Lincoln Electric 355M User's Manual

View Safety Info
View Safety Info
View Safety Info
!
Return to Master TOC
!
ER
W
PO
ing
sc
ipi
ad t ut
er
un
tu cid
ing
te
sc
tin
ec
ipi
ns od
ad t ut
co ism
un
et eu at tuer
ing
am h
er te tincid
sc
nib am ec
sit
ipi
y
ns od
lor m
qu co
ad t ut
ism
do umm ali et
un
ing
eu at tuer
nnu na
sc
um no
cid
am h
er te
ipi
tin
ips m mag sit
nib
ec
ad t ut
m dia e lor my quam ns od
er
un
re
co ism
lor
m
tu cid
Lo ed do do nnuum ali et
t,
eu at te tin
na
et um no
am h
er ec
eli
re ips m mag
nib am ns od
sit
co ism
y
lao m dia e
lor m
quet
re
lor
ing
do umm aliam h eu erat
Lo ed do
sc
t,
nnu na
et
um
ipi
nib
sit
eli
no
am
re ips
ag
y
ad t ut
m mlor m
qu
lao m
er
un
dia edo umm ali
tu cid
re
lor
nnu na
te
ing
Lo ed doum no
tin
ec
t,
sc
ag
et ips m m
eli
ns od
ipi
rem dia e
co ism
ad t ut
lor
laore ed
ing
et eu at
er
un
Lo
do
sc
t,
am h
er tetu cid
ipi
et
eli
tin
nib am
sit
re
ec
ad t ut
y
ns od
lor m
lao
er
un
qu
ing
tu cid
co ism
do umm ali
sc
te
et eu at
nnu na
ipi
tin
um no
ec
ad t ut
am h
er
ns od
ips m mag
er
un
nib am
sit
co ism
m dia e
tu cid
y
et eu at te
re
lor m
qu
lor
tin
Lo ed do
do umm ali
am h
er ec
t,
nnu na
et
nib am ns od
sit
eli
um no
co ism
y
re
lor m
ips m mag
quet
lao m
eu at
do umm ali
dia e
ng
er
re
nnu na am h
lor
ci
um no
nib am
sit
Lo ed do
is
y
t,
ips m maglor
et
ip ut
eli
m dia e do mm aliqu
re
re
lor
nnuum
lao
Return to Master TOC
!
ad nt
na
Lo ed do um no
ng
er du
t,
ag
ci
et ips
m
tu ci
eli
m
is
rem
te tin
dia e
ip ut
laore
lor
ec
Lo ed do
ad nt
t,
ns mod
et
eli
er du
re
co is
tu ci
lao
et eu erat te tin
bh m ec od
t am
ns
si y ni ua co ism
r
iq
lo mm al et eu at
er
do nu
num na t am bh m
m
ni
ag
su no m r si y iqua
ip am
lo m al
m di lore do umm
n na
re ed do m nu
Lo it, t su no mag
el ee ip am re
or
la rem di lo
ed do
Lo it, t
el ee
or
la
Copyright © Lincoln Global Inc.
• World's Leader in Welding and Cutting Products •
• Sales and Service through Subsidiaries and Distributors Worldwide •
Return to Master TOC
!
ing
sc
ipi
ad t ut
er
un
tu cid
ing
te
sc
tin
ec
ipi
ns od
ad t ut
co ism
un
et eu at tuer
cid
ing
am h
er te
tin
sc
nib am ec
sit
ipi
y
ns od
lor m
qu co
ad t ut
ism
do umm ali et
er
un
eu at
nnu
tu
na
cid
um no
am h
er te
tin
ips m mag sit
nib
ec
ing
m dia e lor my quam ns od
sc
re
ipi
co ism
lor
m
Lo ed do do nnuum ali et
ad t ut
eu at
na
er
un
et um no
am h
er
tu cid
re ips m mag
nib am
sit
te
y
lao m dia e
tin
ec
lor m
qu
re
ing
lor
ns od
do umm ali
Lo ed do
sc
co ism
t,
nnu na
ipi
et
um no
eli
et eu at
ad t ut
re ips
ag
m m
am h
er
er
un
lao m
tu cid
ing
nib am
sit
dia e
re
te
y
lor
sc
tin
lor m
qu
Lo ed do
ec
ipi
t,
do umm ali
ns od
ad t ut
et
eli
nnu na
co ism
re
er
un
um no
et eu at tu cid
lao
ips m mag
am h
er ecte tin
m dia e
re
nib am ns od
sit
lor
y
Lo ed do
lor m
qu co ism
ing
t,
et
do umm ali et eu at
sc
eli
re
nnu na am h
ipi
er
um no
ad t ut
lao
ips m mag sit y nib am
er
un
m dia e lor m
qu
tu cid
re
te
lor do umm ali
tin
ec
Lo ed
nnu
E
M OT
RE
W
WA ARN
IN
RN
G
IN
G
t,
eli
do um
na
t,
ns od
ng
no ag
et
eli
ci
co ism
re ips m m
is
et eu at
lao rem dia e
ip ut
lor
am h
er
Lo ed do
ad nt
t,
nib am
sit
et
y
ng
eli
er du
lor m
qu
re
ci
tu ci
do umm ali
is
lao
te tin
nnu na
ip ut
um no
ec
ad nt
ips m mag
ns mod
m dia e
er du
re
co is
lor
tu ci
Lo ed do
et eu erat te tin
t,
et
eli
bh m ec od
re
t am
ns
lao
si y ni ua co ism
r
iq
lo mm al et eu at
er
do nu
num na t am bh m
m
ni
ag
su no m r si y iqua
ip am
lo m al
m di lore do umm
n na
re ed do m nu
Lo it, t su no mag
el ee ip am re
or
la rem di lo
ed do
Lo it, t
el ee
or
la
NG
NI
W AR
W
R
E
W
O
P
5
35
E
V
A
ON
O FF
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.
A
A T
PR VIS TEN
EC O D TIO
AU E N
CIO
N
Safety Depends on You
POWER WAVE 355M/405M
For use with machine code numbers 11141, 11142
View Safety Info
January, 2008
Return to Master TOC
SVM181-A
RETURN TO MAIN MENU
SERVICE MANUAL
Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com
SAFETY
Return to Master TOC
i
i
WARNING
CALIFORNIA PROPOSITION 65 WARNINGS
Diesel engine exhaust and some of its constituents
The engine exhaust from this product contains
are known to the State of California to cause canchemicals known to the State of California to cause
cer, birth defects, and other reproductive harm.
cancer, birth defects, or other reproductive harm.
The Above For Gasoline Engines
The Above For Diesel Engines
ARC WELDING can be hazardous. PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH.
KEEP CHILDREN AWAY. PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING.
Return to Master TOC
Return to Master TOC
Return to Master TOC
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.
FOR ENGINE
powered equipment.
1.a. Turn the engine off before troubleshooting and maintenance
work unless the maintenance work requires it to be running.
____________________________________________________
1.b.Operate engines in open, well-ventilated
areas or vent the engine exhaust fumes
outdoors.
____________________________________________________
1.c. Do not add the fuel near an open flame welding arc or when the engine is running. Stop
the engine and allow it to cool before refueling to prevent spilled fuel from vaporizing on
contact with hot engine parts and igniting. Do
not spill fuel when filling tank. If fuel is spilled,
wipe it up and do not start engine until fumes
have been eliminated.
____________________________________________________
1.d. Keep all equipment safety guards, covers and devices in position and in good repair.Keep hands, hair, clothing and tools
away from V-belts, gears, fans and all other moving parts
when starting, operating or repairing equipment.
____________________________________________________
1.e. In some cases it may be necessary to remove safety
guards to perform required maintenance. Remove
guards only when necessary and replace them when the
maintenance requiring their removal is complete.
Always use the greatest care when working near moving
parts.
___________________________________________________
1.f. Do not put your hands near the engine fan. Do
not attempt to override the governor or idler
by pushing on the throttle control rods while
the engine is running.
1.h. To avoid scalding, do not remove the
radiator pressure cap when the engine is
hot.
ELECTRIC AND
MAGNETIC FIELDS
may be dangerous
2.a. Electric current flowing through any conductor causes
localized Electric and Magnetic Fields (EMF). Welding
current creates EMF fields around welding cables and
welding machines
2.b. EMF fields may interfere with some pacemakers, and
welders having a pacemaker should consult their physician
before welding.
2.c. Exposure to EMF fields in welding may have other health
effects which are now not known.
2.d. All welders should use the following procedures in order to
minimize exposure to EMF fields from the welding circuit:
2.d.1. Route the electrode and work cables together - Secure
them with tape when possible.
2.d.2. Never coil the electrode lead around your body.
2.d.3. Do not place your body between the electrode and
work cables. If the electrode cable is on your right
side, the work cable should also be on your right side.
2.d.4. Connect the work cable to the workpiece as close as
possible to the area being welded.
___________________________________________________
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.
2.d.5. Do not work next to welding power source.
Mar ‘95
Return to Master TOC
Return to Master TOC
ii
SAFETY
ELECTRIC SHOCK can kill.
3.a. The electrode and work (or ground) circuits
are electrically “hot” when the welder is on.
Do not touch these “hot” parts with your bare
skin or wet clothing. Wear dry, hole-free
gloves to insulate hands.
3.b. Insulate yourself from work and ground using dry insulation.
Make certain the insulation is large enough to cover your full
area of physical contact with work and ground.
In addition to the normal safety precautions, if welding
must be performed under electrically hazardous
conditions (in damp locations or while wearing wet
clothing; on metal structures such as floors, gratings or
scaffolds; when in cramped positions such as sitting,
kneeling or lying, if there is a high risk of unavoidable or
accidental contact with the workpiece or ground) use
the following equipment:
• Semiautomatic DC Constant Voltage (Wire) Welder.
• DC Manual (Stick) Welder.
• AC Welder with Reduced Voltage Control.
3.c. In semiautomatic or automatic wire welding, the electrode,
electrode reel, welding head, nozzle or semiautomatic
welding gun are also electrically “hot”.
3.d. Always be sure the work cable makes a good electrical
connection with the metal being welded. The connection
should be as close as possible to the area being welded.
3.e. Ground the work or metal to be welded to a good electrical
(earth) ground.
3.f. Maintain the electrode holder, work clamp, welding cable and
welding machine in good, safe operating condition. Replace
damaged insulation.
Return to Master TOC
3.g. Never dip the electrode in water for cooling.
3.h. Never simultaneously touch electrically “hot” parts of
electrode holders connected to two welders because voltage
between the two can be the total of the open circuit voltage
of both welders.
3.i. When working above floor level, use a safety belt to protect
yourself from a fall should you get a shock.
3.j. Also see Items 6.c. and 8.
ARC RAYS can burn.
4.a.
ii
Use a shield with the proper filter and cover
plates to protect your eyes from sparks and
the rays of the arc when welding or observing
open arc welding. Headshield and filter lens
should conform to ANSI Z87. I standards.
4.b. Use suitable clothing made from durable flame-resistant
material to protect your skin and that of your helpers from
the arc rays.
4.c. Protect other nearby personnel with suitable, non-flammable
screening and/or warn them not to watch the arc nor expose
themselves to the arc rays or to hot spatter or metal.
FUMES AND GASES
can be dangerous.
5.a. Welding may produce fumes and gases
hazardous to health. Avoid breathing these
fumes and gases.When welding, keep
your head out of the fume. Use enough
ventilation and/or exhaust at the arc to keep
fumes and gases away from the breathing zone. When
welding with electrodes which require special
ventilation such as stainless or hard facing (see
instructions on container or MSDS) or on lead or
cadmium plated steel and other metals or coatings
which produce highly toxic fumes, keep exposure as
low as possible and below Threshold Limit Values (TLV)
using local exhaust or mechanical ventilation. In
confined spaces or in some circumstances, outdoors, a
respirator may be required. Additional precautions are
also required when welding on galvanized steel.
5. b. The operation of welding fume control equipment is affected
by various factors including proper use and positioning of the
equipment, maintenance of the equipment and the specific
welding
procedure
and
application
involved.
Worker exposure level should be checked upon installation
and periodically thereafter to be certain it is within applicable
OSHA PEL and ACGIH TLV limits.
5.c. Do not weld in locations near chlorinated hydrocarbon 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.
Return to Master TOC
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
Return to Master TOC
iii
WELDING SPARKS can
cause fire or explosion.
SAFETY
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.
Return to Master TOC
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.
Return to Master TOC
Return to Master TOC
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.
CYLINDER may explode
if damaged.
iii
7.a. Use only compressed gas cylinders
containing the correct shielding gas for the
process used and properly operating
regulators designed for the gas and
pressure used. All hoses, fittings, etc. should be suitable for
the application and maintained in good condition.
7.b. Always keep cylinders in an upright position securely
chained to an undercarriage or fixed support.
7.c. Cylinders should be located:
• Away from areas where they may be struck or subjected to
physical damage.
• A safe distance from arc welding or cutting operations and
any other source of heat, sparks, or flame.
7.d. Never allow the electrode, electrode holder or any other
electrically “hot” parts to touch a cylinder.
7.e. Keep your head and face away from the cylinder valve outlet
when opening the cylinder valve.
7.f. Valve protection caps should always be in place and hand
tight except when the cylinder is in use or connected for
use.
7.g. Read and follow the instructions on compressed gas
cylinders, associated equipment, and CGA publication P-l,
“Precautions for Safe Handling of Compressed Gases in
Cylinders,” available from the Compressed Gas Association
1235 Jefferson Davis Highway, Arlington, VA 22202.
FOR ELECTRICALLY
powered equipment.
8.a. Turn off input power using the disconnect
switch at the fuse box before working on
the equipment.
8.b. Install equipment in accordance with the U.S. National
Electrical Code, all local codes and the manufacturer’s
recommendations.
8.c. Ground the equipment in accordance with the U.S. National
Electrical Code and the manufacturer’s recommendations.
Mar ‘95
Return to Master TOC
Return to Master TOC
Return to Master TOC
Return to Master TOC
iv
PRÉCAUTIONS DE SÛRETÉ
SAFETY
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 LʼArc
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.
iv
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.
5. Toujours porter des lunettes de sécurité dans la zone de
soudage. Utiliser des lunettes avec écrans lateraux dans les
zones où l’on pique le laitier.
Mar ‘93
SAFETY
Return to Master TOC
Return to Master TOC
Return to Master TOC
v
v
Electromagnetic Compatibility (EMC)
Conformance
Products displaying the CE mark are in conformity with European Community Council Directive of 3 May
1989 on the approximation of the laws of the Member States relating to electromagnetic compatibility
(89/336/EEC). It was manufactured in conformity with a national standard that implements a harmonized
standard: EN 60974-10 Electromagnetic Compatibility (EMC) Product Standard for Arc Welding Equipment.
It is for use with other Lincoln Electric equipment. It is designed for industrial and professional use.
Introduction
All electrical equipment generates small amounts of electromagnetic emission. Electrical emission may be
transmitted through power lines or radiated through space, similar to a radio transmitter. When emissions
are received by other equipment, electrical interference may result. Electrical emissions may affect many
kinds of electrical equipment; other nearby welding equipment, radio and TV reception, numerical controlled
machines, telephone systems, computers, etc. Be aware that interference may result and extra precautions
may be required when a welding power source is used in a domestic establishment.
Installation and Use
The user is responsible for installing and using the welding equipment according to the manufacturer’s
instructions. If electromagnetic disturbances are detected then it shall be the responsibility of the user of the
welding equipment to resolve the situation with the technical assistance of the manufacturer. In some cases
this remedial action may be as simple as earthing (grounding) the welding circuit, see Note. In other cases
it could involve construction an electromagnetic screen enclosing the power source and the work complete
with associated input filters. In all cases electromagnetic disturbances must be reduced to the point where
they are no longer troublesome.
Note: The welding circuit may or may not be earthed for safety reasons according to national
codes. Changing the earthing arrangements should only be authorized by a person who is
competent to access whether the changes will increase the risk of injury, e.g., by allowing
parallel welding current return paths which may damage the earth circuits of other equipment.
Assessment of Area
Before installing welding equipment the user shall make an assessment of potential electromagnetic problems in the surrounding area. The following shall be taken into account:
a) other supply cables, control cables, signaling and telephone cables; above, below and adjacent to the
welding equipment;
b) radio and television transmitters and receivers;
c) computer and other control equipment;
d) safety critical equipment, e.g., guarding of industrial equipment;
Return to Master TOC
e) the health of the people around, e.g., the use of pacemakers and hearing aids;
f) equipment used for calibration or measurement
g) the immunity of other equipment in the environment. The user shall ensure that other equipment being
used in the environment is compatible. This may require additional protection measures;
h) the time of day that welding or other activities are to be carried out.
L10093
3-1-96H
SAFETY
Return to Master TOC
vi
vi
Electromagnetic Compatibility (EMC)
The size of the surrounding area to be considered will depend on the structure of the building and other
activities that are taking place. The surrounding area may extend beyond the boundaries of the premises.
Methods of Reducing Emissions
Return to Master TOC
Return to Master TOC
Mains Supply
Welding equipment should be connected to the mains supply according to the manufacturer’s recommendations. If interference occurs, it may be necessary to take additional precautions such as filtering of the
mains supply. Consideration should be given to shielding the supply cable of permanently installed welding
equipment, in metallic conduit or equivalent. Shielding should be electrically continuous throughout its
length. The shielding should be connected to the welding power source so that good electrical contact is
maintained between the conduit and the welding power source enclosure.
Maintenance of the Welding Equipment
The welding equipment should be routinely maintained according to the manufacturer’s recommendations.
All access and service doors and covers should be closed and properly fastened when the welding equipment is in operation. The welding equipment should not be modified in any way except for those changes
and adjustments covered in the manufacturers instructions. In particular, the spark gaps of arc striking and
stabilizing devices should be adjusted and maintained according to the manufacturer’s recommendations.
Welding Cables
The welding cables should be kept as short as possible and should be positioned close together, running at
or close to floor level.
Equipotential Bonding
Bonding of all metallic components in the welding installation and adjacent to it should be considered.
However, metallic components bonded to the work piece will increase the risk that the operator could
receive a shock by touching these metallic components and the electrode at the same time. The operator
should be insulated from all such bonded metallic components.
Earthing of the Workpiece
Where the workpiece is not bonded to earth for electrical safety, not connected to earth because of its size
and position, e.g., ships hull or building steelwork, a connection bonding the workpiece to earth may reduce
emissions in some, but not all instances. Care should be taken to prevent the earthing of the workpiece
increasing the risk of injury to users, or damage to other electrical equipment. Where necessary, the connection of the workpiece to earth should be made by a direct connection to the workpiece, but in some
countries where direct connection is not permitted, the bonding should be achieved by suitable capacitance,
selected according to national regulations.
Return to Master TOC
Screening and Shielding
Selective screening and shielding of other cables and equipment in the surrounding area may alleviate
problems of interference. Screening of the entire welding installation may be considered for special applications. 1
_________________________
1 Portions of the preceding text are contained in EN 60974-10: “Electromagnetic Compatibility (EMC)
product standard for arc welding equipment.”
