
CAC-C
* The electrode voltage 67 sense lead is integral to the
control cable to the wire feeder.
Work Voltage Sensing
The standard POWER WAVE 355M/405M default to the work stud (work sense lead disabled)
For processes requiring work voltage sensing, connect the (21) work voltage sense lead (K940) from the Power Wave work sense lead receptacle to the work piece. Attach the sense lead to the work piece as close to the weld as practical, but not in the return current path. Enable the work voltage sensing in the Power Wave as follows:
67 lead required 21 lead optional
Voltage sense at studs Voltage sense at studs Voltage sense at studs Voltage sense at studs
Voltage sense at studs Voltage sense at studs
WARNING
• Do not touch electrically live parts or electrodes with your skin or wet clothing.
• Insulate yourself from the work and ground.
• Always wear dry insulating gloves.
5. Replace the wrap around and screws. The PC board will “read” the switch at power up, and configure the work voltage sense lead appropriately.
ELECTRODE VOLTAGE SENSING
Enabling or disabling electrode voltage sensing is auto­matically configured through software. The 67 elec­trode sense lead is internal to the cable to the wire feeder and always connected when a wire feeder is present.
PF10M feeder has user preference features to select voltage senses temporarily for testing sense leads.
CAUTION
Important: The electrode polarity must be config­ured at the feed head for all semi-automatic processes. Failure to do so may result in extreme­ly high welding outputs.
------------------------------------------------------------------------
POWER WAVE TO SEMI-AUTOMATIC POW­ERFEED WIRE FEEDER INTERCONNEC­TIONS
The POWER WAVE 355M/405M and semi-automatic Power Feed family communicate via a 5 conductor control cable (K1543). The control cable consists of two power leads, one twisted pair for digital communica­tion, and one lead for voltage sensing. The cables are designed to be connected end to end for ease of exten­sion. The output receptacle on the POWER WAVE 405M is on the case front. The input receptacle on the Power Feed is typically located at the back of the feed­er, or on the bottom of the user interface.
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1. Turn off power to the power source at the disconnect switch.
2. Remove the wrap around cover from the power source.
3. The control board is on the center assembly facing the case front. Locate the 8-position DIP switch and look for switch 8 of the DIP switch.
4. Using a pencil or other small object, slide the switch to the OFF position if the work sense lead is NOT connected. Conversely, slide the switch to the ON position if the work sense lead is present.
O N
12 3 456 7 8
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Due to the flexibility of the platform the configuration may vary. The following is a general description of the system. For specific configuration information, consult the semi-automatic Power Feed instruction manual.
POWER WAVE 355M/405M
A-7 A-7
INSTALLATION
SYSTEM DESCRIPTION
The POWER WAVE 355M/405M and Power Feed 10/11 family of products utilize a digital communication system called Arclink. Simply put, Arclink allows large amounts of information to be passed at very high speeds between components (nodes) in the system. The system requires only two wires for communication, and because of its bus-like structure, the components may be connected to the network in any order, thus simplifying the system set-up.
Each "system" must contain only one power source. The power source may be connected to a maximum of four feeder groups. Each group containing one user interface (UI), and up to seven Feed Heads (FH). SEE FIGURE A.1. The UI controls all of the FH’s of that group. The UI’s and FH’s are assigned to groups by setting a code on the DIP switches mounted on their individual control boards. For example all of the FH’s to be controlled by a given UI must have their "Group ID" switches set to the same group number as the UI. In addition, each FH must be assigned a separate FH number within that group. See the system set-up sec­tion for further details.
From a network perspective, each component in the system is considered a separate node, regardless of its physical location. For example, even though a UI and FH may be physically mounted together, they are still viewed as separate pieces (nodes) by the network, and can only communicate via Arclink. The connection is generally made externally through the Linc-Net Control Cable, but can also be made internally, as with the PF­10 bench model feeder.
The most common Arclink configuration (called a sim­ple system) consists of one power source, one user interface and one feeder. Under these circumstances the group and feed head ID DIP switches are ignored and the system will function regardless of their posi­tion. The same is true for the minimum system consist­ing of a power source and one UI (Example: a stick welding system).
System Model
FIGURE A.1
Maximum
Configuration
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POWER WAVE 355M/405M
A-8 A-8
INSTALLATION
SYSTEM SET-UP
Basic Rules
• Each group is required to have one user interface. No group may have more than one user interface.
• Each group can have up to seven Feed Heads. Exception: Group 3 is limited to a maximum of six Feed Heads.
• Each system has only one power source. For network purposes, the PS belongs to Group 3, which is why group 3 is only allowed 6 feed heads in addition to it’s user interface.
• No two feed heads can have identical Group and Feed Head numbers.
• Group and Feed Head ID numbers must be set on the appropriate dip switches at each node. Consult the PF-10/11 Instruction Manual for specific details regarding dip switch settings.
Simple System
• Feed head “0” not allowed. Exception: Simple sys­tem ignores all ID numbers, therefore “FH0” will func­tion.
• Each node must be connected to the Linc-Net com­munication network. The order of connection is not important, as each node is identified by it’s unique Group and Feed Head ID number as defined on it’s dip switches. See Figures A.2 thru A.5.
FIGURE A.2
Group and Feed Head ID numbers are ignored in a simple system.
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POWER WAVE 355M/405M
A-9 A-9
Multiple Group System
INSTALLATION
FIGURE A.3
No “FH0 Allowed!
Single Group Multi-Head System
FIGURE A.4
No “FH0 Allowed!
The Dual Head option allows the ability to maintain 2 sets of procedures. If more then 2 heads are used, odd #’s use FH1 settings, even #’s use FH2 settings.
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POWER WAVE 355M/405M
A-10 A-10
Single Group Multi-Head System (Alternate Method)
INSTALLATION
FIGURE A.5
No “FH0 Allowed!
When a standard User Interface is used in a group with multi­ple Feed Heads, all of the Feed Heads use a single set of proce-
.
dures
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POWER WAVE 355M/405M
A-11 A-11
Connect All Work Sense Leads at the End of the Joint
Connect All Welding Work Leads at the Beginning of the Joint
Travel
Direction
P
OWER W
P
OWER WAAVVE 355/405E 355/405
POWER WPOWER WAAVVE 355/405E 355/405
INSTALLATION
WELDING WITH MULTIPLE POWER WAVES
CAUTION
Special care must be taken when more than one Power Wave is welding simultaneously on a single part. Arc blow and arc interference may occur or be magnified.
Each power source requires a work lead from the work stud to the welding fixture. Do not combine all of the work leads into one lead. The welding travel directions should be in the direction moving away from the work lead as shown below. Connect all of the work sense leads from each power source to the work piece at the end of the weld.
For the best results when pulse welding, set the wire size and wire feed speed the same for all the Power Waves. When these parameters are identical, the puls­ing frequency will be the same, helping to stabilize the arcs.
CONTROL CABLE SPECIFICATIONS
It is recommended that genuine Lincoln control cables be used at all times. Lincoln cables are specifically designed for the communication and power needs of the Power Wave / Power Feed system.
CAUTION
The use of non-standard cables, especially in lengths greater than 25 feet, can lead to communi­cation problems such as: system shutdowns, poor motor acceleration, poor arc starting) and low wire driving force (wire feeding problems).
-----------------------------------------------------------------------­The K1543 series of control cables can be connected end to end for ease of extension. Do not exceed more
than 100 feet (30.5 m) total control cable length.
Every welding gun requires a separate shielding gas regulator for proper flow rate and shielding gas cover­age.
Do not attempt to supply shielding gas for two or more guns from only one regulator.
If an anti-spatter system is in use then each gun must have its own anti-spatter system. (See Figure A.6)
FIGURE A.6
TWO POWER WAVES
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POWER WAVE 355M/405M
A-12 A-12
INSTALLATION
MULTIPLE ARC UNSYNCHRONIZED SENSE LEAD AND WORK LEAD PLACEMENT GUIDELINES
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POWER WAVE 355M/405M
A-13 A-13
CONTROL BOARD (DIP Switch Location)
INSTALLATION
I / O RECEPTACLE SPECIFICATIONS
TABLE A.2
WIRE FEEDER RECEPTACLE
PIN LEAD# FUNCTION
A 53 Communication Bus L B 54 Communication Bus H C 67A Electrode Voltage Sense D 52 +40vdc E 51 0vdc
TABLE A.3
VOLTAGE SENSE RECEPTACLE
PIN LEAD# FUNCTION
3 21A Work Voltage Sense
TABLE A.4
RS232 RECEPTACLE
PIN LEAD# FUNCTION
2 253 RS232 Receive 3 254 RS232 Transmit 4#Pin5 5#Pin4 6 # # Pin20 20 # # Pin6 7 251 RS232 Common
CONTROL BOARD DIP SWITCH:
switch 1 = reserved for future use switch 2 = reserved for future use switch 3 = reserved for future use switch 4 = reserved for future use switch 5 = reserved for future use switch 6 = reserved for future use switch 7 = reserved for future use switch 8* = work sense lead
switch 8*
off work sense lead not connected on work sense lead connected
*Factory setting for Switch 8 is OFF.
work sense lead
FIGURE A.7
DIP SWITCH SETTINGS AND LOCATIONS
DIP switches on the P.C. Boards allow for custom con­figuration of the Power Wave. To access the DIP switch­es:
WARNING
1. Turn off power to the power source at the dis­connect switch.
------------------------------------------------------------------------
2. Remove the wrap around cover from the power source.
3. The control board is on the center assembly facing the case front. Locate the 8-position DIP switch and look for switch 8 of the DIP switch.
4. Using a pencil or other small object, slide the switch to the OFF position if the work sense lead is NOT connected. Conversely, slide the switch to the ON position if the work sense lead is present.
5. Replace the wrap around and screws. The PC board will “read” the switch at power up, and configure the work voltage sense lead appropriately.
NOTE: For PF10M Dual Boom Feeder set/up and op -
eration. The Power Wave 355M/405M control board dip switches must be set with 3, 4, 7 to the “ON” position (Power Wave 355M/405M input on/off switch must be cycled to enable any change of dip switches).
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O N
12 3 456 7 8
POWER WAVE 355M/405M
A-14 A-14
B
A
C
FIGURE A.3
POWER WAVE
WORK
A
C
B
POWER WAVE
FIGURE A.4
K1796 COAXIAL CABLE
MEASURE FROM END OF OUTER JACKET OF CABLE
C
A
B
WORK
SLIDING
WORK
INSTALLATION
CABLE INDUCTANCE, AND ITS EFFECTS ON PULSE WELDING
For Pulse Welding processes, cable inductance will cause the welding performance to degrade. For the total welding loop length less than tional welding cables may be used without any effects on welding performance. For the total welding loop length greater than
50 ft.(15.24m)), the K1796 Coaxial
Welding Cables are recommended. The welding loop length is defined as the total of electrode cable length (A) + work cable length (B) + work length (C) (See Figure A.3).
For long work piece lengths, a sliding ground should be considered to keep the total welding loop length less
50 ft.(15.24m). (See Figure A.4.)
than
50 ft.(15.24m), tradi-
Most welding applications run with the electrode being positive (+). For those applications, connect the elec­trode cable between the wire feeder and the positive (+) output Twist-Mate terminal on the power source. Connect the other end of the electrode cable to the wire drive feed plate. The electrode cable lug must be against the feed plate. Be sure the connection to the feed plate makes tight metal-to-metal electrical con­tact. The electrode cable should be sized according to the specifications given in the output cable connec­tions section. Connect a work lead from the negative (-) power source output Twist-Mate terminal to the work piece. The work piece connection must be firm and secure, especially if pulse welding is planned.
For additional Safety information regarding the elec­trode and work cable set-up, See the standard "SAFE­TY INFORMATION" located in the front of the Instruction Manuals.
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POWER WAVE 355M/405M
B-1 B-1
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-1
Safety Precautions.......................................................................................................................................B-2
General Description .....................................................................................................................................B-2
Recommended Processes and Equipment .................................................................................................B-2
Required Equipment ....................................................................................................................................B-3
Limitations....................................................................................................................................................B-3
Duty Cycle and Time Period ........................................................................................................................B-3
Case Front Controls.....................................................................................................................................B-3
Making a Weld .............................................................................................................................................B-4
TABLE OF CONTENTS - OPERATION SECTION
Welding Adjustments ...................................................................................................................................B-4
Constant Voltage Welding............................................................................................................................B-5
Tig (GTAW) ...................................................................................................................................................B-6
Special Welding Processes Available ..........................................................................................................B-6
Power Mode.................................................................................................................................................B-7
Pulse Welding (GMAW-P) ............................................................................................................................B-8
Pulse-on-Pulse (GMAW-PP) ......................................................................................................................B-10
Benefits of Pulse-on-Pulse Welding ..........................................................................................................B-10
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POWER WAVE 355M/405M
B-2 B-2
OPERATION
SAFETY PRECAUTIONS
Read this entire section of operating instructions before operating the machine.
WARNING
ELECTRIC SHOCK can kill.
• Unless using cold feed feature, when feeding with gun trigger, the elec­trode and drive mechanism are always electrically energized and could remain energized several sec-
onds after the welding ceases.
• Do not touch electrically live parts or electrodes with your skin or wet clothing.
• Insulate yourself from the work and ground.
• Always wear dry insulating gloves.
-----------------------------------------------------------
FUMES AND GASES can be dangerous.
GENERAL DESCRIPTION
The Power Wave semi-automatic power source is designed to be a part of a modular, multi-process weld­ing system. Depending on configuration, it can support constant current, constant voltage, and pulse welding modes.
The Power Wave power source is designed to be used with the semi automatic family of Power Feed M wire feeders, operating as a system. Each component in the system has special circuitry to "talk with" the other sys­tem components, so each component (power source, wire feeder, user interface) knows what the other is doing at all times. These components communicate with Arclink.
