Lincoln Electric SVM173-A User Manual

POWER WAVE 455M/STT

POWERWAVE 455

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POWERWAVE 455

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For use with machines having Code Numbers: 10942 10957

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.

SVM173-A

April, 2007

TM

11007 11008 11057 11153

11152

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SERVICE MANUAL

• World's Leader in Welding and Cutting Products •

• Sales and Service through Subsidiaries and Distributors Worldwide •

Cleveland, Ohio 44117-1199 U.S.A. TEL: 1-888-935-3877 WEB SITE: www.lincolnelectric.com

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FOR ENGINE powered equipment.

1.a. Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running.

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1.b.Operate engines in open, well-ventilated areas or vent the engine exhaust fumes outdoors.

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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.

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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.

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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.

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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.

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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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SAFETY

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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.

WARNING

Mar ‘95

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.

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.

1.h. To avoid scalding, do not remove the radiator pressure cap when the engine is hot.

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 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 Diesel Engines

The Above For Gasoline Engines

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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.

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.

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 OSHAPEL and ACGIH TLV limits.

5.c.

Do not weld in locations near chlorinated hydrocarbon

vapors coming from degreasing, cleaning or spraying operations. The heat and rays of the arc can react with solvent vapors

to form phosgene, a highly toxic gas, and other irritating products.

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.

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

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SAFETY

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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.

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.

Mar ‘95

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.

Remember that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas. Avoid welding near hydraulic lines. Have a fire extinguisher readily available.

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

though

they have been “cleaned”. For information, purchase “Recommended Safe Practices for the

Preparation

for Welding and Cutting of Containers and Piping That Have Held Hazardous Substances”, AWS F4.1 from the American Welding Society

(see address above).

6.e. Vent hollow castings or containers before heating, cutting or welding. They may explode.

6.f.

Sparks and spatter are thrown from the welding arc. Wear oil free protective garments such as leather gloves, heavy shirt, cuffless trousers, high shoes and a cap over your hair. Wear ear plugs when welding out of position or in confined places. Always wear safety glasses with side shields when in a welding area.

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.

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SAFETY

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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:

Sûreté Pour Soudage A L’Arc

1. Protegez-vous contre la secousse électrique:

a. Les circuits à l’électrode et à la piéce sont sous tension

quand la machine à souder est en marche. Eviter toujours tout contact entre les parties sous tension et la peau nue ou les vétements mouillés. Porter des gants secs et sans trous pour isoler les mains.

b. Faire trés attention de bien s’isoler de la masse quand on

soude dans des endroits humides, ou sur un plancher 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:

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.

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

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

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SAFETY

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- MASTER TABLE OF CONTENTS FOR ALL SECTIONS -

POWER WAVE 455M/MSTT

Page

Safety.................................................................................................................................................i-iv

Installation.............................................................................................................................Section A

Operation...............................................................................................................................Section B

Accessories ..........................................................................................................................Section C

Maintenance..........................................................................................................................Section D

Theory of Operation .............................................................................................................Section E

Troubleshooting and Repair ................................................................................................Section F

Electrical Diagrams..............................................................................................................Section G

Parts Manuals .................................................................................P438 (455M) & P450 (455M/STT)

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Installation.............................................................................................................................Section A

Technical Specifications.......................................................................................................A-2, A-3

Safety Precautions......................................................................................................................A-4

Select Suitable Location..............................................................................................................A-4

Lifting....................................................................................................................................A-4

Stacking................................................................................................................................A-4

Machine Grounding .....................................................................................................................A-4

High Frequency Protection..........................................................................................................A-4

Input Connection.........................................................................................................................A-5

Input Fuse and Supply Wire Considerations........................................................................A-5

Input Voltage Change Over (For Multiple Input Voltage Machines Only).............................A-6

Welding with Multiple Power Waves...........................................................................................A-6

Electrode and Work Cable Connections.....................................................................................A-7

Negative Electrode Polarity.........................................................................................................A-7

Voltage Sensing..........................................................................................................................A-8

Work Voltage Sensing ..........................................................................................................A-9

Electrode Voltage Sensing...................................................................................................A-9

Power Wave / Power Feed Wire Feeder Interconnections.........................................................A-9

Control Cable Specifications ................................................................................................A-9

External I/O Connector.........................................................................................................A-9

Dip Switch Settings and Locations.....................................................................................A-10

Control Board Dip Switch ...................................................................................................A-10

Feed Head Board Dip Switch.............................................................................................A-10

Devicenet/Gateway Board Dip Switch, Bank (S2) ..............................................................A-11

Section A Section A

TABLE OF CONTENTS

- INSTALLATION SECTION -

POWER WAVE 455M/MSTT

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A-2

INSTALLATION

POWER WAVE 455M/MSTT

A-2

TECHNICAL SPECIFICATIONS - POWER WAVE 455M (K2202-1, K2202-3)

OUTPUT

RECOMMENDED INPUT WIRE AND FUSE SIZES FOR MAXIMUM RATED OUTPUT

PHYSICAL DIMENSIONS

TEMPERATURE RANGES

INPUT AT RATED OUTPUT - THREE PHASE ONLY

INPUT VOLTS-

FREQUENCY

208/230/460/575V - 60HZ.

200/220/440/575V - 50HZ.

OPEN

CIRCUIT

VOLTAGE

75 VDC

INPUT

VOLTAGE /

FREQUENCY

208/50/60HZ 230/50/60HZ 460/50/60HZ 575/50/60HZ

HEIGHT

26.10 in 663 mm

WIDTH

19.86 in 505 mm

DEPTH

32.88 in

835 mm

WEIGHT

286 lbs.

130 kg.

TYPE 75°C

(SUPER LAG)

OR BREAKER

SIZE (AMPS)

110 100

50 40

TYPE 75°C

GROUND WIRE IN

CONDUIT AWG[IEC]

SIZES (MM2)

6(16) 6(16) 10(6) 10(6)

TYPE 75°C

COPPER WIRE IN

CONDUIT AWG[IEC]

SIZES (MM2)

4(25) 4(25) 8(10) 10(6)

MIG/MAG

FCAW

SMAW

GTAW

Pulse

50-570 Average Amps 40-570 Average Amps 30-570 Average Amps 15-500 Average Amps

5-750 Peak Amps

PULSE

VOLTAGE

RANGE

5 - 55 VDC

AUXILIARY POWER

(CIRCUIT BREAKER PROTECTED)

40 VDC AT

10 AMPS

115VAC AT

10 AMPS

PULSE AND

BACKGROUND

TIME RANGE

100 MICRO SEC.

-3.3 SEC.

CURRENT

RANGE

AMPS

5 - 570A

PULSE

FREQUENCY

0.15 - 1000 Hz

INPUT

CURRENT

AMPS

58/53/25/22 82/78/37/31

49/45/23/18 67/61/31/25

IDLE

POWER

400 Watts

Max.

POWER FACTOR

@ RATED OUTPUT

.95 MIN.

EFFICIENCY

@ RATED

OUTPUT

88%

OUTPUT

CONDITIONS

AMPS / VOLTS / DUTY CYCLE

450A@38V.100%

570A@43V. 60%

400A@36V.100%

500A@40V. 60%

OPERATING TEMPERATURE RANGE

-20°C to +40°C

STORAGE TEMPERATURE RANGE

-40°C to +40°C

PROCESS CURRENT RANGE (DC) CURRENT

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A-3

INSTALLATION

POWER WAVE 455M/MSTT

A-3

TECHNICAL SPECIFICATIONS - POWER WAVE 455M/STT (K2203-1)

OUTPUT

RECOMMENDED INPUT WIRE AND FUSE SIZES FOR MAXIMUM RATED OUTPUT

PHYSICAL DIMENSIONS

TEMPERATURE RANGES

INPUT AT RATED OUTPUT - THREE PHASE ONLY

INPUT VOLTS

208/230/460/575V - 60HZ.

200/220/440/575V - 50HZ.

OPEN

CIRCUIT

VOLTAGE

75 VDC

INPUT

VOLTAGE /

FREQUENCY

208/50/60HZ 230/50/60HZ 460/50/60HZ 575/50/60HZ

HEIGHT

26.10 in 663 mm

WIDTH

19.86 in 505 mm

DEPTH

32.88 in 835 mm

WEIGHT

293 lbs.

133 kg.

TYPE 75°C

(SUPER LAG)

OR BREAKER

SIZE (AMPS)

110 100

50 40

TYPE 75°C

GROUND WIRE IN

CONDUIT AWG

SIZES (mm

2

)

6(16) 6(16) 10(6) 10(6)

TYPE 75°C

COPPER WIRE IN

CONDUIT AWG

SIZES (mm

2

)

4(25) 4(25) 8(10) 10(6)

PROCESS CURRENT RANGES (DC)

MIG/MAG

FCAW

SMAW

Pulse

STT

CURRENT

50-570 Average Amps 40-570 Average Amps 30-570 Average Amps

5-750 Peak Amps

40-325 Average Amps

PULSE

VOLTAGE

RANGE

5 - 55 VDC

AUXILIARY POWER

(CIRCUIT BREAKER PROTECTED)

40 VDC AT

10 AMPS

115VAC AT

10 AMPS

PULSE AND

BACKGROUND

TIME RANGE

100 MICRO SEC.

-3.3 SEC.

CURRENT

RANGE/

STT

5-575/5-325

PULSE

FREQUENCY

0.15 - 1000 Hz

INPUT

CURRENT

AMPS

58/53/25/22 82/78/37/31

49/45/23/18 67/61/31/25

IDLE

POWER

400 Watts

Max.

POWER FACTOR

@ RATED OUTPUT

.95 MIN.

EFFICIENCY

@ RATED

OUTPUT

88%

OUTPUT

CONDITIONS

450A@38V.100%

570A@43V. 60%

400A@36V.100%

500A@40V. 60%

OPERATING TEMPERATURE RANGE

-20°C to +40°C

STORAGE TEMPERATURE RANGE

-40°C to +40°C

SAFETY PRECAUTIONS

Read this entire installation section before you start installation.

ELECTRIC SHOCK can kill.

• Only qualified personnel should perform this installation.

• Turn the input power OFF at the dis-

connect switch or fuse box before working on this equipment. Turn of f the input power to any other equipment connected to the welding system at the disconnect switch or fuse box before working on the equipment.

• Do not touch electrically hot parts.

• Always connect the Power Wave grounding lug (located inside the reconnect input access door) to a proper safety (Earth) ground.

SELECT SUITABLE LOCATION

Do not use Power Waves in outdoor environments. The Power Wave power source should not be subjected to falling water, nor should any parts of it be submerged in water. Doing so may cause improper operation as well as pose a safety hazard. The best practice is to keep the machine in a dry, sheltered area.

Place the welder where clean cooling air can freely circulate in through the rear louvers and out through the case sides and bottom. Dirt, dust, or any foreign material that can be drawn into the welder should be kept at a minimum. Do not use air filters on the air intake, because the air flow will be restricted. Failure to observe these precautions can result in excessive operating temperatures and nuisance shutdowns.

Machines above code 10500 are equipped with F.A.N. (fan as needed) circuitry. The fan runs whenever the output is enabled, whether under loaded or open circuit conditions. The fan also runs for a period of time (approximately 5 minutes) after the output is disabled, to ensure all components are properly cooled.

If desired, the F.A.N. feature can be disabled (causing the fan to run whenever the power source is on). To disable F.A.N., connect leads 444 and X3A together at the output of the solid state fan control relay , located on the back of the Control PC board enclosure. (See the Wiring Diagram.)

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.

LIFTING

Lift the machine by the lift bail only. The lift bail is designed to lift the power source only. Do not attempt to lift the Power Wave with accessories attached to it.

STACKING

Power Wave machines can be stacked a maximum of three high.

The bottom machine must always be placed on a firm, secure, level surface. There is a danger of machines toppling over if this precaution is not taken.

MACHINE GROUNDING

The frame of the welder must be grounded. A ground terminal marked with the symbol is located inside the reconnect/input access door for this purpose. See your local and national electrical codes for proper grounding methods.

HIGH FREQUENCY PROTECTION

Locate the Power Wave away from radio controlled machinery.

The normal operation of the Power Wave may adversely affect the operation of RF controlled equipment, which may result in bodily injury or damage to the equipment.

A-4 A-4

INSTALLATION

POWER WAVE 455M/MSTT

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CAUTION

WARNING

CAUTION

INPUT CONNECTION

Only a qualified electrician should connect the input leads to the Power Wave. Connections should be made in accordance with all local and national electrical codes and the connection diagram located on the inside of the reconnect/input access door of the machine. Failure to do so may result in bodily injury or death.

Use a three-phase supply line. A 1.75 inch (45 mm) diameter access hole for the input supply is located on the upper left case back next to the input access door. Connect L1, L2, L3 and ground according to the Input Supply Connection Diagram decal located on the inside of the input access door, or refer to Figure A.1.

INPUT FUSE AND SUPPLY WIRE CONSIDERATIONS

Refer to the Technical Specifications at the beginning of this Installation section for recommended fuse and wire sizes. Fuse the input circuit with the recommended super lag fuse or delay type breakers (also called “inverse time” or “thermal/magnetic” circuit breakers). Choose an input and grounding wire size according to local or national electrical codes. Using fuses or circuit breakers smaller than recommended may result in “nuisance” shut-offs from welder inrush currents, even if the machine is not being used at high currents.

A-5 A-5

INSTALLATION

POWER WAVE 455M/MSTT

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WARNING

NOTE: Turn main input power to the machine OFF before performing connection procedure. Failure to do

so will result in damage to the machine.

FIGURE A.1

(K1761-1) CONNECTION DIAGRAM ON CONNECTION/INPUT ACCESS DOOR

200-208V

220-230V

440-460V

550-575V

200-208V

220-230V

VOLTAGE = 220-230V

220-230V

200-208V

220-230V

440-460V

550-575V

200-208V

U / L1

550-575V

440-460V

inspecting or servicing ma ch in e. Do not operate with covers

removed. Do not touch electrically live parts. Only qualified persons should install,

use or service this equipment.