L10093
3-1-96H
I
- MASTER TABLE OF CONTENTS FOR ALL SECTIONS RETURN
TO MAIN INDEX
RETURN TO MAIN MENU
Page
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .i-vi
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section A
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section B
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section C
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section D
Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section E
Troubleshooting and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section F
Electrical Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section G
Parts Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .P-418 Series
POWER WAVE 355M/405M
I
Return to Master TOC
A-1
TABLE OF CONTENTS - INSTALLATION SECTION
A-1
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-1
Technical Specifications 355M . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-2
Technical Specifications 405M . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-3
Safety Precautions .....................................................................................................................................A-4
Stacking......................................................................................................................................................A-4
Return to Master TOC
Tilting ..........................................................................................................................................................A-4
Input Grounding Connections ....................................................................................................................A-4
Power Cord Connection.............................................................................................................................A-4
Output Cables, Connections and Limitations ............................................................................................A-5
Negative Electrode Polarity ........................................................................................................................A-5
Voltage Sensing..........................................................................................................................................A-5
Power Wave to Semi-Automatic Wire Feeder ...........................................................................................A-6
System Description ....................................................................................................................................A-7
System Set-up ...........................................................................................................................................A-8
Return to Master TOC
Multiple Group System...............................................................................................................................A-9
Single Group Multi-Head System ............................................................................................................A-10
Welding with Multiple Power Waves ........................................................................................................A-11
Control Cable Specifications....................................................................................................................A-11
I/0 Receptacle Specifications ..................................................................................................................A-13
Return to Master TOC
Dip Switch Settings and Locations..........................................................................................................A-13
POWER WAVE 355M/405M
INSTALLATION
Return to Master TOC
Return to Section TOC
A-2
TECHNICAL SPECIFICATIONS - POWER WAVE 355
INPUT AC VOLTAGE & DC OUTPUT
Product Ordering
Input AC
Rated DC Output
Name Information Voltage Amps/Volts/Duty Cycle
Power
Wave
355
K2152-1
200-208
220-240
380-415
440-480
575
Return to Section TOC
Return to Master TOC
Return to Master TOC
Output
Range
(continuous)
350A / 34V / 60%
1 & 3 Phase
AMPS
Weight
with Cord
(81.5 lbs.)
(37.0 kg.)
5-425
300A / 32V / 100%
1 & 3 Phase
60/50 HZ
Return to Section TOC
A-2
Dimensions
HxWxD
14.8” x 13.3” x
27.8”*
(373 x 338 x
706*)mm
*Includes
Handles
* Overall Length Including Handle, 21.6” (549mm) without handle.
POWER WAVE 355 INPUT CURRENT
Recommended Fuse Sizes Base On The U.S. National Electrical Code And Maximum Machine Outputs
Input 50/60 Hz
Output
Recommended
Notes
Voltage
Phases
300Amps @
350Amps @
Fuse size
Line Cord
32Volts(100%)
34Volts(60%)
AWG
Note 1
200
1
Not
Not
--Recommended Recommended
Note 2
208
1
76
94
125A
2
Note 2
230
1
69
85
125A
4
Note 1
380
1
Not
Not
--Recommended Recommended
Note 1
400
1
Not
Not
----Recommended Recommended
Note 2
415
1
41
64
80A
6
460
1
36
42
70A
8
575
1
31
37
50A
8
200
208
230
380
400
415
460
575
3
3
3
3
3
3
3
3
41
39
36
23
22
22
19
16
50
50
42
28
27
26
23
18
6
6
8
8
8
8
8
8
Note 2
Note 2
80A
80A
70A
50A
50A
50A
50A
35A
Note 1. Not rated is indicated by 4-x’s in the box on the rating plate.
Note 2. When operating on these inputs, the line cord should be changed to an input conductor of 6 AWG or larger.
Return to Master TOC
Return to Section TOC
OUTPUT CABLES, CONNECTIONS AND LIMITATIONS
Select The output cable size based upon the following chart.*
Cable sizes for Combined Length of Electrode and Work Cable (Copper) 75C rated:
DUTY CYCLE
CURRENT
LENGTH UP 200FT.(61m)
100%
300
1/0
60%
350
1/0
*Lincoln Electric recommends using a minimum of 2/0 welding cable for pulse welding.
POWER WAVE 355M/405M
200-250 FT. (61-76m)
1/0
2/0
INSTALLATION
Return to Master TOC
Return to Section TOC
A-3
A-3
TECHNICAL SPECIFICATIONS - POWER WAVE 405
INPUT AC VOLTAGE & DC OUTPUT
Product
Name
Power
Wave
405
Ordering Input AC
Rated DC Output
Information Voltage Amps/Volts/Duty Cycle
K 2152-2
200-208 /
220-240/
380-415/
3/50/60
350A / 34V / 60%
3 Phase
320A / 33V / 60%
1 Phase
Output
Range
(continuous)
Weight
with Cord
Dimensions
HxWxD
14.7”x12.5”x
AMPS
5-425
27.8”*
(373x318x
706*)mm
86.5lbs
(37.4 kg)
Return to Master TOC
Return to Section TOC
60/50 Hz 275A / 31V /100%
1 Phase
300A / 32V / 100%
3 Phase
* Includes
handles
* Overall Length Including Handle, 21.6” (549mm) without handle.
POWER WAVE 405 INPUT CURRENT
Recommended Fuse Sizes Based On The U.S. National Electrical Code And Maximum Machine Outputs
Input 50/60 Hz
Output
Recommended
Voltage
Phases
300Amps@
350Amps@
Line Cord
Size Fuse Size
Notes
32Volts(100%)
34Volts(60%)
Size mm2
200
3
41
48
16
80A
Note 2
220
3
37
48
16
80A
Note 2
380
3
23
28
10
50A
400
3
22
27
10
50A
415
3
22
26
10
50A
Return to Master TOC
Return to Section TOC
Voltage
Phases
275Amps@
320Amps@
Line Cord
Fuse Size
Notes
31Volts(100%)
33Volts(60%)
Size mm2
200
1
Not Recommended Not Recommended
------Note 1
220
1
64
82
20
125A
Note 2
380
1
44
55
16
80A
Note 2
400
1
40
50
10
80A
415
1
38
48
10
80A
1. Not rated is indicated by 4-x's in the box on the rating plate
2. When operating on these inputs, the line cord should be changed to an input conductor of 6 AWG or larger.
Return to Master TOC
Return to Section TOC
OUTPUT CABLES, CONNECTIONS AND LIMITATIONS
Select the output cable size based upon the following chart.
Cable sizes for Combined Length of Electrode and Work Cable (Copper) 75C rated:
DUTY CYCLE
CURRENT
LENGTH UP 61m (200 FT)
100%
275
1/0
60%
350
1/0
POWER WAVE 355M/405M
61-76m (200-250 FT)
1/0
2/0
Return to Master TOC
Return to Section TOC
A-4
SAFETY PRECAUTIONS
INSTALLATION
WARNING
ELECTRIC SHOCK can kill.
• TURN THE INPUT POWER OFF AT
THE DISCONNECT SWITCH BEFORE
ATTEMPTING TO CONNECT OR DISCONNECT INPUT POWER LINES, OUTPUT
CABLES, OR CONTROL CABLES.
• Only qualified personnel should perform this
installation.
• Connect the green/yellow lead of the power cord
to ground per U.S.National Electrical Code.
----------------------------------------------------------------------
!
!
WA
WA
RN
dolor
sit
my
amet
aliquam
ing
adipisc ut
nt
ing
adipisc ut
nt
tetuer
tincidu
d
elit,
laoreet
dolor
sit
my
consec
aliquam euismo
amet
erat
nibh
cing
nibh
nonum sit
ipsum
magna my
ut
aliquam
diam dolor
adipis
Lorem ed dolore nonum
er unt
cing
ipsum
elit,
magna
diam
ut
ctetu tincid
laoreet
Lorem ed dolore
adipis
od
elit,
er unt
conse
laoreet
euismerat ctetu tincid
amet
od
m
sit nibh conse
mmy a aliqua euismerat
dolor
amet
m
nonu
sit nibh
magn
ipsum
e
mmy a aliqua
diam
dolor
ed dolor nonu
Lorem et
magn
ipsum
elit,
e
diam
laore
ed dolor
Lorem et
elit,
laore
nonum
magna
dolore
ipsum
diam
Lorem ed
elit,
laoreet
ing
tetuer
tincidu
d
adipisc ut
consec
nt
euismo
ing
amet
erat tetuer tincidu
nibh
sit
d
my
adipisc ut
consec
nt
aliquam
ing
euismo
amet
erat tetuer
nonum
tincidu
nibh
magna sit
d
adipisc ut
nt
my
dolor
aliquam consec
euismo tetuer tincidu
nonum
amet
erat d
ipsum
nibh
magna sit
consec
diam
my
euismo
ing
aliquam
dolore dolor
amet
erat
nibh
nonum sit
adipisc ut
ipsum
magna my
nt
laoreet
aliquam
diam dolor
tetuer
ing
Lorem ed dolore nonum
tincidu
d
ipsum
magna
elit,
consec
diam
adipisc ut
nt
laoreet ed
ing
euismo
Lorem
dolore
amet
erat tetuer
elit,
tincidu
nibh
sit
adipisc ut
d
nt
laoreet
my
ing
dolor
aliquam consec
tetuer
tincidu
euismo
nonum
d
adipisc ut
amet
erat
nt
ipsum
magna sit
nibh
consec
diam
my
euismo tetuer tincidu
Lorem ed dolore dolor
aliquam
amet
erat d
dolore
dolor
Lorem ed
elit,
laoreet
ipsum
diam
Lorem ed
elit,
AT
AV TE
PR ISO
NT
EC DE IO
AU
N
CIO
N
AMP
S
V
A
LIN
CO
ELE LN
CTR
IC
OUT
VOL
TS
PUT
WELD
TERM
INALS
IN
WARNI
!
!
ing
adipisc ut
nt
A
RN
ING
ING
ing
cing
consec
euismo
ut
amet
erat
adipis
nibh
sit
er unt
my
cing
dolor
aliquam
ut
ctetu tincid
nonum
adipis
od
magna
er unt
conse
dolore
euismerat ctetu tincid
amet
od
m
laoreet
sit nibh conse
mmy a aliqua euismerat
dolor
amet
m
nonu
sit nibh
magn
ipsum
e
mmy a aliqua
diam
dolor
ed dolor nonu
Lorem et
magn
ipsum
elit,
e
diam
laore
ed dolor
Lorem et
elit,
laore
ipsum
diam
Lorem ed
elit,
euismo tetuer
erat
tincidu
d
consec
aliquam euismo
amet
erat
nibh
my
aliquam
nonum
magna
nibh
dolor
my
amet
laoreet
sit
nonum sit
magna
dolore
dolor
ipsum
diam
laoreet
Lorem ed dolore
elit,
ipsum
diam
magna
• The machine must be located where there is free circulation of clean air such that air movement in the
back, out the sides and bottom will not be restricted.
adipisc ut
nt
consec
dolore
Lorem ed
elit,
ing
tetuer
tincidu
d
adipisc ut
consec
nt
euismo
erat tetuer tincidu
nibh
d
laoreet
ipsum
diam
Lorem ed
elit,
laoreet
euismo
amet
erat tetuer
nonum
tincidu
nibh
ing
magna sit
d
my
dolor
aliquam consec
adipisc ut
euismo
nt
nonum
amet
erat
ipsum
nibh
magna sit
tetuer
tincidu
diam
my
d
ing
aliquam
dolore dolor
consec
nonum
euismo
adipisc ut
nt
ipsum
amet
erat
magna
laoreet
ing
nibh
sit
diam
tetuer
tincidu
Lorem ed dolore
my
d
dolor
aliquam
adipisc ut
elit,
nt
consec
nonum
dolore
Lorem ed
elit,
Return to Master TOC
CAUTION
laoreet
Return to Master TOC
Cord Length
10 Feet
5 Meters
ipsum
diam
Return to Master TOC
Machine
PW 355
PW 405
In order to assure long life and reliable operation,
the owner of this machine should follow these simple preventative measures:
NG
REMOT
E
VE
SELE
CT
RT
EC
V3
50
-P
RO
POWER
ON
OFF
• Dirt and dust that can be drawn into the machine
should be kept to a minimum. Failure to observe
these precautions can result in excessive operating
temperatures and nuisance shutdown.
CAUTION
Return to Section TOC
POWER CORD CONNECTION
A power cord is provided and wired into the machine.
Follow the power cord connection instructions.
• Incorrect connection may result in equipment
damage.
• Keep machine dry. Shelter from rain and snow. Do not
place on wet ground or in puddles.
Return to Section TOC
• Open the access panel on the rear of the machine.
• For 200 or 230: Position the large switch to 200230.
For higher voltages: Position the large switch to
380-575.
• Move the "A" lead to the appropriate terminal.
Lorem ed
elit,
Return to Section TOC
SELECT SUITABLE LOCATION
A-4
• DO NOT MOUNT OVER COMBUSTIBLE SURFACES.
Where there is a combustible surface directly under
stationary or fixed electrical equipment, that surface
shall be covered with a steel plate at least .06”(1.6mm)
thick, which shall extend not less than 5.90”(150mm)
beyond the equipment on all sides.
STACKING
POWER WAVE 355M/405M cannot be stacked.
TILTING
Place the machine directly on a secure, level surface or
on a recommended undercarriage. The machine may
topple over if this procedure is not followed.
INPUT AND GROUNDING CONNECTIONS
• Only a qualified electrician should connect the
POWER WAVE 355M/405M. Installation should be
made in accordance with the appropriate National
Electrical Code, all local codes and the information
detailed below.
• When received directly from the factory, multiple voltage machines are internally connected for the highest
voltage. Always double-check connections before
powering up the machine.
• Initial 200VAC - 415VAC and 575VAC operation will
require an Input voltage panel setup.
Single Phase Input (PW 355M)
Connect green lead to ground per National Electrical
Code.
Connect black and white leads to power.
Wrap red lead with tape to provide 600V insulation.
Three Phase Input (PW 355M)
Connect green lead to ground per National Electric
Code.
Connect black, red and white leads to power.
Lead Color
Green
Black
White
Red
Single Phase
Three Phase
Connect to
Connect to
ground per NEC ground per NEC
Power Lead
Power Lead
Tape, provide
600V insulation
Power Lead
Power Lead
Power Lead
Single Phase Input (PW 405M)
Connect green/yellow lead to ground per National
Electrical Code.
Connect blue and brown leads to power.
Wrap black lead with tape to provide 600V insulation.
Three Phase Input (PW 405M)
Connect green/yellow lead to ground per National
Electric Code.
Connect black, blue and brown leads to power.
POWER WAVE 355M/405M
INSTALLATION
Return to Master TOC
10
UNDERCARRIAGE MOUNTINGS
CAUTION
NOTE: MOUNTING SCREWS CA N NOT PROTRUDE MORE THAN
0.5 INCHES INSIDE THE MACHINE.
3.50
1/4-20 NUT (4 PLACES)
5.50
11.84
Return to Section TOC
OUTPUT CABLES, CONNECTIONS AND
LIMITATIONS
Connect a work lead of sufficient size and length
between the proper output terminal on the power
source and the work. Be sure the connection to the
work makes tight metal-to-metal electrical contact. To
avoid interference problems with other equipment and
to achieve the best possible operation, route all cables
directly to the work or wire feeder. Avoid excessive
lengths and do not coil excess cable.
Return to Master TOC
Return to Master TOC
CAUTION
Return to Section TOC
Excessive voltage drops caused by poor work
piece connections often result in unsatisfactory
welding performance.
-----------------------------------------------------------------------
NEGATIVE ELECTRODE POLARITY
When negative electrode polarity is required, such as
in some Innershield applications, reverse the output
connections at the power source (electrode cable to
the negative (-) Twist-Mate terminal, and work cable
to the positive (+) Twist-Mate terminal.
4/01
M19527
Return to Section TOC
A-5
MOUNTING HOLE LOCATIONS
10.00
Return to Master TOC
4
Return to Section TOC
A-5
When using inverter type power sources like the
Power Waves, use the largest welding (electrode
and work) cables that are practical. At least 2/0
copper wire - even if the average output current
would not normally require it. When pulsing, the
pulse current can reach very high levels. Voltage
drops can become excessive, leading to poor welding characteristics, if undersized welding cables
are used.
-----------------------------------------------------------------------Most welding applications run with the electrode being
positive (+). For those applications, connect the electrode cable between the wire feeder and the positive
(+) output Twist-Mate terminal on the power source.
Connect the other end of the electrode cable to the
wire drive feed plate. The electrode cable lug must be
against the feed plate. Be sure the connection to the
feed plate makes tight metal-to-metal electrical contact. The electrode cable should be sized according to
the specifications given in the output cable connections
section. Connect a work lead from the negative (-)
power source output Twist-Mate terminal to the work
piece. The work piece connection must be firm and
secure, especially if pulse welding is planned.
When operating with electrode polarity negative the
"Electrode Sense Polarity" DIP switch must be set to
the "Negative" position on the Wire Drive Feed Head
PC Board. The default setting of the switch is positive
electrode polarity. Consult the Power Feed instruction
manual for further details.
VOLTAGE SENSING
The best arc performance occurs when the
PowerWaves have accurate data about the arc conditions. Depending upon the process, inductance within
the electrode and work lead cables can influence the
voltage apparent at the studs of the welder. Voltage
sense leads improve the accuracy of the arc conditions
and can have a dramatic effect on performance.
Sense Lead Kits (K940-10, -25 or -50) are available for
this purpose.
CAUTION
If the voltage sensing is enabled but the sense
leads are missing, improperly connected, or if the
electrode polarity switch is improperly configured,
extremely high welding outputs may occur.
-----------------------------------------------------------------------The ELECTRODE sense lead (67) is built into the control cable, and is automatically enabled for all semiautomatic processes. The WORK sense lead (21) connects to the Power Wave at the four pin connector. By
default the WORK voltage is monitored at the output
stud in the POWER WAVE 355/405. For more information on the WORK sense lead (21), see"Work Voltage
Sensing” in the following paragraph.
For additional Safety information regarding the electrode and work cable set-up, See the standard "SAFETY INFORMATION" located in the front of the
Instruction Manuals.
POWER WAVE 355M/405M
INSTALLATION
Return to Master TOC
Return to Section TOC
A-6
Enable the voltage sense leads as follows:
TABLE A.1
Process Electrode Voltage
Work Voltage
Sensing 67 lead *
Sensing 21 lead
GMAW 67 lead required
21 lead optional
GMAW-P 67 lead required
21 lead optional
FCAW 67 lead required
21 lead optional
GTAW Voltage sense at studs Voltage sense at studs
GMAW Voltage sense at studs Voltage sense at studs
SAW
67 lead required
21 lead optional
CAC-C Voltage sense at studs Voltage sense at studs
Return to Master TOC
Return to Section TOC
* The electrode voltage 67 sense lead is integral to the
control cable to the wire feeder.
Work Voltage Sensing
The standard POWER WAVE 355M/405M default to
the work stud (work sense lead disabled)
For processes requiring work voltage sensing, connect
the (21) work voltage sense lead (K940) from the
Power Wave work sense lead receptacle to the work
piece. Attach the sense lead to the work piece as close
to the weld as practical, but not in the return current
path. Enable the work voltage sensing in the Power
Wave as follows:
WARNING
Return to Master TOC
Return to Section TOC
• 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.