The POWER WAVE 355M/405M is a high perfor­mance, digitally controlled inverter welding power source capable of complex, high-speed waveform con­trol. Properly equipped, it can support the GMAW, GMAW-P, FCAW, SMAW, GTAW, and CAC-A process­es. It carries an output rating of 350 Amps, 34 Volts at 60% duty cycle and 300 Amps, 32 volts at 100% duty cycle.
• Keep your head out of fumes.
• Use ventilation or exhaust to remove fumes from breathing zone.
-----------------------------------------------------------
WELDING SPARKS can cause fire or explosion.
• Keep flammable material away.
• Do not weld on containers that have held combustibles.
-----------------------------------------------------------
ARC RAYS can burn.
• Wear eye, ear, and body protection.
-----------------------------------------------------------
Observe additional guidelines detailed in the beginning of this manual.
RECOMMENDED PROCESSES AND EQUIPMENT
RECOMMENDED PROCESSES
The POWER WAVE 355M/405M can be set up in a number of configurations, some requiring optional equipment or welding programs. Each machine is fac­tory preprogrammed with multiple welding procedures, typically including GMAW, GMAW-P, FCAW, GTAW, and CAC-A for a variety of materials, including mild steel, stainless steel, cored wires, and aluminum.
The POWER WAVE 355M/405M is recommended for semi-automatic welding, and may also be suitable for basic hard automation applications.
• This Power Wave is not recommended for processes other than those listed.
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POWER WAVE 355M/405M
B-3 B-3
OPERATION
POWER WAVE 355M/405M – Semi-Automatic Operation
Semi Automatic Power Waves can only be used with Arclink compatible Power Feed semi-automatic wire feeders. In addition, the Power Feed semi-automatic wire feeders may require optional equipment to access certain weld modes in the Power Wave. Other models of Lincoln feeders, or any models of non-Lincoln wire feeders, cannot be used.
All welding programs and procedures are selected through the Power Feed semi-automatic user interface
REQUIRED EQUIPMENT
Any Arclink compatible semi-automatic wire feeding equipment. Specifically, the semi-automatic Power Feed family (PF10M Series, Power Feed 15M and Power Feed 25M).
LIMITATIONS
• Only Arclink compatible Power Feed semi-automatic wire feeders and users interfaces may be used. Other Lincoln wire feeders or non-Lincoln wire feed­ers cannot be used.
• POWER WAVE 355M/405M Output Limitations
The POWER WAVE 355M/405M will support maxi­mum average output current of 350 Amps @ 60% duty cycle.
NOTE: The POWER WAVE 355M/405M status light will flash green, and sometimes red and green, for up to one minute when the machine is first turned on. This is a normal situation as the machine goes through a self test at power up.
TABLE B.1
Light
Condition
Steady Green
Blinking Green
Alternating Green and Red
System OK. Power source communicating normally with wire feeder and its components if other feeder & components show they are powered up.
Occurs during a reset, and indicates the POWER WAVE 355M/405M is mapping (identifying) each component in the system. Normal for first 1-10 seconds after power is turned on, or if the system configuration is changed during operation
Non-recoverable system fault. If the PW Status light is flashing any combination of red and green, errors are present in the POWER WAVE 355M/405M. Read the error code
before the machine is turned off.
Error Code interpretation through the Status light is detailed in the LED Status Chart. 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.
Meaning
DUTY CYCLE AND TIME PERIOD
The duty cycle is based upon a ten minute period. A 60% duty cycle represents 6 minutes of welding and 4 minutes of idling in a ten minute period.
CASE FRONT CONTROLS
All operator controls and adjustments are located on the case front of the Power Wave. (See Figure B.1)
1. POWER SWITCH: Controls input power to the
Power Wave.
2. STATUS LIGHT: A two color light that indicates sys-
tem errors. Normal operation is a steady green light. Error conditions are indicated, per table B.1.
To clear the error, turn power source off, and back on to reset.
Steady Red
Blinking Red
Non recoverable hardware fault. Generally indicates nothing is connected to the POWER WAVE 355M/405M wire feeder receptacle. See Trouble Shooting Section.
Not applicable.
3. HIGH TEMPERATURE LIGHT (thermal overload): A yellow light that comes on when an over temper­ature situation occurs. Output is disabled and the fan continues to run, until the machine cools down. When cool, the light goes out and output is enabled.
4. CB1 WIRE FEEDER CIRCUIT BREAKER: Protects 40 volt DC wire feeder power supply.
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POWER WAVE 355M/405M
B-4 B-4
OPERATION
FIGURE B.1
2
3
7
6
8
4
1
9
10
5
CASE FRONT LAYOUT
POWER WAVE 355M/405M
5.
Internal POWER CIRCUIT BREAKER: volt AC circuit.
6. LEAD CONNECTOR (SENSE LEAD)
7. DIAGNOSTIC CONNECTOR (RS-232)
8. WIRE FEEDER RECEPTACLE (5-PIN)
9. NEGATIVE TWIST- MATE TERMINAL
10. POSITIVE TWIST- MATE TERMINAL
Protects 115
NOMINAL PROCEDURES
The Power Wave is designed to operate with 3/4" elec­trode stick-out for CV and Pulse processes.
FRINGE PROCEDURES
Excessively short or long electrode stick-outs may function only on a limited basis, if at all.
MAKING A WELD
WARNING
The serviceability of a product or structure utiliz­ing the welding programs is and must be the sole responsibility of the builder/user. Many variables beyond the control of The Lincoln Electric Company affect the results obtained in applying these programs. These variables include, but are not limited to, welding procedure, plate chemistry and temperature, weldment design, fabrication methods and service requirements. The available range of a welding program may not be suitable for all applications, and the build/user is and must be solely responsible for welding program selection.
------------------------------------------------------------------------
The steps for operating the Power Wave will vary depending upon the options installed in the user inter­face (control box) of the welding system. The flexibility of the Power Wave system lets the user customize operation for the best performance.
First, consider the desired welding process and the part to be welded. Choose an electrode material, diam­eter, shielding gas and process (GMAW, GMAW-P, etc.)
Second, find the program in the welding software that best matches the desired welding process. The stan­dard software shipped with the Power Waves encom­passes a wide range of common processes and will meet most needs. If a special welding program is desired, contact the local Lincoln Electric sales repre­sentative.
To make a weld, the Power Wave needs to know the desired welding parameters. The Power Feed (PF) family of feeders communicate settings to the Power Wave through control cable connection. Arc length, wire feed speed, arc control, etc. are all communicated digitally via the control cable.
WELDING ADJUSTMENTS
All adjustments are made on the system component known as the User Interface (Control Box), which con­tains the switches, knobs, and digital displays neces­sary to control both the Power Wave and a Power Feed wire feeder. Typically, the Control Box is supplied as part of the wire feeder. It can be mounted directly on the wire feeder itself, the front of the power source, or mounted separately, as might be done in a welding boom installation.
Because the Control Box can be configured with many different options, your system may not have all of the following adjustments. Regardless of availability, all controls are described below. For further information, consult the Power Feed wire feeder instruction manual.
WFS / AMPS: In synergic welding modes (synergic CV, pulse GMAW) WFS (wire feed speed) is the dominant control para­meter, controlling all other variables. The user adjusts WFS according to factors such as weld size, penetra­tion requirements, heat input, etc. The Power Wave then uses the WFS setting to adjust its output charac­teristics (output voltage, output current) according to pre-programmed settings contained in the Power Wave.
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POWER WAVE 355M/405M
B-5 B-5
OPERATION
In non-synergic modes, the WFS control behaves more like a conventional CV power source where WFS and voltage are independent adjustments. Therefore to maintain the arc characteristics, the operator must adjust the voltage to compensate for any changes made to the WFS.
In constant current modes (stick, TIG) this control adjusts the output current, in amps.
VOLTS / TRIM: In constant voltage modes (synergic CV, standard CV) the control adjusts the welding voltage.
In pulse synergic welding modes (pulse GMAW only) the user can change the Trim setting to adjust the arc length. It is adjustable from 0.500 to 1.500. A Trim set­ting of 1.000 is a good starting point for most condi­tions.
• WELDING MODE
May be selected by name (CV/MIG, CC/Stick Crisp, Gouge, etc.) or by a mode number (10, 24, 71, etc.) depending on the Control Box options. Selecting a welding mode determines the output characteristics of the Power Wave power source. A more complete description of all modes can be found in this section.
• ARC CONTROL
CONSTANT VOLTAGE WELDING
Synergic CV:
For each wire feed speed, a corresponding voltage is preprogrammed into the machine through special soft­ware at the factory. The nominal preprogrammed volt­age is the best average voltage for a given wire feed speed, but may be adjusted to preference. When the wire feed speed changes, the Power Wave automati­cally adjusts the voltage level correspondingly to main­tain similar arc characteristics throughout the WFS range.
Non Synergic CV:
This type of CV mode behaves more like a convention­al CV power source. Voltage and WFS are independent adjustments. Therefore to maintain the arc characteris­tics, the operator must adjust the voltage to compen­sate for any changes made to the WFS.
All CV Modes:
Arc Control, often referred to as wave control, adjusts the inductance of the wave shape. The wave control adjustment is similar to the "pinch" function in that it is inversely proportional to inductance. Therefore, increasing wave control greater than 0.0 results in a harsher, colder arc while decreasing the wave control to less than 0.0 provides a softer, hotter arc. (See Figure B.2)
Also known as Inductance or Wave Control. Allows operator to vary the arc characteristics from "soft" to "harsh" in all weld modes. It is adjustable from -10.0 to +10.0, with a nominal setting of 00.0 (The nominal set­ting of 00.0 may be displayed as OFF on some Power Feed wire feeder control panels). See the Welding Mode descriptions for a more detailed explanations of how the Arc Control affects each mode.
Current
FIGURE B.2
CURRENT WAVE FORM (CV)
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POWER WAVE 355M/405M
B-6 B-6
OPERATION
TIG GTAW
The TIG mode features continuous control from 5 to 425 amps. The TIG mode can be run in either the Touch Start TIG or Scratch start mode.
The Arc Control level selects the starting mode.
Between –10 and 0, the Touch Start TIG mode is selected. The OCV is controlled below 10V and the short circuit "TIG touch" current is maintained at approximately 25 amps, independent of the preset current. When the tungsten is lifted, an arc is initiated and the output is regulated at the preset value. A set­ting of 0, results in the most positive arc initiation. A setting of -10 reduces the start procedure to start the weld, and from there, to ramp to the welding proce­dure over a specified amount of time.
A setting above 0 selects a Scratch Start. Full OCV is available when the arc initiates the output is regulated to the preset value
Typically starting procedure on a higher “+” setting is known as a “Hot Start”. Setting a starting procedure on a lower setting is known as a “Cold Start”.
NOTE: Later versions of weld software
eliminated the Arc Control Function in TIG mode and only allow for “Touch Start” operation.
SMAW
In SMAW (STICK mode), the arc control adjusts the arc force. It can be set to the lower range (0 to -10) for a soft and less penetrating arc characteristic or to the higher range (0 to +10) for a crisp and more penetrat­ing arc. Normally, when welding with cellulosic types of electrodes (E6010, E7010, E6011), a higher energy arc is required to maintain arc stability. This is usually indicated when the electrode sticks to the work-piece or when the arc pops-out during manipulative tech­nique. For low hydrogen types of electrodes (E7018, E8018, E9018, etc.) a softer arc is usually desirable and the lower end of the Arc Control suits these types of electrodes. In either case the arc control is available to increase or decrease the energy level delivered to the arc.
Recommended Welding Procedures for Power Mode
TABLE B.2
MATERIAL Aluminum 4043 Aluminum 5356 Mild Steel Mild Steel Mild Steel Mild Steel Mild Steel Mild Steel Stainless Steel Stainless Steel
WIRE E4043 E5356 L56 L56 L56 L56 L56 L56 E308L E308L
WIRE SIZE 0.035 0.035 0.025 0.025 0.030 0.030 0.035 0.035 0.030 0.035
GAS 100% Agr. 100% Agr.
22 ga.
20 ga. 120 / 1.0 120 / 1.0 100 / 0.7 100 / 1.0 80 / 1.5 50 / 0.5
18 ga. 140 / 1.7 140 / 1.5 110 / 1.5 110 / 1.5 100 / 2.5 100 / 2.5 110 / 2.0 110 / 2.0
16 ga. 190 / 2.0 190 / 2.0 125 / 2.0 125 / 2.0 125 / 3.0 125 / 3.0 140 / 2.5 130 / 2.7
14 ga. 400 / 2.0 400 / 2.5 260 / 3.0 260 / 3.0 160 / 2.3 160 / 2.3 160 / 3.8 160 / 3.5 210 / 3.0 190 / 3.5
12 ga. 330 / 5.0 330 / 4.5 230 / 3.5 230 / 3.5 200 / 5.0 200 / 4.5 270 / 5.0 230 / 6.0
MATERIAL THICKNESS
10 ga. 500 / 7.0 500 / 7.0 300 / 6.0 300 / 6.0 240 / 6.5 240 / 7.0 325 / 6.5 300 / 7.0
WFS / POWER MODE SETTING
3/16 570 / 90 600 / 7.8 400 / 7.5 400 / 7.0
1/4 700 / 9.1 700 / 8.5
COMMENTS
Not
Recommended
below 400
WFS
Not
Recommended
below 400
WFS
100% CD275/25 Ar/CO2100% CD275/25 Ar/CO2100% CD275/25 Ar/CO
Not
recommended
100 / 0.8
Not
recommended
90 / 1.0
Tri-mix Tri-mix
2
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POWER WAVE 355M/405M
B-7 B-7
STEEL BUTTED TOGTHER
WELD GROOVES CREATED BY ARC GOUGING
OPERATION
ARC GOUGING
Gouging is basically removing metal to form a bevel or groove in a piece of steel with controlled forced air and a carbon rod.