'A'

VOLTAGE = 440-460V

'A'

S25198

VOLTAGE = 200-208V

THE LINCOLN ELECTRIC CO. CLEVELAND, OHIO U.S.A.

XA

'A'

VOLTAGE = 550-575V

CR1

W / L3

V / L2

440-460V

550-575V

Disconnect input power before

INPUT SUPPLY CONNECTION DIAGRAM

WARNING

CAN KILL

SHOCK

ELECTRIC

(K1761-2) CONNECTION DIAGRAM ON CONNECTION/INPUT ACCESS DOOR

200-208V

220-230V

380-415V

440-460V

200-208V

220-230V

VOLTAGE=220-230V

220-230V

200-208V

220-230V

380-415V

440-460V

200-208V

U / L1

440-460V

380-415V

.

inspecting or servicing machine. Do not operate with covers

.

removed. Do not touch electrically live parts.

.

Only qualified persons should install, use or service this equipment.

.

'A'

VOLTAGE=380-415V

'A'

S23847

VOLTAGE=200-208V

THE LINCOLN ELECTRIC CO. CLEVELAND, OHIO U.S.A.

A

'A'

VOLTAGE=440-460V

CR1

W / L3

V / L2

380-415V

440-460V

Disconnect input power before

INPUT SUPPLY CONNECTION DIAGRAM

WARNING

ELECTRIC

SHOCK

CAN KILL

ELECTRIC

SHOCK

CAN KILL

WARNING

A-6 A-6

INSTALLATION

POWER WAVE 455M/MSTT

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INPUT VOLTAGE CHANGE OVER (FOR MULTIPLE INPUT VOLTAGE

MACHINES ONLY)

Welders are shipped connected for the highest input voltage listed on the rating plate. To move this connection to a different input voltage, see the diagram located on the inside of the input access door. (Figure A.1.) If the main reconnect switch or link position is placed in the wrong position, the welder will not produce output power.

If the Auxiliary (A) lead is placed in the wrong position, there are two possible results. If the lead is placed in a position higher than the applied line voltage, the welder may not come on at all. If the auxiliary (A) lead is placed in a position lower than the applied line voltage, the welder will not come on, and the two circuit breakers in the reconnect area will open. If this occurs, turn off the input voltage, properly connect the (A) lead, reset the breakers, and try again.

WELDING WITH MULTIPLE POWER WAVES

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 terminal 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 in Figure A.2. 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.

CAUTION

POWERWAVE 455/R

I ON

O OFF

POWERWAVE 455/R

I ON

O OFF

FIGURE A.2 – MULTIPLE POWER WAVE CONNECTIONS

TWO POWER WAVES

SENSE LEAD

ELECTRODE

SENSE LEAD

CONNECT ALL WORK SENSE LEADS AT THE END OF THE JOINT

CONNECT ALL WELDING WORK LEADS AT THE BEGINNING OF THE JOINT

TRAVEL

DIRECTION

WORK LEAD WORK LEAD

When these parameters are identical, the pulsing frequency will be the same, helping to stabilize the arcs.

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, each gun must have its own anti-spatter system. See Figure A.2.

ELECTRODE AND WORK CABLE CONNECTIONS

Connect a work lead of sufficient size and length (per Table A.1) 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. Do not tightly bundle the electrode and work cables together.

Use K1796 coaxial welding cables wherever possible. Minimum work and electrode cables sizes are as

follows:

TABLE A.1

(Current (60% Duty Cycle)

MINIMUM COPPER

WORK CABLE SIZE AWG

Up To 100 Ft. Length (30 m)

400 Amps 2/0 (67 mm2) 500 Amps 3/0 (85 mm2) 600 Amps 3/0 (85 mm2)

When using an inverter type power source like the Power Wave, use the largest welding (electrode and ground) cables that are practical. At least 2/0 copper wire - even if the average output current would not normally require it.

When pulsing, the pulse current can reach very high levels. Voltage drops can become excessive, leading to poor welding characteristics, if undersized welding cables are used.

Most welding applications run with the electrode being positive (+). For those applications, connect one end of the electrode cable to the positive (+) output terminal on the power source (located beneath the spring loaded output cover near the bottom of the case front). Connect the other end of the electrode cable to the wire drive feed plate using the stud, lockwasher, and nut provided on 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 Table A.1. Connect a work lead from the negative (-) power source output terminal to the work piece. The work piece connection must be firm and secure, especially if pulse welding is planned.

Excessive voltage drops caused by poor work piece connections often result in unsatisfactory welding performance.

When welding with the STT process, use the positive output connection labeled (STT) for STT welding. (If desired, other welding modes can be used on this terminal; however, their average output current will be limited to 325 amps.) For non-STT processes, use the positive output connection labeled (Power Wave), so that the full output range of the machine is available.

Do not connect the STT and Power Wave terminals together. Paralleling the terminals will bypass STT circuitry and severely deteriorate STT 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 (-) terminal, and work cable to the positive (+) terminal).

When operating with electrode polarity negative, the Dip switch 7 must be set to ON on the Wire Feed Head PC Board. The default setting of the switch is OFF to represent positive electrode polarity.

To set the Negative Polarity switch on Wire Feed Head PC board, refer to the section DIP SWITCH SETTINGS

AND LOCATIONS.

A-7 A-7

INSTALLATION

POWER WAVE 455M/MSTT

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CAUTION

VOLTAGE SENSING

The best arc performance occurs when the Power Wave has 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 terminals of the welder. Voltage sense leads improve the accuracy of the arc conditions and can have a dramatic effect on performance.

If the voltage sensing is enabled but the sense leads are missing or improperly connected, extremely high welding outputs may occur.

Do not tightly bundle the work sense lead to the work lead.

The sense leads connect to the Power Wave at the four-pin connector located underneath the output terminal cover. Lead 67 senses electrode voltage. Lead 21 senses work voltage.

Enable the voltage sense leads as follows:

TABLE A.2

Process Electrode Voltage Work Voltage

Sensing 67 lead * Sensing 21 lead

GMAW 67 lead required 21 lead optional GMAW-P 67 lead required 21 lead optional FCAW 67 lead required 21 lead optional STT 67 lead required 21 lead required GTAW Voltage sense at Voltage sense at

terminals terminals

SAW 67 lead required 21 lead optional

* The electrode voltage 67 sense lead is integral to the con-

trol cable to the wire feeder.

A-8 A-8

INSTALLATION

POWER WAVE 455M/MSTT

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POWER

W

AVE 455/R

I ON

O OFF

POWER

WA

VE 455/R

FIGURE A.3 – DIP SWITCH LOCATION

CAUTION

REMOVE FRONT COVER

WIRE FEED HEAD BOARD ON RIGHT

CONTROL BOARD ON LEFT

WORK VOLTAGE SENSING

The Power Wave is shipped from the factory with the work sense lead enabled.

For processes requiring work voltage sensing, connect the (21) work voltage sense lead from the Power Wave to the work. Attach the sense lead to the work as close to the weld as practical. To enable the work voltage sensing in the Power Wave, refer to the section DIP

SWITCH SETTINGS AND LOCATIONS.

ELECTRODE VOLTAGE SENSING

Enabling or disabling electrode voltage sensing is automatically configured through software. Electrode sense lead 67 must be connected at the wire feeder.

POWER WAVE / POWER FEED WIRE FEEDER INTERCONNECTIONS

Connect the control cable between the power source and wire feeder. The wire feeder connection on the robotic Power Wave is located under the spring loaded output cover, near the bottom of the case front. The control cable is keyed and polarized to prevent improper connection.

For convenience sake, the electrode and control cables can be routed behind the left or right strain reliefs (under the spring loaded output cover), and along the channels formed into the base of the Power Wave, out the back of the channels, and then to the wire feeder.

Output connections on some Power Waves are made via 1/2-13 threaded output terminals located beneath the spring-loaded output cover at the bottom of the case front. On machines which carry the CE mark, output connections are made via Twist-Mate receptacles, also located beneath the spring-loaded output cover at the bottom of the case front.

A work lead must be run from the negative (-) power source output connection to the work piece. The work piece connection must be firm and secure, especially if pulse welding is planned.

Excessive voltage drops at the work piece connection often result in unsatisfactory pulse welding performance.

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.

The use of non-standard cables, especially in lengths greater than 25 feet, can lead to communication problems (system shutdowns), poor motor acceleration (poor arc starting) and low wire driving force (wire feeding problems).

Lincoln control cables are copper 22 conductor cable in a SO-type rubber jacket.

EXTERNAL I/O CONNECTOR

The Power Wave is equipped with a port for making simple input signal connections. The port is divided into three groups: Trigger group, Cold Inch Group and Shutdown Group. Because the Power Wave is a “slave” on the DeviceNet network, the Trigger and Cold Inch Groups are disabled when the DeviceNet/Gateway is active.

The Shutdown Group is always enabled. Shutdown 2 is used for signaling low flow in the water cooler. Unused shutdowns must be jumpered. Machines from the factory come with the shutdowns already jumpered. (See Figure A.4)

A-9 A-9

INSTALLATION

POWER WAVE 455M/MSTT

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CAUTION

D

E

F

1

2

3

4

5

6

78

910

11

12

G

H

I

A

B

C

+15 VDC for Trigger Group

Trigger Input

Dual Procedure Input

4 Step Input

+15 VDC for Cold Inch Group

Cold Inch Forward

Cold Inch Reverse

Gas Purge Input

+15 for shutdown group

Shutdown1 input

Shutdown2 input

Reserved for future use

FIGURE A.4 – INPUT PORT CONNECTIONS

DIP SWITCH SETTINGS AND LOCATIONS

DIP switches on the PC boards allow for custom configuration of the Power Wave. Access the DIP switches as follows:

ELECTRIC SHOCK CAN KILL.

• 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.

• Turn off power at the disconnect switch.

• Remove the top four screws securing the front access panel.

• Loosen, but do not completely remove, the bottom two screws holding the access panel.

• Open the access panel, allowing the weight of the panel to be carried by the bottom two screws. Make sure to prevent the weight of the access panel from hanging on the harness.

• Adjust the DIP switches as necessary. Using a pencil or other small object, slide the switch left for the ON position or to the right for the OFF position, as appropriate.

• Replace the panel and screws and restore power.

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 work sense lead

off work sense lead not connected on work sense lead connected

FEED HEAD 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 = negative polarity switch switch 8 = high speed gear

switch 7 electrode polarity

off positive on negative

switch 8 wire drive gear

off low speed gear on high speed gear

A-10 A-10

INSTALLATION

POWER WAVE 455M/MSTT

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CONTROL BOARD (LOCATED IN CONTROL BOX BEHIND CASE FRONT)

FEED HEAD BOARD (LOCATED IN CONTROL BOX BEHIND CASE FRONT)

BANK S1 BANK S2

RIGHT

LEFT

DEVICENET/ GATEWAY BOARD (LOCATED BEHIND FRONT COVER)

FRONT COVER

CASE FRONT

OPENING IN CASE FRONT TO ACCESS CONTROL BOX

WARNING

DEVICENET/GATEWAY BOARD DIP SWITCH, BANK (S2):

switch 1,2 = configure the baud rate

for DeviceNET

Prior to S24958-6 software

switch 1 switch 2 baud rate

off off -------

on off 125K

off on 250K

on on 500

S24958-6 and later software

switch 1 switch 2 baud rate

off off 125K

off on 250K on off 500K on on 500K

Programmable value. Consult local Lincoln Technical representative.

switch 5 = reserved for future use switch 6 = reserved for future use switch 7 = reserved for future use switch 8 = reserved for future use

A-11 A-11

INSTALLATION

POWER WAVE 455M/MSTT

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A-12 A-12

NOTES

POWER WAVE 455M/MSTT

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Operation...............................................................................................................................Section B

Safety Precautions......................................................................................................................B-2

Graphic Symbols .........................................................................................................................B-3

General Description ....................................................................................................................B-4

Design Features and Advantages........................................................................................B-4

Recommended Processes and Equipment.................................................................................B-5

Recommended Processes....................................................................................................B-5

Recommended Equipment...................................................................................................B-5

Required Equipment.............................................................................................................B-5

Limitations.............................................................................................................................B-5

Duty Cycle and Time Period.................................................................................................B-5

Case Front Controls....................................................................................................................B-6

Welding Mode Descriptions ........................................................................................................B-7

Constant Voltage Welding ....................................................................................................B-7

Pulse Welding.................................................................................................................. .....B-8

STT Welding.........................................................................................................................B-9

Section B-1 Section B-1

TABLE OF CONTENTS

- OPERATION SECTION -

POWER WAVE 455M/MSTT

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SAFETY PRECAUTIONS

Read this entire section of operating instructions before operating the machine.

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 seconds 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.

• 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.

B-2 B-2

OPERATION

POWER WAVE 455M/MSTT

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WARNING

B-3 B-3

OPERATION

POWER WAVE 455M/MSTT

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INPUT POWER

ON

OFF

HIGH TEMPERATURE

MACHINE STATUS

CIRCUIT BREAKER

WIRE FEEDER

POSITIVE OUTPUT

NEGATIVE OUTPUT

3 PHASE INVERTER

INPUT POWER

THREE PHASE

DIRECT CURRENT

GMAW

FCAW

GTAW

OPEN CIRCUIT VOLTAGE

INPUT VOLTAGE

OUTPUT VOLTAGE

INPUT CURRENT

OUTPUT CURRENT

PROTECTIVE GROUND

WARNING OR CAUTION

GRAPHIC SYMBOLS THAT APPEAR ON

THIS MACHINE OR IN THIS MANUAL

U

0

U

1

U

2

I

1

I

2

SMAW

GENERAL DESCRIPTION

The Power Wave 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, Surface Tension Transfer and pulse welding modes.

The Power Wave power source is designed to be used with the 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, electrical accessories) knows what the other is doing at all times. The components communicate using ArcLink protocol.

Robotic systems can communicate with other industrial machines via DeviceNET protocol. The result is a highly intigrated and flexible welding cell.