1. Turn off power to the power source at the disconnect
switch.
2. Remove the wrap around cover from the power
source.
5. Replace the wrap around and screws. The PC board
will “read” the switch at power up, and configure the
work voltage sense lead appropriately.
ELECTRODE VOLTAGE SENSING
Enabling or disabling electrode voltage sensing is automatically configured through software. The 67 electrode sense lead is internal to the cable to the wire
feeder and always connected when a wire feeder is
present.
PF10M feeder has user preference features to select
voltage senses temporarily for testing sense leads.
CAUTION
Important: The electrode polarity must be configured at the feed head for all semi-automatic
processes. Failure to do so may result in extremely high welding outputs.
------------------------------------------------------------------------
POWER WAVE TO SEMI-AUTOMATIC POWERFEED WIRE FEEDER INTERCONNECTIONS
The POWER WAVE 355M/405M and semi-automatic
Power Feed family communicate via a 5 conductor
control cable (K1543). The control cable consists of two
power leads, one twisted pair for digital communication, and one lead for voltage sensing. The cables are
designed to be connected end to end for ease of extension. The output receptacle on the POWER WAVE
405M is on the case front. The input receptacle on the
Power Feed is typically located at the back of the feeder, or on the bottom of the user interface.
Due to the flexibility of the platform the configuration
may vary. The following is a general description of the
system. For specific configuration information, consult
the semi-automatic Power Feed instruction manual.
Return to Master TOC
Return to Section TOC
3. The control board is on the center assembly facing
the case front. Locate the 8-position DIP switch and
look for switch 8 of the DIP switch.
4. Using a pencil or other small object, slide the switch
to the OFF position if the work sense lead is NOT
connected. Conversely, slide the switch to the ON
position if the work sense lead is present.
O
N
1
2
3
4
5
6
7
A-6
8
POWER WAVE 355M/405M
Return to Master TOC
Return to Master TOC
Return to Section TOC
Return to Section TOC
A-7
SYSTEM DESCRIPTION
INSTALLATION
The POWER WAVE 355M/405M and Power Feed
10/11 family of products utilize a digital communication
system called Arclink. Simply put, Arclink allows large
amounts of information to be passed at very high
speeds between components (nodes) in the system.
The system requires only two wires for communication,
and because of its bus-like structure, the components
may be connected to the network in any order, thus
simplifying the system set-up.
Each "system" must contain only one power source.
The power source may be connected to a maximum of
four feeder groups. Each group containing one user
interface (UI), and up to seven Feed Heads (FH). SEE
FIGURE A.1. The UI controls all of the FH’s of that
group. The UI’s and FH’s are assigned to groups by
setting a code on the DIP switches mounted on their
individual control boards. For example all of the FH’s to
be controlled by a given UI must have their "Group ID"
switches set to the same group number as the UI. In
addition, each FH must be assigned a separate FH
number within that group. See the system set-up section for further details.
System Model
From a network perspective, each component in the
system is considered a separate node, regardless of its
physical location. For example, even though a UI and
FH may be physically mounted together, they are still
viewed as separate pieces (nodes) by the network, and
can only communicate via Arclink. The connection is
generally made externally through the Linc-Net Control
Cable, but can also be made internally, as with the PF10 bench model feeder.
The most common Arclink configuration (called a simple system) consists of one power source, one user
interface and one feeder. Under these circumstances
the group and feed head ID DIP switches are ignored
and the system will function regardless of their position. The same is true for the minimum system consisting of a power source and one UI (Example: a stick
welding system).
FIGURE A.1
Return to Section TOC
Return to Master TOC
Return to Master TOC
Maximum
Configuration
Return to Section TOC
A-7
POWER WAVE 355M/405M
INSTALLATION
A-8
SYSTEM SET-UP
Return to Master TOC
Return to Section TOC
A-8
Basic Rules
• Each group is required to have one user interface. No
group may have more than one user interface.
• Each group can have up to seven Feed Heads.
Exception: Group 3 is limited to a maximum of six
Feed Heads.
• Each system has only one power source. For network
purposes, the PS belongs to Group 3, which is why
group 3 is only allowed 6 feed heads in addition to it’s
user interface.
Return to Master TOC
Return to Section TOC
• No two feed heads can have identical Group and
Feed Head numbers.
• Group and Feed Head ID numbers must be set on the
appropriate dip switches at each node. Consult the
PF-10/11 Instruction Manual for specific details
regarding dip switch settings.
• Feed head “0” not allowed. Exception: Simple system ignores all ID numbers, therefore “FH0” will function.
Return to Master TOC
Return to Section TOC
• Each node must be connected to the Linc-Net communication network. The order of connection is not
important, as each node is identified by it’s unique
Group and Feed Head ID number as defined on it’s
dip switches. See Figures A.2 thru A.5.
Simple System
FIGURE A.2
Return to Master TOC
Return to Section TOC
Group and Feed
Head ID numbers are
ignored in a simple
system.
POWER WAVE 355M/405M
A-9
Return to Section TOC
Return to Master TOC
Return to Section TOC
Return to Master TOC
Multiple Group System
INSTALLATION
FIGURE A.3
A-9
No “FH0 Allowed!
Single Group Multi-Head System
Return to Section TOC
Return to Master TOC
Return to Section TOC
Return to Master TOC
FIGURE A.4
No “FH0 Allowed!
The Dual Head option
allows the ability to
maintain 2 sets of
procedures. If more
then 2 heads are
used, odd #’s use
FH1 settings, even #’s
use FH2 settings.
POWER WAVE 355M/405M
INSTALLATION
A-10
FIGURE A.5
Return to Section TOC
Return to Master TOC
Return to Master TOC
No “FH0 Allowed!
When a standard
User Interface is used
in a group with multiple Feed Heads, all of
the Feed Heads use a
single set of procedures.
Return to Master TOC
Return to Master TOC
Single Group Multi-Head System (Alternate Method)
Return to Section TOC
Return to Section TOC
Return to Section TOC
A-10
POWER WAVE 355M/405M
INSTALLATION
Return to Master TOC
Return to Master TOC
Return to Section TOC
Return to Section TOC
A-11
WELDING WITH MULTIPLE POWER
WAVES
CAUTION
Special care must be taken when more than one
Power Wave is welding simultaneously on a single
part. Arc blow and arc interference may occur or be
magnified.
Each power source requires a work lead from the work
stud to the welding fixture. Do not combine all of the
work leads into one lead. The welding travel directions
should be in the direction moving away from the work
lead as shown below. Connect all of the work sense
leads from each power source to the work piece at the
end of the weld.
A-11
CONTROL CABLE SPECIFICATIONS
It is recommended that genuine Lincoln control cables
be used at all times. Lincoln cables are specifically
designed for the communication and power needs of
the Power Wave / Power Feed system.
CAUTION
The use of non-standard cables, especially in
lengths greater than 25 feet, can lead to communication problems such as: system shutdowns, poor
motor acceleration, poor arc starting) and low wire
driving force (wire feeding problems).
-----------------------------------------------------------------------The K1543 series of control cables can be connected
end to end for ease of extension. Do not exceed more
than 100 feet (30.5 m) total control cable length.
For the best results when pulse welding, set the wire
size and wire feed speed the same for all the Power
Waves. When these parameters are identical, the pulsing frequency will be the same, helping to stabilize the
arcs.
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.
Return to Master TOC
Return to Section TOC
If an anti-spatter system is in use then each gun must
have its own anti-spatter system. (See Figure A.6)
FIGURE A.6
POWER WA
WAVE 355/405
POWER WA
WAVE 355/405
TWO POWER WAVES
Return to Master TOC
Return to Section TOC
Travel
Direction
Connect All Work
Sense Leads at the End
of the Joint
Connect All Welding
Work Leads at the
Beginning of the Joint
POWER WAVE 355M/405M
Return to Section TOC
Return to Master TOC
Return to Section TOC
Return to Master TOC
Return to Master TOC
Return to Section TOC
Return to Master TOC
Return to Section TOC
A-12
MULTIPLE ARC UNSYNCHRONIZED SENSE LEAD AND WORK LEAD PLACEMENT GUIDELINES
INSTALLATION
POWER WAVE 355M/405M
A-12
INSTALLATION
Return to Master TOC
Return to Section TOC
A-13
I / O RECEPTACLE SPECIFICATIONS
TABLE A.2
WIRE FEEDER RECEPTACLE
PIN
LEAD#
FUNCTION
A
53
Communication Bus L
B
54
Communication Bus H
C
67A
Electrode Voltage Sense
D
52
+40vdc
E
51
0vdc
Return to Master TOC
Return to Section TOC
TABLE A.3
VOLTAGE SENSE RECEPTACLE
PIN
LEAD#
FUNCTION
3
21A
Work Voltage Sense
TABLE A.4
RS232 RECEPTACLE
LEAD#
FUNCTION
253
RS232 Receive
254
RS232 Transmit
#
Pin5
#
Pin4
##
Pin20
##
Pin6
251
RS232 Common
PIN
2
3
4
5
6
20
7
A-13
CONTROL BOARD DIP SWITCH:
switch
switch
switch
switch
switch
switch
switch
switch
1 = reserved for future
2 = reserved for future
3 = reserved for future
4 = reserved for future
5 = reserved for future
6 = reserved for future
7 = reserved for future
8* = work sense lead
switch 8*
off
on
use
use
use
use
use
use
use
work sense lead
work sense lead not connected
work sense lead connected
*Factory setting for Switch 8 is OFF.
FIGURE A.7
CONTROL BOARD (DIP Switch Location)
DIP SWITCH SETTINGS AND
LOCATIONS
DIP switches on the P.C. Boards allow for custom configuration of the Power Wave. To access the DIP switches:
Return to Master TOC
Return to Section TOC
WARNING
1. Turn off power to the power source at the disconnect switch.
-----------------------------------------------------------------------2. Remove the wrap around cover from the power
source.
3. The control board is on the center assembly facing
the case front. Locate the 8-position DIP switch and
look for switch 8 of the DIP switch.
NOTE: For PF10M Dual Boom Feeder set/up and operation. The Power Wave 355M/405M control
board dip switches must be set with 3, 4, 7 to
the “ON” position (Power Wave 355M/405M
input on/off switch must be cycled to enable
any change of dip switches).
Return to Master TOC
Return to Section TOC
4. Using a pencil or other small object, slide the switch
to the OFF position if the work sense lead is NOT
connected. Conversely, slide the switch to the ON
position if the work sense lead is present.
5. Replace the wrap around and screws. The PC board
will “read” the switch at power up, and configure the
work voltage sense lead appropriately.
O
N
1
2
3
4
5
6
7
8
POWER WAVE 355M/405M
INSTALLATION
Return to Master TOC
Return to Section TOC
A-14
CABLE INDUCTANCE, AND ITS EFFECTS
ON PULSE WELDING
For Pulse Welding processes, cable inductance will
cause the welding performance to degrade. For the
total welding loop length less than 50 ft.(15.24m), traditional welding cables may be used without any effects
on welding performance. For the total welding loop
length greater than 50 ft.(15.24m)), the K1796 Coaxial
Welding Cables are recommended. The welding loop
length is defined as the total of electrode cable length
(A) + work cable length (B) + work length (C) (See
Figure A.3).
FIGURE A.3
Return to Master TOC
Return to Section TOC
POWER
WAVE
A
C
FIGURE A.4
A
B
Return to Master TOC
K1796 COAXIAL CABLE
Return to Master TOC
For additional Safety information regarding the electrode and work cable set-up, See the standard "SAFETY INFORMATION" located in the front of the
Instruction Manuals.
A
C
Return to Section TOC
Most welding applications run with the electrode being
positive (+). For those applications, connect the electrode cable between the wire feeder and the positive
(+) output Twist-Mate terminal on the power source.
Connect the other end of the electrode cable to the
wire drive feed plate. The electrode cable lug must be
against the feed plate. Be sure the connection to the
feed plate makes tight metal-to-metal electrical contact. The electrode cable should be sized according to
the specifications given in the output cable connections section. Connect a work lead from the negative
(-) power source output Twist-Mate terminal to the
work piece. The work piece connection must be firm
and secure, especially if pulse welding is planned.
For long work piece lengths, a sliding ground should be
considered to keep the total welding loop length less
than 50 ft.(15.24m). (See Figure A.4.)
POWER
WAVE
Return to Section TOC
WORK
B
WORK
SLIDING WORK
A-14
C
B
MEASURE FROM END
OF OUTER JACKET OF
CABLE
POWER WAVE 355M/405M
Return to Master TOC
B-1
TABLE OF CONTENTS - OPERATION SECTION
B-1
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-1
Safety Precautions.......................................................................................................................................B-2
General Description .....................................................................................................................................B-2
Recommended Processes and Equipment .................................................................................................B-2
Required Equipment ....................................................................................................................................B-3
Return to Master TOC
Limitations....................................................................................................................................................B-3
Duty Cycle and Time Period........................................................................................................................B-3
Case Front Controls.....................................................................................................................................B-3
Making a Weld .............................................................................................................................................B-4
Welding Adjustments ...................................................................................................................................B-4
Constant Voltage Welding............................................................................................................................B-5
Tig (GTAW) ...................................................................................................................................................B-6
Special Welding Processes Available ..........................................................................................................B-6
Power Mode.................................................................................................................................................B-7
Return to Master TOC
Return to Master TOC
Pulse Welding (GMAW-P) ............................................................................................................................B-8
Pulse-on-Pulse (GMAW-PP) ......................................................................................................................B-10
Benefits of Pulse-on-Pulse Welding ..........................................................................................................B-10
POWER WAVE 355M/405M
Return to Master TOC
Return to Section TOC
B-2
SAFETY PRECAUTIONS
OPERATION
GENERAL DESCRIPTION
Read this entire section of operating instructions
before operating the machine.
WARNING
ELECTRIC SHOCK can kill.
Return to Master TOC
Return to Section TOC
• 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.
Return to Master TOC
Return to Section TOC
-----------------------------------------------------------
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.
-----------------------------------------------------------
The Power Wave semi-automatic power source is
designed to be a part of a modular, multi-process welding system. Depending on configuration, it can support
constant current, constant voltage, and pulse welding
modes.
The Power Wave power source is designed to be used
with the semi automatic family of Power Feed M wire
feeders, operating as a system. Each component in the
system has special circuitry to "talk with" the other system components, so each component (power source,
wire feeder, user interface) knows what the other is
doing at all times. These components communicate
with Arclink.
The POWER WAVE 355M/405M is a high performance, digitally controlled inverter welding power
source capable of complex, high-speed waveform control. Properly equipped, it can support the GMAW,
GMAW-P, FCAW, SMAW, GTAW, and CAC-A processes. It carries an output rating of 350 Amps, 34 Volts at
60% duty cycle and 300 Amps, 32 volts at 100% duty
cycle.
RECOMMENDED PROCESSES
AND EQUIPMENT
RECOMMENDED PROCESSES
The POWER WAVE 355M/405M can be set up in a
number of configurations, some requiring optional
equipment or welding programs. Each machine is factory preprogrammed with multiple welding procedures,
typically including GMAW, GMAW-P, FCAW, GTAW,
and CAC-A for a variety of materials, including mild
steel, stainless steel, cored wires, and aluminum.
The POWER WAVE 355M/405M is recommended for
semi-automatic welding, and may also be suitable for
basic hard automation applications.
• This Power Wave is not recommended for processes
other than those listed.
Return to Master TOC
Observe additional guidelines detailed in the
beginning of this manual.
Return to Section TOC
B-2
POWER WAVE 355M/405M
OPERATION
Return to Master TOC
Return to Section TOC
B-3
POWER WAVE 355M/405M – Semi-Automatic
Operation
Semi Automatic Power Waves can only be used with
Arclink compatible Power Feed semi-automatic wire
feeders. In addition, the Power Feed semi-automatic
wire feeders may require optional equipment to access
certain weld modes in the Power Wave. Other models
of Lincoln feeders, or any models of non-Lincoln wire
feeders, cannot be used.
All welding programs and procedures are selected
through the Power Feed semi-automatic user interface
Return to Master TOC
Return to Section TOC
REQUIRED EQUIPMENT
NOTE: The POWER WAVE 355M/405M status light
will flash green, and sometimes red and green, for up
to one minute when the machine is first turned on. This
is a normal situation as the machine goes through a
self test at power up.
TABLE B.1
Meaning
Light
Condition
Steady Green System OK. Power source communicating
normally with wire feeder and its components
if other feeder & components show they are
powered up.
Blinking
Green
Occurs during a reset, and indicates the
POWER WAVE 355M/405M is mapping
(identifying) each component in the system.
Normal for first 1-10 seconds after power is
turned on, or if the system configuration is
changed during operation
Alternating
Green and
Red
Non-recoverable system fault. If the PW
Status light is flashing any combination of red
and green, errors are present in the POWER
WAVE 355M/405M. Read the error code
before the machine is turned off.
Any Arclink compatible semi-automatic wire feeding
equipment. Specifically, the semi-automatic Power
Feed family (PF10M Series, Power Feed 15M and
Power Feed 25M).
LIMITATIONS
• Only Arclink compatible Power Feed semi-automatic
wire feeders and users interfaces may be used.
Other Lincoln wire feeders or non-Lincoln wire feeders cannot be used.
Error Code interpretation through the Status
light is detailed in the LED Status Chart.
Individual code digits are flashed in red with
a long pause between digits. If more than
one code is present, the codes will be separated by a green light.
• POWER WAVE 355M/405M Output Limitations
The POWER WAVE 355M/405M will support maximum average output current of 350 Amps @ 60%
duty cycle.
To clear the error, turn power source off, and
back on to reset.
Return to Master TOC
Return to Section TOC
DUTY CYCLE AND TIME PERIOD
The duty cycle is based upon a ten minute period. A
60% duty cycle represents 6 minutes of welding and 4
minutes of idling in a ten minute period.
Return to Master TOC
Non recoverable hardware fault. Generally
indicates nothing is connected to the
POWER WAVE 355M/405M wire feeder
receptacle. See Trouble Shooting Section.
Blinking Red
Not applicable.
1. POWER SWITCH: Controls input power to the
Power Wave.
2. STATUS LIGHT: A two color light that indicates system errors. Normal operation is a steady green light.
Error conditions are indicated, per table B.1.
Return to Section TOC
Steady Red
CASE FRONT CONTROLS
All operator controls and adjustments are located on
the case front of the Power Wave. (See Figure B.1)
B-3
3. HIGH TEMPERATURE LIGHT (thermal overload):
A yellow light that comes on when an over temperature situation occurs. Output is disabled and the
fan continues to run, until the machine cools down.
When cool, the light goes out and output is enabled.
4. CB1 WIRE FEEDER CIRCUIT BREAKER: Protects
40 volt DC wire feeder power supply.
POWER WAVE 355M/405M
OPERATION
Return to Master TOC
Return to Section TOC
B-4
FIGURE B.1
2
The steps for operating the Power Wave will vary
depending upon the options installed in the user interface (control box) of the welding system. The flexibility
of the Power Wave system lets the user customize
operation for the best performance.
3
7
6
4
8
1
Return to Master TOC
Return to Section TOC
9
10
5
CASE FRONT LAYOUT
POWER WAVE 355M/405M
5. Internal POWER CIRCUIT BREAKER: Protects 115
volt AC circuit.