The common procedures for Arc Gouging metal are:
• Removing poor welds from a weldment so that new welds can be made.
• Creating a welding groove or grooves in two pieces of steel butted together. (See Example below)
Power Mode™ is a method of high speed regulation of the output power whenever an arc is established. It provides a fast response to changes in the arc. The higher the Power Mode Setting, the longer the arc. If a welding procedure is not established, the best way to determine the Power Mode Setting is by experimenta­tion until the desired output result is established.
In the Power Mode variables need to be set:
• Wire Feed Speed
• Output
• Arc Control
Setting up a Power Mode procedure is similar to set­ting a CV MIG procedure. Select a shielding gas appropriate for a short arc process.
• For steel, use 75/25 Ar/CO2 shield gas.
Mode 9 in the POWER WAVE 355M is specifically for gouging. Gouging can also be done in the stick soft and crisp modes. Setting the output of the Stick Soft mode to 425 amps will enable the arc-gouging mode. The actual output current will depend on the size of carbon used. The recommended maximum size carbon
is 5/16".
POWER MODE™
The Power Mode™ process was developed by Lincoln to maintain a stable and smooth arc at low procedure settings which are needed to weld thin metal without pop-outs or burning-through. For Aluminum welding, it provides excellent control and the ability to maintain constant arc length. This results in improved welding performance in two primary types of applications.
• Short Arc MIG at low procedure settings.
• Aluminum MIG welding.
• For Stainless, select a Helium blend Tri-Mix.
• For Aluminum, use 100% Ar.
Start by setting the wire feed speed based upon mate­rial thickness and appropriate travel speed. Then adjust the Output knob as follows:
• For steel, listen for the traditional “frying egg” sound of a good short-arc MIG procedure to know you have the process set correctly.
• For aluminum, simply adjust the Output knob until the desired arc length is obtained.
Note the Volts display is simply a relative number and DOES NOT correspond to voltage.
Some Power Mode procedure recommendations appear in Table B.2.
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POWER WAVE 355M/405M
B-8 B-8
PEAK AMPS
FREQUENCY
SPRAY TRANSITION
CURRENT
EACH PULSE DELIVERS ONE DROPLET OF WELD MATERIAL
OPERATION
SPECIAL WELDING PROCESSES AVAILABLE ON THIS MACHINE
PULSE WELDING (GMAW-P)
The pulsed-arc process is, by definition, a spray trans­fer process wherein spray transfer occurs in pulses at regularly spaced intervals. In the time between pulses, the welding current is reduced and no metal transfer occurs.
Pulsed-arc transfer is obtained by operating a power source between low and high current levels. The high current level or “pulse” forces an electrode drop to the workpiece. The low current level or “background” main­tains the arc between pulses. (See Figure B.3).
Pulsed MIG is an advanced form of welding that takes the best of all the other forms of transfer while mini­mizing or eliminating their disadvantages. Unlike short circuit, pulsed MIG does not create spatter or run the risk of cold lapping. The welding positions in pulsed MIG are not limited as they are with globular or spray and its wire use is definitely more efficient. Unlike the spray arc process, pulsing offers controlled heat input that allows better welding on thin materials. Pulsing allows for lower wire feed speeds which leads to less distortion and improved overall quality and appear­ance. This is especially important with stainless, nick­el and other alloys that are sensitive to heat input.
In GMAW-P mode, arc control adjusts the background current and frequency of the wave. When arc control goes up, the frequency increases thus increasing the droplet transfer.
FIGURE B.3
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POWER WAVE 355M/405M
B-9 B-9
OPERATION
PULSE WELDING
Pulse welding procedures are set by controlling an overall "arc length" variable. When pulse welding, the arc voltage is highly dependent upon the waveform. The peak current, back ground current, rise time, fall time and pulse frequency all affect the voltage. The exact voltage for a given wire feed speed can only be predicted when all the pulsing waveform parameters are known. Using a preset voltage becomes impracti­cal, and instead the arc length is set by adjusting "trim".
Trim adjusts the arc length and ranges from 0.50 to
1.50, with a nominal value of 1.00. Trim values greater than 1.00 increase the arc length, while values less than 1.00 decrease the arc length.
All pulse welding programs are synergic. As the wire feed speed is adjusted, the Power Wave will automati­cally recalculate the waveform parameters to maintain similar arc properties.
The Power Wave utilizes "adaptive control" to compen­sate for changes in electrical stick out while welding. (Contact to Work Distance is the distance from the contact tip to the work piece.) The Power Wave wave forms are optimized for a 0.75" (19mm) stick-out. The adaptive behavior supports a range of stickouts from
0.50" (13mm) to 1.25" (32mm). At very low or high wire feed speeds, the adaptive range may be less due to reaching physical limitations of the welding process.
FIGURE B.3
CURRENT WAVE FORM (PULSE)
Current
Time
Arc Control, often referred to as wave control, in pulse programs usually adjusts the focus or shape of the arc. Wave control values greater than 0.0 increase the pulse frequency while decreasing the background cur­rent, resulting in a tight, stiff arc best for high speed sheet metal welding. Wave control values less than 0.0 decrease the pulse frequency while increasing the background current, for a soft arc good for out-of-posi­tion welding.
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POWER WAVE 355M/405M
B-10 B-10
PEAK AMPS
BACKGROUND AMPS
TIME
HIGH HEAT PULSES
LOW HEAT PULSES
"N" PULSES "N" PULSES
Aluminum 4043 Aluminum 4043 Aluminum 5356 Aluminum 5356
100% Ar. 100% Ar. 100% Ar. 100% Ar.
E4043 E4043 E5356 E5356
0.035 3/64 0.035 3/64
14 ga. 250 / 0 200 / 0 230 / 0 225 / 0
10 ga. 400 / 0 280 / 0 425 / 0 400 / 0
3/16 550 / 0 340 / 0 670 / 0 500 / 0
1/4 600 / 0 400 / 0 700 / 0 550 / 0
WFS /
ARC CONTROL
MATERIAL
THICKNESS
MATERIAL
GAS
WIRE
WIRE SIZE
Not Recommended
below 200 WFS
COMMENTS
Not Recommended
below 200 WFS
Not Recommended
below 100 WFS
Not Recommended
below 200 WFS
OPERATION
PULSE-ON-PULSE™ (GMAW-PP)
Pulse on Pulse™ is a Lincoln process specifically designed for use in welding relatively thin (less than 1/4" thick) aluminum (See the table below). It gives weld beads with very consistent uniform ripple.
In Pulse on Pulse modes, two distinct pulse types are used, instead of the single pulse type normally used in GMAW-P. A number of high energy pulses are used to obtain spray transfer and transfer metal across the arc. Such pulses are shown in the figure below. After a number "N" of such pulses, depending on the wire feed speed used, an identical number "N" of low energy pulses are performed. These low energy pulses, shown in the figure below, do not transfer any filler metal across the arc and help to cool the arc and keep the heat input low.
The Peak Current, Background Current, and Frequency are identical for the high energy and low energy pulses. In addition to cooling the weld down, the major effect of the low energy pulses is that they form a weld ripple. Since they occur at very regular time intervals, the weld bead obtained is very uniform with a very consistent ripple pattern. In fact, the bead has its best appearance if no oscillation of the welding gun ("whipping") is used.(See the figure below)
When Arc Control is used in the Pulse on Pulse modes, it does the same things it does in the other pulsed modes: decreasing the Arc Control decreases the droplet transfer and weld deposition rate. Increasing the Arc Control increases the droplet trans­fer and weld deposition rate. Since Arc Control varies weld droplet transfer rate, the Arc Control can be used to vary the ripple spacing in the weld bead.
BENEFITS OF PULSE ON PULSE FROM LINCOLN ELECTRIC
• Excellent appearance of the weld bead
• Improved cleaning action
• Reduced porosity
Table B.3 shows WFS and Trim settings for common aluminum types and wire sizes when welding with Pulse-on-Pulse. The welds made to obtain the values in the table were fillet welds in the flat position. The val­ues in the table can be helpful as a starting point to establish a welding procedure. From there, adjust­ments need to be made to set the proper procedure for each specific application (out-of-position, other types of joints, etc.).
The comments on the table below show values of WFS below which it is not recommended to weld. The rea­son is, that below these values the weld transfer will change from a spray arc to a short-arc, which is not advisable when welding aluminum.
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TABLE B.3
WELDING PROCEDURES FOR PULSE-ON-PULSE
POWER WAVE 355M/405M
C-1 C-1
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-1
Optional Equipment ....................................................................................................................................C-2
TABLE OF CONTENTS - ACCESSORIES SECTION
Field Installed .................................................................................................................................C-2
Compatible Lincoln Equipment ......................................................................................................C-2
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POWER WAVE 355M/405M
C-2 C-2
ACCESSORIES
OPTIONAL EQUIPMENT
FACTORY INSTALLED
None Available.
FIELD INSTALLED
K940-Work Voltage Sense Lead Kit K1764-1-Undercarriage* K1838-1-Valet Style Undercarriage K1796-Coaxial Welding Cable­K2176-1 Twist-mate to Lug Adapters * Dual Cylinder Kit for K1764-1 is K1702-1 K2436-1 Ethernet/Devicenet Communication Interface
Welding Cable Connectors: K852-70 1/0-2/0 CABLE K852-95 2/0-3/0 CABLE
COMPATIBLE LINCOLN EQUIPMENT
(Requires Adapter K2176-1)
Any ARC Link compatible wire feeding equipment PF10M, PF15M, PF25M series.
NOTE: No Linc-Net semi-automatic wire feeding equip­ment is compatible. Specifically, the semi-automatic Power Feed family (PF-10, PF-10X2, PF-11) will not work with a PW355M/405M.
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POWER WAVE 355M/405M
D-1 D-1
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-1
Safety Precautions.......................................................................................................................................D-2
Capacitor Discharge Procedure ..................................................................................................................D-2
Visual Inspection..........................................................................................................................................D-2
Routine Maintenance...................................................................................................................................D-2
Periodic Maintenance ..................................................................................................................................D-2
Major Component Locations .......................................................................................................................D-3
TABLE OF CONTENTS - MAINTENANCE SECTION
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POWER WAVE 355M/405M
D-2 D-2
CAPACITOR TERMINALS
RESISTOR
MAINTENANCE
VISUAL INSPECTION
WARNING
Have qualified personnel do the maintenance wo rk. A l w a y s use the g r e atest c a re when working near moving parts.
Do not put your hands near the cooling blower fan. I f a proble m can n o t b e co r recte d by following the instructions, take the machine to the nearest Lincoln Field Service Shop.
-----------------------------------------------------------------------
ELECTRIC SHOCK can kill.
• Do not touch electrically live parts or electrode with skin or wet clothing.
• Insula t e yoursel f f r o m w o r k and
ground
• Always wear dry insulating gloves.
------------------------------------------------------------------------
EXPLODING PARTS can cause injury.
Failed parts can explode or cause other parts to explode when power is applied.
Always wear a face shield and long sleeves
• when servicing.
------------------------------------------------------------------------
See a ddi tio na l w arn ing i nfo rma ti on throughout this Manual.
------------------------------------------------------------------------
Clean interior of machine with a low pressure air stream. Make a thorough inspection of all compo­nents. Look for signs of overheating, broken leads or other obvious problems. Many problems can be uncovered with a good visual inspection.
ROUTINE MAINTENANCE
1. Every 6 months or so the machine should be cleaned with a low pressure airstream. Keeping the machine clean will result in cooler operation and higher reliability. Be sure to clean these areas:
• All printed circuit boards
• Power switch
• Main transformer
• Input rectifier
• Auxiliary Transformer
• Reconnect Switch Area
• Fan (Blow air through the rear louvers)
2. Examine the sheet metal case for dents or breakage.
Repair the case as required. Keep the case in good condition to insure that high voltage parts are protected and correct spacings are maintained. All external sheet metal screws must be in place to insure case strength and electrical ground continuity.
PERIODIC MAINTENANCE
CAPACITOR DISCHARGE PROCEDURE
1. Obtain a power resistor (25 ohms, 25 watts).
2. Hold resistor body with electrically insulated glove. DO NOT TOUCH TERMINALS. tor terminals across the two studs in the position shown. Hold in each position for 1 second. Repeat for all four capacitors.
3. Use a DC voltmeter to check that voltage is not
present across the terminals on all four capaci­tors.
Connect the resis-
Calibration of the POWER WAVE 355M/405M is critical to its operation. Generally speaking the calibration will not need adjustment. However, neglected or improper­ly calibrated machines may not yield satisfactory weld performance. To ensure optimal performance, the cali­bration of output Voltage and Current should be checked yearly.
Calibration is accomplished with our Diagnostic Utility software found on the Lincoln Electric Service Navigator CD or on our web site at www.lincoln ­electric.com.
If a welder has difficulty in being calibrated some things to look for proper configuration of the sense leads. Make sure your meter is measuring at the same point as the power source - local (studs) or remote (feeder).
All meters used for calibration checks must be calibrat­ed and traceable to National Standards. Some digital meters may not function properly with inverter sup­plies. Try an analog type meter and calibrate around 300 amps @ 30V loading in all cases.
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POWER WAVE 355M/405M
D-3 D-3
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MAINTENANCE
FIGURE D.1 – MAJOR COMPONENT LOCATIONS
1. Center Panel
2. Case Back
3. Case Front
4. Base Assembly
5. Case Wraparound
Use parts page exploded views to also help iso­late and identify smaller parts. Parts page num­bers can be found on the Master Table of Contents in the front of this manual.