The Power Wave 455/R 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, GT A W and STTprocesses. It carries an output rating of either 450 amps, 38 volts; or 400 amps, 36 volts (both at 100% duty cycle), depending on input voltage and frequency . The Surface Tension transfer process (STT) is supported at currents up to 325 amps, at 100% duty cycle.

If the duty cycle is exceeded, a thermostat will shut off the output until the machine cools to a reasonable operating temperature.

DESIGN FEATURES AND ADVANTAGES

• Designed to the IEC 974-1 Standard.

• Power Wave 455 multiple process output ranges: 5 - 570 amps

• Easy access for input connections. Connections are simple strip and clamp (no lugs required).

• F.A.N. (Fan As Needed). Cooling fan runs only when necessary (above Code 10500 only, and all STT machines).

• Modular construction for easy servicing.

• Thermostatically protected.

• Electronic over-current protection.

• Input over-voltage protection.

• Utilizes digital signal processing and microprocessor control.

• Simple, reliable input voltage change over.

• All system components communicate and transfer information.

• Auto device recognition simplifies accessory cable connections.

B-4 B-4

OPERATION

POWER WAVE 455M/MSTT

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RECOMMENDED PROCESSES AND EQUIPMENT

RECOMMENDED PROCESSES

The Power Wave 455/R 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 STT for a variety of materials, including mild steel, stainless steel, cored wires, and aluminum. The STT process supports mild steel and stainless steel welding.

The Power Wave 455/R is recommended only for automatic or mechanized applications such as robotic welding.

RECOMMENDED EQUIPMENT

Automatic Operation

All welding programs and procedures are set through software for the robotic Power Wave. FANUC robots equipped with RJ-3 controllers may communicate directly with the Power Wave. Other pieces of equipment such as PLCs or computers can communicate with the Power Wave using DeviceNET. All wire welding processes require a robotic Power Feed wire feeder.

REQUIRED EQUIPMENT

• PF-10/R Wire Feeder, K1780-1

• Control Cables (22 pin to 22 pin), K1795-10,-25,-50,100

• Control Cables (for use on FANUC robot arm, 22 pin to 14 pin, 10 ft), K1804-1

• Control Cables (for use on FANUC robot arm, 22 pin to 14 pin, 18 in), K1805-1

• Control Cables (for use on FANUC robot arm, 22 pin to 14 pin, 18 in), K1804-2

LIMITATIONS

• The Power Wave 455/R is not suitable for SMAW, CAC-A or other processes not listed.

• Power Waves are not to be used in outdoor environments.

• Only ArcLink Power Feed wire feeders and user interfaces may be used. Other Lincoln wire feeders or non-Lincoln wire feeders cannot be used.

DUTY CYCLE AND TIME PERIOD

The Power Feed wire feeders are capable of welding at a 100% duty cycle (continuous welding). The power source will be the limiting factor in determining system duty cycle capability. Note that the duty cycle is based upon a ten minute period. A60% duty cycle represents 6 minutes of welding and 4 minutes of idling in a ten minute period.

B-5 B-5

OPERATION

POWER WAVE 455M/MSTT

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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: Atwo color light that indicates system errors. Normal operation is a steady green light. Error conditions are indicated, per Table B.1.

NOTE: The robotic Power Waves’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

Meaning

Condition

Steady System OK. Power source

Green communicating normally with

wire feeder and its components.

Blinking Normal for first 1-10 seconds

Green after power is turned on.

Alternating Non-recoverable system fault.

Green Must turn power source off, find

and Red source of error, and turn power

back on to reset. See

Troubleshooting Guide.

Steady See Troubleshooting Guide.

Red

3. HIGH TEMPERATURE LIGHT (thermal overload): A yellow light that comes on when an over temperature situation occurs. Output is disabled until the machine cools down. When cool, the light goes out and output is enabled.

4. 10 AMP WIRE FEEDER CIRCUIT BREAKER: Protects 40 volt DC wire feeder power supply.

5. 10 AMPAUXILIARYPOWER CIRCUIT BREAKER: Protects 115 volt AC case front receptacle auxiliary supply.

6. LEAD CONNECTOR S2 (SENSE LEAD)

7. 5-PIN ARC LINK S1

8. 5-PIN DEVICENET CONNECTOR S5

9. I / O CONNECTOR

10. NEGATIVE OUTPUT TERMINAL

11. INTERFACE CONNECTOR S6

12. STT TERMINAL

13. POSITIVE OUTPUT TERMINAL

14. AUXILIARY OUTPUT

B-6 B-6

OPERATION

POWER WAVE 455M/MSTT

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POWERWAVE 455/R

I ON

O OFF

FIGURE B.1 – POWER WAVE CASE FRONT CONTROLS

1

11 12 13

2 3

4145

6 7

8

9

10

WELDING MODE DESCRIPTIONS

CONSTANT VOLTAGE WELDING

For each wire feed speed, a corresponding voltage is preprogrammed into the machine through special software at the factory. The preprogrammed voltage is the best average voltage for a given wire feed speed. With synergic programs, when the wire feed speed changes, the Power Wave will automatically adjust the corresponding voltage.

Wave control adjusts the inductance of the wave shape. (This adjustment is often referred to as "pinch". Inductance is inversely proportional to pinch.) Increasing wave control greater than 0 results in a harsher, colder arc, while decreasing the wave control to less than 0 provides a softer, hotter arc. (See Figure B.2.)

B-7 B-7

OPERATION

POWER WAVE 455M/MSTT

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Current

Time

Wave Control +10.0

Wave Control -10.0

Wave Control 0.00

FIGURE B.2 – CV WAVE CONTROL CHARACTERISTICS

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, background 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.

Most 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. (Electrical stick-out is the distance from the contact tip to the work piece.) The Power Wave waveforms 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 the physical limitations of the welding process.

Wave control in pulse programs usually adjusts the focus or shape of the arc. Wave control values greater than 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 decrease the pulse frequency while increasing the background current for a soft arc good for out-of-position welding. (See Figure B.3.)

B-8 B-8

OPERATION

POWER WAVE 455M/MSTT

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Current

Time

Wave Control +10.0

Wave Control -10.0

Wave Control 0.00

FIGURE B.3 – PULSE WAVE CONTROL CHARACTERISTICS

STT WELDING

The pictures illustrate the wave shape of current for the process. They are not drawn to scale, and are intended only for the purpose of showing how the variables affect the waveform.

Trim in the STT mode adjusts the tailout and background portion of the waveform. Trim values greater than 1.0 add more energy to the weld and make the weld puddle hotter; trim values less than 1.0 reduce energy to weld. A nominal value of 1.0 will work for most applications. (See Figure B.4.)

B-9 B-9

OPERATION

POWER WAVE 455M/MSTT

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Current

Time

Trim 1.50

Trim 1.00

Trim 0.50

FIGURE B.4 – STT TRIM CONTROL CHARACTERISTICS

Current

Time

Wave Control +10.0

Wave Control -10.0

Wave Control 0.00

FIGURE B.5 – STT WAVE CONTROL CHARACTERISTICS

For most programs, peak current is adjusted by wave control values. A value of +10.0 maximizes the peak current, while a wave control of -10.0 minimizes peak current. In general, the peak current is proportional to torch arc length. (See Figure B.5.)

NOTE: The ranges on Wave Control and Trim are

dependent on the weld programs. The values shown are typical ranges.

B-10 B-10

NOTES

POWER WAVE 455M/MSTT

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Accessories ..........................................................................................................................Section C

Optional Equipment ....................................................................................................................C-2

Factory Installed...................................................................................................................C-2

Field Installed .......................................................................................................................C-2

Section C-1 Section C-1

TABLE OF CONTENTS

- ACCESSORIES SECTION -

POWER WAVE 455M/MSTT

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OPTIONAL EQUIPMENT

FACTORY INSTALLED

There are no factory installed options available for the Power Wave 455R.

FIELD INSTALLED

• Gas Guard Regulator (K659-1)

The Gas Guard regulator is available as an optional accessory for the Power Feed Robotic wire drive unit. Install the 5/8-18 male outlet on the regulator to the proper 5/8-18 female gas inlet on the back panel of the wire drive. Secure the fitting with the flow adjuster key at the top.

•Voltage Sense Leads (K940-10, -25 or -50)

The voltage sense leads connect at the front of the machine. (See Figure A.2.)

• Power Wave Water Cooler (K1767-1)*

The K1767-1 is the recommended water cooler for the Power Wave. Incorporated into the cooler is an automatic flow sensor to detect low coolant flow. In the event of a low flow condition, a fault signal is sent to the Power Wave, and welding output automatically stops to protect the torch.

The water cooler is designed to cool only one welding gun and should be not used to cool multiple guns or other devices.

Water cooler manufacturers often specify additives to the coolant such as fungicides or alkalies. Follow the manufacturers’ recommendations to achieve proper operation and long lifetime without clogging.

•Water Flow Sensor (K1536-1)

Water cooled guns can be damaged very quickly if they are used even momentarily without water flowing. Recommend practice is to install a water flow sensor such as on the water return line of the torch. When fully integrated into the welding system, the sensor will prevent welding if no water flow is present.

• Dual Cylinder Undercarriage, K1570-1*

• Coaxial Welding Cable, K1796

*The Dual Cylinder Undercarriage, K1570-1, is not

compatible in combination with the Power Wave Water Cooler K1767-1.

C-2 C-2

ACCESSORIES

POWER WAVE 455M/MSTT

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Maintenance..........................................................................................................................Section D

Safety Precautions ......................................................................................................................D-2

Routine and Periodic Maintenance .............................................................................................D-2

Main Assembly (Exploded View) ...............................................................................................D-3

Section D-1 Section D-1

TABLE OF CONTENTS

- MAINTENANCE SECTION -

POWER WAVE 455M/MSTT

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SAFETY PRECAUTIONS

ELECTRIC SHOCK can kill.

• Only Qualified personnel should perform this maintenance.

• Turn the input power OFF at the disconnect switch or fuse box before working on this equipment.

• Do not touch electrically hot parts.

ROUTINE AND PERIODIC MAINTENANCE

1. Disconnect input AC power supply lines to the machine before performing periodic maintenance, tightening, cleaning, or replacing parts. See

Figure D.1.

PERFORM THE FOLLOWING DAILY:

1. Check that no combustible materials are in the welding or cutting area or around the machine.

2. Remove any debris, dust, dirt, or materials that could block the air flow to the machine for cooling.

3. Inspect the electrode cables for any slits or punctures in the cable jacket, or any condition that would affect the proper operation of the machine.

PERFORM PERIODICALLY:

Clean the inside of the machine with a low pressure air stream. Clean the following parts. Refer to Figure

D.1.

• Transformer and output rectifier assembly.

• Electrode and work cable connections.

• PC board connections..

• Intake and outlet louvers on the machine case.

• Any obvious accumulations of dirt within the

machine.

• Fan Assembly.

NOTE: The fan motor has sealed bearings which

require no maintenance.

D-2 D-2

MAINTENANCE

POWER WAVE 455M/MSTT

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WARNING

D-3 D-3

MAINTENANCE

POWER WAVE 455M/MSTT

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1

7

3

4

6

5

2

FIGURE D.1 – MAIN ASSEMBLY (EXPLODED VIEW)

1. CASE FRONT ASSEMBLY

2. TRANSFORMER AND OUTPUT RECTIFIER ASSEMBLY

3. INPUT ASSEMBLY

4. CONTROL BOX AND VERTICAL DIVIDER ASSEMBLY

5. BASE, LIFT BAIL AND FAN ASSEMBLY

6. SWITCH BOARD HEATSINK ASSEMBLY

7. CASE PARTS

D-4 D-4

NOTES

POWER WAVE 455M/MSTT

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Theory of Operation .............................................................................................................Section E

Block Logic Diagram...................................................................................................................E-1

General Description ....................................................................................................................E-2

Input Voltage and Precharge......................................................................................................E-3

Switch Boards and Main Transformer.........................................................................................E-4

DC Bus Board, Power Board, Feed Head Board, Gateway Board

and Voltage Sense Board...........................................................................................................E-5

Power Wave Communications Diagram.....................................................................................E-6

Control Board..............................................................................................................................E-7

Output Rectifier, Output Choke and STT Chopper Board ..........................................................E-8

Thermal Protection, Protective Circuits, Over Current Protection

and Under/Over Voltage Protection............................................................................................E-9

General Description of STT (Surface Tension Transfer) Process.............................................E-10

Insulated Gate Bipolar Transistor (IGBT) Operation.................................................................E-11

Pulse Width Modulation ............................................................................................................E-12

Section E-1 Section E-1

TABLE OF CONTENTS

- THEORY OF OPERATION SECTION -

POWER WAVE 455M/MSTT

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+

INPUT BOARD

RECONNECT SWITCH

LEFT SWITCH BOARD

RIGHT SWITCH BOARD

INPUT RECTIFIER

CR1

GATEWAY BOARD

DC BUS BOARD

FEED HEAD BOARD

POWER BOARD

CONTROL BOARD

STT CHOPPER BOARD

OUTPUT CHOKE

STT ELECTRODE TERMINAL

ELECTRODE TERMINAL

THERMOSTATS

T1

T2

AUX RECONNECT

RELAY

WATER COOLER

115 VAC RECP.

115 VAC FAN

ARC LINK

WIRE FEEDER RECP.

S1

S6

CONNECTION TO WIRE DRIVE

S1

S6

VOLT SENSE BOARD

MAIN TRANSFORMER

S5

CONTACTOR AND PRECHARGE CONTROL SIGNALS FROM CONTROL BOARD

FROM CONTROL BOARD

2 4 V A C

115 VAC

52 VAC

230 VAC

40 VDC

+20 VDC TO CHOPPER BOARD

40 VDC

ARC LINK

CONNECTION TO ROBOT

VOLTAGE SENSE OUTPUT

+20 VDC FROM POWER BOARD

CT CURRENT TO CONTROL BOARD

CAP . V/F

FEEDBACK

CAP . V/F

FEEDBACK

IGBT DRIVE FROM CONTROL BOARD

CT CURRENT TO CONTROL BOARD

-15 V

+15 V

+5 V

+5 V ARC LINK

+5V RS232

+15V SPI

STATUS THERMAL

LIGHT LIGHT

S2 WORK SENSE

LEFT S.B. CAP . V/F

RIGHT S.B. CAP . V/F

S3 RS232

LEFT CT CURRENT FB

C U R R E N T

F B

S T T

F B

STT DRIVE

ARC LINK

IGBT DRIVES

TO LEFT S.B.