6. LEAD CONNECTOR (SENSE LEAD)
7. DIAGNOSTIC CONNECTOR (RS-232)
8. WIRE FEEDER RECEPTACLE (5-PIN)
9. NEGATIVE TWIST- MATE TERMINAL
10. POSITIVE TWIST- MATE TERMINAL
NOMINAL PROCEDURES
Return to Master TOC
Return to Master TOC
Return to Section TOC
The Power Wave is designed to operate with 3/4" electrode stick-out for CV and Pulse processes.
Return to Section TOC
B-4
FRINGE PROCEDURES
Excessively short or long electrode stick-outs may
function only on a limited basis, if at all.
First, consider the desired welding process and the
part to be welded. Choose an electrode material, diameter, shielding gas and process (GMAW, GMAW-P,
etc.)
Second, find the program in the welding software that
best matches the desired welding process. The standard software shipped with the Power Waves encompasses a wide range of common processes and will
meet most needs. If a special welding program is
desired, contact the local Lincoln Electric sales representative.
To make a weld, the Power Wave needs to know the
desired welding parameters. The Power Feed (PF)
family of feeders communicate settings to the Power
Wave through control cable connection. Arc length,
wire feed speed, arc control, etc. are all communicated
digitally via the control cable.
WELDING ADJUSTMENTS
All adjustments are made on the system component
known as the User Interface (Control Box), which contains the switches, knobs, and digital displays necessary to control both the Power Wave and a Power Feed
wire feeder. Typically, the Control Box is supplied as
part of the wire feeder. It can be mounted directly on
the wire feeder itself, the front of the power source, or
mounted separately, as might be done in a welding
boom installation.
MAKING A WELD
WARNING
The serviceability of a product or structure utilizing the welding programs is and must be the sole
responsibility of the builder/user. Many variables
beyond the control of The Lincoln Electric
Company affect the results obtained in applying
these programs. These variables include, but are
not limited to, welding procedure, plate chemistry
and temperature, weldment design, fabrication
methods and service requirements. The available
range of a welding program may not be suitable for
all applications, and the build/user is and must be
solely responsible for welding program selection.
------------------------------------------------------------------------
Because the Control Box can be configured with many
different options, your system may not have all of the
following adjustments. Regardless of availability, all
controls are described below. For further information,
consult the Power Feed wire feeder instruction manual.
• WFS / AMPS:
In synergic welding modes (synergic CV, pulse GMAW)
WFS (wire feed speed) is the dominant control parameter, controlling all other variables. The user adjusts
WFS according to factors such as weld size, penetration requirements, heat input, etc. The Power Wave
then uses the WFS setting to adjust its output characteristics (output voltage, output current) according to
pre-programmed settings contained in the Power
Wave.
POWER WAVE 355M/405M
Return to Master TOC
Return to Section TOC
B-5
OPERATION
In non-synergic modes, the WFS control behaves more
like a conventional CV power source where WFS and
voltage are independent adjustments. Therefore to
maintain the arc characteristics, the operator must
adjust the voltage to compensate for any changes
made to the WFS.
In constant current modes (stick, TIG) this control
adjusts the output current, in amps.
Return to Master TOC
Return to Section TOC
• VOLTS / TRIM:
In constant voltage modes (synergic CV, standard CV)
the control adjusts the welding voltage.
In pulse synergic welding modes (pulse GMAW only)
the user can change the Trim setting to adjust the arc
length. It is adjustable from 0.500 to 1.500. A Trim setting of 1.000 is a good starting point for most conditions.
• WELDING MODE
May be selected by name (CV/MIG, CC/Stick Crisp,
Gouge, etc.) or by a mode number (10, 24, 71, etc.)
depending on the Control Box options. Selecting a
welding mode determines the output characteristics of
the Power Wave power source. A more complete
description of all modes can be found in this section.
B-5
CONSTANT VOLTAGE WELDING
Synergic CV:
For each wire feed speed, a corresponding voltage is
preprogrammed into the machine through special software at the factory. The nominal preprogrammed voltage is the best average voltage for a given wire feed
speed, but may be adjusted to preference. When the
wire feed speed changes, the Power Wave automatically adjusts the voltage level correspondingly to maintain similar arc characteristics throughout the WFS
range.
Non Synergic CV:
This type of CV mode behaves more like a conventional CV power source. Voltage and WFS are independent
adjustments. Therefore to maintain the arc characteristics, the operator must adjust the voltage to compensate for any changes made to the WFS.
All CV Modes:
Arc Control, often referred to as wave control, adjusts
the inductance of the wave shape. The wave control
adjustment is similar to the "pinch" function in that it is
inversely proportional to inductance. Therefore,
increasing wave control greater than 0.0 results in a
harsher, colder arc while decreasing the wave control
to less than 0.0 provides a softer, hotter arc.
(See Figure B.2)
Return to Master TOC
Return to Section TOC
• ARC CONTROL
Also known as Inductance or Wave Control. Allows
operator to vary the arc characteristics from "soft" to
"harsh" in all weld modes. It is adjustable from -10.0 to
+10.0, with a nominal setting of 00.0 (The nominal setting of 00.0 may be displayed as OFF on some Power
Feed wire feeder control panels). See the Welding
Mode descriptions for a more detailed explanations of
how the Arc Control affects each mode.
FIGURE B.2
Return to Master TOC
Return to Section TOC
CURRENT WAVE FORM (CV)
Current
POWER WAVE 355M/405M
OPERATION
Return to Section TOC
Return to Master TOC
Return to Section TOC
Return to Master TOC
B-6
TIG GTAW
B-6
NOTE: Later versions of weld software
eliminated the Arc Control Function
in TIG mode and only allow for
“Touch Start” operation.
The TIG mode features continuous control from 5 to
425 amps. The TIG mode can be run in either the
Touch Start TIG or Scratch start mode.
The Arc Control level selects the starting mode.
SMAW
In SMAW (STICK mode), the arc control adjusts the
arc force. It can be set to the lower range (0 to -10) for
a soft and less penetrating arc characteristic or to the
higher range (0 to +10) for a crisp and more penetrating arc. Normally, when welding with cellulosic types of
electrodes (E6010, E7010, E6011), a higher energy
arc is required to maintain arc stability. This is usually
indicated when the electrode sticks to the work-piece
or when the arc pops-out during manipulative technique. For low hydrogen types of electrodes (E7018,
E8018, E9018, etc.) a softer arc is usually desirable
and the lower end of the Arc Control suits these types
of electrodes. In either case the arc control is available
to increase or decrease the energy level delivered to
the arc.
Between –10 and 0, the Touch Start TIG mode is
selected. The OCV is controlled below 10V and the
short circuit "TIG touch" current is maintained at
approximately 25 amps, independent of the preset
current. When the tungsten is lifted, an arc is initiated
and the output is regulated at the preset value. A setting of 0, results in the most positive arc initiation. A
setting of -10 reduces the start procedure to start the
weld, and from there, to ramp to the welding procedure over a specified amount of time.
A setting above 0 selects a Scratch Start. Full OCV is
available when the arc initiates the output is regulated
to the preset value
Typically starting procedure on a higher “+” setting is
known as a “Hot Start”. Setting a starting procedure
on a lower setting is known as a “Cold Start”.
Recommended Welding Procedures for Power Mode
Return to Master TOC
MATERIAL
Return to Master TOC
Return to Section TOC
Aluminum 4043 Aluminum 5356
Mild Steel
Mild Steel
Mild Steel
Mild Steel
Mild Steel
Mild Steel
Stainless Steel Stainless Steel
WIRE
E4043
E5356
L56
L56
L56
L56
L56
L56
E308L
E308L
WIRE SIZE
0.035
0.035
0.025
0.025
0.030
0.030
0.035
0.035
0.030
0.035
GAS
100% Agr.
100% Agr.
100% CD2
100% CD2
75/25 Ar/CO2
Tri-mix
Tri-mix
80 / 1.5
50 / 0.5
WFS / POWER MODE SETTING
MATERIAL THICKNESS
Return to Section TOC
TABLE B.2
75/25 Ar/CO2
100% CD2
75/25 Ar/CO2
22 ga.
Not
recommended
100 / 0.8
Not
recommended
90 / 1.0
20 ga.
120 / 1.0
120 / 1.0
100 / 0.7
100 / 1.0
18 ga.
140 / 1.7
140 / 1.5
110 / 1.5
110 / 1.5
100 / 2.5
100 / 2.5
110 / 2.0
110 / 2.0
16 ga.
190 / 2.0
190 / 2.0
125 / 2.0
125 / 2.0
125 / 3.0
125 / 3.0
140 / 2.5
130 / 2.7
260 / 3.0
260 / 3.0
160 / 2.3
160 / 2.3
160 / 3.8
160 / 3.5
210 / 3.0
190 / 3.5
330 / 5.0
330 / 4.5
230 / 3.5
230 / 3.5
200 / 5.0
200 / 4.5
270 / 5.0
230 / 6.0
240 / 6.5
240 / 7.0
325 / 6.5
300 / 7.0
14 ga.
400 / 2.0
400 / 2.5
12 ga.
10 ga.
500 / 7.0
500 / 7.0
300 / 6.0
300 / 6.0
3/16
570 / 90
600 / 7.8
400 / 7.5
400 / 7.0
1/4
700 / 9.1
700 / 8.5
COMMENTS
Not
Not
Recommended Recommended
below 400
below 400
WFS
WFS
POWER WAVE 355M/405M
OPERATION
Return to Master TOC
Return to Section TOC
B-7
ARC GOUGING
Gouging is basically removing metal to form a bevel or
groove in a piece of steel with controlled forced air and
a carbon rod.
The common procedures for Arc Gouging metal are:
• Removing poor welds from a weldment so that new
welds can be made.
Power Mode™ is a method of high speed regulation of
the output power whenever an arc is established. It
provides a fast response to changes in the arc. The
higher the Power Mode Setting, the longer the arc. If a
welding procedure is not established, the best way to
determine the Power Mode Setting is by experimentation until the desired output result is established.
In the Power Mode variables need to be set:
• Creating a welding groove or grooves in two pieces
of steel butted together. (See Example below)
Return to Master TOC
WELD GROOVES CREATED BY ARC GOUGING
Return to Section TOC
B-7
Setting up a Power Mode procedure is similar to setting a CV MIG procedure. Select a shielding gas
appropriate for a short arc process.
STEEL BUTTED TOGTHER
• For steel, use 75/25 Ar/CO2 shield gas.
Mode 9 in the POWER WAVE 355M is specifically for
gouging. Gouging can also be done in the stick soft
and crisp modes. Setting the output of the Stick Soft
mode to 425 amps will enable the arc-gouging mode.
The actual output current will depend on the size of
carbon used. The recommended maximum size carbon
is 5/16".
Return to Section TOC
Return to Master TOC
Return to Master TOC
POWER MODE™
Return to Section TOC
• Wire Feed Speed
• Output
• Arc Control
The Power Mode™ process was developed by Lincoln
to maintain a stable and smooth arc at low procedure
settings which are needed to weld thin metal without
pop-outs or burning-through. For Aluminum welding, it
provides excellent control and the ability to maintain
constant arc length. This results in improved welding
performance in two primary types of applications.
• Short Arc MIG at low procedure settings.
• For Stainless, select a Helium blend Tri-Mix.
• For Aluminum, use 100% Ar.
Start by setting the wire feed speed based upon material thickness and appropriate travel speed. Then
adjust the Output knob as follows:
• For steel, listen for the traditional “frying egg”
sound of a good short-arc MIG procedure to know
you have the process set correctly.
• For aluminum, simply adjust the Output knob until
the desired arc length is obtained.
Note the Volts display is simply a relative number and
DOES NOT correspond to voltage.
Some Power Mode procedure recommendations
appear in Table B.2.
• Aluminum MIG welding.
POWER WAVE 355M/405M
OPERATION
Return to Master TOC
Return to Section TOC
B-8
SPECIAL WELDING PROCESSES
AVAILABLE ON THIS MACHINE
PULSE WELDING (GMAW-P)
The pulsed-arc process is, by definition, a spray transfer process wherein spray transfer occurs in pulses at
regularly spaced intervals. In the time between pulses,
the welding current is reduced and no metal transfer
occurs.
Return to Master TOC
Return to Section TOC
Pulsed-arc transfer is obtained by operating a power
source between low and high current levels. The high
current level or “pulse” forces an electrode drop to the
workpiece. The low current level or “background” maintains the arc between pulses. (See Figure B.3).
B-8
Pulsed MIG is an advanced form of welding that takes
the best of all the other forms of transfer while minimizing or eliminating their disadvantages. Unlike short
circuit, pulsed MIG does not create spatter or run the
risk of cold lapping. The welding positions in pulsed
MIG are not limited as they are with globular or spray
and its wire use is definitely more efficient. Unlike the
spray arc process, pulsing offers controlled heat input
that allows better welding on thin materials. Pulsing
allows for lower wire feed speeds which leads to less
distortion and improved overall quality and appearance. This is especially important with stainless, nickel and other alloys that are sensitive to heat input.
In GMAW-P mode, arc control adjusts the background
current and frequency of the wave. When arc control
goes up, the frequency increases thus increasing the
droplet transfer.
EACH PULSE DELIVERS ONE DROPLET OF WELD MATERIAL
PEAK AMPS
Return to Master TOC
Return to Section TOC
FIGURE B.3
FREQUENCY
Return to Master TOC
Return to Section TOC
SPRAY TRANSITION
CURRENT
POWER WAVE 355M/405M
Return to Master TOC
Return to Section TOC
B-9
PULSE WELDING
OPERATION
Pulse welding procedures are set by controlling an
overall "arc length" variable. When pulse welding, the
arc voltage is highly dependent upon the waveform.
The peak current, back ground current, rise time, fall
time and pulse frequency all affect the voltage. The
exact voltage for a given wire feed speed can only be
predicted when all the pulsing waveform parameters
are known. Using a preset voltage becomes impractical, and instead the arc length is set by adjusting
"trim".
Return to Master TOC
Return to Master TOC
Return to Master TOC
Return to Section TOC
Return to Section TOC
FIGURE B.3
CURRENT WAVE FORM (PULSE)
Current
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.
Return to Section TOC
B-9
All pulse welding programs are synergic. As the wire
feed speed is adjusted, the Power Wave will automatically recalculate the waveform parameters to maintain
similar arc properties.
The Power Wave utilizes "adaptive control" to compensate for changes in electrical stick out while welding.
(Contact to Work Distance is the distance from the
contact tip to the work piece.) The Power Wave wave
forms are optimized for a 0.75" (19mm) stick-out. The
adaptive behavior supports a range of stickouts from
0.50" (13mm) to 1.25" (32mm). At very low or high wire
feed speeds, the adaptive range may be less due to
reaching physical limitations of the welding process.
Arc Control, often referred to as wave control, in pulse
programs usually adjusts the focus or shape of the arc.
Wave control values greater than 0.0 increase the
pulse frequency while decreasing the background current, resulting in a tight, stiff arc best for high speed
sheet metal welding. Wave control values less than 0.0
decrease the pulse frequency while increasing the
background current, for a soft arc good for out-of-position welding.
POWER WAVE 355M/405M
Time
Return to Master TOC
Return to Master TOC
Return to Master TOC
Return to Section TOC
Return to Section TOC
Return to Section TOC
B-10
PULSE-ON-PULSE™ (GMAW-PP)
OPERATION
B-10
When Arc Control is used in the Pulse on Pulse
modes, it does the same things it does in the other
pulsed modes: decreasing the Arc Control decreases
the droplet transfer and weld deposition rate.
Increasing the Arc Control increases the droplet transfer and weld deposition rate. Since Arc Control varies
weld droplet transfer rate, the Arc Control can be used
to vary the ripple spacing in the weld bead.
Pulse on Pulse™ is a Lincoln process specifically
designed for use in welding relatively thin (less than
1/4" thick) aluminum (See the table below). It gives
weld beads with very consistent uniform ripple.
In Pulse on Pulse modes, two distinct pulse types are
used, instead of the single pulse type normally used in
GMAW-P. A number of high energy pulses are used to
obtain spray transfer and transfer metal across the arc.
Such pulses are shown in the figure below. After a
number "N" of such pulses, depending on the wire feed
speed used, an identical number "N" of low energy
pulses are performed. These low energy pulses, shown
in the figure below, do not transfer any filler metal
across the arc and help to cool the arc and keep the
heat input low.
BENEFITS OF PULSE ON PULSE FROM
LINCOLN ELECTRIC
• Excellent appearance of the weld bead
• Improved cleaning action
• Reduced porosity
"N" PULSES
"N" PULSES
HIGH HEAT
PULSES
Table B.3 shows WFS and Trim settings for common
aluminum types and wire sizes when welding with
Pulse-on-Pulse. The welds made to obtain the values
in the table were fillet welds in the flat position. The values in the table can be helpful as a starting point to
establish a welding procedure. From there, adjustments need to be made to set the proper procedure for
each specific application (out-of-position, other types
of joints, etc.).
LOW HEAT
PULSES
PEAK
AMPS
BACKGROUND
AMPS
TIME
The Peak Current, Background Current, and
Frequency are identical for the high energy and low
energy pulses. In addition to cooling the weld down, the
major effect of the low energy pulses is that they form
a weld ripple. Since they occur at very regular time
intervals, the weld bead obtained is very uniform with a
very consistent ripple pattern. In fact, the bead has its
best appearance if no oscillation of the welding gun
("whipping") is used.(See the figure below)
The comments on the table below show values of WFS
below which it is not recommended to weld. The reason is, that below these values the weld transfer will
change from a spray arc to a short-arc, which is not
advisable when welding aluminum.
TABLE B.3
WELDING PROCEDURES FOR PULSE-ON-PULSE
MATERIAL
Aluminum 4043
Aluminum 4043
Aluminum 5356
Aluminum 5356
WIRE
E4043
E4043
E5356
E5356
WFS /
ARC CONTROL
WIRE SIZE
MATERIAL
THICKNESS
Return to Master TOC
Return to Section TOC
GAS
100% Ar.
0.035
100% Ar.
3/64
100% Ar.
0.035
100% Ar.
3/64
14 ga.
250 / 0
200 / 0
230 / 0
225 / 0
3/16
550 / 0
340 / 0
670 / 0
500 / 0
10 ga.
1/4
COMMENTS
400 / 0
600 / 0
Not Recommended
below 200 WFS
280 / 0
400 / 0
Not Recommended
below 100 WFS
425 / 0
700 / 0
Not Recommended
below 200 WFS
POWER WAVE 355M/405M
400 / 0
550 / 0
Not Recommended
below 200 WFS
Return to Master TOC
C-1
TABLE OF CONTENTS - ACCESSORIES SECTION
C-1
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-1
Optional Equipment ....................................................................................................................................C-2
Field Installed .................................................................................................................................C-2
Return to Master TOC
Return to Master TOC
Return to Master TOC
Compatible Lincoln Equipment......................................................................................................C-2
POWER WAVE 355M/405M
Return to Master TOC
Return to Master TOC
Return to Section TOC
Return to Section TOC
C-2
ACCESSORIES
OPTIONAL EQUIPMENT
FACTORY INSTALLED
None Available.