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POWER WAVE 355M/405M
D-4 D-4
NOTES
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POWER WAVE 355M/405M
E-1 E-1
Control Board
Choke
Positive Output Terminal
Negative Output Terminal
To Control Board
Cur
r ent
Feedbac
k
Reconnect Switch
O
u
t
p
u
t
V
o
l
t
a
g
e
Se
n
se
Input switch
Input Rectifier
Auxiliary Transformer
Fan
Power Board
220 Receptacle
RS232 Supply +5VDC
Machine Control Supply +15VDC, -15VDC, +5VDC
40VDC
42VAC
220 VAC
Main Switch Board
115VAC Fan Supply
F
a
n
Co
n
t
ro
l
V/F Capacitor Feedback (2)
Soft Start Control
Input Relay Control
Primary Current Feedback(2)
IGB
T D
r
i
ve S i
g n a l
P
rimary Current S
ensor
Primary C
urrent Sensor
{
P o w e
r
W
a
v
e
4 0 5
o n
l
y
65VAC
DC
Bus
Board
Wire
Feeder
Recp.
40VDC
Can Supply +5VDC
Arc Link
Electrode Sense
21 Lead
Voltage
Sense Recp.
R232 Connector
Yellow Thermal LED
Status Red/Green LED
Thermostats 2
To
Feeder
TABLE OF CONTENTS-THEORY OF OPERATION SECTION
Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-1
General Description ...................................................................................................................................E-2
Input Line Voltage, Auxiliary Transformer and Precharge..........................................................................E-2
Switch Board and Main Transformer .........................................................................................................E-3
DC Bus Board, Power board and Control Board ......................................................................................E-4
Output Rectifier and Choke .......................................................................................................................E-5
Thermal Protection ...................................................................................................................................E-6
Protective Circuits......................................................................................................................................E-6
Over current Protection .......................................................................................................................E-6
Under/Over Voltage Protection ...........................................................................................................E-6
Insulated Gate Bipolar Transistor (IGBT) Operation ..................................................................................E-7
Pulse Width Modulation.............................................................................................................................E-8
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Minimum/Maximum Output ................................................................................................................E-8
FIGURE E.1 BLOCK LOGIC DIAGRAM
POWER WAVE 355M/405M
E-2 E-2
C
ontrol Board
C
hoke
Positive Output Terminal
Negative Output Terminal
To Control Board
C u
rre n
t
Fe e
d b
a c k
Reconnect
Switch
Output V
ol
tage Sense
Input switch
Input Rectifier
Auxiliary Transformer
F
an
Power Board
220 Receptacle
RS232 Supply +5VDC
Machine Control Supply
+
15VDC, -15VDC, +5VDC
40VDC
42VAC
220 VAC
M
ain Switch Board
115VAC Fan Supply
Fa
n
Co
n
tro
l
V
/F Capacitor Feedback (2)
Soft Start Control
Input Relay Control
P
rimary Current Feedback(2)
I
G B T Dr
i
ve S
i
g n a l
Primary C
urrent
Sensor
Primary C
urrent
Sensor
{
P
o
w
e
r
W
a v e
4 0 5
o n
l
y
6
5
VAC
D
C
Bus
Board
Wire
F
eeder
Recp.
40VDC
C
an Supply +5VDC
Arc Link
Electrode Sense
21 Lead
V
oltage Sense Recp.
R232 Connector
Yellow Thermal LED
Status Red/Green LED
Thermostats 2
THEORY OF OPERATION
FIGURE E.2 - GENERAL DISCRIPTION
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GENERAL DESCRIPTION
The Power Wave semi-automatic power source is designed to be a part of a modular, multi-process welding system. Depending on configuration, it can support constant current, constant voltage, and pulse welding modes.
The Power Wave power source is designed to be used with the semi-automatic family of power feed wire feeders, operating as a system. Each component in the system has special circuitry to “talk with” the other system components, so each component (power source, wire feeder, user interface) knows what the other is doing at all times. These components com­municate with Arc Link (a digital communications sys­tem).
The POWER WAVE 355M/405M is a high performance, digitally controlled inverter welding power source capable of complex, high speed waveform control. Properly equipped, it can support the GMAW, GMAW­P, FCAW, SMAW, GTAW, and CAC-A processes. It car­ries an output rating of 350 Amps, 34 Volts at 60% duty cycle and 300 Amps, 32 volts at 100% duty cycle.
INPUT LINE VOLTAGE, AUXILIARY TRANSFORMER, & PRECHARGE
The POWER WAVE 355M/405M can be connected for a variety of three-phase or single-phase input volt­ages. The initial power is applied to the 355M/405M through a line switch located on the front of the machine. Two phases of the input voltage are applied to the auxiliary transformer. The auxiliary transformer
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develops three different secondary voltages. The 115VAC is applied, via the main switch board, to the fan motor. The 42VAC is rectified and filtered. The 65VDC produced by the Bus board rectifier is used by the Bus board to provide 40VDC to the power board. 40VDC is also applied to the wire feeder receptacle. PW405 models have an additional 220VAC winding that is connected to a 220 AC receptacle.
The input voltage is rectified by the input rectifier and the resultant DC voltage is applied to the switch board through the reconnect switch assembly located at the rear of the machine. The reconnect switch connects the two pairs of input capacitors either in a parallel (lower voltage) or series (higher voltage) configuration to accommodate the applied input voltage.
During the precharge time the DC input voltage is applied to the input capacitors through a current limit­ing circuit. The input capacitors are charged slowly and current limited. A voltage to frequency converter circuit located on the switch board monitors the capacitor voltages. This signal is coupled to the con­trol board. When the input capacitors have charged to an acceptable level, the control board energizes the input relays, that are located on the switch board, making all of the input power, without current limiting, available to the input capacitors. If the capacitors become under or over voltage the control board will de-energize the input relays and the 355M/405M out­put will be disabled. Other possible faults may also cause the input relays to drop out.
NOTE: Unshaded areas of Block Logic
Diagram are the subject of discussion
POWER WAVE 355M/405M
E-3 E-3
C
ontrol Board
C
hoke
P
ositive Output Terminal
Negative Output Terminal
To Control Board
C u
rre n
t
F e e d b a c k
Reconnect Switch
Out
p
ut
Vo
lt
a
ge
S
en
s
e
Input switch
Input Rectifier
Auxiliary Transformer
Fan
Power
Board
220 Receptacle
RS232 Supply +5VDC
Machine Control Supply +15VDC, -15VDC, +5VDC
40VDC
42VAC
220 VAC
M
ain Switch Board
115VAC Fan Supply
Fa
n
Co
n
t
r
o
l
V/F Capacitor Feedback (2)
Soft Start Control
Input Relay Control
P
rimary Current Feedback(2)
I G
B T D r
i
v e
S i
g n a l
P
rimary Current S
ensor
Primary C
urrent S
ensor
{
P
o
w
e
r
W
a v e
4 0 5
o n
l
y
65VAC
DC Bus
Board
Wire
Feeder
Recp.
40VDC
Can Supply +5VDC
Arc Link
Electrode S
ense
2
1 Lead
Voltage Sense Recp.
R232 Connector
Yellow T
hermal
LED
Status Red/Green LED
Thermostats 2
To
THEORY OF OPERATION
FIGURE E.3 – SWITCH BOARD & MAIN TRANSFORMER
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SWITCH BOARD & MAIN TRANSFORMER
There is one switch board in the POWER WAVE 355M/405M. This board incorporates two pairs of input capacitors, two insulated gate bipolar transistor (IGBT) switching circuits, a fan motor drive circuit, and a voltage/frequency capacitor feedback circuit. The two capacitors in a pair are always in series with each other. When the reconnect switch is in the lower volt­age position the capacitor pairs are in parallel - that is, two series capacitors in parallel with two series capac­itors. When the reconnect switch is in the high voltage position the two capacitor pairs are in series or, four capacitors in series. This is required to accommodate the higher input voltages.
When the input capacitors are fully charged they act as power supplies for the IGBT switching circuits. When welding output is required the Insulated Gate Bipolar Transistors switch the DC power from the input capacitors, "on and off" thus supplying a pulsed DC current to the main transformer primary windings. See
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IGBT Operation Discussion and Diagrams in this section. Each IGBT switching circuit feeds current to a separate, oppositely wound primary winding in the main transformer. The reverse directions of current flow through the main transformer primaries and the offset timing of the IGBT switching circuits induce an
AC square wave output signal at the secondary of the main transformer. The two current transformers (CT) located on the switch board monitor these primary currents. If the primary currents become abnormally high the control board will shut off the IGBTs, thus dis­abling the machine output. The DC current flow through each primary winding 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, creating a constant 20 KHZ output. In some low open circuit Tig modes the firing frequency is reduced to 5KHZ.
The POWER WAVE 355M/405M has a F.A.N. (fan as needed) circuit. The fan operates when the welding output terminals are energized or when a thermal over temperature condition exists. Once the fan is activat­ed it will remain on for a minimum of five minutes. The fan driver circuit is housed on the switch board but it is activated by a signal from the control board.
NOTE: Unshaded areas of Block Logic
POWER WAVE 355M/405M
Diagram are the subject of discussion
E-4 E-4
Control Board
C
hoke
Positive Output Terminal
N
egative Output Terminal
To Control Board
C u
r r e
n t
F e e d b a ck
R
econnect
Switch
O
u
t
p
u
t
V
o
lt
a
g
e
S
e
n
s
e
Input switch
Input
Rectifier
Auxiliary Transformer
F
an
Power
Board
220 Receptacle
RS232 Supply +5VDC
Machine Control Supply +15VDC, -15VDC, +5VDC
40VDC
42VAC
220 VAC
M
ain Switch Board
115VAC Fan Supply
F
an C
ontr
ol
V/F Capacitor Feedback (2)
Soft Start Control
Input Relay Control
P
rimary Current Feedback(2)
IG B
T Drive
S ig n
a l
Primary C
urrent
S
ensor
P
rimary Current S
ensor
{
P o w e
r
W
a v e
4 0 5
o n
l
y
65VAC
DC
Bus
Board
Wire
Feeder
Recp.
40VDC
Can Supply +5VDC
A
rc
Link
Electrode Sense
21 Lead
Voltage
Sense Recp.
R232 C
onnector
Yellow Thermal LED
Status Red/Green LED
Thermostats
2
To
Feeder
THEORY OF OPERATION
FIGURE E.4 – POWER BOARD, CONTROL BOARD AND SERIAL PERIPHERAL INTERFACE (SPI) COMMUNICATIONS
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DC BUS BOARD, POWER BOARD AND CONTROL BOARD
DC BUS BOARD
The DC Bus Board receives approximately 65VDC from the bus board rectifier. The DC Bus Board regu­lates that 65VDC to a +40VDC supply. This regulated 40VDC is applied to the Power Board and the wire feed receptacles.
POWER BOARD
The power board, utilizing a switching power supply, processes the 40VDC input and develops several reg­ulated positive and negative DC supplies. Three DC supplies are fed to the control board for machine con­trol supplies. A +5VDC is used for the RS232 connec­tion supply. Another +5VDC supply is utilized by the CAN digital communication circuitry. An over or under input voltage detection and shutdown circuit is also part of the power board’s circuitry.
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NOTE: Unshaded areas of Block Logic
Diagram are the subject of discussion
CONTROL BOARD
The Control Board performs the primary interfacing functions to establish and maintain output control of the POWER WAVE 355M/405M. The function genera­tor and weld files exist within the Control Board hard­ware and software. Digital command signals received
POWER WAVE 355M/405M
from the user interface/feed head and feedback infor­mation received from the current sensor and output voltage sensing leads, are processed at the control board. Software within the control board processes the command and feedback information and sends the appropriate pulse width modulation (PWM) signals (See PULSE WIDTH MODULATION in this section) to the switch board IGBT’s. In this manner, the digitally controlled high speed welding waveform is created.
In addition, the Control Board monitors the ther­mostats, the main transformer primary currents and input filter capacitor voltages. Depending on the fault condition, the Control Board will activate the thermal and/or the status light and will disable or reduce the machine’s output.
E-5 E-5
C
ontrol Board
Choke
Positive O
utput
T
erminal
Negative O
utput
Terminal
To Control Board
C u
r r e
n t
F e e d b a ck
Reconnect
Switch
Ou
t
p
u
t
V
o
lt
a
g
e
S
e
n
s
e
Input switch
Input Rectifier
Auxiliary Transformer
Fan
Power
Board
220 Receptacle
RS232 Supply +5VDC
Machine Control Supply +15VDC, -15VDC, +5VDC
40VDC
42VAC
220 VAC
M
ain Switch Board
115VAC Fan Supply
F
a
n
C
o
n
tr
o
l
V
/F Capacitor Feedback (2)
Soft Start Control
I
nput Relay Control
Primary Current Feedback(2)
IG B
T Drive
S ig n
a l
P
rimary Current Sensor
Primary Current S
ensor
{
P
o
w
e
r
W
a v e
4 0 5
o n
l
y
65VAC
DC
Bus
Board
Wire
Feeder
Recp.
40VDC
Can Supply +5VDC
Arc L
ink
Electrode Sense
21 Lead
Voltage
Sense
Recp.
R232 Connector
Yellow Thermal LED
Status Red/Green LED
T
hermostats
2
To
Feeder
THEORY OF OPERATION
FIGURE E.5 – OUTPUT RECTIFIER AND CHOKE
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OUTPUT RECTIFIER AND CHOKE
The output rectifier receives the AC output from the main transformer secondary and rectifies it to a DC voltage level. Since the output choke is in series with the negative leg of the output rectifier and also in series with the welding load, a filtered DC output is applied to the machine’s output terminals.