TO RIGHT S.B.

67A

67B

SW1

BUS BOARD RECTIFIER

CURRENT TRANSDUCER

OUTPUT DIODES D1 -D4

115 VAC

40 VDC

DEVICE NET

VOLTAGE SENSE SELECT

IGBT DRIVE FROM CONTROL BOARD

+5V SPI

RIGHT CT CURRENT FB

TO FAN RELAY CONTACTOR AND

PRECHARGE CONTROL SIGNALS

65 VDC

WORK TERMINAL

POWER W AVE 455/R

FIGURE E.1 – BLOCK LOGIC DIAGRAM

GENERAL DESCRIPTION

The Power Wave 455M/MSTT power source is designed to be a part of a modular, multi-process welding system. It is a high performance, digitally controlled inverter welding power source capable of complex, high-speed waveform control. Depending upon configuration, it can support constant current, constant voltage, surface tension transfer and pulse welding modes. Each machine is factory preprogrammed with multiple welding procedures. Typically these procedures include GMAW, GMAW-P, FCAW, GTAW and

STT (Surface Tension Transfer) for a variety of materials such as mild steel, stainless steel, cored wires and aluminum. The STT process supports mild steel and stainless steel welding. PW455M/STT only.

The Power Wave 455M/STT has an output rating of either 450 amps at 38 volts or 400 amps at 36 volts. The two output ratings are dependent upon input voltage and frequency. Both have a duty cycle of 100%. The STT process is rated at currents up to 325 amps at a 100% duty cycle.

E-2 E-2

THEORY OF OPERATION

POWER WAVE 455M/MSTT

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+

INPUT BOARD

RECONNECT SWITCH

LEFT SWITCH BOARD

RIGHT SWITCH BOARD

INPUT RECTIFIER

CR1

GATEWAY BOARD

DC BUS BOARD

FEED HEAD BOARD

POWER BOARD

CONTROL BOARD

STT CHOPPER BOARD

OUTPUT CHOKE

STT ELECTRODE TERMINAL

ELECTRODE TERMINAL

THERMOSTATS

T1

T2

AUX RECONNECT

RELAY

WATER COOLER

115 VAC RECP.

115 VAC FAN

ARC LINK

WIRE FEEDER RECP.

S1

S6

CONNECTION TO WIRE DRIVE

S1

S6

VOLT SENSE BOARD

MAIN TRANSFORMER

S5

CONTACTOR AND PRECHARGE CONTROL SIGNALS FROM CONTROL BOARD

FROM CONTROL BOARD

2 4 V A C

115 VAC

52 VAC

230 VAC

40 VDC

+20 VDC TO CHOPPER BOARD

40 VDC

ARC LINK

CONNECTION TO ROBOT

VOLTAGE SENSE OUTPUT

+20 VDC FROM POWER BOARD

CT CURRENT TO CONTROL BOARD

CAP. V/F

FEEDBACK

CAP. V/F

FEEDBACK

IGBT DRIVE FROM CONTROL BOARD

CT CURRENT TO CONTROL BOARD

-15 V

+15 V

+5 V

+5 V ARC LINK

+5V RS232

+15V SPI

STATUS THERMAL

LIGHT LIGHT

S2 WORK SENSE

LEFT S.B. CAP. V/F

RIGHT S.B. CAP. V/F

S3 RS232

LEFT CT CURRENT FB

C U R R E N T

F B

S T T

F B

STT DRIVE

ARC LINK

IGBT DRIVES

TO LEFT S.B.

TO RIGHT S.B.

67A

67B

SW1

BUS BOARD RECTIFIER

CURRENT TRANSDUCER

OUTPUT DIODES D1 -D4

115 VAC

40 VDC

DEVICE NET

VOLTAGE SENSE SELECT

IGBT DRIVE FROM CONTROL BOARD

+5V SPI

RIGHT CT CURRENT FB

TO FAN RELAY

CONTACTOR AND PRECHARGE CONTROL SIGNALS

65 VDC

WORK TERMINAL

POWER W AVE 455/R

FIGURE E.2 – INPUT VOLTAGE AND PRECHARGE

NOTE: Unshaded areas of Block Logic Diagram are the subject of discussion.

INPUT VOLTAGE AND PRECHARGE

The Power Wave 455M can be connected for a variety of three-phase input voltages. Refer to Figure E.2. The initial input power is applied to the Power Wave 455M through a line switch located on the front of the machine. Two phases of the three-phase input power are applied to the Input Board and both auxiliary transformers. The various secondary voltages developed by transformer T1 are applied to the Input Board, the fan motor (via a control relay) and the Bus Board rectifier. The 65VDC produced from the Bus Board rectifier is used by the Bus Board to provide various DC voltages for the Power Board, the Feed Head Board and the wire feeder receptacle. The 115/230VAC developed on the secondary of auxiliary transformer T2 is applied to the 115VAC receptacle and to the water cooler receptacle.

The two phases that are connected to the Input Board, through the input line switch SW1, are connected to the input rectifier through the CR1 precharge relay . During

the precharge or "soft start" sequence, these two phases are current limited by the Input Board. The AC input voltage is rectified, and the resultant DC voltage is applied through the reconnect switches to the input capacitors located on the right and left switch boards. The Control Board monitors the voltage across the capacitors. When the capacitors have charged to an acceptable level, the Control Board signals the Input Board to energize the main input contactor, making all three phases of input power, without current limiting, available to the input capacitors. At this point the Power Wave 455M is in the "Run Mode" of operation. If the capacitors become undervoltaged, overvoltaged, or unbalanced, the Control Board will signal the Input Board to de-energize the main input contactor, and the Power Wave 455M will be disabled. See Figure E.2.

E-3 E-3

THEORY OF OPERATION

POWER WAVE 455M/MSTT

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SWITCH BOARDS AND MAIN TRANSFORMER

There are two switch boards in the Power Wave 455M machine. Each contains an input capacitor and insulated gate bipolar transistor (IGBT) switching circuitry. Refer to Figure E.3. When the machine reconnect switches are configured for a lower input voltage (below 300VAC), the input capacitors are connected in parallel. When the machine is configured for higher input voltages (300VAC and above), the input capacitors are connected in series.

When the input capacitors are fully charged, they act as power supplies for the IGBT switching circuits. The insulated gate bipolar transistors switch the DC power from the input capacitors "on and off," thus supplying pulsed DC current to the main transformer primary windings. See IGBT OPERA TION DISCUSSION AND DIAGRAMS in this section.

Each switch board 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 switch boards induce an AC square wave output signal at the secondary of the main transformer. Current transformers located on the switch boards monitor the primary currents. If the primary currents become abnormally high, the Control Board will shut off the IGBTs, thus disabling the machine’s output. The firing of the two switch boards occurs during halves of a 50microsecond interval, creating a constant 20 KHZ output.

E-4 E-4

THEORY OF OPERATION

POWER WAVE 455M/MSTT

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NOTE: Unshaded areas of Block Logic Diagram are the subject of discussion.

FIGURE E.3 - SWITCH BOARDS AND MAIN TRANSFORMER

+

INPUT BOARD

RECONNECT SWITCH

LEFT SWITCH BOARD

RIGHT SWITCH BOARD

INPUT RECTIFIER

CR1

GATEWAY BOARD

DC BUS BOARD

FEED HEAD BOARD

POWER BOARD

CONTROL BOARD

STT CHOPPER BOARD

OUTPUT CHOKE

STT ELECTRODE TERMINAL

ELECTRODE TERMINAL

THERMOSTATS

T1

T2

AUX RECONNECT

RELAY

WATER COOLER

115 VAC RECP.

115 VAC FAN

ARC LINK

WIRE FEEDER RECP.

S1

S6

CONNECTION TO WIRE DRIVE

S1

S6

VOLT SENSE BOARD

MAIN TRANSFORMER

S5

CONTACTOR AND PRECHARGE CONTROL SIGNALS FROM CONTROL BOARD

FROM CONTROL BOARD

2 4 V A C

115 VAC

52 VAC

230 VAC

40 VDC

+20 VDC TO CHOPPER BOARD

40 VDC

ARC LINK

CONNECTION TO ROBOT

VOLTAGE SENSE OUTPUT

+20 VDC FROM POWER BOARD

CT CURRENT TO CONTROL BOARD

CAP. V/F

FEEDBACK

CAP. V/F

FEEDBACK

IGBT DRIVE FROM CONTROL BOARD

CT CURRENT TO CONTROL BOARD

-15 V

+15 V

+5 V

+5 V ARC LINK

+5V RS232

+15V SPI

STATUS THERMAL

LIGHT LIGHT

S2 WORK SENSE

LEFT S.B. CAP. V/F

RIGHT S.B. CAP. V/F

S3 RS232

LEFT CT CURRENT FB

C U R R E N T

F B

S T T

F B

STT DRIVE

ARC LINK

IGBT DRIVES

TO LEFT S.B.

TO RIGHT S.B.

67A

67B

SW1

BUS BOARD RECTIFIER

CURRENT TRANSDUCER

OUTPUT DIODES D1 -D4

115 VAC

40 VDC

DEVICE NET

VOLTAGE SENSE SELECT

IGBT DRIVE FROM CONTROL BOARD

+5V SPI

RIGHT CT CURRENT FB

TO FAN RELAY CONTACTOR AND

PRECHARGE CONTROL SIGNALS

65 VDC

WORK TERMINAL

POWER W AVE 455/R

DC BUS BOARD, POWER BOARD, AND GATEWAY 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 Feed Head Board, the Power Board, and the wire feeder receptacle.

The switching power supplies on the Power Board supply a variety of regulated DC voltages to the Control Board and a +20VDC to the STT Chopper Board. The Control Board uses these regulated voltages to power the many circuits and communication functions incorporated within the Control Board.

When the Feed Head Board activates the Voltage Sense Board, the actual arc voltage is sensed (lead

67), and this information is delivered through the voltage sense board to the Control Board.

The Power Wave 455M uses two digital communication platforms. Internally the PC boards communicate via ArcLink. Externally the Power Wave 455R communicates using the industry standard Device Net protocols. The Gateway Board makes the translation between the two platforms possible. The Power Wave 455R does not have a dedicated interface device or board. The robot (or other input device – PLC, etc.) acts as the user interface, issuing commands through the Device Net protocol that are translated by the Gateway Board to ArcLink compatible messages. The following block diagram (Figure E.5) depicts the flow of communication information.

E-5 E-5

THEORY OF OPERATION

POWER WAVE 455M/MSTT

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NOTE: Unshaded areas of Block Logic Diagram are the subject of discussion.

+

INPUT BOARD

RECONNECT SWITCH

LEFT SWITCH BOARD

RIGHT SWITCH BOARD

INPUT RECTIFIER

CR1

GATEWAY BOARD

DC BUS BOARD

FEED HEAD BOARD

POWER BOARD

CONTROL BOARD

STT CHOPPER BOARD

OUTPUT CHOKE

STT ELECTRODE TERMINAL

ELECTRODE TERMINAL

THERMOSTATS

T1

T2

AUX RECONNECT

RELAY

WATER COOLER

115 VAC RECP.

115 VAC FAN

ARC LINK

WIRE FEEDER RECP.

S1

S6

CONNECTION TO WIRE DRIVE

S1

S6

VOLT SENSE BOARD

MAIN TRANSFORMER

S5

CONTACTOR AND PRECHARGE CONTROL SIGNALS FROM CONTROL BOARD

FROM CONTROL BOARD

2 4 V A C

115 VAC

52 VAC

230 VAC

40 VDC

+20 VDC TO CHOPPER BOARD

40 VDC

ARC LINK

CONNECTION TO ROBOT

VOLTAGE SENSE OUTPUT

+20 VDC FROM POWER BOARD

CT CURRENT TO CONTROL BOARD

CAP. V/F

FEEDBACK

CAP. V/F

FEEDBACK

IGBT DRIVE FROM CONTROL BOARD

CT CURRENT TO CONTROL BOARD

-15 V

+15 V

+5 V

+5 V ARC LINK

+5V RS232

+15V SPI

STATUS THERMAL

LIGHT LIGHT

S2 WORK SENSE

LEFT S.B. CAP. V/F

RIGHT S.B. CAP. V/F

S3 RS232

LEFT CT CURRENT FB

C U R R E N T

F B

S T T

F B

STT DRIVE

ARC LINK

IGBT DRIVES

TO LEFT S.B.

TO RIGHT S.B.

67A

67B

SW1

BUS BOARD RECTIFIER

CURRENT TRANSDUCER

OUTPUT DIODES D1 -D4

115 VAC

40 VDC

DEVICE NET

VOLTAGE SENSE SELECT

IGBT DRIVE FROM CONTROL BOARD

+5V SPI

RIGHT CT CURRENT FB

TO FAN RELAY

CONTACTOR AND PRECHARGE CONTROL SIGNALS

65 VDC

WORK TERMINAL

POWER W AVE 455/R

FIGURE E-4 – DC BUS BOARD, POWER BOARD, FEED HEAD BOARD,

GATEWAY BOARD AND VOLTAGE SENSE BOARD

E-6 E-6

THEORY OF OPERATION

POWER WAVE 455M/MSTT

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FIGURE E.5 – POWER WAVE 455/R COMMUNICATIONS

Arc Link

AArrcc LLiinnkk

Device Net

DDeevviiccee NNeett

PW-455R

CCoonnttrrooll

BBooaarrdd

Weld Controller / Sequencer

GGaatteewwaayy

BBooaarrdd

Translator

FFeeeedd

HHeeaadd

BBooaarrdd

Robot

Controller

PF-10R

CONTROL BOARD

The Control Board performs the primary interfacing functions to establish and maintain output control of the Power Wave 455R machine. The function generator and weld files exist within the Control Board hardware and software. Digital command signals and feedback information is received and 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 IGBTs. In this manner, the digitally controlled high-speed welding waveform is created.