FIELD INSTALLED
K940-Work Voltage Sense Lead Kit
K1764-1-Undercarriage*
K1838-1-Valet Style Undercarriage
K1796-Coaxial Welding Cable-(Requires Adapter K2176-1)
K2176-1 Twist-mate to Lug Adapters
* Dual Cylinder Kit for K1764-1 is K1702-1
K2436-1 Ethernet/Devicenet Communication Interface
Welding Cable Connectors:
K852-70 1/0-2/0 CABLE
K852-95 2/0-3/0 CABLE
COMPATIBLE LINCOLN EQUIPMENT
Any ARC Link compatible wire feeding equipment
PF10M, PF15M, PF25M series.
Return to Section TOC
Return to Master TOC
Return to Section TOC
Return to Master TOC
NOTE: No Linc-Net semi-automatic wire feeding equipment is compatible. Specifically, the semi-automatic
Power Feed family (PF-10, PF-10X2, PF-11) will not
work with a PW355M/405M.
POWER WAVE 355M/405M
C-2
Return to Master TOC
D-1
TABLE OF CONTENTS - MAINTENANCE SECTION
D-1
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-1
Safety Precautions.......................................................................................................................................D-2
Capacitor Discharge Procedure ..................................................................................................................D-2
Visual Inspection..........................................................................................................................................D-2
Routine Maintenance...................................................................................................................................D-2
Major Component Locations .......................................................................................................................D-3
Return to Master TOC
Return to Master TOC
Return to Master TOC
Periodic Maintenance ..................................................................................................................................D-2
POWER WAVE 355M/405M
MAINTENANCE
Return to Master TOC
Return to Master TOC
Return to Section TOC
Return to Section TOC
D-2
D-2
VISUAL INSPECTION
WARNING
Have qualified personnel do the maintenance
work. Always use the greatest care when
working near moving parts.
Do not put your hands near the cooling blower
fan. If a problem cannot be corrected by
following the instructions, take the machine to
the nearest Lincoln Field Service Shop.
----------------------------------------------------------------------ELECTRIC SHOCK can kill.
• Do not touch electrically live parts or
electrode with skin or wet clothing.
• Insulate yourself from work and
ground
• Always wear dry insulating gloves.
------------------------------------------------------------------------
EXPLODING PARTS can cause
injury.
• Failed parts can explode or cause other
parts to explode when power is applied.
• Always wear a face shield and long sleeves
when servicing.
------------------------------------------------------------------------
See additional warning information
throughout this Manual.
Clean interior of machine with a low pressure air
stream. Make a thorough inspection of all components. Look for signs of overheating, broken leads or
other obvious problems. Many problems can be
uncovered with a good visual inspection.
ROUTINE MAINTENANCE
1. Every 6 months or so the machine should be
cleaned with a low pressure airstream. Keeping
the machine clean will result in cooler operation
and higher reliability. Be sure to clean these
areas:
•
•
•
•
•
•
•
All printed circuit boards
Power switch
Main transformer
Input rectifier
Auxiliary Transformer
Reconnect Switch Area
Fan (Blow air through the rear louvers)
2. Examine the sheet metal case for dents or breakage.
Repair the case as required. Keep the case in good
condition to insure that high voltage parts are protected
and correct spacings are maintained. All external sheet
metal screws must be in place to insure case strength
and electrical ground continuity.
------------------------------------------------------------------------
Return to Master TOC
Return to Section TOC
PERIODIC MAINTENANCE
CAPACITOR DISCHARGE PROCEDURE
1. Obtain a power resistor (25 ohms, 25 watts).
2. Hold resistor body with electrically insulated glove.
DO NOT TOUCH TERMINALS. Connect the resistor terminals across the two studs in the position
shown. Hold in each position for 1 second. Repeat
for all four capacitors.
Calibration is accomplished with our Diagnostic Utility
software found on the Lincoln Electric Service
Navigator CD or on our web site at www.lincolnelectric.com.
If a welder has difficulty in being calibrated some things
to look for proper configuration of the sense leads.
Make sure your meter is measuring at the same point
as the power source - local (studs) or remote (feeder).
Return to Master TOC
Return to Section TOC
RESISTOR
Calibration of the POWER WAVE 355M/405M is critical
to its operation. Generally speaking the calibration will
not need adjustment. However, neglected or improperly calibrated machines may not yield satisfactory weld
performance. To ensure optimal performance, the calibration of output Voltage and Current should be
checked yearly.
CAPACITOR
TERMINALS
3. Use a DC voltmeter to check that voltage is not
present across the terminals on all four capacitors.
All meters used for calibration checks must be calibrated and traceable to National Standards. Some digital
meters may not function properly with inverter supplies. Try an analog type meter and calibrate around
300 amps @ 30V loading in all cases.
POWER WAVE 355M/405M
Return to Master TOC
R
WE
1
ST
AT
US
MAL
TH
ER
LIN
C
ELOLN
EC
TR
IC
ON
Return to Section TOC
Return to Master TOC
PO
POWER WAVE 355M/405M
Return to Section TOC
35
5
P
Return to Master TOC
!
VE
WA
ER
OW
Return to Section TOC
rem ed do
Lo t, t
eli ree
lao
F
OF
W
WA ARN
IN
RN
G
IN
G
!
!
5
A
A T
PR VIS TEN
EC O D TIO
AU E N
CIO
N
y qu co ism t
lor mm ali et eu
do nu a am h era
gn
am
um no
sit y nib qu
ma
ips m e lor
ali
dia lor do mm a
nu gn
rem ed do
Lo t, t um no ma
eli ree ips m e
dia lor
lao
TE
MO
RE
g
cin
pis
ut
adi
nt
er
g
idu
tetu
cin
tinc
pis
sec od
ut
adi
con sm
nt
er
t
et eui
idu
g
am h
era tetu tinc
cin
nib
sit
sec od
pis
uam
or my
ut
adi
con sm
g
nt
dol um aliq et
t
er
eui
cin
idu
um non gna am h
era tetu
pis
tinc
ips m ma sit
nib
ut
adi
uam sec od
nt
em dia ore or my
er
con sm
idu
Lor , ed dol dol um aliq et
t tetu
eui
t um
tinc
non gna am h
erasec
elit
ree ips m ma
od
nib
sit
lao em dia
uamcon sm
g
t
ore or my
et eui
dol um aliq
Lor , ed dol
cin
am h
era
t
pis
um non gnasit
nib
elit
ut
ree ips
uam
adi
m maor my
nt
lao
er
em dia oredol um aliq
idu
g
tetu
Lor , ed dolum non gna
tinc
cin
t ips m
sec
pis
ma
od
elit
ree
ut
con sm
adi
em dia ore
g
nt
lao ed
t
et eui
er
cin
Lor ,
idu
t dol
am h
era tetu
pis
elit
ut
tinc
nib
sit
ree
adi
g
nt
uam sec od
or my
lao
er
cin
idu
dol um aliq con sm
g
tetu
t
et eui
pis
tinc
um non gna
ut
cin
h
sec
adi
am
era
od
nt
ips m ma
pis
er
nib
sit
con sm
ut
idu
adi
uam
em dia ore
or my
t tetu
et eui
nt
er
tinc
Lor , ed dol
dol um aliq
g
am h
erasec
idu
t
od
tetu
cin
nib
sit
elit
um non gna
tinc
ree
uamcon sm
pis
or my
sec od
ips m ma
t
et
ut
lao
adi
dol um aliq h eui
con sm
nt
em dia ore
am
era
ing
er
t
et
um
idu
eui
nib
g
Lor , ed dol
non gnasit
sc
am h
era tetu tinc
uam
ips m maor my
t
cin
ipi ut
elit
nib
sit
sec od
ree
pis
em dia ore dol um aliq
uam
ad t
or my
ut
lao
adi
r un
con sm
Lor , ed dolum non gna
nt
ing
dol um aliq et
t ips
t
er
ue cid
eui
m ma
idu
elit
sc
um non gna am h
ree
era tetu
tet tin
g
em dia ore
ipi ut
tinc
ips m ma sit
nib
lao
cin
ec
Lor , ed dol
uam sec od
ad t
or my
em dia
t
pis
r un
ore
ns od
con sm
elit
ut
Lor , ed dol dol um aliq et
adi
ree
t
co ism t ue cid
eui
nt
t um
er
lao
non gna am h
era
elit
et eu era tet tin
idu
ree ips m ma
nib
h
sit
tetu
ec
tinc
lao em dia
am
g
uam
sec od
ore or my
am ns od
cin
dol um aliq
sit y nib qu co ism t
Lor , ed dol
con sm
pis
t
um non gna
ut
t
elit
et eui
lor mm ali et eu
adi
ree
nt
ips
m ma
am h
era
do nu a am h era
er
g
lao
idu
nib
sit
em dia ore
gn
cin
am
tetu
uam
um no
sit y nib qu
or my
tinc
Lor , ed dol
pis
ma
sec od
ut
t
dol um aliq
ips m e lor
adi
ali
elit
nt
con sm
ree
er
um non gna
dia lor do mm a
idu
t
et eui
nu gn
lao
rem ed do
ips m ma
am h
era tetu tinc
Lo t, t um no ma
em dia ore
sec od
nib
sit
g
eli ree ips m e
uamcon
Lor , ed dol
or my
sm
t
cin
t
dol um aliq et eui
elit
lao rem dia lor
pis
ree
era
ut
um non gna am h
ed do
adi
lao
Lo t, t
nib
nt
ips m ma sit
er
uam
or my
idu
eli ree
em dia ore dol
tetu
um aliq
tinc
Lor , ed dol
lao
sec od
t um non gna
ing
elit
con sm
ree ips m ma
sc
t
et eui
lao em dia ore
ipi ut
am h
era
Lor , ed dol
ad t
nib
sit
t
r un
elit
uam
ing
or my
ree
ue cid
sc
dol um aliq
lao
tet tin
ipi ut
um non gna
ec
ad t
ips m ma
r un
ns od
em dia ore
co ism t ue cid
Lor , ed dol
et eu era tet tin
t
h
elit
ec
ree
am
am ns od
lao
sit nib
ING
RN
WA
Use parts page exploded views to also help isolate and identify smaller parts. Parts page numbers can be found on the Master Table of
Contents in the front of this manual.
FIGURE D.1 – MAJOR COMPONENT LOCATIONS
Return to Section TOC
Return to Master TOC
1. Center Panel
2. Case Back
3. Case Front
4. Base Assembly
5. Case Wraparound
D-3
MAINTENANCE
D-3
!
2
9
20
3
7
20
4
Return to Section TOC
Return to Master TOC
Return to Section TOC
Return to Master TOC
Return to Master TOC
Return to Section TOC
Return to Master TOC
Return to Section TOC
D-4
NOTES
POWER WAVE 355M/405M
D-4
TABLE OF CONTENTS-THEORY OF OPERATION SECTION
Return to Master TOC
E-1
E-1
Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-1
General Description ...................................................................................................................................E-2
Input Line Voltage, Auxiliary Transformer and Precharge..........................................................................E-2
Switch Board and Main Transformer .........................................................................................................E-3
DC Bus Board, Power board and Control Board ......................................................................................E-4
Output Rectifier and Choke .......................................................................................................................E-5
Thermal Protection ...................................................................................................................................E-6
Protective Circuits......................................................................................................................................E-6
Return to Master TOC
Over current Protection .......................................................................................................................E-6
Under/Over Voltage Protection ...........................................................................................................E-6
Insulated Gate Bipolar Transistor (IGBT) Operation ..................................................................................E-7
Pulse Width Modulation.............................................................................................................................E-8
Minimum/Maximum Output ................................................................................................................E-8
FIGURE E.1 BLOCK LOGIC DIAGRAM
To Control
Board
Main Switch Board
Current
Feedback
Return to Master TOC
Input switch
Primary
Current
Sensor
Choke
Primary
Current
Sensor
Fan
4
0
5
o
n
l
y
Power
Board
Soft Start Control
V/F Capacitor Feedback (2)
Machine Control Supply
+15VDC, -15VDC, +5VDC
Control Board
Status
Red/Green
LED
Can Supply +5VDC
DC
Bus
Board
Arc
Link
40VDC
Negative
Output
Terminal
Yellow
Thermal
LED
RS232 Supply +5VDC
42VAC
220
Receptacle
Fan Control
{
40VDC
65VAC
W
a
v
e
220 VAC
Auxiliary
Transformer
Input Relay Control
IGBT Drive Signal
Primary Current Feedback(2)
115VAC Fan Supply
Positive
Output
Terminal
Output Voltage Sense
Reconnect
Switch
P
o
w
e
r
Return to Master TOC
Input
Rectifier
Electrode
Sense
Wire
Feeder
Recp.
To
Feeder
POWER WAVE 355M/405M
21 Lead
Voltage
Sense
Recp.
Thermostats
2
R232
Connector
THEORY OF OPERATION
Return to Master TOC
FIGURE E.2 - GENERAL DISCRIPTION
Main Switch Board
E-2
To Control
Board
Current
Feedback
Input
Rectifier
Input switch
Primary
Current
Sensor
Choke
Reconnect
Switch
Primary
Current
Sensor
Fan
Return to Master TOC
4
0
5
o
n
l
y
40VDC
Power
Board
Machine Control Supply
+15VDC, -15VDC, +5VDC
Return to Master TOC
Control Board
Status
Red/Green
LED
Can Supply +5VDC
DC
Bus
Board
Arc
Link
40VDC
Negative
Output
Terminal
Yellow
Thermal
LED
RS232 Supply +5VDC
42VAC
220
Receptacle
Fan Control
{
Auxiliary
Transformer
Electrode
Sense
Wire
Feeder
Recp.
21 Lead
Voltage
Sense
Recp.
R232
Connector
Thermostats
2
To
GENERAL DESCRIPTION
The Power Wave semi-automatic power source is
designed to be a part of a modular, multi-process
welding system. Depending on configuration, it can
support constant current, constant voltage, and pulse
welding modes.
Return to Master TOC
Return to Section TOC
Return to Section TOC
Return to Section TOC
W
a
v
e
220 VAC
65VAC
P
o
w
e
r
Primary Current Feedback(2)
Input Relay Control
Soft Start Control
V/F Capacitor Feedback (2)
IGBT Drive Signal
115VAC Fan Supply
Positive
Output
Terminal
Output Voltage Sense
Return to Section TOC
E-2
The Power Wave power source is designed to be used
with the semi-automatic family of power feed wire
feeders, operating as a system. Each component in
the system has special circuitry to “talk with” the other
system components, so each component (power
source, wire feeder, user interface) knows what the
other is doing at all times. These components communicate with Arc Link (a digital communications system).
The POWER WAVE 355M/405M is a high performance,
digitally controlled inverter welding power source
capable of complex, high speed waveform control.
Properly equipped, it can support the GMAW, GMAWP, FCAW, SMAW, GTAW, and CAC-A processes. It carries an output rating of 350 Amps, 34 Volts at 60%
duty cycle and 300 Amps, 32 volts at 100% duty cycle.
INPUT LINE VOLTAGE, AUXILIARY
TRANSFORMER, & PRECHARGE
The POWER WAVE 355M/405M can be connected for
a variety of three-phase or single-phase input voltages. The initial power is applied to the 355M/405M
through a line switch located on the front of the
machine. Two phases of the input voltage are applied
to the auxiliary transformer. The auxiliary transformer
develops
The
Feeder three different secondary voltages.
115VAC is applied, via the main switch board, to the
fan motor. The 42VAC is rectified and filtered. The
65VDC produced by the Bus board rectifier is used by
the Bus board to provide 40VDC to the power board.
40VDC is also applied to the wire feeder receptacle.
PW405 models have an additional 220VAC winding
that is connected to a 220 AC receptacle.
The input voltage is rectified by the input rectifier and
the resultant DC voltage is applied to the switch board
through the reconnect switch assembly located at the
rear of the machine. The reconnect switch connects
the two pairs of input capacitors either in a parallel
(lower voltage) or series (higher voltage) configuration
to accommodate the applied input voltage.
During the precharge time the DC input voltage is
applied to the input capacitors through a current limiting circuit. The input capacitors are charged slowly
and current limited. A voltage to frequency converter
circuit located on the switch board monitors the
capacitor voltages. This signal is coupled to the control board. When the input capacitors have charged
to an acceptable level, the control board energizes the
input relays, that are located on the switch board,
making all of the input power, without current limiting,
available to the input capacitors. If the capacitors
become under or over voltage the control board will
de-energize the input relays and the 355M/405M output will be disabled. Other possible faults may also
cause the input relays to drop out.
NOTE: Unshaded areas of Block Logic
Diagram are the subject of discussion
POWER WAVE 355M/405M
THEORY OF OPERATION
E-3
Return to Master TOC
FIGURE E.3 – SWITCH BOARD & MAIN TRANSFORMER
To Control
Board
Main Switch Board
Current
Feedback
Input
Rectifier
Input switch
Primary
Current
Sensor
Choke
Reconnect
Switch
Primary
Current
Sensor
Fan
W
a
v
e
4
0
5
o
n
l
y
Auxiliary
Transformer
40VDC
Power
Board
Soft Start Control
V/F Capacitor Feedback (2)
Machine Control Supply
+15VDC, -15VDC, +5VDC
Control Board
Status
Red/Green
LED
Can Supply +5VDC
DC
Bus
Board
Arc
Link
40VDC
Negative
Output
Terminal
Yellow
Thermal
LED
RS232 Supply +5VDC
42VAC
220
Receptacle
Fan Control
{
220 VAC
65VAC
Return to Master TOC
Return to Section TOC
P
o
w
e
r
Primary Current Feedback(2)
Input Relay Control
IGBT Drive Signal
115VAC Fan Supply
Positive
Output
Terminal
Output Voltage Sense
Return to Section TOC
E-3
Electrode
Sense
Wire
Feeder
Recp.
21 Lead
Voltage
Sense
Recp.
R232
Connector
Thermostats
2
To
Feeder
Return to Master TOC
Return to Master TOC
Return to Section TOC
Return to Section TOC
SWITCH BOARD &
MAIN TRANSFORMER
There is one switch board in the POWER WAVE
355M/405M. This board incorporates two pairs of
input capacitors, two insulated gate bipolar transistor
(IGBT) switching circuits, a fan motor drive circuit, and
a voltage/frequency capacitor feedback circuit. The
two capacitors in a pair are always in series with each
other. When the reconnect switch is in the lower voltage position the capacitor pairs are in parallel - that is,
two series capacitors in parallel with two series capacitors. When the reconnect switch is in the high voltage
position the two capacitor pairs are in series or, four
capacitors in series. This is required to accommodate
the higher input voltages.
When the input capacitors are fully charged they act
as power supplies for the IGBT switching circuits.
When welding output is required the Insulated Gate
Bipolar Transistors switch the DC power from the input
capacitors, "on and off" thus supplying a pulsed DC
current to the main transformer primary windings. See
IGBT Operation Discussion and Diagrams in this
section. Each IGBT switching circuit feeds current to
a separate, oppositely wound primary winding in the
main transformer. The reverse directions of current
flow through the main transformer primaries and the
offset timing of the IGBT switching circuits induce an
AC square wave output signal at the secondary of the
main transformer. The two current transformers (CT)
located on the switch board monitor these primary
currents. If the primary currents become abnormally
high the control board will shut off the IGBTs, thus disabling the machine output. The DC current flow
through each primary winding is clamped back to
each respective input capacitor when the IGBTs are
turned off. This is needed due to the inductance of the
transformer primary winding. The firing of the two
switch boards occurs during halves of a 50 microsecond interval, creating a constant 20 KHZ output. In
some low open circuit Tig modes the firing frequency
is reduced to 5KHZ.