NOTE: Unshaded areas of Block Logic
Diagram are the subject of discussion
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POWER WAVE 355M/405M
E-6 E-6
THEORY OF OPERATION
THERMAL PROTECTION
Three normally closed (NC) thermostats protect 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 switch board, one is located on the output choke and the third thermostat is located on the DC Bus Board. Excessive tempera­tures may be caused by a lack of cooling air or oper­ating the machine beyond its duty cycle or output rat­ing. If excessive operating temperatures should occur, the thermostats will prevent output from the machine. The yellow thermal light, located on the front of the machine, will be illuminated. The thermostats are self­resetting once the machine cools sufficiently. If the thermostat 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.
PROTECTIVE CIRCUITS
Protective circuits are designed into the POWER WAVE 355M/405M to sense trouble and shut down the machine before damage occurs to the machine's internal components.
OVER CURRENT PROTECTION
If the average current exceeds 450 amps for one sec­ond, then the output will be limited to 100 amps until the load is removed. If the peak current exceeds 600 amps for 150 ms, the output will be limited to 100 amps until the load is removed.
UNDER/OVER VOLTAGE PROTECTION
Protective circuits are included on the switch and con­trol boards to monitor the voltage across the input capacitors. In the event that a capacitor pair voltage is too high, or too low, the machine output will be dis­abled. The protection circuits will prevent output if any of the following conditions exist.
1. Voltage across a capacitor pair exceeds 467 volts. (High line surges or improper input voltage connections.)
2. Voltage across a capacitor pair is under 190 volts. (Due to improper input voltage connections.)
3. Any major internal component damage.
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POWER WAVE 355M/405M
E-7 E-7
DRAIN
SOURCE
GATE
INJECTING LAYER
BUFFER LAYER
DRAIN DRIFT REGION
BODY REGION
p +
n +
n -
p
n + n +
DRAIN
SOURCE
GATE
INJECTING LAYER
BUFFER LAYER
DRAIN DRIFT REGION
BODY REGION
p +
n +
n
-
p
n + n +
POSITIVE VOLTAGE APPLIED
B. ACTIVE
A. PASSIVE
THEORY OF OPERATION
INSULATED GATE BIPOLAR TRANSISTOR (IGBT) OPERATION
An IGBT is a type of transistor. IGBT are semiconduc­tors well suited for high frequency switching and high current applications.
Example A in Figure E.6 shows an IGBT in passive mode. There is no gate signal, zero volts relative to the source, and therefore, no current flow. The drain ter­minal of the IGBT may be connected to a voltage sup­ply; but since there is no conduction, the circuit will not supply current to components connected to the source. The circuit is turned OFF like a light switch.
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
FIGURE E.6 – IGBT
capable of conducting current. A voltage supply con­nected 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.
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POWER WAVE 355M/405M
E-8 E-8
THEORY OF OPERATION
FIGURE E.7 — TYPICAL IGBT OUTPUTS.
PULSE WIDTH MODULATION
The term Pulse Width Modulation is used to describe how much time is devoted to conduction 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.
MINIMUM OUTPUT
By controlling the duration of the gate signal, the IGBT is turned on and off for different durations during the cycle. The top drawing in Figure E.7 shows the mini­mum output signal possible over a 50-microsecond time period.
The positive portion of the signal represents one IGBT
group1conducting for one microsecond. The negative
portion is the other IGBT group1. 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 conducting, the output power is minimized.
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.
1
An IGBT group consists of two IGBT modules feed­ing one transformer primary winding.
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POWER WAVE 355M/405M
F-1 F-1
TABLE OF CONTENTS - TROUBLESHOOTING AND REPAIR
Troubleshooting and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-1
How to Use Troubleshooting Guide ..........................................................................................................F-2
PC Board Troubleshooting Procedures and Replacement .......................................................................F-3
Troubleshooting Guide .............................................................................................................................F-4
Test Procedures
Input Filter Capacitor Discharge Procedure .....................................................................................F-13
Main Switch Board Test....................................................................................................................F-15
Input Rectifier Test............................................................................................................................F-19
Power Board Test .............................................................................................................................F-23
DC Bus Board Test...........................................................................................................................F-27
Output Rectifier Modules Test ..........................................................................................................F-31
Auxiliary Transformer Test.................................................................................................................F-35
Current Transducer Test ...................................................................................................................F-39
Fan Control and Motor Test..............................................................................................................F-43
Replacement Procedures
Control Board Removal and Replacement.......................................................................................F-47
Main Switch Board Removal and Replacement...............................................................................F-51
Snubber Board Removal and Replacement.....................................................................................F-55
Power Board Removal and Replacement ........................................................................................F-57
DC Bus Board Removal and Replacement ......................................................................................F-61
Input Rectifier Removal and Replacement.......................................................................................F-65
Output Rectifier Modules Removal and Replacement .....................................................................F-69
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Current Transducer Removal and Replacement ..............................................................................F-73
Retest after Repair............................................................................................................................F-78
POWER WAVE 355M/405M
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 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: output problems, function prob­lems, wire feeding problems, and welding problems.
Step 2. PERFORM EXTERNAL TESTS.
The second column labeled “POSSIBLE AREAS OF MISADJUSTMENT(S)” lists the obvious external possibilities that may con­tribute to the machine symptom. Perform these tests/checks in the order listed. In general, these tests can be conducted with­out removing the case wrap-around cover.
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 one possibility at a time until you locate the cause of your problem.
All of the referenced test procedures referred to in the Troubleshooting Guide are described in detail at the end of this chapter. Refer to the Troubleshooting and Repair Table of Contents to locate each specific Test Procedure. All of the 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.
to eliminate
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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 1-888-935-3877.
-----------------------------------------------------------------------------------------------------------------------------------
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POWER WAVE 355M/405M
F-3 F-3
TROUBLESHOOTING AND REPAIR
PC BOARD TROUBLESHOOTING PROCEDURES
WARNING
ELECTRIC SHOCK can kill.
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 par ts.
CAUTION
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 troubleshooting and replacing PC boards, please use the following procedure:
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.
3. If the problem persists, replace the suspect PC board using standard practices to avoid static electrical damage and electrical shock. Read the warning inside the static resistant bag and perform the following procedures:
PC board can be damaged by static electricity.
- Re m o ve you r body ’s s t atic charge before opening the static­shielding bag. Wear an anti-static wrist strap. For safety, use a 1 Meg ohm resistive cord connected to a grounded part of the equipment
ATTENTION Static-Sensitive Devices Handle only at Static-Safe Workstations
frame.
- If you don’t have a wrist strap, touch an un-pa inted, grounded, par t of the equipment frame. Keep touc h i ng th e fram e to pr eve n t stat i c bui l d -up. B e s u re n o t t o touch any electrically live parts at the same time.
- Remove the PC board from the static-shielding bag and place it directly into the equipment. Don’t set the PC board on or near paper, plastic or cloth which could have a static charge. If the PC board can’t be installed immediately, put it back in the static-shield­ing bag.
- If the PC board uses protective shorting jumpers, don’t remove them until installation is complete.
- If you return a PC board to The Lincoln Electric Company for credit, it must be in the static-shielding bag. This will prevent further damage and allow prop­er failure analysis.
4. Test the machin e to determin e if the failure symp t o m has b een co r recte d by the replacement PC board.
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 operat ing temperature.
5. Rem o ve the r eplac e ment P C boa r d an d subs t i tute i t with t h e ori g inal P C board t o recreate the original problem.
a. If the original problem does not reappear by
substituting the original board, then the PC board was not the problem. Continue to look for ba d connections in the control wiring harness, junction blocks, and terminal strips.
b. If the original problem is recreated by the
substitution of the original board, then the PC boar d wa s t he probl e m . Rein s tall th e replacement PC board and test the machine.
6. Always in d icate th a t t his proc e dure was fo l lowed whe n war r a nty repo r ts ar e to be submitted.
NOTE: Following this procedure and writing on the warranty report, “INSTALLED AND SWITCHED PC BOARDS TO VERIFY PROBLEM,” will help avoid denial of legitimate PC board warranty claims.
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- Tools which come in contact with the PC board must be either conductive, anti-static or static-dissipative.
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POWER WAVE 355M/405M
F-4 F-4
Observe Safety Guidelines detailed in the beginning of this manual.
TROUBLESHOOTING AND REPAIR
PROBLEMS
(SYMPTOMS)

Major physical or electrical damage is evident when the sheet metal cover is removed.

The machine is dead—no output— no LED’s.

POSSIBLE AREAS OF
MISADJUSTMENT(S)
OUTPUT PROBLEMS
1. Contact your local authorized Lincoln Electric Field Service Facility for technical assistance.
1. Make sure the input line switch is in the ON position.
2. Check the main input line fuses.
If open , replace.
3. Check the 15 amp circuit break-
er (CB1). Reset if tripped. Also check CB3.
4. Make sure the reconnect switch and jumper lead is configured correctly for the applied input voltage.
5. If the machine is being operated with single phase input voltage make sure the correct lead is not connected. See the Installation Section.
RECOMMENDED
COURSE OF ACTION
1. Contact the Lincoln Electric Service Department, 1-888-935-3877.
1. Perform the Auxiliary Trans -
former Test.
2. Perform the DC Bus Board Test.
2. Perform the Power Board Test.
3. The Bus Board rectifier and or associated filter capacitor (C5) may be faulty. Check and replace as necessary.
4. The Control Board may be faulty.
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The main input fuses (or breaker) repeatedly fail.

1. Make certain the fuses or break­ers are sized properly.
2. Make sure the reconnect switch and jumper lead is configured correctly for the applied input voltage.
3. The welding procedure may be drawing too much input current or the duty cycle may be too high. Reduce the welding cur­rent and /or reduce the duty cycle.
1. Check the reconnect switches and associated wiring. See the Wiring Diagram.
2. Perform the Input Rectifier Test.
3. Perform the Main Switch Board
Test.
4. Perform the Output Diode Module Test.
5. The Input Filter Capacitors may be faulty. Check, and if any are faulty replace all four.
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 1-888-935-3877.
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POWER WAVE 355M/405M
F-5 F-5
Observe Safety Guidelines detailed in the beginning of this manual.
TROUBLESHOOTING AND REPAIR
PROBLEMS
(SYMPTOMS)
The machine does not have weld­ing output.
POSSIBLE AREAS OF
MISADJUSTMENT(S)
OUTPUT PROBLEMS
1. Make sure the reconnect switch is configured correctly for the input voltage applied.
2. Primary current limit has been exceeded. Possible short in output circuit. Turn machine off. Remove all loads from the output of the machine. Turn back on. If condition persists, turn power off, and contact an authorized Lincoln Electric Field Service Facility.
3. This problem will normally be accompanied by an error code. Error codes are displayed as a series of red and green flashes by the status LED.
4. If an error code is displayed
see Fault Code Explanations. If thermal light is on, wait for machine to cool.
RECOMMENDED
COURSE OF ACTION
1. Check the reconnect switch and associated leads for loose or faulty connections. See the wiring diagram.
2. Perform the DC Bus Board Test.
3. Perform the Main Switch
Board Test.
4. Perform the Power Board
Test.
5. Perform the Output Diode Module Test.
6. The control board may be faulty.
7. The input filter capacitors may be faulty. Check and replace if necessary.
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The POWER WAVE 355M/405M will not produce full output.

1. The input voltage may be too low, limiting the output capabili­ty of the machine. Make cer­tain the input voltage is correct for the machine and the recon­nect switch and jumper lead configuration are correct.
2. The output current or voltage may not be calibrated correctly. Check the values displayed on the Power Feed 10/11 versus readings on an external voltage and ammeter.
3. The welding current may be too high . The machine will fold back to 100 amps if the weld­ing current exceeds 450 amps.
1. Perform the Output Rectifier
Test.
2. Perform the Main Switch Board Test.
3. Perform the Power Board Test.
4. Perform the Current Transducer Test.
5. The 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 1-888-935-3877.
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POWER WAVE 355M/405M
F-6 F-6
Observe Safety Guidelines detailed in the beginning of this manual.
TROUBLESHOOTING AND REPAIR
PROBLEMS
(SYMPTOMS)

The machine regularly overheats and the yellow thermal light is ON indicating a thermal overload.

An attached wire feeder will not function correctly. Apparently the wire feeder is not being powered­up.
POSSIBLE AREAS OF
MISADJUSTMENT(S)
FUNCTION PROBLEMS
1. The welding application may be exceeding the recommended duty cycle of the POWER WAVE 355M/405M.
2. Dirt and dust may have clogged
the cooling channels inside the machine.
3. Air intake and exhaust louvers
may be blocked due to inade­quate clearance around the machine.
4. Make certain the fan as needed
(F.A.N.) is operating properly. The fan should operate when welding voltage is present and/or when there is an over temperature condition.
1. Make certain the wire feeder
control cable is connected to the wire feeder receptacle. See the Wiring Diagram.
RECOMMENDED
COURSE OF ACTION
1. The 115VAC fan motor is con­trolled by the control board via the main switch board. Perform the Fan Motor And Control
Test.
1. A thermostat or associated cir­cuitry may be faulty. See the wiring diagram. One normally closed thermostat is located on the output choke, one on the DC Bus Board and the other is located on the main switch board heat sink. See the wiring diagram.
Note: The Main Switch Board
Removal Procedure will be required to gain access to the heat sink thermostat.
1. Check for 40 VDC on pin “D” (+)
and pin “E” (-) at the Power Wave wire feeder receptacle. See Wiring Diagram.
2. Check the two circuit breakers located at the front of the machine. Reset if tripped.
3. The wire feeder or control cable
may be faulty.
CAUTION
If 40 volts DC is Not present at the Power Wave wire feeder receptacle, perform the DC Bus
Board Test.