The Control Board also monitors and controls the STT (Surface Tension Transfer) circuitry incorporated in the Power Wave 455R. STT output currents and arc voltages are monitored, and the appropriated gate firing signals are applied (or removed) from the STT Chopper Board and switch boards to create a low spatter, low fume MIG welding process. See GENERAL

DESCRIPTION OF STT (SURFACE TENSION TRANSFER PROCESS) in this section.

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 output. In some conditions the input contactor will be de-energized.

E-7 E-7

THEORY OF OPERATION

POWER WAVE 455M/MSTT

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FIGURE E.6 – CONTROL BOARD

+

INPUT BOARD

RECONNECT SWITCH

LEFT SWITCH BOARD

RIGHT SWITCH BOARD

INPUT RECTIFIER

CR1

GATEWAY BOARD

DC BUS BOARD

FEED HEAD BOARD

POWER BOARD

CONTROL BOARD

STT CHOPPER BOARD

OUTPUT CHOKE

STT ELECTRODE TERMINAL

ELECTRODE TERMINAL

THERMOSTATS

T1

T2

AUX RECONNECT

RELAY

WATER COOLER

115 VAC RECP.

115 VAC FAN

ARC LINK

WIRE FEEDER RECP.

S1

S6

CONNECTION TO WIRE DRIVE

S1

S6

VOLT SENSE BOARD

MAIN TRANSFORMER

S5

CONTACTOR AND PRECHARGE CONTROL SIGNALS FROM CONTROL BOARD

FROM CONTROL BOARD

2 4 V A C

115 VAC

52 VAC

230 VAC

40 VDC

+20 VDC TO CHOPPER BOARD

40 VDC

ARC LINK

CONNECTION TO ROBOT

VOLTAGE SENSE OUTPUT

+20 VDC FROM POWER BOARD

CT CURRENT TO CONTROL BOARD

CAP. V/F

FEEDBACK

CAP. V/F

FEEDBACK

IGBT DRIVE FROM CONTROL BOARD

CT CURRENT TO CONTROL BOARD

-15 V

+15 V

+5 V

+5 V ARC LINK

+5V RS232

+15V SPI

STATUS THERMAL

LIGHT LIGHT

S2 WORK SENSE

LEFT S.B. CAP. V/F

RIGHT S.B. CAP. V/F

S3 RS232

LEFT CT CURRENT FB

C U R R E N T

F B

S T T

F B

STT DRIVE

ARC LINK

IGBT DRIVES

TO LEFT S.B.

TO RIGHT S.B.

67A

67B

SW1

BUS BOARD RECTIFIER

CURRENT TRANSDUCER

OUTPUT DIODES D1 -D4

115 VAC

40 VDC

DEVICE NET

VOLTAGE SENSE SELECT

IGBT DRIVE FROM CONTROL BOARD

+5V SPI

RIGHT CT CURRENT FB

TO FAN RELAY

CONTACTOR AND PRECHARGE CONTROL SIGNALS

65 VDC

WORK TERMINAL

POWER W AVE 455/R

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 outuput choke is in series with the negative leg of hte output rectifier and also in series with the welding load, a filtered DC output is applied to the machine output terminals. Refer to Figure E.7.

When in the STT mode, the control circuit monitors the voltage conditions at the arc, and turns the STT chopper module on or of as necessary to generate an STT output waveform. The STT current transducer in the STT circuit signals the control board to limit output to 375 amps maximum.

E-8 E-8

THEORY OF OPERATION

POWER WAVE 455M/MSTT

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FIGURE E.7 – OUTPUT RECTIFIER, OUTPUT CHOKE AND STT CHOPPER BOARD

+

INPUT BOARD

RECONNECT SWITCH

LEFT SWITCH BOARD

RIGHT SWITCH BOARD

INPUT RECTIFIER

CR1

GATEWAY BOARD

DC BUS BOARD

FEED HEAD BOARD

POWER BOARD

CONTROL BOARD

STT CHOPPER BOARD

OUTPUT CHOKE

STT ELECTRODE TERMINAL

ELECTRODE TERMINAL

THERMOSTATS

T1

T2

AUX RECONNECT

RELAY

WATER COOLER

115 VAC RECP.

115 VAC FAN

ARC LINK

WIRE FEEDER RECP.

S1

S6

CONNECTION TO WIRE DRIVE

S1

S6

VOLT SENSE BOARD

MAIN TRANSFORMER

S5

CONTACTOR AND PRECHARGE CONTROL SIGNALS FROM CONTROL BOARD

FROM CONTROL BOARD

2 4 V A C

115 VAC

52 VAC

230 VAC

40 VDC

+20 VDC TO CHOPPER BOARD

40 VDC

ARC LINK

CONNECTION TO ROBOT

VOLTAGE SENSE OUTPUT

+20 VDC FROM POWER BOARD

CT CURRENT TO CONTROL BOARD

CAP. V/F

FEEDBACK

CAP. V/F

FEEDBACK

IGBT DRIVE FROM CONTROL BOARD

CT CURRENT TO CONTROL BOARD

-15 V

+15 V

+5 V

+5 V ARC LINK

+5V RS232

+15V SPI

STATUS THERMAL

LIGHT LIGHT

S2 WORK SENSE

LEFT S.B. CAP. V/F

RIGHT S.B. CAP. V/F

S3 RS232

LEFT CT CURRENT FB

C U R R E N T

F B

S T T

F B

STT DRIVE

ARC LINK

IGBT DRIVES

TO LEFT S.B.

TO RIGHT S.B.

67A

67B

SW1

BUS BOARD RECTIFIER

CURRENT TRANSDUCER

OUTPUT DIODES D1 -D4

115 VAC

40 VDC

DEVICE NET

VOLTAGE SENSE SELECT

IGBT DRIVE FROM CONTROL BOARD

+5V SPI

RIGHT CT CURRENT FB

TO FAN RELAY

CONTACTOR AND PRECHARGE CONTROL SIGNALS

65 VDC

WORK TERMINAL

POWER W AVE 455/R

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 output rectifier, one on the DC bus, and one on the output choke. Excessive temperatures may be caused by a lack of cooling air or by 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 self-resetting 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 intake air louvers are obstructed, the power must be removed from the machine and the fan condition or air obstruction corrected. On later production machines (above code 10500) the cooling fan runs only when necessary. The F.A.N. (fan as needed) system is controlled by the Control Board via a solid state relay.

PROTECTIVE CIRCUITS

Protective circuits are designed into the Power Wave 455/R 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 570 amps, the peak current will be limited to 100 amps until the average current decreases to under 50 amps or the system is retriggered.

UNDER/OVER VOLTAGE PROTECTION

A protective circuit is included on the Control Board to monitor the voltage across the input capacitors. In the event that a capacitor voltage is too high, too low, or becomes unbalanced side-to-side, the protection circuit will de-energize the input contactor. Machine output will be disabled, and the "soft start" mode will be repeated. The protection circuit will prevent output if any of the following circumstances occur.

1. Capacitor conditioning is required. (This may be required if the machine has been off for a long period of time and is connected for high input voltage operation.)

2. Voltage across a capacitor exceeds 390 volts. (This could result from high line surges or improper input voltage connections.)

3. Voltage across a capacitor is under 70 volts. (This would be due to improper input voltage connections.)

4. Internal component damage.

E-9 E-9

THEORY OF OPERATION

POWER WAVE 455M/MSTT

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GENERAL DESCRIPTION OF THE STT (SURFACE TENSION TRANSFER) PROCESS

The STT process cannot be classified as either a constant current (CC) or a constant voltage (CV) application. The STT function produces current of a desired waveform to reduce spatter and fumes. The STT process is optimized for short-circuit GMAW welding only.

E-10 E-10

THEORY OF OPERATION

POWER WAVE 455M/MSTT

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FIGURE E.8 – STT WAVEFORMS

Current

Time

Wave Control +10.0

Wave Control -10.0

Wave Control 0.00

Current

Time

Trim 1.50

Trim 1.00

Trim 0.50

STT Wave control characteristics

STT Trim control characteristics

INSULATED GATE BIPOLAR TRANSISTOR (IGBT) OPERATION

An IGBT is a type of transistor. IGBTs are semiconductors well suited for high frequency switching and high current applications.

Drawing Ashows an IGBT in a 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 in the OFF position.

Drawing B shows the IGBT in an active mode. When the gate signal, a positive DC voltage relative to the source, is applied to the gate terminal of the IGBT, it is capable of conducting current. Avoltage supply connected to the drain terminal will allow the IGBT to conduct and supply current to 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.

E-11 E-11

THEORY OF OPERATION

POWER WAVE 455M/MSTT

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FIGURE E.9 – IGBT OPERATION

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

PULSE WIDTH MODULATION

The term PULSE WIDTH MODULATION (PWM) 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 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 a cycle. The top drawing below shows the minimum output signal possible over a 50-microsecond time period.

The shaded portion of the signal represents one IGBT group

1

, conducting for 1 microsecond. The negative portion is the other IGBT group. The dwell time (off time) is 48 microseconds (both IGBT groups off). Since only 2 microseconds of the 50-microsecond time period are devoted to conducting, the output power is minimized.

MAXIMUM OUTPUT

By holding the gate signals on for 24 microseconds each and allowing only 2 microseconds of dwell or off time (one microsecond during each half cycle) during the 50 microsecond cycle, the output is maximized. The darkened area under the minimum output curve can be compared to the area under the maximum output curve. The more darkened area, the more power is present.

E-12 E-12

THEORY OF OPERATION

POWER WAVE 455M/MSTT

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FIGURE E.10 – TYPICAL IGBT OUTPUTS

MINIMUM OUTPUT

50

sec

25

sec

MAXIMUM OUTPUT

sec

24

sec

24

sec

1

50

sec

1

An IGBT group consists of the sets of IGBT modules grouped onto one switch board.

Section F-1 Section F-1

TABLE OF CONTENTS

- TROUBLESHOOTING & REPAIR SECTION -

Troubleshooting & Repair ...................................................................................................Section F

How to Use Troubleshooting Guide ...........................................................................................F-2

PC Board Troubleshooting Procedures.......................................................................................F-3

Troubleshooting Guide................................................................................................................F-4

Test Procedures ..........................................................................................................................F-9

Input Filter Capacitor Discharge Procedure .........................................................................F-9

Switch Board Test ...............................................................................................................F-11

Input Rectifier Test .......................................................................................................... ...F-15

Input Contactor Test............................................................................................................F-19

DC Bus Power Supply PC Board Test................................................................................F-23

Power Board Test ..............................................................................................................F-27

Input Board Test .................................................................................................................F-31

STT Chopper Board Test....................................................................................................F-35

Power Wave Current Transducer Test ...............................................................................F-39

STT Current Transducer Test ............................................................................................F-43

Output Rectifier Test ..........................................................................................................F-47

Auxiliary Transformer No. 1 Test .......................................................................................F-49

Auxiliary Transformer No. 2 Test .......................................................................................F-53

Component Removal and Replacement Procedures................................................................F-55

Input Rectifier Removal and Replacement ........................................................................F-55

Input Contactor Removal and Replacement ......................................................................F-57

Auxiliary Transformer No. 1 Removal and Replacement Procedure..................................F-59

Auxiliary Transformer No. 2 Removal and Replacement Procedure..................................F-63

Control, Feed Head, or Voltage Sense PC Board Removal and Replacement.................F-67

Gateway PC Board Removal and Replacement ...............................................................F-71

STT Current Transducer Removal and Replacement ...................................................... F-73

Power Wave Current Transducer Removal and Replacement.......................................... F-77

Output Rectifier, STT Chopper Board and Rectifier Module Removal

and Replacement ........................................................................................................F-81

Switch Board and Filter Capacitor Removal and Replacement .........................................F-85

Retest after Repair ...................................................................................................................F-88

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POWER WAVE 455M/MSTT

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 two main categories: Output Problems and Function 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 cover.

Step 3. PERFORM COMPONENT TESTS. The last column, labeled “Recommended Course of Action” lists the most likely components that may have failed in your machine. It also specifies the appropriate test procedure to verify that the subject component is either good or bad. If there are a number of possible components, check the components in the order listed to eliminate one possibility at a time until you locate the cause of your problem.

All of the referenced test procedures referred to in the Troubleshooting Guide are described in detail at the end of this section. Refer to the Troubleshooting and Repair Table of Contents to locate each specific Test Procedure. All of the referred to test points, components, terminal strips, etc., can be found on the referenced electrical wiring diagrams and schematics. Refer to the Electrical Diagrams Section Table of Contents to locate the appropriate diagram.

F-2 F-2

TROUBLESHOOTING & REPAIR

POWER WAVE 455M/MSTT

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HOW TO USE TROUBLESHOOTING GUIDE

Service and repair should be performed by only Lincoln Electric Factory Trained Personnel. Unauthorized repairs performed on this equipment may result in danger to the technician and machine operator and will invalidate your factory warranty. For your safety and to avoid Electrical Shock, please observe all safety notes and precautions detailed throughout this manual.

WARNING

CAUTION

If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.

In addition to the troubleshooting information in this manual, Lincoln Electric offers a System Update Utility to reprogram digital power sources. The utility will examine the welding system allowing you to upgrade to the current release of the operating system software and welding programs available for the machine if necessary. This software can be reviewed and downloaded from powerwavesoftware.com or from mylincolnelectric.com. Download and review the entire user manual before attempting to use the software.

ELECTRIC SHOCK can kill.

Have an electrician install and service this equipment. Turn the machine OFF before working on equipment. Do not touch electrically hot parts.

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.

• Remove your body’s static charge before opening the static-shielding bag. Wear an anti-static wrist strap. For safety, use a 1 Meg ohm resistive cord connected to a grounded part of the equipment frame.