The POWER WAVE 355M/405M has a F.A.N. (fan as
needed) circuit. The fan operates when the welding
output terminals are energized or when a thermal over
temperature condition exists. Once the fan is activated it will remain on for a minimum of five minutes. The
fan driver circuit is housed on the switch board but it
is activated by a signal from the control board.
NOTE: Unshaded areas of Block Logic
Diagram are the subject of discussion
POWER WAVE 355M/405M
THEORY OF OPERATION
E-4
Return to Master TOC
FIGURE E.4 – POWER BOARD, CONTROL BOARD AND SERIAL PERIPHERAL INTERFACE (SPI) COMMUNICATIONS
To Control
Board
Main Switch Board
Current
Feedback
Return to Section TOC
E-4
Input
Rectifier
Input switch
Primary
Current
Sensor
Choke
Primary
Current
Sensor
W
a
v
e
4
0
5
o
n
l
y
Auxiliary
Transformer
40VDC
Power
Board
Soft Start Control
V/F Capacitor Feedback (2)
Machine Control Supply
+15VDC, -15VDC, +5VDC
Yellow
Thermal
LED
Control Board
RS232 Supply +5VDC
42VAC
220
Receptacle
Fan Control
{
220 VAC
Status
Red/Green
LED
Can Supply +5VDC
65VAC
Return to Master TOC
P
o
w
e
r
Primary Current Feedback(2)
Input Relay Control
IGBT Drive Signal
Return to Section TOC
Fan
115VAC Fan Supply
DC
Bus
Board
Arc
Link
40VDC
Negative
Output
Terminal
Output Voltage Sense
Reconnect
Switch
Positive
Output
Terminal
Electrode
Sense
Wire
Feeder
Recp.
21 Lead
Voltage
Sense
Recp.
R232
Connector
Thermostats
2
Return to Master TOC
Return to Section TOC
To
Feeder
DC BUS BOARD, POWER BOARD
AND CONTROL BOARD
DC BUS BOARD
The DC Bus Board receives approximately 65VDC
from the bus board rectifier. The DC Bus Board regulates that 65VDC to a +40VDC supply. This regulated
40VDC is applied to the Power Board and the wire
feed receptacles.
Return to Master TOC
Return to Section TOC
POWER BOARD
The power board, utilizing a switching power supply,
processes the 40VDC input and develops several regulated positive and negative DC supplies. Three DC
supplies are fed to the control board for machine control supplies. A +5VDC is used for the RS232 connection supply. Another +5VDC supply is utilized by the
CAN digital communication circuitry. An over or under
input voltage detection and shutdown circuit is also
part of the power board’s circuitry.
CONTROL BOARD
The Control Board performs the primary interfacing
functions to establish and maintain output control of
the POWER WAVE 355M/405M. The function generator and weld files exist within the Control Board hardware and software. Digital command signals received
from the user interface/feed head and feedback information received from the current sensor and output
voltage sensing leads, are processed at the control
board. Software within the control board processes
the command and feedback information and sends the
appropriate pulse width modulation (PWM) signals
(See PULSE WIDTH MODULATION in this section) to
the switch board IGBT’s. In this manner, the digitally
controlled high speed welding waveform is created.
In addition, the Control Board monitors the thermostats, the main transformer primary currents and
input filter capacitor voltages. Depending on the fault
condition, the Control Board will activate the thermal
and/or the status light and will disable or reduce the
machine’s output.
NOTE: Unshaded areas of Block Logic
Diagram are the subject of discussion
POWER WAVE 355M/405M
THEORY OF OPERATION
E-5
Return to Master TOC
FIGURE E.5 – OUTPUT RECTIFIER AND CHOKE
To Control
Board
Main Switch Board
Current
Feedback
Return to Section TOC
E-5
Input
Rectifier
Input switch
Primary
Current
Sensor
Choke
Primary
Current
Sensor
W
a
v
e
4
0
5
o
n
l
y
Auxiliary
Transformer
40VDC
Power
Board
Soft Start Control
V/F Capacitor Feedback (2)
Machine Control Supply
+15VDC, -15VDC, +5VDC
Yellow
Thermal
LED
Control Board
RS232 Supply +5VDC
42VAC
220
Receptacle
Fan Control
{
220 VAC
DC
Bus
Board
Arc
Link
40VDC
Electrode
Sense
Wire
Feeder
Recp.
21 Lead
Voltage
Sense
Recp.
Thermostats
2
Return to Section TOC
Return to Master TOC
Return to Master TOC
To
Feeder
Return to Section TOC
Status
Red/Green
LED
Can Supply +5VDC
65VAC
Return to Master TOC
P
o
w
e
r
Primary Current Feedback(2)
Input Relay Control
IGBT Drive Signal
Return to Section TOC
Fan
115VAC Fan Supply
Negative
Output
Terminal
Output Voltage Sense
Reconnect
Switch
Positive
Output
Terminal
OUTPUT RECTIFIER AND CHOKE
The output rectifier receives the AC output from the
main transformer secondary and rectifies it to a DC
voltage level. Since the output choke is in series with
the negative leg of the output rectifier and also in
series with the welding load, a filtered DC output is
applied to the machine’s output terminals.
NOTE: Unshaded areas of Block Logic
Diagram are the subject of discussion
POWER WAVE 355M/405M
R232
Connector
Return to Master TOC
Return to Master TOC
Return to Section TOC
Return to Section TOC
E-6
THEORY OF OPERATION
THERMAL PROTECTION
OVER CURRENT PROTECTION
Three normally closed (NC) thermostats protect the
machine from excessive operating temperatures.
These thermostats are wired in series and are connected to the control board. One of the thermostats is
located on the heat sink of the switch board, one is
located on the output choke and the third thermostat
is located on the DC Bus Board. Excessive temperatures may be caused by a lack of cooling air or operating the machine beyond its duty cycle or output rating. If excessive operating temperatures should occur,
the thermostats will prevent output from the machine.
The yellow thermal light, located on the front of the
machine, will be illuminated. The thermostats are selfresetting once the machine cools sufficiently. If the
thermostat shutdown was caused by excessive output
or duty cycle and the fan is operating normally, the
power switch may be left on and the reset should
occur within a 15-minute period. If the fan is not turning or the air intake louvers are obstructed, then the
power must be removed from the machine, and the
fan problem or air obstruction corrected.
If the average current exceeds 450 amps for one second, then the output will be limited to 100 amps until
the load is removed. If the peak current exceeds 600
amps for 150 ms, the output will be limited to 100
amps until the load is removed.
PROTECTIVE CIRCUITS
UNDER/OVER VOLTAGE PROTECTION
Protective circuits are included on the switch and control boards to monitor the voltage across the input
capacitors. In the event that a capacitor pair voltage
is too high, or too low, the machine output will be disabled. The protection circuits will prevent output if any
of the following conditions exist.
1. Voltage across a capacitor pair exceeds 467
volts. (High line surges or improper input voltage
connections.)
2. Voltage across a capacitor pair is under 190 volts.
(Due to improper input voltage connections.)
3. Any major internal component damage.
Return to Section TOC
Return to Master TOC
Return to Master TOC
Protective circuits are designed into the POWER
WAVE 355M/405M to sense trouble and shut down
the machine before damage occurs to the machine's
internal components.
Return to Section TOC
E-6
POWER WAVE 355M/405M
THEORY OF OPERATION
Return to Master TOC
Return to Section TOC
E-7
INSULATED GATE BIPOLAR
TRANSISTOR (IGBT)
OPERATION
An IGBT is a type of transistor. IGBT are semiconductors well suited for high frequency switching and high
current applications.
E-7
capable of conducting current. A voltage supply connected to the drain terminal will allow the IGBT to conduct and supply current to the circuit components
coupled to the source. Current will flow through the
conducting IGBT to downstream components as long
as the positive gate signal is present. This is similar to
turning ON a light switch.
Return to Master TOC
Return to Section TOC
Example A in Figure E.6 shows an IGBT in passive
mode. There is no gate signal, zero volts relative to the
source, and therefore, no current flow. The drain terminal of the IGBT may be connected to a voltage supply; but since there is no conduction, the circuit will not
supply current to components connected to the
source. The circuit is turned OFF like a light switch.
Example B shows the IGBT in an active mode. When
the gate signal , a positive DC voltage relative to the
source, is applied to the gate terminal of the IGBT, it is
FIGURE E.6 – IGBT
POSITIVE
VOLTAGE
APPLIED
GATE
GATE
SOURCE
SOURCE
Return to Section TOC
Return to Master TOC
Return to Section TOC
Return to Master TOC
n+
n+
n+
n+
p
BODY REGION
p
BODY REGION
n-
DRAIN DRIFT REGION
n-
DRAIN DRIFT REGION
n+
BUFFER LAYER
n+
BUFFER LAYER
p+
INJECTING LAYER
p+
INJECTING LAYER
DRAIN
DRAIN
B. ACTIVE
A. PASSIVE
POWER WAVE 355M/405M
Return to Section TOC
Return to Master TOC
Return to Section TOC
Return to Master TOC
E-8
THEORY OF OPERATION
FIGURE E.7 — TYPICAL IGBT OUTPUTS.
Return to Master TOC
Return to Section TOC
PULSE WIDTH
MODULATION
MAXIMUM OUTPUT
The term Pulse Width Modulation is used to describe
how much time is devoted to conduction in the positive and negative portions of the cycle. Changing the
pulse width is known as modulation. Pulse Width
Modulation (PWM) is the varying of the pulse width
over the allowed range of a cycle to affect the output
of the machine.
By holding the gate signal on for 24 microseconds
each, and allowing only two microseconds of dwell
time (off time) during the 50-microsecond cycle, the
output is maximized. The darkened area under the top
curve can be compared to the area under the bottom
curve. The more dark area that is under the curve indicates that more power is present.
1An IGBT group consists of two IGBT modules feeding one transformer primary winding.
MINIMUM OUTPUT
By controlling the duration of the gate signal, the IGBT
is turned on and off for different durations during the
cycle. The top drawing in Figure E.7 shows the minimum output signal possible over a 50-microsecond
time period.
Return to Master TOC
The positive portion of the signal represents one IGBT
group1 conducting for one microsecond. The negative
Return to Section TOC
E-8
portion is the other IGBT group1. The dwell time (off
time) is 48 microseconds (both IGBT groups off). Since
only two microseconds of the 50-microsecond time
period is devoted to conducting, the output power is
minimized.
POWER WAVE 355M/405M
Return to Master TOC
F-1
TABLE OF CONTENTS - TROUBLESHOOTING AND REPAIR
Troubleshooting and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-1
How to Use Troubleshooting Guide..........................................................................................................F-2
PC Board Troubleshooting Procedures and Replacement.......................................................................F-3
Troubleshooting Guide .............................................................................................................................F-4
Test Procedures
Return to Master TOC
Input Filter Capacitor Discharge Procedure .....................................................................................F-13
Main Switch Board Test....................................................................................................................F-15
Input Rectifier Test............................................................................................................................F-19
Power Board Test .............................................................................................................................F-23
DC Bus Board Test ...........................................................................................................................F-27
Output Rectifier Modules Test ..........................................................................................................F-31
Auxiliary Transformer Test.................................................................................................................F-35
Current Transducer Test ...................................................................................................................F-39
Fan Control and Motor Test..............................................................................................................F-43
Return to Master TOC
Replacement Procedures
Control Board Removal and Replacement.......................................................................................F-47
Main Switch Board Removal and Replacement...............................................................................F-51
Snubber Board Removal and Replacement.....................................................................................F-55
Power Board Removal and Replacement ........................................................................................F-57
DC Bus Board Removal and Replacement ......................................................................................F-61
Input Rectifier Removal and Replacement.......................................................................................F-65
Output Rectifier Modules Removal and Replacement.....................................................................F-69
Current Transducer Removal and Replacement ..............................................................................F-73
Return to Master TOC
F-1
Retest after Repair............................................................................................................................F-78
POWER WAVE 355M/405M
Return to Master TOC
Return to Section TOC
F-2
TROUBLESHOOTING AND REPAIR
HOW TO USE TROUBLESHOOTING GUIDE
WARNING
Service and Repair should only be performed by Lincoln Electric Factory Trained
Personnel. Unauthorized repairs performed on this equipment may result in danger to
the technician and machine operator and will invalidate your factory warranty. For your
safety and to avoid Electrical Shock, please observe all safety notes and precautions
detailed throughout this manual.
---------------------------------------------------------------------------------------------------------------------------
Return to Master TOC
Return to Master TOC
Return to Master TOC
Return to Section TOC
Return to Section TOC
Return to Section TOC
This Troubleshooting Guide is provided to
help you locate and repair possible machine
malfunctions. Simply follow the three-step
procedure listed below.
Step 1. LOCATE PROBLEM (SYMPTOM).
Look under the column labeled “PROBLEM
(SYMPTOMS)”. This column describes possible symptoms that the machine may exhibit. Find the listing that best describes the
symptom that the machine is exhibiting.
Symptoms are grouped into the following
categories: output problems, function problems, wire feeding problems, and welding
problems.
Step 2. PERFORM EXTERNAL TESTS.
The second column labeled “POSSIBLE
AREAS OF MISADJUSTMENT(S)” lists the
obvious external possibilities that may contribute to the machine symptom. Perform
these tests/checks in the order listed. In
general, these tests can be conducted without removing the case wrap-around cover.
Step 3. RECOMMENDED
COURSE OF ACTION
The last column labeled “Recommended
Course of Action” lists the most likely components that may have failed in your
machine. It also specifies the appropriate
test procedure to verify that the subject component is either good or bad. If there are a
number of possible components, check the
components in the order listed 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 chapter.
Refer to the Troubleshooting and Repair
Table of Contents to locate each specific
Test Procedure. All of the specified test
points, components, terminal strips, etc. can
be found on the referenced electrical wiring
diagrams and schematics. Refer to the
Electrical Diagrams Section Table of
Contents to locate the appropriate diagram.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the
tests/repairs safely, contact the Lincoln Electric Service Department for technical troubleshooting
assistance before you proceed. Call 1-888-935-3877.
-----------------------------------------------------------------------------------------------------------------------------------
POWER WAVE 355M/405M
F-2
TROUBLESHOOTING AND REPAIR
Return to Master TOC
Return to Section TOC
F-3
PC BOARD TROUBLESHOOTING PROCEDURES
WARNING
ELECTRIC SHOCK
can kill.
• Have an electrician install and
service this equipment. Turn the
input power OFF at the fuse box
before working on equipment. Do
not touch electrically hot parts.
Return to Master TOC
Return to Section TOC
CAUTION
Sometimes machine failures appear to be due to PC
board failures. These problems can sometimes be
traced to poor electrical connections. To avoid problems when troubleshooting and replacing PC boards,
please use the following procedure:
1. Determine to the best of your technical ability
that the PC board is the most likely component
causing the failure symptom.
2. Check for loose connections at the PC board to
assure that the PC board is properly connected.
Return to Master TOC
Return to Master TOC
Return to Section TOC
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:
Return to Section TOC
F-3
PC board can be damaged by static electricity.
ATTENTION
Static-Sensitive
Devices
Handle only at
Static-Safe
Workstations
- Remove your body’s static
charge before opening the staticshielding bag. Wear an anti-static
wrist strap. For safety, use a 1 Meg
ohm resistive cord connected to a
grounded part of the equipment
frame.
- If you don’t have a wrist strap,
touch an un-painted, 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.
- Remove the PC board from the static-shielding bag
and place it directly into the equipment. Don’t set the
PC board on or near paper, plastic or cloth which
could have a static charge. If the PC board can’t be
installed immediately, put it back in the static-shielding bag.
- If the PC board uses protective shorting jumpers,
don’t remove them until installation is complete.
- If you return a PC board to The Lincoln Electric
Company for credit, it must be in the static-shielding
bag. This will prevent further damage and allow proper failure analysis.
4. Test the machine to determine if the failure
symptom has been corrected by the
replacement PC board.
NOTE: It is desirable to have a spare (known good)
PC board available for PC board troubleshooting.
NOTE: Allow the machine to heat up so that all
electrical components can reach their 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 repor ts 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.
- Tools which come in contact with the PC board must
be either conductive, anti-static or static-dissipative.
POWER WAVE 355M/405M
TROUBLESHOOTING AND REPAIR
F-4
Return to Master TOC
PROBLEMS
(SYMPTOMS)
Return to Master TOC
Return to Master TOC
Return to Section TOC
RECOMMENDED
COURSE OF ACTION
Major physical or electrical damage
is evident when the sheet metal
cover is removed.
1. Contact the Lincoln Electric
Service Department,
1-888-935-3877.
The machine is dead—no output—
no LED’s.
1. Make sure the input line switch is
in the ON position.
1. Perform the Auxiliary Transformer Test.
2. Check the main input line fuses.
If open , replace.
2. Perform the DC Bus Board Test.
3. Check the 15 amp circuit breaker (CB1). Reset if tripped. Also
check CB3.
4. Make sure the reconnect switch
and jumper lead is configured
correctly for the applied input
voltage.
2. Perform the Power Board Test.
3. The Bus Board rectifier and or
associated filter capacitor (C5)
may be faulty.
Check and
replace as necessary.
4. The Control Board may be faulty.
5. If the machine is being operated
with single phase input voltage
make sure the correct lead is not
connected. See the Installation
Section.
The main input fuses (or breaker)
repeatedly fail.
Return to Section TOC
POSSIBLE AREAS OF
MISADJUSTMENT(S)
OUTPUT PROBLEMS
1. Contact your local authorized
Lincoln Electric Field Service
Facility for technical assistance.
Return to Master TOC
Return to Section TOC
Return to Section TOC
Observe Safety Guidelines detailed in the beginning of this manual.
F-4
1. Make certain the fuses or breakers are sized properly.
2. Make sure the reconnect switch
and jumper lead is configured
correctly for the applied input
voltage.
3. The welding procedure may be
drawing too much input current
or the duty cycle may be too
high. Reduce the welding current and /or reduce the duty
cycle.
1. Check the reconnect switches
and associated wiring. See the
Wiring Diagram.
2. Perform the Input Rectifier
Test.
3. Perform the Main Switch Board
Test.
4. Perform the
Module Test.
Output
Diode
5. The Input Filter Capacitors may
be faulty. Check, and if any are
faulty replace all four.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely,
contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed.
Call 1-888-935-3877.
POWER WAVE 355M/405M
TROUBLESHOOTING AND REPAIR
F-5
Return to Master TOC
PROBLEMS
(SYMPTOMS)
The machine does not have welding output.
POSSIBLE AREAS OF
MISADJUSTMENT(S)
OUTPUT PROBLEMS
1. Make sure the reconnect switch
is configured correctly for the
input voltage applied.
2. Primary current limit has been
exceeded. Possible short in
output circuit. Turn machine
off. Remove all loads from the
output of the machine. Turn
back on. If condition persists,
turn power off, and contact an
authorized Lincoln Electric Field
Service Facility.