2. Check the DC Bus Board rectifi­er. See Wiring Diagram.
3. Perform the T1 Auxiliary trans- former Test.
4. If the 40 volts DC is present at the Power Wave wire feeder receptacle, the problem is in the control cable or the wire drive/control box.
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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 1-888-935-3877.
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POWER WAVE 355M/405M
F-7 F-7
Observe Safety Guidelines detailed in the beginning of this manual.
TROUBLESHOOTING AND REPAIR
PROBLEMS
(SYMPTOMS)

The machine often “noodle welds” with a particular procedure. The output is limited to approximately 100 amps.

Excessively long and erratic arc. 1. Check for proper configuration

POSSIBLE AREAS OF
MISADJUSTMENT(S)
FUNCTION PROBLEMS
1. The machine may be trying to deliver too much power. When the average output current exceeds a maximum limit, the machine will “phase back” to protect itself. Adjust the proce­dure or reduce the load to lower the current draw from the Power Wave machine.
and implementation of voltage sensing circuits.
RECOMMENDED
COURSE OF ACTION
1. Perform the Current Transducer Test.
2. The control board may be faulty.
1. Check the connections between the voltage sense receptacle and the control board. See the Wiring Diagram.
2. The control board may be faulty.
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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 1-888-935-3877.
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POWER WAVE 355M/405M
F-8 F-8
Observe Safety Guidelines detailed in the beginning of this manual.
TROUBLESHOOTING AND REPAIR
PROBLEMS
(SYMPTOMS)

Auxiliary receptacle is “dead” no auxiliary voltage.

A fault or error code is displayed. 1. See Fault Code Explanations. 1. See Fault Code Explanations.

General degradation of the weld performance.

POSSIBLE AREAS OF
MISADJUSTMENT(S)
FUNCTION PROBLEMS
1. Circuit breaker CB1 (on case front) may have opened. Reset.
2. Circuit breaker CB3 (in recon­nect area) may have opened. Reset.
3. On PW 405 models, the circuit breaker CB4 protects the 220VAC receptacle. Reset if tripped.
1. Check for feeding problems, bad connections, excessive loops in cabling, etc.
2. Verify weld mode is correct for processes.
3. The power source may require calibration.
4. Check the actual current dis­played on the Power Feed 10 vs. actual current measured via external meter.
RECOMMENDED
COURSE OF ACTION
1. Perform the Auxiliary Transformer Test.
1. Perform the Voltage and Current Calibration Procedure using the Power Wave software program.
2. Perform the Current Transducer Test.
2. Perform the Output Diode Module Test.
5. The control board may be faulty.
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5. Check the actual voltage dis­played on the Power Feed 10 vs. actual voltage measured via external meter.
6. Check the actual WFS displayed on the Power Feed 10 vs. actual WFS measured via external meter.
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 1-888-935-3877.
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POWER WAVE 355M/405M
F-9 F-9
TROUBLESHOOTING AND REPAIR
USING THE STATUS LED TO TROUBLESHOOT SYSTEM PROBLEMS
The Power Wave / Power Feed are best diagnosed as a system. Each component (power source, user interface, and feed head) has a status light, and when a problem occurs it is important to note the condition of each. In addition, errors displayed on the user interface in most cases indicate only that a problem exists in the power source, not what the problem may be. Therefore, prior to cycling power to the sys-
tem, check the power source status light for error sequences as noted below. This is especially important if the user interface displays “Err 006” or “Err 100”.
Included in this section is information about the
LIGHT CONDITION INDICATION
Status LED is solid green (no blinking)
power source Status LED, and some basic trou­bleshooting charts for both machine and weld perfor­mance.
The STATUS LIGHT is a two color light that indicates system errors. Normal operation is a steady green light. Error conditions are indicated in the following chart.
NOTE: The POWER WAVE 355M/405M status light will flash green, and sometimes red and green, for up to one minute when the machine is first turned on. This is a normal situation as the machine goes through a self test at power up.
1. System OK. Power source communicating nor­mally with wire feeder and its components.
Status LED is blinking green
Status LED is blinking red and green
2. Occurs during a reset, and indicates the POWER WAVE 355M/405M is mapping (identi­fying) each component in the system. Normal for first 1-10 seconds after power is turned on, or if the system configuration is changed during operation.
3. Non-recoverable system fault. If the PS Status light is flashing any combination of red and green, errors are present in the POWER WAVE 355M/405M. Read the error code before the machine is turned off.
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. The codes will be separated by a green light. There may be more than one error code indicated.
To clear the error, turn power source off, and back on to reset.
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Status LED is solid red (no blinking).
Status LED is blinking red.
Non-recoverable hardware fault. Generally indi­cates nothing is connected to the POWER WAVE 355M/405M wire feeder receptacle. See
Trouble Shooting Section.
Not applicable
POWER WAVE 355M/405M
F-10 F-10
TROUBLESHOOTING AND REPAIR
ERROR CODES FOR THE POWER WAVE
The following is a list of possible error codes that the POWER WAVE 355M/405M can output via the status light If connected to a PF-10/11 these error codes will generally be accompanied by an “Err 006” or “Err 100” on the user interface display.
Individual code digits are flashed in RED with a long pause between digits. Complete codes are seprated by one GREEN light. There may be more than one error code indicated
Example: Error code 31 - Red, red, red pause, red, green.
Error codes 32 & 34 - Red, red, red, pause Red,red, Green, Red,red,red, pause
Red,red,red,red, Green. Sequence will repeat continuously.
STATUS LED ERROR CODE TABLE
11
12
21
22
23
31
32
33
34
35 Capacitor “B” overvoltage.
36 Thermal error.
37 Softstart error.
41 Secondary overcurrent error
CAN communication bus off.
User interface time out error.
Unprogrammed weld mode.
Empty weld table.
Weld table checksum error.
Primary overcurrent error.
Capacitor “A” under voltage.
Capacitor “B” under voltage.
Capacitor “A” overvoltage.
Probably due to excessive number of communication errors.
UI is no longer responding to the Power Source. The most likely cause is a fault/bad connection in the communication leads or control cable.
Contact the service department for instructions on reloading the Welding Software.
Contact the service department for instructions on reloading the Welding Software.
Contact the service department for instructions on reloading the Welding Software.
Excessive Primary current present. May be related to a short in the main transformer or output rectifier.
Low voltage on the main capacitors. May be caused by improper input configuration.
When accompanied by an overvoltage error on the same side, it indicates no capacitor voltage present on that side, and is usually the result of an open or short in the primary side of the machine.
Excessive voltage on the main capacitors. May be caused by improper input configuration.
When accompanied by an under voltage error on the same side, it indicates no capacitor voltage present on that side, and is usually the result of an open or short in the primary side of the machine.
Indicates over temperature. Usually accompanied by ther­mal LED. Check fan operation. Be sure process does not exceed duty cycle limit of the machine.
Capacitor precharge failed. Usually accompanied by codes 32-35.
The secondary (weld) current limit has been exceeded. When this occurs the machine output will phase back to 100 amps, typically resulting in a condition referred to as “noodle welding”
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NOTE: The secondary limit is 570 for the standard stud, and 325 amps for all single phase operation.
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POWER WAVE 355M/405M
F-11 F-11
43 Capacitor delta error. The maximum voltage difference between the main capaci-
Other
TROUBLESHOOTING AND REPAIR
tors has been exceeded. May be accompanied by errors 32-35. Check the output diodes.
Error codes that contain three or four digits are defined as fatal errors. These codes generally indicate internal errors on the 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.
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POWER WAVE 355M/405M
F-12 F-12
NOTES
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POWER WAVE 355M/405M
F-13 F-13
TROUBLESHOOTING AND REPAIR
INPUT FILTER CAPACITOR DISCHARGE PROCEDURE
WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid 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 perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical trou­bleshooting assistance before you proceed. Call 1-888-935-3877.
TEST DESCRIPTION
This procedure will drain off any charge stored in the four large capacitors that are part of the switch board assembly. This procedure MUST be performed, as a safety pre­caution, before conducting any test or repair procedure that requires you to touch inter­nal components of the machine.
MATERIALS NEEDED
5/16” Nut Driver
Insulated Pliers Insulated Gloves High Wattage Resistor (25-1000 ohms and 25 watts minimum) DC Volt Meter
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POWER WAVE 355M/405M
F-14 F-14
- +- +
- +- +
- +- +
- +- +
CAPACITOR
TERMINALS
POWER
RESISTOR
INSULATED
GLOVES
INSULATED
PLIERS
EIGHT
TROUBLESHOOTING AND REPAIR
INPUT FILTER CAPACITOR DISCHARGE PROCEDURE (continued)
WARNING
ELECTRIC SHOCK can kill.
• 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.
• Prior to performing preventative maintenance, perform the following capacitor discharge procedure to avoid electric shock.
DISCHARGE PROCEDURE
1. Remove the input power to the POWER WAVE
355M/405M.
2. Using the 5/16” wrench remove the screws from
the case wraparound cover.
3. Be careful not to make contact with the capacitor
terminals located at the top and bottom of the switch board.
4. Obtain a high resistance and high wattage resistor (25-1000 ohms and 25 watts minimum). This resistor is not with the machine. NEVER USE A SHORTING STRAP FOR THIS PROCEDURE.
5. Locate the eight capacitor terminals shown in fig­ure F.1.
6. Using electrically insulated gloves and pliers, hold the body of the resistor with the pliers and con­nect the resistor leads across the two capacitor terminals. Hold the resistor in place for 10 sec­onds. DO NOT TOUCH CAPACITOR TERMINALS WITH YOUR BARE HANDS.
7. Repeat the discharge procedure for the other three capacitors.
8. Check the voltage across the terminals of all capacitors with a DC voltmeter. Polarity of the capacitor terminals is marked on the PC board above the terminals. Voltage should be zero. If any voltage remains, repeat this capacitor dis-
charge procedure.
FIGURE F.1 – LOCATION OF INPUT FILTER CAPACITOR TERMINALS
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POWER WAVE 355M/405M
F-15 F-15
TROUBLESHOOTING AND REPAIR
MAIN SWITCH BOARD TEST
WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid 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 perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical trou­bleshooting assistance before you proceed. Call 1-888-935-3877.
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 resistance test is preferable to a voltage test with the machine energized because this board can be damaged easily. In addition, it is dangerous to work on this board with the machine ener­gized.
MATERIALS NEEDED
Analog Volt/Ohmmeter
5/16 in. Wrench
7/16 in. Wrench
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POWER WAVE 355M/405M
F-16 F-16
- +- +
- +- +
- +- + - +- +
208
201
209
204
205
206
203
J21
J20
J22
202
207
TROUBLESHOOTING AND REPAIR
MAIN SWITCH BOARD TEST (continued)
FIGURE F.2 MAIN SWITCH BOARD LEAD LOCATIONS
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TEST PROCEDURE
1. Remove input power to the POWER WAVE 355M/405M.
2. Using a 5/16” nut driver, remove the case wraparound.
3. Perform the Input Filter Capacitor Discharge Procedure detailed earlier in this section.
POWER WAVE 355M/405M
4. Using a 7/16” wrench locate, label and remove leads 201, 202, 203, 204, 205, 206, 207 and 208 from the switch board. Note lead and washer placement for reassembly. Clear leads.
5. Using the Analog ohmmeter, perform the resis­tance tests detailed in Table F.1. Refer to fig- ure F.2 for test point locations. Note: Test using an Analog ohmmeter on the Rx1 range. Make sure the test probes are making electri­cal contact with the conductor surfaces on the PC board.
F-17 F-17
TROUBLESHOOTING AND REPAIR
MAIN SWITCH BOARD TEST (continued)
6. If any test fails replace the switch board. See
Main Switch Board Removal and Replacement.
7. If the switch board resistance tests are OK, check connections on plugs J20, J21, J22 and all asso­ciated wiring. See wiring diagram.
TABLE F.1. SWITCH BOARD RESISTANCE TEST
APPLY POSITIVE TEST
PROBE TO TERMINAL
APPLY NEGATIVE TEST
PROBE TO TERMINAL
+206
+208
+202
8. Reconnect leads 201, 202, 203, 204, 205, 206, 207, and 208 to the switch board. Ensure that the leads are installed in their proper locations. Pre­Torque all leads nuts to 25 inch lbs. before tight­ening them to 44 inch lbs.
9. Replace the case wraparound cover using a 5/16” nut driver.
NORMAL
RESISTANCE READING
-205
-203
-204
Greater than 1000 ohms
Greater than 1000 ohms
Greater than 1000 ohms
+201
+205
+203
+204
+207
-207
-206
-208
-202
-201
Greater than 1000 ohms
Less than 100 ohms
Less than 100 ohms
Less than 100 ohms
Less than 100 ohms
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POWER WAVE 355M/405M
F-18 F-18
NOTES
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POWER WAVE 355M/405M
F-19 F-19
TROUBLESHOOTING AND REPAIR
INPUT RECTIFIER TEST
WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid 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 perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical trou­bleshooting assistance before you proceed. Call 1-888-935-3877.
TEST DESCRIPTION
This test will help determine if the input rectifier has “shorted” or “open” diodes.