• If you don’t have a wrist strap, touch an unpainted, grounded, part of the equipment frame. Keep touching the frame to prevent static build-up. Be sure not to touch any electrically live parts at the same time.

• Tools which come in contact with the PC Board must be either conductive, anti-static or static-dissipative.

• Remove the PC Board from the static-shielding bag and place it directly into the equipment. Don’t set the PC Board on or near paper, plastic or cloth which could have a static charge. If the PC Board can’t be installed immediately, put it back in the staticshielding 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 machine to determine if the failure symp-

tom has been corrected by the replacement PC board.

NOTE: Allow the machine to heat up so that all electri-

cal components can reach their operating temperature.

5. Remove the replacement PC board and substitute

it with the original PC board to 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 bad 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 board was the problem. Reinstall the replacement PC board and test the machine.

6. Always indicate that this procedure was followed

when warranty reports are 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.

F-3 F-3

TROUBLESHOOTING & REPAIR

POWER WAVE 455M/MSTT

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PC BOARD TROUBLESHOOTING PROCEDURES

WARNING

ATTENTION Static-Sensitive Devices Handle only at Static-Safe Workstations

Observe Safety Guidelines TROUBLESHOOTING GUIDE detailed in the beginning of this manual.

CAUTION

If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.

PROBLEMS (SYMPTOMS)

POSSIBLE AREAS OF MISADJUSTMENT(S)

RECOMMENDED COURSE OF ACTION

OUTPUT PROBLEMS

The input fuses repeatedly fail or the input circuit breakers keep tripping.

1. Make certain the fuses or breakers are properly sized.

2. Make certain the reconnect panel is configured properly for the applied 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 Switch Board Test.

4. Perform the Input Contactor Test.

F-4 F-4

TROUBLESHOOTING & REPAIR

POWER WAVE 455M/MSTT

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TROUBLESHOOTING GUIDE Observe Safety Guidelines

detailed in the beginning of this manual.

CAUTION

If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.

PROBLEMS (SYMPTOMS)

POSSIBLE AREAS OF MISADJUSTMENT(S)

RECOMMENDED COURSE OF ACTION

OUTPUT PROBLEMS

The machine is dead—no lights— no output—the machine appears to be off.

1. Make certain the input power switch SW1 is in the ON position.

2. Check the main input fuses (or breakers). If open, replace or reset.

3. Check the 6 amp CB4 breaker located in the reconnect area. Reset if tripped.

4. Make certain the reconnect panel is configured correctly for the applied input voltage.

1. Check the input power switch SW1 for proper operation. Also check the associated leads for loose or faulty connections. See the Wiring Diagram.

2. Check circuit breaker CB4 for

proper operation.

3. Perform the DC Bus Board

Test.

4. The power board rectifier may be faulty. Check rectifier and associated wiring. See the Wiring Diagram

5. Perform the Power Board Test.

6. Perform the T1 Auxiliary

Transformer Test.

7. The Control Board may be faulty.

F-5 F-5

TROUBLESHOOTING & REPAIR

POWER WAVE 455M/MSTT

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Observe Safety Guidelines TROUBLESHOOTING GUIDE detailed in the beginning of this manual.

CAUTION

If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.

PROBLEMS (SYMPTOMS)

POSSIBLE AREAS OF MISADJUSTMENT(S)

RECOMMENDED COURSE OF ACTION

OUTPUT PROBLEMS

The Power Wave 455M does not have welding output. The main input contactor CR1 is not activating. Fan may be running.

1. Turn the input power off and make certain the reconnect panel is configured correctly for the applied input voltage.

2. If the Thermal light is lit, See next.

1. Check status led on case front evaluate

2. Perform the Input Contactor

Test.

3. Perform the Input Board Test.

4. Perform the T1 Auxiliary

Transformer Test.

5. Perform the Input Rectifier Test.

6. Perform the Switch Board Test.

7. Perform the Power Board Test.

8. The Control Board may be faulty.

F-6 F-6

TROUBLESHOOTING & REPAIR

POWER WAVE 455M/MSTT

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The thermal light is lit. The machine regularly "overheats."

1. The welding application may be exceeding the recommended duty cycle and/or current limits of the machine.

2. Dirt and dust may have clogged the cooling channels inside the machine. Refer to the Maint- enance Section of this manual.

3. Air intake and exhaust louvers may be blocked due to inadequate clearance around the machine.

4. Make sure the fan is functioning correctly. Machines above code 10500 are equipped with F.A.N. (fan as needed) circuitry. The fan runs whenever the output is enabled, whether under load or open circuit conditions. The fan also runs for a period of time (approximately 5 minutes) after the output is disabled.

1. One of the thermostats may be faulty. Also check associated wiring for loose or faulty connections. See the Wiring Diagram.

TROUBLESHOOTING GUIDE Observe Safety Guidelines

detailed in the beginning of this manual.

CAUTION

If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.

PROBLEMS (SYMPTOMS)

POSSIBLE AREAS OF MISADJUSTMENT(S)

RECOMMENDED COURSE OF ACTION

FUNCTION PROBLEMS

The machine often "noodle welds" when running a particular process. The output is limited to approximately 100 amps.

1. The machine may be trying to deliver too much power. When the average output current exceeds 570 amps, the machine will "phase back" to protect itself. Adjust the procedure or reduce the load to lower the current draw from the Power Wave 455R machine.

1. Perform the Current

Transducer Test.

2. The Control Board may be faulty.

The machine often "noodle welds" when running an STT process.

STT work/ Electrode sense lead routing

1. Refer to sense lead route recommendations section

2. Perform the Current

Transducer Test.

The Power Wave 455R 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 panel configuration.

2. Make sure all three phases of input power are being applied to the machine.

3. If using the STT output terminal, be aware that the STT output is limited to 325 amps.

1. Perform the Output Rectifier

Test.

2. Perform the Current Trans-

ducer Test.

3. Perform the Power Board Test.

4. The Control Board may be faulty.

5. If using the STT output terminal, the STT Chopper Board may be faulty. See the Wiring Diagram.

F-7 F-7

TROUBLESHOOTING & REPAIR

POWER WAVE 455M/MSTT

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Observe Safety Guidelines TROUBLESHOOTING GUIDE detailed in the beginning of this manual.

CAUTION

If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.

PROBLEMS (SYMPTOMS)

POSSIBLE AREAS OF MISADJUSTMENT(S)

RECOMMENDED COURSE OF ACTION

FUNCTION PROBLEMS

The Auxiliary Receptacle is "dead." The 120VAC is not present at the receptacle.

1. Check the 3.5 amp circuit breaker (CB3) located in the reconnect area. Reset if necessary.

1. Check the receptacle and associated wiring for loose or faulty connections. See the Wiring Diagram.

2. Perform the T2 Auxiliary

Transformer Test.

The Power Wave 455M is "triggered" for output but there is no welding output.

1. Make sure that the triggering method and device is correct and operating properly.

Use troubleshooting software to find the problem.

Refer to L.E. setup utility user manual section.

When in the STT mode, the spatter is higher than normal and the arc is inconsistent.

1. Make certain the work sense lead (21) is connected properly.

2. Make certain the electrode cable is connected only to the STT output terminal and NOT the Power Wave positive output terminal, or both.

3. Make sure the welding parameters are correct for the process.

1. Perform the STT Chopper

Board Test.

2. Perform the Current

Transducer (STT) Test.

3. Check calibration using L.E. dianolostic software, and confirm correct wire feed speed to display

4. The Control Board may be faulty.

F-8 F-8

TROUBLESHOOTING & REPAIR

POWER WAVE 455M/MSTT

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TROUBLESHOOTING & REPAIR

F-9 F-9

POWER WAVE 455M/MSTT

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.

DESCRIPTION

This “safety” procedure should be performed before any internal maintenance or repair procedures are attempted on the Power Wave 455M. Capacitance normally discharges within 2 minutes of removing input power. This procedure is used to check that the capacitors have properly discharged.

MATERIALS NEEDED

3/8” Nut driver Volt-ohmmeter 25-1000 ohms @ 25 watts (minimum) resistor Electrically insulated gloves and pliers

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TROUBLESHOOTING & REPAIR

F-10 F-10

POWER WAVE 455M/MSTT

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SWITCH BOARD

CAPACITOR TERMINALS

FIGURE F.1 – CAPACITOR DISCHARGE PROCEDURE

INPUT FILTER CAPACITOR DISCHARGE PROCEDURE (CONTINUED)

TEST PROCEDURE

1. Remove input power to the Power Wave 455M.

2. Using the 3/8” nut driver , remove the left and right case sides.

3. Be careful not to make contact with the capacitor terminals that are located in the bottom center of the left and right side switch boards. See Figure F.1.

4. Carefully check for a DC voltage at the capacitor terminals on both boards. Note the polarity is marked on the PC board and also lead #19 is positive.

5. If any voltage is present, proceed to Step #6. If no voltage is present, the capacitors are discharged.

NOTE: Normally the capacitors discharge in

about two minutes after input power is removed.

6. Using the high wattage resistor (25-1000 ohms @ 25 watts (minimum), electrically insulated gloves and pliers, connect the resistor across the two capacitor terminals. Hold the resistor in place for 10 seconds. DO NOT TOUCH THE CAPACITOR TERMINALS WITH YOUR BARE HANDS. NEVER

USE A SOLID CONDUCTOR W/LESS THAN 25 OHM RESISTANCE FOR THIS PROCEDURE.

7. Repeat procedure for the other capacitor.

8. Recheck the voltage across the capacitor terminals. The voltage should be zero. If any voltage remains, repeat the discharge procedure.

TROUBLESHOOTING & REPAIR

F-11 F-11

POWER WAVE 455M/MSTT

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.

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 these boards can be damaged easily. In addition, it is dangerous to work on these boards with the machine energized.

MATERIALS NEEDED

3/8” Nut driver 3/8” Wrench Analog/Digital volt-ohmmeter Wiring Diagram

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F-12 F-12

19C

19D

RECONNECT SWITCHES

TROUBLESHOOTING & REPAIR

SWITCH BOARD TEST (CONTINUED)

FIGURE F.2 – RECONNECT SWITCHES

TEST PROCEDURE

1. Remove input power to the Power Wave 455M.

2. Perform the Capacitor Discharge Procedure.

3. Locate label and remove leads 19C and 19D from the reconnect switches with the 3/8” wrench. Note lead placement for reassembly. Clear leads. Refer to Figure F.2.

4. Using the Analog ohmmeter, perform the following

resistance tests. Refer to Figure F.3 for the test points. Any readings below 100 ohms can be considered a short circuit. However, readings usually are below 30 ohms.

Check 11/12 to -20 and 11/12 to +19

Check 13/14 to -20 and +19 to 13/14

5. If any test fails isolate the PC board and retest, if board still fails, replace switch board. See Switch Board Removal and

Replacement.

6. If the switch board tests are OK, check the molex pin connections and associated wiring from the switch boards to the control board. See the Wiring Diagram.

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POWER WAVE 455M/MSTT

F-13 F-13

SWITCH

BOARD

11/12

OR

15/16

13/14

OR

17/18

-20 +19

TROUBLESHOOTING & REPAIR

SWITCH BOARD TEST (CONTINUED)

FIGURE F.3 – SWITCH BOARD TEST POINTS

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8. Reconnect leads 19C and 19D to the reconnect switches. Ensure that the leads are installed in the same location they were removed from.

POWER WAVE 455M/MSTT

9. Install the right and left case sides and top using the 3/8” nut driver.

F-14 F-14

NOTES

POWER WAVE 455M/MSTT

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TROUBLESHOOTING & REPAIR

F-15 F-15

POWER WAVE 455M/MSTT

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 volt-ohmmeter Phillips head screw driver Wiring Diagram 3/8” Nut driver

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F-16 F-16

NEG (-)

POS (+)

A

B

C

INPUT

RECTIFIER

TROUBLESHOOTING & REPAIR

INPUT RECTIFIER TEST (CONTINUED)

FIGURE F.4 – INPUT RECTIFIER TEST

TEST PROCEDURE

1. Remove input power to the Power Wave 455M.

2. Using the 3/8” nut driver, remove the case top.

3. Perform the Capacitor Discharge Procedure.

4. Locate the Input Rectifier and lead locations. Refer to Figure F.4.

NOTE: Some silicone sealant may have to be

5. With the phillips head screw driver remove

removed from the input rectifier terminals. The G.E. silicone or equivalent should be replaced when test is complete.

the positive and negative leads from the rectifier.

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POWER WAVE 455M/MSTT

TROUBLESHOOTING & REPAIR

F-17 F-17

POWER WAVE 455M/MSTT

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INPUT RECTIFIER TEST (CONTINUED)

6. Use the analog ohmmeter to perform the

tests detailed in Table F.1.

7. If the input rectifier does not meet the

acceptable readings outlined in the table, the component may be faulty. Replace.

NOTE: Before replacing the input rectifier, per-

form the Switch Board Test.

8. When installing a new input rectifier, see

Input Rectifier Removal and Replacement

procedure.

9. If the input rectifier is good, be sure to reconnect the positive and negative leads to the correct terminals and torque to 31 in.-lbs. See the Wiring Diagram.

10. Replace any silicone sealant previously removed.

11. Reassemble and test.

TEST POINT TERMINALS

A B

C

A B C

NEG NEG NEG

POS POS POS

NEG NEG NEG

POS POS POS

A B

C

A B

C

Greater than 1000 ohms Greater than 1000 ohms Greater than 1000 ohms

Approx. 500 ohms or less Approx. 500 ohms or less Approx. 500 ohms or less

Greater than 1000 ohms Greater than 1000 ohms Greater than 1000 ohms

TABLE F.1 – INPUT RECTIFIER TEST POINTS AND ACCEPTABLE READINGS

ANALOG METER X100

RANGE

Acceptable Meter Readings

+ Probe - Probe

This test can be performed using a digital volt/ohm meter on the “diode test” setting. Acceptable meter readings are: open or O.L., For the “Greater than 1000 ohms” and a decimal value less than one (example 0.045) in the approx 500 ohms position.