Return to Master TOC
Return to Section TOC
Return to Section TOC
Observe Safety Guidelines detailed in the beginning of this manual.
3. This problem will normally be
accompanied by an error code.
Error codes are displayed as a
series of red and green flashes
by the status LED.
4. If an error code is displayed
see Fault Code Explanations.
If thermal light is on, wait for
machine to cool.
Return to Master TOC
Return to Section TOC
The POWER WAVE 355M/405M
will not produce full output.
1. The input voltage may be too
low, limiting the output capability of the machine. Make certain the input voltage is correct
for the machine and the reconnect switch and jumper lead
configuration are correct.
2. The output current or voltage
may not be calibrated correctly.
Check the values displayed on
the Power Feed 10/11 versus
readings on an external voltage
and ammeter.
F-5
RECOMMENDED
COURSE OF ACTION
1. Check the reconnect switch and
associated leads for loose or
faulty connections. See the
wiring diagram.
2. Perform the DC Bus Board
Test.
3. Perform the Main Switch
Board Test.
4. Perform the Power Board
Test.
5. Perform the Output Diode
Module Test.
6. The control board may be faulty.
7. The input filter capacitors may
be faulty. Check and replace if
necessary.
1. Perform the Output Rectifier
Test.
2. Perform the Main Switch
Board Test.
3. Perform the Power Board
Test.
4. Perform the Current
Transducer Test.
5. The control board may be
faulty.
Return to Master TOC
Return to Section TOC
3. The welding current may be too
high . The machine will fold
back to 100 amps if the welding current exceeds 450 amps.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely,
contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed.
Call 1-888-935-3877.
POWER WAVE 355M/405M
TROUBLESHOOTING AND REPAIR
F-6
Return to Master TOC
Return to Section TOC
Observe Safety Guidelines detailed in the beginning of this manual.
PROBLEMS
(SYMPTOMS)
The machine regularly overheats
and the yellow thermal light is ON
indicating a thermal overload.
POSSIBLE AREAS OF
MISADJUSTMENT(S)
FUNCTION PROBLEMS
1. The welding application may
be exceeding the recommended
duty cycle of the POWER WAVE
355M/405M.
3. Air intake and exhaust louvers
may be blocked due to inadequate clearance around the
machine.
Return to Master TOC
Return to Section TOC
2. Dirt and dust may have clogged
the cooling channels inside the
machine.
4. Make certain the fan as needed
(F.A.N.) is operating properly.
The fan should operate when
welding voltage is present
and/or when there is an over
temperature condition.
Return to Section TOC
Return to Master TOC
Return to Section TOC
Return to Master TOC
An attached wire feeder will not
function correctly. Apparently the
wire feeder is not being poweredup.
F-6
RECOMMENDED
COURSE OF ACTION
1. The 115VAC fan motor is controlled by the control board via
the main switch board. Perform
the Fan Motor And Control
Test.
1. A thermostat or associated circuitry may be faulty. See the
wiring diagram. One normally
closed thermostat is located on
the output choke, one on the DC
Bus Board and the other is
located on the main switch
board heat sink. See the wiring
diagram.
Note: The Main Switch Board
Removal Procedure will be
required to gain access to
the heat sink thermostat.
1. Make certain the wire feeder
control cable is connected to
the wire feeder receptacle. See
the Wiring Diagram.
1. Check for 40 VDC on pin “D” (+)
and pin “E” (-) at the Power Wave
wire feeder receptacle. See
Wiring Diagram.
2. Check the two circuit breakers
located at the front of the
machine. Reset if tripped.
If 40 volts DC is Not present at
the Power Wave wire feeder
receptacle, perform the DC Bus
Board Test.
3. The wire feeder or control cable
may be faulty.
2. Check the DC Bus Board rectifier. See Wiring Diagram.
3. Perform the T1 Auxiliary transformer Test.
4. If the 40 volts DC is present at
the Power Wave wire feeder
receptacle, the problem is in the
control cable or the wire
drive/control box.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely,
contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed.
Call 1-888-935-3877.
POWER WAVE 355M/405M
TROUBLESHOOTING AND REPAIR
F-7
Return to Master TOC
Return to Master TOC
Return to Master TOC
Return to Master TOC
Return to Section TOC
Return to Section TOC
Return to Section TOC
Return to Section TOC
Observe Safety Guidelines detailed in the beginning of this manual.
PROBLEMS
(SYMPTOMS)
POSSIBLE AREAS OF
MISADJUSTMENT(S)
FUNCTION PROBLEMS
F-7
RECOMMENDED
COURSE OF ACTION
The machine often “noodle welds”
with a particular procedure. 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 a maximum limit, the
machine will “phase back” to
protect itself. Adjust the procedure or reduce the load to lower
the current draw from the Power
Wave machine.
1. Perform
the
Transducer Test.
Current
Excessively long and erratic arc.
1. Check for proper configuration
and implementation of voltage
sensing circuits.
1. Check the connections between
the voltage sense receptacle
and the control board. See the
Wiring Diagram.
2. The control board may be faulty.
2. The control board may be faulty.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely,
contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed.
Call 1-888-935-3877.
POWER WAVE 355M/405M
TROUBLESHOOTING AND REPAIR
F-8
Return to Master TOC
Return to Section TOC
Observe Safety Guidelines detailed in the beginning of this manual.
PROBLEMS
(SYMPTOMS)
Auxiliary receptacle is “dead” no
auxiliary voltage.
POSSIBLE AREAS OF
MISADJUSTMENT(S)
FUNCTION PROBLEMS
1. Circuit breaker CB1 (on case
front) may have opened. Reset.
F-8
RECOMMENDED
COURSE OF ACTION
1. Perform the Auxiliary
Transformer Test.
2. Circuit breaker CB3 (in reconnect area) may have opened.
Reset.
Return to Master TOC
Return to Section TOC
3. On PW 405 models, the circuit
breaker CB4 protects the
220VAC receptacle. Reset if
tripped.
A fault or error code is displayed.
1. See Fault Code Explanations.
1. See Fault Code Explanations.
General degradation of the weld
performance.
1. Check for feeding problems,
bad connections, excessive
loops in cabling, etc.
1. Perform the Voltage and
Current Calibration Procedure
using the Power Wave software
program.
2. Verify weld mode is correct for
processes.
Return to Master TOC
Return to Section TOC
3. The power source may require
calibration.
4. Check the actual current displayed on the Power Feed 10
vs. actual current measured via
external meter.
2. Perform the Current
Transducer Test.
2. Perform the Output Diode
Module Test.
5. The control board may be
faulty.
5. Check the actual voltage displayed on the Power Feed 10
vs. actual voltage measured via
external meter.
Return to Master TOC
Return to Section TOC
6. Check the actual WFS displayed
on the Power Feed 10 vs. actual
WFS measured via external
meter.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely,
contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed.
Call 1-888-935-3877.
POWER WAVE 355M/405M
Return to Master TOC
Return to Master TOC
TROUBLESHOOTING AND REPAIR
USING THE STATUS LED TO
TROUBLESHOOT SYSTEM PROBLEMS
The Power Wave / Power Feed are best diagnosed as
a system. Each component (power source, user
interface, and feed head) has a status light, and when
a problem occurs it is important to note the condition
of each. In addition, errors displayed on the user
interface in most cases indicate only that a problem
exists in the power source, not what the problem may
be. Therefore, prior to cycling power to the system, check the power source status light for error
sequences as noted below. This is especially
important if the user interface displays “Err 006”
or “Err 100”.
Included in this section is information about the
F-9
power source Status LED, and some basic troubleshooting charts for both machine and weld performance.
The STATUS LIGHT is a two color light that indicates
system errors. Normal operation is a steady green
light. Error conditions are indicated in the following
chart.
NOTE: The POWER WAVE 355M/405M status light
will flash green, and sometimes red and green, for up
to one minute when the machine is first turned on.
This is a normal situation as the machine goes
through a self test at power up.
LIGHT CONDITION
INDICATION
Status LED is solid green (no blinking)
1. System OK. Power source communicating normally with wire feeder and its components.
Status LED is blinking green
2. Occurs during a reset, and indicates the
POWER WAVE 355M/405M is mapping (identifying) each component in the system. Normal
for first 1-10 seconds after power is turned on,
or if the system configuration is changed during
operation.
Status LED is blinking red and green
3. Non-recoverable system fault. If the PS Status
light is flashing any combination of red and
green, errors are present in the POWER WAVE
355M/405M. Read the error code before the
machine is turned off.
Return to Master TOC
Return to Section TOC
Return to Section TOC
Return to Section TOC
F-9
Error Code interpretation through the Status
light is detailed in the Service Manual.
Individual code digits are flashed in red with a
long pause between digits. The codes will be
separated by a green light. There may be more
than one error code indicated.
Return to Master TOC
Return to Section TOC
To clear the error, turn power source off, and
back on to reset.
Status LED is solid red (no blinking).
Non-recoverable hardware fault. Generally indicates nothing is connected to the POWER
WAVE 355M/405M wire feeder receptacle. See
Trouble Shooting Section.
Status LED is blinking red.
Not applicable
POWER WAVE 355M/405M
TROUBLESHOOTING AND REPAIR
Return to Master TOC
Return to Section TOC
F-10
F-10
ERROR CODES FOR THE POWER WAVE
The following is a list of possible error codes that the POWER WAVE 355M/405M can output via the status light
If connected to a PF-10/11 these error codes will generally be accompanied by an “Err 006” or “Err 100” on the
user interface display.
Individual code digits are flashed in RED with a long pause between digits. Complete codes are seprated by one
GREEN light. There may be more than one error code indicated
Example: Error code 31
- Red, red, red pause, red, green.
Error codes 32 & 34 - Red, red, red, pause Red,red, Green, Red,red,red, pause
Red,red,red,red, Green. Sequence will repeat continuously.
Return to Master TOC
Return to Master TOC
Return to Master TOC
Return to Section TOC
Return to Section TOC
Return to Section TOC
STATUS LED ERROR CODE TABLE
11
CAN communication bus off.
Probably due to excessive number of communication errors.
12
User interface time out error.
UI is no longer responding to the Power Source. The most
likely cause is a fault/bad connection in the communication
leads or control cable.
21
Unprogrammed weld mode.
Contact the service department for instructions on reloading
the Welding Software.
22
Empty weld table.
Contact the service department for instructions on reloading
the Welding Software.
23
Weld table checksum error.
Contact the service department for instructions on reloading
the Welding Software.
31
Primary overcurrent error.
Excessive Primary current present. May be related to a
short in the main transformer or output rectifier.
32
Capacitor “A” under voltage.
Low voltage on the main capacitors. May be caused by
improper input configuration.
33
Capacitor “B” under voltage.
When accompanied by an overvoltage error on the same
side, it indicates no capacitor voltage present on that side,
and is usually the result of an open or short in the primary
side of the machine.
34
Capacitor “A” overvoltage.
Excessive voltage on the main capacitors. May be caused
by improper input configuration.
35
Capacitor “B” overvoltage.
When accompanied by an under voltage error on the same
side, it indicates no capacitor voltage present on that side,
and is usually the result of an open or short in the primary
side of the machine.
36
Thermal error.
Indicates over temperature. Usually accompanied by thermal LED. Check fan operation. Be sure process does not
exceed duty cycle limit of the machine.
37
Softstart error.
Capacitor precharge failed. Usually accompanied by codes
32-35.
41
Secondary overcurrent error
The secondary (weld) current limit has been exceeded.
When this occurs the machine output will phase back to
100 amps, typically resulting in a condition referred to as
“noodle welding”
NOTE: The secondary limit is 570 for the standard stud, and
325 amps for all single phase operation.
POWER WAVE 355M/405M
Return to Master TOC
43
Other
TROUBLESHOOTING AND REPAIR
Capacitor delta error.
Return to Master TOC
Return to Master TOC
F-11
The maximum voltage difference between the main capacitors has been exceeded. May be accompanied by errors
32-35. Check the output diodes.
Error codes that contain three or four digits are defined as
fatal errors. These codes generally indicate internal errors
on the Control Board. If cycling the input power on the
machine does not clear the error, try reloading the operating
system. If this fails, replace the Control Board.
Return to Master TOC
Return to Section TOC
Return to Section TOC
Return to Section TOC
Return to Section TOC
F-11
POWER WAVE 355M/405M
Return to Section TOC
Return to Master TOC
Return to Section TOC
Return to Master TOC
Return to Master TOC
Return to Section TOC
Return to Master TOC
Return to Section TOC
F-12
NOTES
POWER WAVE 355M/405M
F-12
Return to Master TOC
Return to Section TOC
F-13
TROUBLESHOOTING AND REPAIR
INPUT FILTER CAPACITOR DISCHARGE PROCEDURE
WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician
or machine operator and will invalidate your factory warranty. For your safety and to avoid
electrical shock, please observe all safety notes and precautions detailed throughout this
manual.
Return to Master TOC
Return to Section TOC
If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.
TEST DESCRIPTION
This procedure will drain off any charge stored in the four large capacitors that are part
of the switch board assembly. This procedure MUST be performed, as a safety precaution, before conducting any test or repair procedure that requires you to touch internal components of the machine.
MATERIALS NEEDED
Return to Section TOC
Return to Master TOC
Return to Section TOC
Return to Master TOC
5/16” Nut Driver
Insulated Pliers
Insulated Gloves
High Wattage Resistor (25-1000 ohms and 25 watts minimum)
DC Volt Meter
POWER WAVE 355M/405M
F-13
Return to Master TOC
Return to Section TOC
F-14
TROUBLESHOOTING AND REPAIR
INPUT FILTER CAPACITOR DISCHARGE PROCEDURE (continued)
WARNING
ELECTRIC SHOCK can kill.
• Have an electrician install and service
this equipment.
• Turn the input power off at the fuse box
before working on equipment.
• Do not touch electrically hot parts.
Return to Master TOC
• Prior to performing preventative maintenance,
perform the following capacitor discharge procedure
to avoid electric shock.
Return to Section TOC
F-14
4. Obtain a high resistance and high wattage resistor
(25-1000 ohms and 25 watts minimum). This
resistor is not with the machine. NEVER USE A
SHORTING STRAP FOR THIS PROCEDURE.
5. Locate the eight capacitor terminals shown in figure F.1.
6. Using electrically insulated gloves and pliers, hold
the body of the resistor with the pliers and connect the resistor leads across the two capacitor
terminals. Hold the resistor in place for 10 seconds. DO NOT TOUCH CAPACITOR TERMINALS
WITH YOUR BARE HANDS.
7. Repeat the discharge procedure for the other
three capacitors.
DISCHARGE PROCEDURE
1. Remove the input power to the POWER WAVE
355M/405M.
2. Using the 5/16” wrench remove the screws from
the case wraparound cover.
3. Be careful not to make contact with the capacitor
terminals located at the top and bottom of the
switch board.
8. Check the voltage across the terminals of all
capacitors with a DC voltmeter. Polarity of the
capacitor terminals is marked on the PC board
above the terminals. Voltage should be zero. If
any voltage remains, repeat this capacitor discharge procedure.
Return to Master TOC
Return to Section TOC
FIGURE F.1 – LOCATION OF INPUT FILTER CAPACITOR TERMINALS
EIGHT
CAPACITOR
TERMINALS
-
+
-
+
INSULATED
PLIERS
Return to Master TOC
Return to Section TOC
-
+
-
+
POWER
RESISTOR
POWER WAVE 355M/405M
INSULATED
GLOVES
Return to Master TOC
Return to Section TOC
F-15
TROUBLESHOOTING AND REPAIR
MAIN SWITCH BOARD TEST
WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician
or machine operator and will invalidate your factory warranty. For your safety and to avoid
electrical shock, please observe all safety notes and precautions detailed throughout this
manual.
Return to Master TOC
Return to Section TOC
If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.
TEST DESCRIPTION
This test will help determine if the “power section” of the switch boards are functioning
correctly. This test will NOT indicate if the entire PC board is functional. This resistance
test is preferable to a voltage test with the machine energized because this board can be
damaged easily. In addition, it is dangerous to work on this board with the machine energized.
MATERIALS NEEDED
Return to Section TOC
Return to Master TOC
Return to Section TOC
Return to Master TOC
Analog Volt/Ohmmeter
5/16 in. Wrench
7/16 in. Wrench
POWER WAVE 355M/405M
F-15
TROUBLESHOOTING AND REPAIR
FIGURE F.2 MAIN SWITCH BOARD LEAD LOCATIONS
202
207
J22
Return to Master TOC
Return to Section TOC
-
+
-
204
205
208
J21
J20
+
-
Return to Master TOC
TEST PROCEDURE
1. Remove input power to the POWER WAVE
355M/405M.
2. Using a 5/16” nut driver, remove the case
wraparound.
3. Perform the Input Filter Capacitor Discharge
Procedure detailed earlier in this section.
207
Return to Master TOC
+
206
203
Return to Section TOC
+
209
201
-
Return to Section TOC
F-16
MAIN SWITCH BOARD TEST (continued)
Return to Master TOC
Return to Section TOC
F-16
4. Using a 7/16” wrench locate, label and remove
leads 201, 202, 203, 204, 205, 206, 207 and
208 from the switch board. Note lead and
washer placement for reassembly. Clear
leads.
5. Using the Analog ohmmeter, perform the resistance tests detailed in Table F.1. Refer to figure F.2 for test point locations. Note: Test
using an Analog ohmmeter on the Rx1 range.
Make sure the test probes are making electrical contact with the conductor surfaces on the
PC board.
POWER WAVE 355M/405M
TROUBLESHOOTING AND REPAIR
Return to Master TOC
Return to Section TOC
F-17
F-17
MAIN SWITCH BOARD TEST (continued)
6. If any test fails replace the switch board. See
Main Switch Board Removal and Replacement.
7. If the switch board resistance tests are OK, check
connections on plugs J20, J21, J22 and all associated wiring. See wiring diagram.
8. Reconnect leads 201, 202, 203, 204, 205, 206,
207, and 208 to the switch board. Ensure that the
leads are installed in their proper locations. PreTorque all leads nuts to 25 inch lbs. before tightening them to 44 inch lbs.
9. Replace the case wraparound cover using a 5/16”
nut driver.
Return to Master TOC
Return to Master TOC
Return to Master TOC
Return to Section TOC
Return to Section TOC
Return to Section TOC
TABLE F.1. SWITCH BOARD RESISTANCE TEST
APPLY POSITIVE TEST
PROBE TO TERMINAL
APPLY NEGATIVE TEST
PROBE TO TERMINAL
NORMAL
RESISTANCE READING
+206
+208
+202
+201
+205
+203
+204
+207
-205
-203
-204
-207
-206
-208
-202
-201
Greater than 1000 ohms
Greater than 1000 ohms
Greater than 1000 ohms
Greater than 1000 ohms
Less than 100 ohms
Less than 100 ohms
Less than 100 ohms
Less than 100 ohms
POWER WAVE 355M/405M
Return to Section TOC
Return to Master TOC
Return to Section TOC
Return to Master TOC
Return to Master TOC
Return to Section TOC
Return to Master TOC
Return to Section TOC
F-18
NOTES
POWER WAVE 355M/405M
F-18
Return to Master TOC
Return to Section TOC
F-19
TROUBLESHOOTING AND REPAIR
INPUT RECTIFIER TEST
WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician
or machine operator and will invalidate your factory warranty. For your safety and to avoid
electrical shock, please observe all safety notes and precautions detailed throughout this
manual.