MATERIALS NEEDED
Analog Voltmeter/Ohmmeter (Multimeter)
5/16” Nut Driver
Phillips Head Screwdriver
Wiring Diagram
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POWER WAVE 355M/405M
F-20 F-20
#207A
#207
#209A
B
C
3/16" ALLEN BOLTS
FRONT REAR
Small Lead "A"
To Circuit Breaker
Small Lead "H1"
To Auxiliary Transformer
TROUBLESHOOTING AND REPAIR
INPUT RECTIFIER TEST (CONTINUED)
TEST PROCEDURE
1. Remove input power to the POWER WAVE 355M/405M machine.
2. Using a 5/16” nut driver, remove the case wraparound cover.
3. Perform the Capacitor Discharge Procedure detailed earlier in this section.
4. Locate the input rectifier and associated leads. See Figure F.3.
5. Carefully remove the silicone sealant from leads 207, 207A, and 209.
Figure F.3 Input Rectifier
6. Using a phillips head screwdriver, remove leads 207, 207A, and 209 from the input rectifier.
7. Use the analog ohmmeter to perform the tests detailed in Table F.2. See the Wiring Diagram.
8. Visually inspect the three MOV’S for damage (TP1,TP2,TP3). Replace if nec­essary.
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POWER WAVE 355M/405M
F-21 F-21
TROUBLESHOOTING AND REPAIR
INPUT RECTIFIER TEST (CONTINUED)
Table F.2 Input Rectifier Test Points
TEST POINT TERMINALS
+ PROBE
A B C
A B C
A B C
207 207 207
- PROBE
207 207 207
207A 207A 207A
209 209 209
A B C
ANALOG METER
X10 RANGE
Acceptable Meter Readings
Greater than 1000 ohms Greater than 1000 ohms 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 Less than 100 ohms Less than 100 ohms
207A 207A 207A
209 209 209
9. If the input rectifier does not meet the acceptable readings outlined in Table F.2 the component may be faulty. Replace
Note: Before replacing the input rectifier, check the input power switch and recon­nect switches. Perform the Main Switch Board Test. Also check for leaky or faulty filter capacitors.
10. If the input rectifier is good, be sure to reconnect leads 207, 207A, and 209 to the correct terminals and torque to 31 inch lbs. Apply silicone sealant.
A B C
A B C
11. If the input rectifier is faulty, see the
Input Rectifier Bridge Removal & Replacement procedure.
12. Replace the case wraparound cover.
Less than 100 ohms Less than 100 ohms Less than 100 ohms
Greater than 1000 ohms Greater than 1000 ohms Greater than 1000 ohms
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POWER WAVE 355M/405M
F-22 F-22
NOTES
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POWER WAVE 355M/405M
F-23 F-23
TROUBLESHOOTING AND REPAIR
POWER BOARD TEST
WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid 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 perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical trou­bleshooting assistance before you proceed. Call 1-888-935-3877.
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.
MATERIALS NEEDED
Volt-Ohmmeter
3/8” Nut Driver
Wiring Diagram
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POWER WAVE 355M/405M
F-24 F-24
J42
J41
J43
J41
2 1
J42
6 5 4
6 5 4 3 2 1
12 11 10 9 8 7
J43
3 2 1
4 3
TROUBLESHOOTING AND REPAIR
FIGURE F.4 – POWER BOARD TEST
TEST PROCEDURE
1. Remove input power to the Power Wave 355M/405M.
2. Using the 3/8” nut driver, remove the case top.
3. Perform the Capacitor Discharge Procedure.
4. Locate the Power Board and plugs J42 and J43. Do not remove plugs or leads from the Power Board. Refer to Figure F.8.
5. Carefully apply input power to the Power Wave 355M/405M.
WARNING
ELECTRIC SHOCK can kill.
High voltage is present when input power is applied to the machine.
6. Turn on the Power Wave 355M/405M. Carefully test for the correct voltages at the Power Board according to Table F.4.
7. If either of the 40 VDC voltages is low or not present at plug J41, perform the DC Bus PC Board Test. See the Wiring Diagram. Also perform the T1 Auxiliary Transformer
Test.
8. If any of the DC voltages are low or not pre­sent at plugs J42 and/or 43, the Power Board may be faulty.
9. Install the case top using the 3/8” nut driver.
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POWER WAVE 355M/405M
F-25 F-25
TROUBLESHOOTING AND REPAIR
POWER BOARD TEST (CONTINUED)
TABLE F.3 – POWER BOARD VOLTAGE CHECKS
CHECK POINT
LOCATION
POWER BOARD
CONNECTOR
PLUG J41
POWER BOARD
CONNECTOR
PLUG J42
POWER BOARD
CONNECTOR
PLUG J42
POWER BOARD
CONNECTOR
PLUG J42
POWER BOARD
CONNECTOR
PLUG J43
POWER BOARD
CONNECTOR
PLUG J43
POWER BOARD
CONNECTOR
PLUG J43
TEST
DESCRIPTION
CHECK 40 VDC
INPUT FROM
DC BUS BOARD
CHECK +15
VDC SUPPLY FROM
POWER BOARD
CHECK +5 VDC
SUPPLY FROM
POWER BOARD
CHECK -15 VDC
SUPPLY FROM
POWER BOARD
CHECK +5 VDC
ARCLINK SUPPLY
FROM POWER BOARD
CHECK +5 VDC
“RS-232” SUPPLY
FROM POWER BOARD
CHECK +5 VDC
SPI SUPPLY FROM
POWER BOARD
CONNECTOR
PLUG PIN NO.
2 (+)
1 (-)
475 477
1 (+)
5 (-)
412
410
3 (+)
5 (-)
408
410
2 (+)
411
5 (-)
410
5 (+)
10 (-)
1103
4 (+)
9 (-)
405
3 (+)
12 (-)
403
1104
406
401
LEAD NO. OR
IDENTITY
477 (+)
475 (-)
412 (+)
410 (-)
408 (+)
410 (-)
411 (+)
410 (-)
1104 (+)
1103 (-)
406 (+)
405 (-)
403 (+)
401 (-)
NORMAL
ACCEPTABLE
VOLTAGE READING
38 – 42 VDC
+15 VDC
+5 VDC
-15 VDC
+5 VDC
+5 VDC
+5 VDC
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POWER WAVE 355M/405M
F-26 F-26
NOTES
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POWER WAVE 355M/405M
F-27 F-27
TROUBLESHOOTING AND REPAIR
DC BUS BOARD TEST
WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid 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 perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical trou­bleshooting assistance before you proceed. Call 1-888-935-3877.
TEST DESCRIPTION
This test will determine if the DC Bus Power Supply PC Board is receiving and process­ing the proper voltages.
MATERIALS NEEDED
3/8” Nut driver Volt/ohmmeter Wiring Diagram
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POWER WAVE 355M/405M
F-28 F-28
DC BUS BOARD
W
A R
N I
N G
R
E M
O T
E
P
O W
E R
O
F F
O N
S
T
A
T
U
S
T
H
E
R
M
A
L
L
I
N
C
O
L
N
E
L
E
C
T
R
I
C
J46
J47
475
52
51
477
66 65
L11078-1
J46
J47
Thermostat
Bus Rectifier
TROUBLESHOOTING AND REPAIR
DC BUS BOARD TEST (CONTINUED)
FIGURE F.5 – DC BUS POWER SUPPLY POWER SUPPLY PC BOARD
TEST PROCEDURE
1. Remove input power to the machine.
2. Using the 3/8” nut driver, remove the wrap­around cover.
3. Locate the DC Bus Board. See Figure F.5.
4. Carefully apply input power to the Power Wave 355M/405M.
FIGURE F.6 – DC BUS POWER SUPPLY POWER SUPPLY PC BOARD
WARNING
ELECTRIC SHOCK can kill.
High voltage is present when input power is applied to the machine.
5. Turn on the Power Wave 355M/405M. The LED on the DC Bus Power Supply PC Board should light.
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POWER WAVE 355M/405M
F-29 F-29
TROUBLESHOOTING AND REPAIR
DC BUS BOARD TEST(CONTINUED)
6. Check the DC Bus Board input and output voltages according to Table F.4. See Figure F.6 and the Wiring Diagram.
WARNING
ELECTRIC SHOCK can kill.
High voltage is present at the ter­minals of Capacitor C3 near where testing is to be done.
TABLE F.4 – DC BUS POWER SUPPLY PC BOARD VOLTAGE TABLE
Positive Meter Probe
Test Point
Negative Meter Probe
Test Point
7. If all the voltages are correct, the DC Bus Board is operating properly.
8. If any of the output voltages are not correct and the input voltage is correct, the DC Bus Board may be faulty.
9. If the input voltage is not correct, check the leads between the DC Bus Board and the Bus Rectifier. See the Wiring Diagram.
10. When finished testing, replace the case wraparound cover.
Approximate Voltage
Reading
Conditions/Comments
Plug P46 – Pin 1
Lead 65
Plug P47 – Pin 8(+)
Lead 52
Plug P47 – Pin 3(+)
Lead 477
Plug P46 – Pin 3
Lead 66
Plug P47 – Pin 1(-)
Lead 51
Plug P47 – Pin 6(-)
Lead 475
65 – 75 VDC
38.0 – 42.0 VDC
38.0 – 42.0 VDC
Should be same as the
Bus Rectifier
Supply to the Wire
Feeder Receptacle
Supply to Power Board
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POWER WAVE 355M/405M
F-30 F-30
NOTES
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POWER WAVE 355M/405M
F-31 F-31
TROUBLESHOOTING AND REPAIR
OUTPUT RECTIFIER MODULES TEST
WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid 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 perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical trou­bleshooting assistance before you proceed. Call 1-888-935-3877.
TEST DESCRIPTION
This test will help determine if any of the output diodes are “shorted”.
MATERIALS NEEDED
Analog Voltmeter/Ohmmeter Wiring Diagram
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POWER WAVE 355M/405M
F-32 F-32
STSTAATUSTUS THERMALTHERMAL
_
+
NEGATIVE OUTPUT TERMINAL
POSITIVE OUTPUT TERMINAL
TROUBLESHOOTING AND REPAIR
OUTPUT RECTIFIER MODULES TEST (continued)
FIGURE F.7 Machine Output Terminals
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TEST PROCEDURE
1. Remove input power to the POWER WAVE 355M/405M.
2. Locate the output terminals on the front panel of the machine. See Figure F.7.
3. Remove any output cables and load from the output terminals.
POWER WAVE 355M/405M
4. Using the analog ohmmeter test for more than 200 ohms resistance between positive and negative output terminals. Positive test lead to the positive terminal; Negative test lead to the negative terminal. See Figure
F.8.
NOTE: The polarity of the test leads is most important. If the test leads polarity is not cor­rect, the test will have erroneous results.
F-33 F-33
_
+
- PROBE
+ PROBE
TROUBLESHOOTING AND REPAIR
OUTPUT RECTIFIER MODULES TEST (continued)
Figure F.8 Terminal Probes
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5. If 200 ohms is measured then the output diodes are not “shorted”.
NOTE: There is a 250 ohm resistor across the welding output terminals. See Wiring
Diagram
6. If less than 200 ohms is measured, one or more diodes or the snubber board may be faulty.
7. Perform the Filter Capacitor Discharge Procedure detailed in the maintenance sec­tion.
8. Locate the output diode modules and snub­ber board. See Figure F.9.
POWER WAVE 355M/405M
9. Test all output diode modules individually. Test for open diodes also.
NOTE: This may require the disassembly of the leads and the snubber board from the diode modules. Refer to the Output
Rectifier Modules Removal and Replacement Procedure for detailed
instructions.
F-34 F-34
LEFT SIDE
Snubber Board
Output Diode Modules
TROUBLESHOOTING AND REPAIR
Figure F.9 Snubber and Output Diode Locations
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POWER WAVE 355M/405M
F-35 F-35
TROUBLESHOOTING AND REPAIR
AUXILIARY TRANSFORMER TEST
WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid 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 perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical trou­bleshooting assistance before you proceed. Call 1-888-935-3877.
TEST DESCRIPTION
This procedure will determine if the correct voltage is being applied to the primary of aux­iliary transformer and also if the correct voltage is being induced on the secondary wind­ings of the transformer.
MATERIALS NEEDED
Volt-ohmmeter (Multimeter)
5/16” Nut Driver
Wiring Diagram
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POWER WAVE 355M/405M
F-36 F-36
W A
R
N I N
G
R E M
O
T E
P O
W E
R
O F
F
O
N
Auxiliary Transformer
Secondary Lead Plugs P52
S
T
A
T
U S
T H
E R
MA
L
L
I
N
C
O
L
N
E
L
E
C
T
R
I
C
Com 2
532
PW405
Only
(220V)
(115V)
(31)
Plug P52
TROUBLESHOOTING AND REPAIR
AUXILIARY TRANSFORMER TEST (continued)
FIGURE F.10 Auxiliary Transformer
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TEST PROCEDURE
1. Remove input power to the POWER WAVE 355M/405M.
2. Using a 5/16” nut driver, remove the case wraparound cover.
3. Perform the Input Capacitor Discharge Procedure detailed earlier in this section.
FIGURE F.11 Plug Lead Connections Viewed From Transformer Lead Side of Plug
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4. Locate the auxiliary transformer. See Figure F.10.
5. Locate the secondary leads and plug P52. See Figure F.10 and F.11.
POWER WAVE 355M/405M
F-37 F-37
TROUBLESHOOTING AND REPAIR
AUXILIARY TRANSFORMER TEST (continued)
TABLE F.5
LEAD IDENTIFICATION
COM 2 (31) TO 115V (532)
42 TO COM 1A (quick connects)
7. Carefully apply the correct input voltage to the POWER WAVE 355M/405M and check for the correct secondary voltages per table F.5. Make sure the reconnect jumper lead and switch are configured correctly for the input voltage being applied. Make sure circuit breaker (CB3) is functioning properly.
NOTE: The secondary voltages will vary if the input line voltage varies.
8. If the correct secondary voltages are present, the auxiliary transformer is functioning proper­ly. If any of the secondary voltages are miss­ing or low, check to make certain the primary is configured correctly for the input voltage applied. See Wiring Diagram.
NORMAL EXPECTED VOLTAGE
115 VAC
42 VAC
WARNING
High voltage is present at primary of Auxiliary Transformer.