F-18 F-18

NOTES

POWER WAVE 455M/MSTT

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TROUBLESHOOTING & REPAIR

F-19 F-19

POWER WAVE 455M/MSTT

INPUT CONTACTOR TEST

WARNING

Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty . For your safety and to avoid 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 contactor is functional and if the contacts are functioning correctly.

MATERIALS NEEDED

3/8” Nut driver Volt-ohmmeter External 24 VAC supply

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TROUBLESHOOTING & REPAIR

F-20 F-20

POWER WAVE 455M/MSTT

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INPUT CONTACTOR

601

X4

FIGURE F.5 – INPUT CONTACTOR COIL

INPUT CONTACTOR TEST (CONTINUED)

TEST PROCEDURE

1. Remove input power to the Power Wave

455.

2. Using the 3/8” nut driver, remove the input access panel and case top.

3. Locate, mark, and remove the two leads (601, X4) that are connected to the input contactor coil. Refer to Figure F.5.

4. Using the external 24 VAC supply, apply 24 VAC to the terminals of the input contactor coil. If the contactor does NOT activate, the input contactor is faulty. Replace.

TROUBLESHOOTING & REPAIR

F-21 F-21

POWER WAVE 455M/MSTT

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L3

L2

L1

T3

T2

T1

FIGURE F.6 – INPUT CONTACTOR TEST POINTS

INPUT CONTACTOR TEST (CONTINUED)

5. With the input contactor activated, check the continuity across the three sets of contacts. (Zero ohms or very low resistance is normal.) Refer to Figure F.6. If the resistance is high, the input contactor is faulty . Replace the input contactor.

6. When the contactor is NOT activated, the resistance should be infinite or very high across the contacts. If the resistance is low, the input contactor is faulty.

7. Reconnect the two leads (601, X4) to the input contactor coil.

8. Install the input access door and case top using the 3/8” nut driver.

9. Test.

F-22 F-22

NOTES

POWER WAVE 455M/MSTT

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TROUBLESHOOTING & REPAIR

F-23 F-23

DC BUS POWER SUPPLY PC 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 455M/MSTT

TROUBLESHOOTING & REPAIR

F-24 F-24

POWER WAVE 455M/MSTT

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DC BUS POWER SUPPLY PC BOARD

CAPACITOR C3 CAUTION!

J47 J46

J46

J47

3 4 5 6 7 8

LED

1 2 3 4

1 2

POWER BOARD

FAN RELAY

FIGURE F.7 – DC BUS POWER SUPPLY POWER SUPPLY PC BOARD

DC BUS POWER SUPPLY PC BOARD TEST (CONTINUED)

TEST PROCEDURE

1. Remove input power to the machine.

2. Using the 3/8” nut driver, remove the case top.

3. Locate the DC Bus Power Supply PC Board and plugs P46 and P47. See Figure F.7.

4. Carefully apply input power to the Power Wave 455M.

ELECTRIC SHOCK can kill.

High voltage is present when input power is applied to the machine.

5. Turn on the Power W ave 455M. The LED on the DC Bus Power Supply PC Board should light.

WARNING

TROUBLESHOOTING & REPAIR

F-25 F-25

POWER WAVE 455M/MSTT

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DC BUS POWER SUPPLY PC BOARD TEST(CONTINUED)

6. Check the DC Bus Power Supply PC Board input and output voltages according to Table F.3. See Figure F.7 and the Wiring Diagram.

If plug P46 pin 1-3 voltage is missing, perform T1 Auxiliary Transformer Test.

ELECTRIC SHOCK can kill.

High voltage is present at the terminals of Capacitor C3 near where testing is to be done.

7. If all the voltages are correct, the DC Bus Power Supply PC Board is operating properly.

8. If any of the output voltages are not correct and the input voltage is correct, the DC Bus Power Supply PC Board may be faulty, or the supplied board may be bad.

9. If the input voltage is not correct, check the leads between the DC Bus Power Supply PC Board and the Power PC Board Rectifier. See the Wiring Diagram.

10. When finished testing, replace the case top.

WARNING

Plug P46 – Pin 1

Plug P47 – Pin 7

Plug P47 – Pin 8

Plug P47 – Pin 4

Plug P47 – Pin 3

Plug P46 – Pin 3

Plug P47 – Pin 6

Plug P47 – Pin 2

Plug P47 – Pin 1

65 – 75 VDC

38.0 – 42.0 VDC

Should be same as the

Power PC Board

Rectifier

Supply to Power PC

Board

Supply to Power PC

Board

Supply to Feed Head PC

Board

Supply to S1 Wire

Feeder Receptacle

Positive Meter Probe

Test Point

Negative Meter Probe

Test Point

Approximate Voltage

Reading

Conditions/Comments

TABLE F.2 – DC BUS POWER SUPPLY PC BOARD VOLTAGE TABLE

F-26 F-26

NOTES

POWER WAVE 455M/MSTT

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TROUBLESHOOTING & REPAIR

F-27 F-27

POWER WAVE 455M/MSTT

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

3/8” Nut driver Volt-ohmmeter Wiring Diagram

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TROUBLESHOOTING & REPAIR

F-28 F-28

J42

J41

J43

4 5 6

3 4

7 8 9 10 11 12

J42

J41

J43

1 2 3

1 2

1 2 3 4 5 6

POWER BOARD TEST (CONTINUED)

FIGURE F.8 – POWER BOARD TEST

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TEST PROCEDURE

1. Remove input power to the Power Wave 455M.

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 455M.

WARNING

ELECTRIC SHOCK can kill.

High voltage is present when input power is applied to the machine.

POWER WAVE 455M/MSTT

6. Turn on the Power Wave 455M. Carefully test for the correct voltages at the Power Board according to Table F.3.

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. If indicated, 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. If power board is replaced, reassemble and test machine.

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

POWER BOARD

CONNECTOR

PLUG J41

POWER BOARD

CONNECTOR

PLUG J43

POWER BOARD

CONNECTOR

PLUG J43

CHECK 40 VDC

INPUT FROM

DC BUS BOARD

CHECK +15

VDC SUPPL YFROM

POWER BOARD

CHECK +5 VDC

SUPPL Y FROM

POWER BOARD

CHECK -15 VDC

SUPPL Y FROM

POWER BOARD

CHECK +5 VDC

ARCLINK SUPPL Y

FROM POWER BOARD

CHECK +5 VDC

“RS-232” SUPPL Y

FROM POWER BOARD

CHECK +15 VDC

SPI SUPPL YFROM

POWER BOARD

CHECK +40 VDC

INPUT FROM

DC BUS BOARD

CHECK +5 VDC

SPI SUPPL YFROM

POWER BOARD

CHECK +20 VDC STT

SUPPL Y FROM

POWER BOARD

2 (+)

1 (-)

1 (+)

5 (-)

3 (+)

5 (-)

2 (+)

5 (-)

5 (+)

10 (-)

4 (+)

9 (-)

6 (+)

11 (-)

4 (+)

3 (-)

3 (+)

12 (-)

7 (+)

1 (-)

477 (+)

475 (-)

225 (+)

222 (-)

221 (+)

222 (-)

222 (+)

223 (-)

274 (+)

273 (-)

226 (+)

228 (-)

266 (+)

267 (-)

478 (+)

476 (-)

268A(+)

262 (-)

345 (+)

346 (-)

38 – 42 VDC

+15 VDC

+5 VDC

-15 VDC

+5 VDC

+15 VDC

38 – 42 VDC

+5 VDC

+20 VDC

TROUBLESHOOTING & REPAIR

F-29 F-29

POWER WAVE 455M/MSTT

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TABLE F.3 – POWER BOARD VOLTAGE CHECKS

POWER BOARD TEST (CONTINUED)

CHECK POINT

LOCATION

TEST

DESCRIPTION

CONNECTOR

PLUG PIN NO.

LEAD NO. OR

IDENTITY

NORMAL

ACCEPTABLE

VOLTAGE READING

475 477

225

222

221

222

223

222

273

274

228

226

267

266

476 478

262

268A

345

346

F-30 F-30

NOTES

POWER WAVE 455M/MSTT

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TROUBLESHOOTING & REPAIR

F-31 F-31

POWER WAVE 455M/MSTT

INPUT 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 electric troubleshooting assistance before you proceed. Call 1-888-935-3877.

TEST DESCRIPTION

This test will help determine if the Input Board is sending the correct voltages and also if the Input Board is regulating and producing the correct DC voltages.

MATERIALS NEEDED

3/8” Nut driver Volt-ohmmeter Wiring Diagram

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TROUBLESHOOTING & REPAIR

F-32 F-32

POWER WAVE 455M/MSTT

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INPUT CONTACTOR

601

X4

J60

J61

6 7 8 9 10

J61

1 2 3 4

5 6 7 8

1 2 3 4 5

J60

FIGURE F.9 – INPUT CONTACTOR CR1

INPUT BOARD TEST (CONTINUED)

TEST PROCEDURE

1. Remove input power to the Power Wave 455M.

2. Using the 3/8” nut driver, remove the case top, and input access cover.

3. Remove lead X4 from the coil terminal of main input contactor CR1. Insulate lead X4. Refer to Figure F.9.

4. Carefully apply input power to the Power Wave 455M.

ELECTRIC SHOCK can kill.

High voltage is present when input power is applied to the machine.

5. Turn on the Power Wave 455M. Carefully test for the correct voltages according to

Table F.4.

WARNING

TROUBLESHOOTING & REPAIR

F-33 F-33

POWER WAVE 455M/MSTT

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TABLE F.4 – INPUT BOARD VOLTAGE CHECKS

INPUT BOARD FUNCTION TEST(CONTINUED)

TEST POINTS

PLUG J61 PIN 8 (H1D)

TO

PLUG J61 PIN 6 (612)

PLUG J60 PIN 3 (238)

TO

PLUG J60 PIN 4 (604)

PLUG J61 PIN 10 (T3)

TO

PLUG J61 PIN 2 (T1)

PLUG J60 PIN 3 (238)

TO

PLUG J60 PIN 5 (232)

LEAD

NUMBERS

J61

J60

J61

J60

EXPECTED

VOLTAGE

READINGS

SAME AS

INPUT

VOLTAGE

13 – 15 VDC

A LITTLE LESS

THAN INPUT

VOLTAGE

13 – 15 VDC

COMMENTS

Present when Input Switch SW1 is closed. If not, check input lines and line switch and wiring.

This is the Coil Voltage for the Pre-Charge Relay. Normally this DC Voltage will be present 6 seconds after Input Switch SW1 is activated. This 13 - 15 VDC will remain for approximately 6 seconds and then be removed. The Relay is controlled by the Control Board. See the Wiring Diagram.

This is Pre-Charge Voltage and will normally be present 6 seconds after activating Input Switch SW1. The Pre-Charge Voltage should remain for approximately 6 seconds and then be removed. It should start at zero and ramp up to 170 - 200 V.A.C. If zero volts check input board resistors, and check for a shorted main input rectifier.

This is the DC Coil Voltage for the Control Relay. Normally this DC Voltage will be present approximately 12 seconds after Input Switch SW1 is activated. The Relay is controlled by the Control PC Board. See the Wiring Diagram. Voltage will not

be applied if capacitor precharge is incorrect.

#612

H1D

T1

T3

#238

#604

#238

#232

TROUBLESHOOTING & REPAIR

F-34 F-34

POWER WAVE 455M/MSTT

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INPUT BOARD TEST(CONTINUED)

6. Remove input power to the Power Wave 455M. If any of the voltages are low or not present, perform the Input Contactor Test. If that checks out, the Input Board may by faulty.

7. Reconnect lead X4 to the main input contactor CR1 coil terminal.

8. Carefully apply the correct input voltage to the Power Wave 455M.

ELECTRIC SHOCK can kill.

High voltage is present when input power is applied to the machine.

9. Turn on the Power Wave 455M. Check for the presence of 24 VAC from lead X4 to lead 601. See Figure F. 9. If the voltage is not present, perform the Auxiliary

Transformer #1 Test.

9. This 24 VAC is the coil voltage for main

input contactor CR1. It will normally be present approximately 12 seconds after input line switch (SW1) is activated.

10. When the test is completed, remove input power from the Power Wave 455M.

11. Install the case top and reconnect cover using the 3/8” nut driver.

WARNING

TROUBLESHOOTING & REPAIR

F-35 F-35

POWER WAVE 455M/MSTT

STT CHOPPER 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 electric troubleshooting assistance before you proceed. Call 1-888-935-3877.

TEST DESCRIPTION

This test will help determine if the STT Chopper Board is receiving the necessary voltages to function and if the related circuitry is correct.

MATERIALS NEEDED

3/8” Nut driver Volt-ohmmeter Wiring Diagram

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TROUBLESHOOTING & REPAIR

F-36 F-36

POWER WAVE 455M/MSTT

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J7

9 10 11 12 13 14 15 16

1 2 3 4 5 6 7 8

J7

4W 4R

J43

7 8 9 10 11 12

J43

1 2 3 4 5 6

346

345

STT OUTPUT TERMINAL

POWER WAVE + OUTPUT TERMINAL

CONTROL PC BOARD POWER PC BOARD

FIGURE F.10 – STT CHOPPER BOARD TEST DETAILS

STT CHOPPER BOARD TEST (CONTINUED)

TEST PROCEDURE

1. Remove input power to the Power Wave 455M.

2. Using the 3/8” nut driver, remove the case top and the control box cover. See Figure F.10.

3. Perform the following resistance tests:

+ probe on the STT output terminal

- probe on the Power Wave + output terminal

The reading should be approximately 300,000 ohms

+ probe on the Power Wave + output ter-

minal

- probe on the STT output terminal The reading should be less than 500 ohms If both the polarity resistance tests are low,

either the STT Chopper Module is faulty or diode D6 is shorted. See the Wiring Diagram.