9. If the correct input voltage is applied to the primary, and the secondary voltage(s) are not correct, the auxiliary transformer may be faulty.
10. Remove the input power to the POWER WAVE 355M/405M.
11. Install the case wraparound cover using a 5/16” nut driver.
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POWER WAVE 355M/405M
F-38 F-38
NOTES
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POWER WAVE 355M/405M
F-39 F-39
TROUBLESHOOTING AND REPAIR
CURRENT TRANSDUCER TEST
WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid 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 perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical trou­bleshooting assistance before you proceed. Call 1-888-935-3877.
TEST DESCRIPTION
This test will help determine if the current transducer and associated wiring are function­ing correctly.
MATERIALS NEEDED
Volt-ohmmeter
5/16” Nut Driver
Grid Bank
External DC Ammeter
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POWER WAVE 355M/405M
F-40 F-40
802
801
804
806
Plug J8
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Plug J8
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TROUBLESHOOTING AND REPAIR
CURRENT TRANSDUCER TEST (continued)
FIGURE F.12 Metal Plate Removal & Plug J8 Location
TEST PROCEDURE
1. Remove input power to the POWER WAVE 355M/405M.
2. Using the 5/16” nut driver, remove the case wraparound cover.
3. Perform the Input Capacitor Discharge
Procedure.
4. Locate plug J8 on the control board. Do not remove the plug from the P.C. Board.
5. Apply the correct input power to the POWER WAVE 355M/405M.
FIGURE F.13. Plug J8 Viewed From Lead Side of Plug
6. Check for the correct DC supply voltages to the current transducer at plug J8. See Figure F.12.
A. Pin 2 (lead 802+) to pin 6 (lead 806-)
should read +15 VDC.
B. Pin 4 (lead 804+) to pin 6 (lead 806-)
should read -15 VDC.
7. If either of the supply voltages are low or miss­ing, the control board may be faulty.
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POWER WAVE 355M/405M
F-41 F-41
TROUBLESHOOTING AND REPAIR
AUXILIARY TRANSFORMER TEST (continued)
TABLE F.6
OUTPUT LOAD CURRENT
300
250
200
150
100
8. Check the feedback voltage from the current transducer using a resistive load bank and with the POWER WAVE 355M/405M in mode
200. Mode 200 is a constant current test mode. This mode can be accessed using a wire feeder placed in mode 200 or a laptop computer and the appropriate software. Apply the grid load across the output of the POWER WAVE 355M/405M. Set machine output to 300 amps and enable WELD TERMINALS. Adjust the grid load to obtain 300 amps on the external ammeter and check feedback volt­ages per Table F.6.
A. Pin 1 (lead 801) to Pin 6 (lead 806) should
read 2.4 VDC (machine loaded to 300 amps).
EXPECTED TRANSDUCER FEEDBACK
VOLTAGE
2.4
2.0
1.6
1.2
0.8
Before replacing the current transducer, check the leads and plugs between the control board (J8) and the current transducer (J90). See The Wiring Diagram. For access to plug J90 and the current transducer refer to: Current
Transducer Removal and Replacement Procedure.
11. Remove input power to the POWER WAVE 355M/405M.
12. Replace the control box top and any cable ties previously removed.
13. Install the case wraparound cover using the 5/16” nut driver.
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9. If for any reason the machine cannot be loaded to 300 amps, Table F.6. shows what feedback voltage is produced at various cur­rent loads.
10. 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.
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POWER WAVE 355M/405M
F-42 F-42
NOTES
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POWER WAVE 355M/405M
F-43 F-43
TROUBLESHOOTING AND REPAIR
FAN CONTROL AND MOTOR TEST
WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid 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 perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical trou­bleshooting assistance before you proceed. Call 1-888-935-3877.
TEST DESCRIPTION
This test will help determine if the fan motor, control board, switch board, or associated leads and connectors are functioning correctly.
MATERIALS NEEDED
Voltmeter
5/16” Nut Driver
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POWER WAVE 355M/405M
F-44 F-44
J21
J20
J22
Plug J22
Fan Lead
1
2
3
4
Lead 31B(C)
Lead 32A
Fan Lead
TROUBLESHOOTING AND REPAIR
FAN CONTROL AND MOTOR TEST (continued)
TEST PROCEDURE
1. Remove the input power to the POWER WAVE 355M/405M machine.
2. Using the 5/16” nut driver, remove the case wraparound cover.
FIGURE F.14 PLUG J22 LOCATION
3. Perform the Input Filter Capacitor Discharge Procedure.
4. Locate plug J22 on the main switch board. Do not remove the plug from the board. See Figure F.14.
5. Carefully apply the correct input power to the machine.
6. Carefully check for 115VAC at plug J22 pin-2 to J22 pin-3. (leads 32A to 31B(C) See Figure F.15. WARNING: HIGH VOLTAGE IS PRE-
SENT AT THE MAIN SWITCH BOARD.
FIGURE F.15 PLUG J22
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POWER WAVE 355M/405M
F-45 F-45
Plug J20
Lead 715+
1
2
3
4
7
8
65
Lead 716-
TROUBLESHOOTING AND REPAIR
FAN CONTROL AND MOTOR TEST (continued)
7. If the 115VAC is low or not present check cir­cuit breaker CB2 located on the front panel. If the circuit breaker is OK, perform The Auxiliary Transformer Test. Check plug J22, circuit breaker CB2 and associated leads for loose or faulty connections. See the Wiring Diagram.
8. Energize the weld output terminals with the PW 355M/405M in mode 200. This mode can be accessed using a wire feeder placed in mode 200 or a laptop computer and the appro­priate software. Carefully check for 115VAC at plug J22 pin-1 to J22 pin-4 (fan leads). See Figure F.15. If the 115VAC is present and the fan is not running then the fan motor may be faulty. Also check the associated leads between plug J22 and the fan motor for loose or faulty connections. See the Wiring Diagram.
WARNING: HIGH VOLTAGE IS PRESENT AT THE SWITCH BOARD.
9. If the 115VAC is NOT present in the previous step then proceed to the fan control test.
1. Locate plug J20 on the switch board. Do not remove the plug from the switch board. See Figure F.14 and F.16.
2. Energize the weld output terminals (Select Weld Terminals ON) and carefully check for +15VDC at plug J20 pin-6+ to J20 pin-2­(leads 715 to 716). See Figure F.16. If the 15VDC is present and the fan is not running then the switch board may be faulty. If the 15VDC is not present when the weld terminals are energized then the control board may be faulty. Also check plugs J20, J7, and all asso­ciated leads for loose or faulty connections. See the Wiring Diagram.
WARNING: HIGH VOLTAGE IS PRESENT AT THE SWITCH BOARD.
3. Remove the input power to the POWER WAVE 355M/405M.
Note: The fan motor may be accessed by the removal of the rear panel detailed in The
Current Transducer Removal and Replacement Procedure.
FAN CONTROL TEST PROCEDURE
FIGURE F.16 PLUG J20
4. Replace the case wrap-around cover.
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POWER WAVE 355M/405M
F-46 F-46
NOTES
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POWER WAVE 355M/405M
F-47 F-47
TROUBLESHOOTING AND REPAIR
CONTROL BOARD REMOVAL AND REPLACEMENT
WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid 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 perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical trou­bleshooting assistance before you proceed. Call 1-888-935-3877.
DESCRIPTION
The following procedure will aid the technician in removing the control board for mainte­nance or replacement.
MATERIALS NEEDED
5/16” Nut Driver
3/8” Nut Driver
Flathead Screwdriver
Phillips Head Screwdriver
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POWER WAVE 355M/405M
F-48 F-48
S
TSTAATUSTUS THERMALTHERMAL
_
+
Phillips Head Screws
Phillips Head Screws
5/16" Mounting Screws
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TROUBLESHOOTING AND REPAIR
CONTROL BOARD REMOVAL AND REPLACEMENT (continued)
FIGURE F.17 - CONTROL BOARD LOCATION
PROCEDURE
1. Remove input power to the POWER WAVE 355M/405M.
2. Using a 5/16” nut driver remove the case wrap­around cover.
3. Perform the Input Filter Capacitor Discharge Procedure detailed earlier in this section.
FIGURE F.18 CASE FRONT SCREW REMOVAL
4. Locate the control board behind the front panel of the machine. See Figure F.17.
5. Using a 5/16” nut driver remove the two screws from the bottom of the front of the machine. See Figure F.18.
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POWER WAVE 355M/405M
F-49 F-49
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J2
J4
J5
J6
J7
J8
J9
J10A
J10B
TROUBLESHOOTING AND REPAIR
CONTROL BOARD REMOVAL AND REPLACEMENT (continued)
FIGURE F.19 - CONTROL BOARD ALL PLUG LOCATIONS
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CAUTION
Observe static precautions detailed in PC Board Troubleshooting Procedures at the
beginning of this section.
6. Using a phillips head screwdriver remove the two screws and their washers from above and below the input power switch. See Figure F.18.
7. Using a phillips head screwdriver remove the four screws from around the two welder output termi­nals on the front of the machine. See Figure F.18.
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8. The front of the machine may now gently be pulled forward to gain access to the Control Board. Note: The front of the machine cannot be removed completely, only pulled forward a few inches.
9. Beginning at the right side of the control board remove plugs J10A and J10B. Note: Be sure to label each plugs position upon removal. See Figure F.19.
10. Working your way across the top of the board
from right to left, label and remove plugs #J9, #J8, #J7, #J6, and #J5. See Figure F.19.
11. Working your way down the left side of the board,
label and remove plugs #J4 and #J2. See Figure F.19.
POWER WAVE 355M/405M
F-50 F-50
Right Side
Mounting Nuts (3/8")
TROUBLESHOOTING AND REPAIR
CONTROL BOARD REMOVAL AND REPLACEMENT (continued)
12. Using a 3/8” nut driver remove the two mounting nuts from the top two corners of the control board. See Figure F.20.
13. Cut any necessary cable ties.
FIGURE F.20 CONTROL BOARD MOUNTING SCREW LOCATION
14. Replace the control board.
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15. Replace the two 3/8” mounting nuts at the top two corners of the control board.
16. Replace any previously removed cable ties.
17. Replace plugs #J2, #J4, #J5, #J6, #J7, #J8, #J9, #J10B, and #J10A previously removed.
18. Replace the two screws and their washers from above and below the input power switch.
POWER WAVE 355M/405M
19. Replace the four screws from around the two welder output terminals on the front of the machine.
20. Replace the two case front mounting screws at the bottom of the front of the machine.
21. Replace the case wraparound cover.
F-51 F-51
TROUBLESHOOTING AND REPAIR
MAIN SWITCH BOARD REMOVAL & REPLACEMENT
WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid 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 perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical trou­bleshooting assistance before you proceed. Call 1-888-935-3877.
DESCRIPTION
The following procedure will aid the technician in removing the main switch board for maintenance or replacement.
MATERIALS NEEDED
5/16” Nut Driver
Flathead Screwdriver
7/16” mm Socket
3/16” Allen Wrench
3/8” Nut Driver
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POWER WAVE 355M/405M
F-52 F-52
- +- +
- +- +
- +- + - +- +
208
201
209
204
205
206
203
J21
J20
J22
202
207
TROUBLESHOOTING AND REPAIR
MAIN SWITCH BOARD REMOVAL & REPLACEMENT (continued)
FIGURE F.21 – MAIN SWITCH BOARD LEAD LOCATIONS
PROCEDURE
1. Remove the input power to the POWER WAVE 355M/405M.
2. Using a 5/16” nut driver remove the case wrap­around cover.
3. Perform the Input Filter Capacitor Discharge
Observe static precautions detailed in PC Board
Troubleshooting Procedures at the beginning of
this section. Failure to do so can result in perma-
nent damage to equipment.
4. Locate the main switch board and all associat-
Procedure detailed earlier in this section.
CAUTION
ed plug and lead connections. See figure F.21. See Wiring Diagram.
5. Using a 3/8” nut driver, remove the input lead shield from the area at the bottom of the main switch board.
6. Using a 7/16” socket, remove leads 201, 202, 203, 204, 205, 206, 207, 208, 209 from the switch board. Note lead terminal locations and washer positions upon removal.
7. Locate and disconnect the three harness plugs associated with the main switch board. Plugs #J20, #J21, #J22. See Figure F.21.
8. Locate the eight capacitor terminals and remove the nuts using a 7/16” socket or nut driver. Note the position of the washers behind each nut for replacement.
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POWER WAVE 355M/405M
F-53 F-53
- +- +
- +- +
- +- + - +- +
3/16" ALLEN BOLTS
TROUBLESHOOTING AND REPAIR
MAIN SWITCH BOARD REMOVAL & REPLACEMENT (continued)
FIGURE F.22 – 3/16” ALLEN BOLT LOCATION
9. Using a 3/16” allen wrench remove four allen bolts and washers as shown in Figure F.22. At this point, the board is ready for removal.
10. Carefully maneuver the board out of the
machine.
11. Apply a thin coat of Penetrox A-13 to the
IGBT heatsinks on the back of the new switch boards mating surfaces. Note: Keep compound away from the mounting holes.
12. Replace the four allen bolts and washers
previously removed.
13. Replace the eight capacitor terminal nuts,
washers, and necessary leads previously removed.
14. Reconnect the three harness plugs previous-
ly removed.
15. Reconnect the nine leads (#201-#209) that were previously removed.
16. Replace any necessary cable ties previously removed.
17. Pre-torque all screws to 25 inch lbs. before tightening to 44 inch lbs.
18. Replace the input lead shield previously removed.
19. Replace the case wraparound cover.
NOTE: Any instructions that are packaged with
the replacement board will supercede these instructions.
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POWER WAVE 355M/405M
F-54 F-54
NOTES
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POWER WAVE 355M/405M
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