TROUBLESHOOTING & REPAIR

F-37 F-37

POWER WAVE 455M/MSTT

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STT CHOPPER BOARD TEST (CONTINUED)

4. Carefully apply input power to the Power Wave 455M.

ELECTRIC SHOCK can kill.

High voltage is present when input power is applied to the machine.

For steps 5 and 6, see Figure F.10.

5. Turn on the Power Wave 455M. Measure the voltage from Power Board plug J43 lead 345 pin 7 (+) to lead 346 pin 1 (-). The voltage should be approximately 20 VDC. If not correct, the Power Board may be faulty.

6. Measure the voltage from Control Board plug J7 lead 4W pin 13 (-) to lead 4R pin 14 (+). The voltage should be 4 – 5 VDC. This is the pulse width modulation signal to the STT Chopper Board. If not correct, the Control Board may be faulty.

7. When the test is completed, remove input power from the Power Wave 455M.

8. Install the case top and control box cover

using the 3/8” nut driver.

WARNING

F-38 F-38

NOTES

POWER WAVE 455M/MSTT

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TROUBLESHOOTING & REPAIR

F-39 F-39

POWER WAVE 455M/MSTT

POWER WAVE 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 electric troubleshooting assistance before you proceed. Call 1-888-935-3877.

TEST DESCRIPTION

This test will help determine if the Power Wave current transducer and associated wiring is functioning correctly.

MATERIALS NEEDED

3/8” nut driver Volt-Ohmmeter

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TROUBLESHOOTING & REPAIR

F-40 F-40

POWER WAVE 455M/MSTT

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J8

216

211

212

213

P91

CURRENT

TRANSDUCER

1234

CONTROL BOARD

J8

5 6 7 8

1 2 3 4

FIGURE F.11 – POWER WAVE CURRENT TRANSDUCER TEST

POWER WAVE CURRENT TRANSDUCER TEST (CONTINUED)

TEST PROCEDURE

1. Remove input power to the Power Wave

455.

2. Using the 3/8” nut driver, remove the case top and the control box cover.

3. Locate the Power Wave current transducer leads at Control Board plug J8. See Figure F.11.

4. Carefully apply input power to the Power Wave 455.

ELECTRIC SHOCK can kill. High voltage is present when

input power is applied to the machine.

WARNING

TROUBLESHOOTING & REPAIR

F-41 F-41

POWER WAVE 455M/MSTT

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FIGURE F.12 – RECEPTACLE S7 TRIGGERED

POWER WAVE CURRENT TRANSDUCER TEST (CONTINUED)

RECEPTACLE S7

STT

POWER

WAVE

5. Turn on the Power Wave 455. Check for the correct DC supply voltage to the current transducer at plug J8. See Figure F.11.

A. Pin 2 (lead 212+) to pin 6 (lead 216-)

should read +15 VDC.

B. Pin 3 (lead 213-) to pin 6 (lead 216+)

should read -15 VDC.

If the DC supply voltages are not present, the control board may be faulty.

6. If both of the supply voltages are low or missing, check the associated leads between plug J8 and current transducer plug P91 and the Control Board.

NOTE: The machine can be triggered by

jumpering pin 1 to pin 2 at receptacle S7. See Figure F.12.

7. With the Power Wave 455 triggered, check the feedback voltage from the current transducer. The current feedback voltage can be read at plug J8 on the Control Board.

A. Pin 1 (lead 211) to pin 6 (lead 216)

should read 2.0 VDC (machine loaded to 250 amps).

TROUBLESHOOTING & REPAIR

F-42 F-42

POWER WAVE 455M/MSTT

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TABLE F.5 - CURRENT FEEDBACK AT VARIOUS OUTPUT LOADS

POWER WAVE CURRENT TRANSDUCER TEST (CONTINUED)

8. If for any reason the machine cannot be loaded to 250 amps, Table F.5 shows what feedback voltage is produced at various current loads.

9. If the correct supply voltages are applied to the current transducer, and with the machine loaded, the feedback voltage is missing or

not correct, the current transducer may be faulty. Also make certain that lead 211 (plug J8 pin 1) has continuity (zero ohms) between the current transducer and the control board. See the Wiring Diagram.

10. Install the right side case cover using the 3/8” nut driver.

OUTPUT LOAD CURRENT

500 450 400 350 300 250 200 150 100

50

EXPECTED TRANSDUCER FEEDBACK

VOLTAGE

4.0

3.6

3.2

2.8

2.4

2.0

1.6

1.2

0.8

0.4

TROUBLESHOOTING & REPAIR

F-43 F-43

POWER WAVE 455M/MSTT

STT 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 electric troubleshooting assistance before you proceed. Call 1-888-935-3877.

TEST DESCRIPTION

This test will help determine if the STT current transducer and associated wiring is functioning correctly.

MATERIALS NEEDED

3/8” nut driver Volt-Ohmmeter

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TROUBLESHOOTING & REPAIR

F-44 F-44

POWER WAVE 455M/MSTT

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J8

811

813

CURRENT TRANSDUCER

CONTROL BOARD

816 812

P90

1234

J8

5 6 7 8

1 2 3 4

FIGURE F.13 – STT CURRENT TRANSDUCER TEST

STT CURRENT TRANSDUCER TEST (CONTINUED)

TEST PROCEDURE

1. Remove input power to the Power Wave

455.

2. Using the 3/8” nut driver, remove the case top and the control box cover.

3. Locate the STT current transducer leads at Control Board plug J8. See Figure F.13.

4. Carefully apply input power to the Power Wave 455M.

ELECTRIC SHOCK can kill.

High voltage is present when input power is applied to the machine.

WARNING

TROUBLESHOOTING & REPAIR

F-45 F-45

POWER WAVE 455M/MSTT

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RECEPTACLE S7

STT

POWER

WAVE

FIGURE F.14 – RECEPTACLE S7 TRIGGERED

STT CURRENT TRANSDUCER TEST (CONTINUED)

5. Turn on the Power Wave 455M. Check for the correct DC supply voltage to the current transducer at plug J8.

A. Pin 8 (lead 812+) to pin 7 (lead 816-)

should read +15 VDC.

B. Pin 4 (lead 813-) to pin 7 (lead 816+)

should read -15 VDC.

If the DC supply voltages are not present, the control board may be faulty.

6. If both of the supply voltages are low or missing, check the associated leads between plug J8 and current transducer plug P90 and the Control Board.

NOTE: The machine can be triggered by

jumpering pin 1 to pin 2 at receptacle S7. See Figure F. 14.

7. With the Power Wave 455M triggered, check the feedback voltage from the current transducer. The current feedback voltage can be read at plug J8 on the Control Board.

A. Pin 5 (lead 811) to pin 7 (lead 816)

should read 0.4 VDC (machine loaded to 50 amps).

TROUBLESHOOTING & REPAIR

F-46 F-46

POWER WAVE 455M/MSTT

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STT CURRENT TRANSDUCER TEST (CONTINUED)

8. If for any reason the machine cannot be loaded to 50 amps, Table F.6 shows what feedback voltage is produced at various current loads. S.T.T. stud is limited to 325 amps.

9. If the correct supply voltages are applied to the current transducer, and with the machine loaded, the feedback voltage is missing or not correct, the current transducer may be

faulty . Also make certain that lead 811 (plug J8 pin 5) has continuity (zero ohms) between the current transducer and the control board. See the Wiring Diagram.

10. Install the right side case cover using the 3/8” nut driver.

TROUBLESHOOTING & REPAIR

F-47 F-47

POWER WAVE 455M/MSTT

OUTPUT 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

The test will help determine if any of the output rectifiers are shorted.

MATERIALS NEEDED

Analog Volt-Ohmmeter 3/8” Nut driver 5/16” Wrench

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TROUBLESHOOTING & REPAIR

F-48 F-48

POWER WAVE 455M/MSTT

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STT OUTPUT TERMINAL

POSITIVE (+) OUTPUT TERMINAL

NEGATIVE (-) OUTPUT TERMINAL

POWERWAVE 455/R

I ON

O OFF

FIGURE F.15 – OUTPUT RECTIFIER TEST

OUTPUT RECTIFIER TEST (CONTINUED)

TEST PROCEDURE

1. Remove main input supply power to the Power Wave 455M.

2. Remove any output load that may be connected to the Power Wave 455M.

3. With the analog ohmmeter, measure the resistance between the positive and negative output terminals (NOT the STT terminal). Refer to Figure F.15.

4. If the reading is approx. 50 ohms, the output rectifier modules are not shorted. If the reading is less than 10 ohms, one or more of the rectifier modules are shorted. Reverse meter probe and verify low reading. Refer to the Output Rectifier Module Replacement procedure.

5. Remove the case top perform the Input Filter Capacitor Discharge procedure.

IMPORTANT: The positive (+) meter probe must be attached to the positive (+) output terminal and the negative (-) meter probe must be attached to the negative (-) output terminal.

6. Using the 5/16” wrench, remove and insulate lead 202A from the negative output terminal. Repeat step 4 to confirm.

7. Reconnect lead 202A to the negative output terminal.

8. Replace the case top and sides.

TROUBLESHOOTING & REPAIR

F-49 F-49

POWER WAVE 455M/MSTT

AUXILIARY TRANSFORMER NO. 1 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 electric troubleshooting assistance before you proceed. Call 1-888-935-3877.

TEST DESCRIPTION

This test will determine if the correct voltage is being applied to the primary of Auxiliary Transformer No. 1 and also if the correct voltages are being induced on the secondary windings of the transformer.

MATERIALS NEEDED

Volt-ohmmeter (Multimeter) 3/8” Nut driver Wiring Diagram

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TROUBLESHOOTING & REPAIR

F-50 F-50

POWER WAVE 455M/MSTT

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INPUT CONTACTOR

601

X4

FAN MOTOR

LEADS

X3

X5

POWER BOARD

RECTIFIER BRIDGE

X1

X2

+

-

FIGURE F.16 – AUXILIARY TRANSFORMER NO. 1 TEST

AUXILIARY TRANSFORMER NO. 1 TEST (CONTINUED)

TEST PROCEDURE

1. Remove the main input power to the Power Wave 455 machine.

2. Using the 3/8” nut driver, remove the case top.

3. Perform the Capacitor Discharge proce- dure.

4. Locate secondary leads X1 and X2 (at power board rectifier bridge). Refer to Figure F.16.

5. Locate secondary leads X3 and X5 (fan motor leads).

6. Locate secondary lead X4 (at main contactor).

TROUBLESHOOTING & REPAIR

F-51 F-51

POWER WAVE 455M/MSTT

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TABLE F.6 – SECONDARY VOLTAGES

AUXILIARY TRANSFORMER NO. 1 TEST (CONTINUED)

7. Carefully apply the correct input voltage to the Power Wave 455M.

ELECTRIC SHOCK can kill.

High voltage is present at primary of the Auxiliary Transformer.

8. Turn on PW455M.

9. Check for the correct secondary voltages according to Table F.6.

NOTE: The secondary voltages will vary if the

input line voltage varies.

10. If the correct secondary voltages are present, the T1 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 the Wiring Diagram.

11. If the correct input voltage is applied to the

primary, and the secondary voltage(s) are not correct, the T1 transformer may be faulty.

12. Replace any cables ties and insulation removed earlier.

13. Install the case sides and top using the 3/8” nut driver.

LEAD IDENTIFICATION

X1 to X2 X3 to X5 X3 to X4

NORMAL EXPECTED VOLTAGE

52 VAC

115 VAC

24 VAC

WARNING

F-52 F-52

NOTES

POWER WAVE 455M/MSTT

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TROUBLESHOOTING & REPAIR

F-53 F-53

POWER WAVE 455M/MSTT

AUXILIARY TRANSFORMER NO. 2 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 electric troubleshooting assistance before you proceed. Call 1-888-935-3877.

TEST DESCRIPTION

This test will determine if the correct voltage is being applied to the primary of Auxiliary Transformer No. 2 and also if the correct voltages are being induced on the secondary windings of the transformer.

MATERIALS NEEDED

Volt-ohmmeter (Multimeter) 3/8” Nut driver Wiring Diagram

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TROUBLESHOOTING & REPAIR

F-54 F-54

POWER WAVE 455M/MSTT

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P50

P52

5

3 4

3

1 2

H1

H6

33A

350

352

VIEWED FROM TRANSFORMER LEAD END

VIEWED FROM TRANSFORMER LEAD SIDE

FIGURE F.17 – AUXILIARY TRANSFORMER NO. 2 TEST

AUXILIARY TRANSFORMER NO. 2 TEST (CONTINUED)

TEST PROCEDURE

1. Remove the main input power to the Power Wave 455M machine.

2. Remove any load that may be connected to the 115 VAC receptacle.

3. Using the 3/8” nut driver, remove the case top.

4. Locate plugs P52 and P50 at the Auxiliary Transformer No. 2. Refer to Figure F.17.

5. Carefully apply the correct input power.

ELECTRIC SHOCK can kill.

High voltage is present at both plugs.

6. Check for 115 VAC at plug P52 pins 1 and 4 (leads 350 to 33A). Check for 230 VAC at plug P52 pins 1 and 2 (leads 350 to

352).

7. If 115 VAC and 230 VAC are present, Auxiliary Transformer No. 2 is good.

8. If 115 is not present between pins 1 and 4, and 230 V AC is not present between pins 1 and 2, check the associated leads and plugs for loose or faulty connections.

9. Carefully test for the correct AC input voltage applied to the primary windings at plug P50. See the Wiring Diagram.

10. If the correct AC input voltage is applied to the primary of the Auxiliary Transformer No. 2 and the secondary voltage is NOT correct, the transformer may be faulty. Replace.

11. Replace any cables ties and insulation

removed earlier.

12. Install the case top using the 3/8” nut driver.

WARNING

Lincoln Electric SVM173-A User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

SAFETY

The machine is dead—no lights— no output—the machine appears to be off.

The thermal light is lit. The machine regularly "overheats."

The machine often "noodle welds" when running an STT process.

The Auxiliary Receptacle is "dead." The 120VAC is not present at the receptacle.

When in the STT mode, the spatter is higher than normal and the arc is inconsistent.