Return to Master TOC
Return to Master TOC
Return to Master TOC
Return to Section TOC
Return to Section TOC
Return to Section TOC
If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.
TEST DESCRIPTION
This test will help determine if the input rectifier has “shorted” or “open” diodes.
MATERIALS NEEDED
Analog Voltmeter/Ohmmeter (Multimeter)
5/16” Nut Driver
Phillips Head Screwdriver
Wiring Diagram
POWER WAVE 355M/405M
F-19
Return to Master TOC
Return to Section TOC
F-20
TROUBLESHOOTING AND REPAIR
INPUT RECTIFIER TEST (CONTINUED)
TEST PROCEDURE
1. Remove input power to the POWER
WAVE 355M/405M machine.
2. Using a 5/16” nut driver, remove the case
wraparound cover.
3. Perform the Capacitor Discharge
Procedure detailed earlier in this section.
4. Locate the input rectifier and associated
leads. See Figure F.3.
6. Using a phillips head screwdriver,
remove leads 207, 207A, and 209 from
the input rectifier.
7. Use the analog ohmmeter to perform the
tests detailed in Table F.2. See the
Wiring Diagram.
8. Visually inspect the three MOV’S for
damage (TP1,TP2,TP3). Replace if necessary.
Return to Master TOC
Return to Section TOC
5. Carefully remove the silicone sealant
from leads 207, 207A, and 209.
Figure F.3 Input Rectifier
Small Lead "H1"
To Auxiliary Transformer
#207
#207A
Return to Master TOC
Return to Section TOC
B
C
3/16" ALLEN
BOLTS
Return to Master TOC
Return to Section TOC
A
#209
FRONT
REAR
POWER WAVE 355M/405M
Small Lead "A"
To Circuit Breaker
F-20
TROUBLESHOOTING AND REPAIR
Return to Master TOC
Return to Master TOC
Return to Master TOC
Return to Master TOC
Return to Section TOC
Return to Section TOC
Return to Section TOC
Return to Section TOC
F-21
F-21
INPUT RECTIFIER TEST (CONTINUED)
Table F.2 Input Rectifier Test Points
ANALOG METER
X10 RANGE
TEST POINT TERMINALS
+ PROBE
- PROBE
Acceptable Meter Readings
A
B
C
207
207
207
Greater than 1000 ohms
Greater than 1000 ohms
Greater than 1000 ohms
A
B
C
207A
207A
207A
Greater than 1000 ohms
Greater than 1000 ohms
Greater than 1000 ohms
A
B
C
209
209
209
Less than 100 ohms
Less than 100 ohms
Less than 100 ohms
207
207
207
A
B
C
Less than 100 ohms
Less than 100 ohms
Less than 100 ohms
207A
207A
207A
A
B
C
Less than 100 ohms
Less than 100 ohms
Less than 100 ohms
209
209
209
A
B
C
Greater than 1000 ohms
Greater than 1000 ohms
Greater than 1000 ohms
9. If the input rectifier does not meet the
acceptable readings outlined in Table F.2
the component may be faulty. Replace
Note: Before replacing the input rectifier,
check the input power switch and reconnect switches. Perform the Main Switch
Board Test. Also check for leaky or
faulty filter capacitors.
11. If the input rectifier is faulty, see the
Input Rectifier Bridge Removal &
Replacement procedure.
12. Replace the case wraparound cover.
10. If the input rectifier is good, be sure to
reconnect leads 207, 207A, and 209 to
the correct terminals and torque to 31
inch lbs. Apply silicone sealant.
POWER WAVE 355M/405M
Return to Section TOC
Return to Master TOC
Return to Section TOC
Return to Master TOC
Return to Master TOC
Return to Section TOC
Return to Master TOC
Return to Section TOC
F-22
NOTES
POWER WAVE 355M/405M
F-22
Return to Master TOC
Return to Section TOC
F-23
TROUBLESHOOTING AND REPAIR
POWER BOARD TEST
WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician
or machine operator and will invalidate your factory warranty. For your safety and to avoid
electrical shock, please observe all safety notes and precautions detailed throughout this
manual.
Return to Master TOC
Return to Section TOC
If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.
TEST DESCRIPTION
This test will help determine if the power board is receiving the correct voltages and also
if the power board is regulating and producing the correct DC voltages.
MATERIALS NEEDED
Volt-Ohmmeter
3/8” Nut Driver
Return to Section TOC
Return to Master TOC
Return to Section TOC
Return to Master TOC
Wiring Diagram
POWER WAVE 355M/405M
F-23
TROUBLESHOOTING AND REPAIR
J41
J42
J43
6
5
4
4
3
12 11 10 9
8 7
3
2
1
2
1
6
2
J42
J41
5
4 3
1
J43
Return to Master TOC
Return to Section TOC
F-24
FIGURE F.4 – POWER BOARD TEST
Return to Master TOC
Return to Section TOC
F-24
TEST PROCEDURE
Return to Master TOC
Return to Section TOC
1. Remove input power to the Power Wave
355M/405M.
2. Using the 3/8” nut driver, remove the case
top.
3. Perform
the
Procedure.
Capacitor
Discharge
4. Locate the Power Board and plugs J42 and
J43. Do not remove plugs or leads from
the Power Board. Refer to Figure F.8.
5. Carefully apply input power to the Power
Wave 355M/405M.
6. Turn on the Power Wave 355M/405M.
Carefully test for the correct voltages at the
Power Board according to Table F.4.
7. If either of the 40 VDC voltages is low or not
present at plug J41, perform the DC Bus PC
Board Test. See the Wiring Diagram. Also
perform the T1 Auxiliary Transformer
Test.
8. If any of the DC voltages are low or not present at plugs J42 and/or 43, the Power
Board may be faulty.
9. Install the case top using the 3/8” nut driver.
WARNING
Return to Master TOC
Return to Section TOC
ELECTRIC SHOCK can kill.
High voltage is present when
input power is applied to the
machine.
POWER WAVE 355M/405M
Return to Master TOC
Return to Section TOC
F-25
TROUBLESHOOTING AND REPAIR
F-25
POWER BOARD TEST (CONTINUED)
TABLE F.3 – POWER BOARD VOLTAGE CHECKS
CHECK POINT
LOCATION
POWER BOARD
CONNECTOR
PLUG J41
TEST
DESCRIPTION
CONNECTOR
PLUG PIN NO.
LEAD NO. OR
IDENTITY
CHECK 40 VDC
INPUT FROM
DC BUS BOARD
2 (+)
1 (-)
477 (+)
475
NORMAL
ACCEPTABLE
VOLTAGE
READING
38 – 42 VDC
477
475 (-)
POWER BOARD
CONNECTOR
PLUG J42
CHECK +15
VDC SUPPLY FROM
POWER BOARD
+15 VDC
1 (+)
5 (-)
412
412 (+)
Return to Master TOC
Return to Section TOC
410 (-)
410
POWER BOARD
CONNECTOR
PLUG J42
CHECK +5 VDC
SUPPLY FROM
POWER BOARD
3 (+)
5 (-)
+5 VDC
408 (+)
408
410 (-)
410
POWER BOARD
CONNECTOR
PLUG J42
CHECK -15 VDC
SUPPLY FROM
POWER BOARD
411
2 (+)
5 (-)
-15 VDC
411 (+)
410 (-)
410
POWER BOARD
CONNECTOR
PLUG J43
CHECK +5 VDC
ARCLINK SUPPLY
FROM POWER BOARD
5 (+)
10 (-)
+5 VDC
1104
1104 (+)
1103 (-)
Return to Section TOC
Return to Master TOC
Return to Section TOC
Return to Master TOC
1103
POWER BOARD
CONNECTOR
PLUG J43
4 (+)
9 (-)
CHECK +5 VDC
“RS-232” SUPPLY
FROM POWER BOARD
+5 VDC
406
406 (+)
405 (-)
405
POWER BOARD
CONNECTOR
PLUG J43
CHECK +5 VDC
SPI SUPPLY FROM
POWER BOARD
403
+5 VDC
3 (+)
12 (-)
403 (+)
401 (-)
401
POWER WAVE 355M/405M
Return to Section TOC
Return to Master TOC
Return to Section TOC
Return to Master TOC
Return to Master TOC
Return to Section TOC
Return to Master TOC
Return to Section TOC
F-26
NOTES
POWER WAVE 355M/405M
F-26
Return to Master TOC
Return to Section TOC
F-27
TROUBLESHOOTING AND REPAIR
DC BUS BOARD TEST
WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician
or machine operator and will invalidate your factory warranty. For your safety and to avoid
electrical shock, please observe all safety notes and precautions detailed throughout this
manual.
Return to Master TOC
Return to Master TOC
Return to Master TOC
Return to Section TOC
Return to Section TOC
Return to Section TOC
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
POWER WAVE 355M/405M
F-27
TROUBLESHOOTING AND REPAIR
Return to Master TOC
DC BUS BOARD TEST (CONTINUED)
FIGURE F.5 – DC BUS POWER SUPPLY POWER SUPPLY PC BOARD
DC BUS BOARD
STA
TU
S
Return to Master TOC
Return to Section TOC
Return to Section TOC
F-28
TH
ER
MA
L
LIN
CO
EL LN
EC
TR
IC
WA
RN
ING
RE
MO
TE
PO
WE
R
ON
OF
F
TEST PROCEDURE
WARNING
1. Remove input power to the machine.
ELECTRIC SHOCK can kill.
2. Using the 3/8” nut driver, remove the wraparound cover.
High voltage is present when
input power is applied to the
machine.
Return to Master TOC
Return to Section TOC
3. Locate the DC Bus Board. See Figure F.5.
4. Carefully apply input power to the Power
Wave 355M/405M.
5. Turn on the Power Wave 355M/405M. The
LED on the DC Bus Power Supply PC Board
should light.
FIGURE F.6 – DC BUS POWER SUPPLY POWER SUPPLY PC BOARD
J47
J47
Bus
Rectifier
51
475
477
Return to Master TOC
L11078-1
Return to Section TOC
52
J46
66
65
J46
POWER WAVE 355M/405M
Thermostat
F-28
TROUBLESHOOTING AND REPAIR
Return to Master TOC
Return to Section TOC
F-29
DC BUS BOARD TEST(CONTINUED)
6. Check the DC Bus Board input and output
voltages according to Table F.4. See Figure
F.6 and the Wiring Diagram.
WARNING
ELECTRIC SHOCK can kill.
Return to Master TOC
Return to Master TOC
Return to Master TOC
Return to Section TOC
Return to Section TOC
High voltage is present at the terminals of Capacitor C3 near
where testing is to be done.
Return to Section TOC
F-29
7. If all the voltages are correct, the DC Bus
Board is operating properly.
8. If any of the output voltages are not correct
and the input voltage is correct, the DC Bus
Board may be faulty.
9. If the input voltage is not correct, check the
leads between the DC Bus Board and the
Bus Rectifier. See the Wiring Diagram.
10. When finished testing, replace the case
wraparound cover.
TABLE F.4 – DC BUS POWER SUPPLY PC BOARD VOLTAGE TABLE
Positive Meter Probe
Test Point
Negative Meter Probe
Test Point
Approximate Voltage
Reading
Conditions/Comments
Plug P46 – Pin 1
Plug P46 – Pin 3
65 – 75 VDC
Lead 65
Lead 66
Should be same as the
Bus Rectifier
Plug P47 – Pin 8(+)
Lead 52
Plug P47 – Pin 1(-)
Lead 51
38.0 – 42.0 VDC
Supply to the Wire
Feeder Receptacle
Plug P47 – Pin 3(+)
Lead 477
Plug P47 – Pin 6(-)
Lead 475
38.0 – 42.0 VDC
Supply to Power Board
POWER WAVE 355M/405M
Return to Section TOC
Return to Master TOC
Return to Section TOC
Return to Master TOC
Return to Master TOC
Return to Section TOC
Return to Master TOC
Return to Section TOC
F-30
NOTES
POWER WAVE 355M/405M
F-30
Return to Master TOC
Return to Section TOC
F-31
TROUBLESHOOTING AND REPAIR
OUTPUT RECTIFIER MODULES TEST
WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician
or machine operator and will invalidate your factory warranty. For your safety and to avoid
electrical shock, please observe all safety notes and precautions detailed throughout this
manual.
Return to Master TOC
Return to Master TOC
Return to Master TOC
Return to Section TOC
Return to Section TOC
Return to Section TOC
If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.
TEST DESCRIPTION
This test will help determine if any of the output diodes are “shorted”.
MATERIALS NEEDED
Analog Voltmeter/Ohmmeter
Wiring Diagram
POWER WAVE 355M/405M
F-31
Return to Master TOC
Return to Section TOC
F-32
TROUBLESHOOTING AND REPAIR
OUTPUT RECTIFIER MODULES TEST (continued)
FIGURE F.7 Machine Output Terminals
Return to Master TOC
Return to Section TOC
_
+
POSITIVE
OUTPUT
TERMINAL
NEGATIVE
OUTPUT
TERMINAL
TEST PROCEDURE
1. Remove input power to the POWER WAVE
355M/405M.
2. Locate the output terminals on the front
panel of the machine. See Figure F.7.
Return to Master TOC
3. Remove any output cables and load from the
output terminals.
Return to Section TOC
THERMAL
Return to Master TOC
Return to Section TOC
STA
ST
ATUS
4. Using the analog ohmmeter test for more
than 200 ohms resistance between positive
and negative output terminals. Positive test
lead to the positive terminal; Negative test
lead to the negative terminal. See Figure
F.8.
NOTE: The polarity of the test leads is most
important. If the test leads polarity is not correct, the test will have erroneous results.
POWER WAVE 355M/405M
F-32
TROUBLESHOOTING AND REPAIR
Return to Master TOC
Return to Master TOC
Figure F.8 Terminal Probes
_
- PR
OB E
Return to Section TOC
Return to Master TOC
OUTPUT RECTIFIER MODULES TEST (continued)
+
E
R OB
+P
Return to Section TOC
Return to Section TOC
F-33
5. If 200 ohms is measured then the output
diodes are not “shorted”.
9. Test all output diode modules individually.
Test for open diodes also.
NOTE: There is a 250 ohm resistor across
the welding output terminals. See Wiring
Diagram
NOTE: This may require the disassembly of
the leads and the snubber board from the
diode modules.
Refer to the Output
Rectifier
Modules
Removal
and
Replacement Procedure for detailed
instructions.
6. If less than 200 ohms is measured, one or
more diodes or the snubber board may be
faulty.
8. Locate the output diode modules and snubber board. See Figure F.9.
Return to Master TOC
Return to Section TOC
7. Perform the Filter Capacitor Discharge
Procedure detailed in the maintenance section.
POWER WAVE 355M/405M
F-33
Return to Section TOC
Return to Master TOC
Return to Section TOC
Return to Master TOC
Return to Master TOC
Return to Section TOC
Return to Master TOC
Return to Section TOC
F-34
Figure F.9 Snubber and Output Diode Locations
TROUBLESHOOTING AND REPAIR
Output Diode
Modules
Snubber
Board
LEFT SIDE
POWER WAVE 355M/405M
F-34
Return to Master TOC
Return to Section TOC
F-35
TROUBLESHOOTING AND REPAIR
AUXILIARY TRANSFORMER TEST
WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician
or machine operator and will invalidate your factory warranty. For your safety and to avoid
electrical shock, please observe all safety notes and precautions detailed throughout this
manual.
Return to Master TOC
Return to Section TOC
If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.
TEST DESCRIPTION
This procedure will determine if the correct voltage is being applied to the primary of auxiliary transformer and also if the correct voltage is being induced on the secondary windings of the transformer.
MATERIALS NEEDED
Volt-ohmmeter (Multimeter)
5/16” Nut Driver
Return to Section TOC
Return to Master TOC
Return to Section TOC
Return to Master TOC
Wiring Diagram
POWER WAVE 355M/405M
F-35
Return to Section TOC
Return to Master TOC
Return to Section TOC
Return to Master TOC
F-36
TROUBLESHOOTING AND REPAIR
AUXILIARY TRANSFORMER TEST (continued)
FIGURE F.10 Auxiliary Transformer
Auxiliary
Transformer
Secondary Lead
Plugs P52
ST
AT
US
TH
E
RM
AL
LIN
CO
EL LN
EC
TR
IC
WA
RN
ING
RE
MO
TE
PO
WE
R
ON
OF
F
Return to Master TOC
Return to Section TOC
TEST PROCEDURE
1. Remove input power to the POWER WAVE
355M/405M.
4. Locate the auxiliary transformer. See Figure
F.10.
2. Using a 5/16” nut driver, remove the case
wraparound cover.
5. Locate the secondary leads and plug P52.
See Figure F.10 and F.11.
3. Perform the Input Capacitor Discharge
Procedure detailed earlier in this section.
FIGURE F.11 Plug Lead Connections Viewed From Transformer Lead Side of Plug
PW405
Only
(220V)
532
Return to Master TOC
Return to Section TOC
(115V)
Plug P52
Com 2
(31)
POWER WAVE 355M/405M
F-36
Return to Master TOC
Return to Master TOC
Return to Master TOC
Return to Master TOC
Return to Section TOC
Return to Section TOC
Return to Section TOC
Return to Section TOC
F-37
TROUBLESHOOTING AND REPAIR
AUXILIARY TRANSFORMER TEST (continued)
TABLE F.5
LEAD IDENTIFICATION
NORMAL EXPECTED VOLTAGE
COM 2 (31) TO 115V (532)
115 VAC
42 TO COM 1A (quick connects)
42 VAC
7. Carefully apply the correct input voltage to the
POWER WAVE 355M/405M and check for the
correct secondary voltages per table F.5.
Make sure the reconnect jumper lead and
switch are configured correctly for the input
voltage being applied. Make sure circuit
breaker (CB3) is functioning properly.
NOTE: The secondary voltages will vary if the
input line voltage varies.
8. If the correct secondary voltages are present,
the auxiliary transformer is functioning properly. If any of the secondary voltages are missing or low, check to make certain the primary
is configured correctly for the input voltage
applied. See Wiring Diagram.
WARNING
High voltage is present at primary of
Auxiliary Transformer.
9. If the correct input voltage is applied to the
primary, and the secondary voltage(s) are not
correct, the auxiliary transformer may be
faulty.
10. Remove the input power to the POWER WAVE
355M/405M.
11. Install the case wraparound cover using a
5/16” nut driver.
POWER WAVE 355M/405M
F-37
Return to Section TOC
Return to Master TOC
Return to Section TOC
Return to Master TOC
Return to Master TOC
Return to Section TOC
Return to Master TOC
Return to Section TOC
F-38
NOTES
POWER WAVE 355M/405M
F-38
TROUBLESHOOTING AND REPAIR
Return to Master TOC
Return to Section TOC
F-39
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.
Return to Master TOC
Return to Section TOC
If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.
TEST DESCRIPTION
This test will help determine if the current transducer and associated wiring are functioning correctly.
MATERIALS NEEDED
Volt-ohmmeter
5/16” Nut Driver
Grid Bank
Return to Section TOC
Return to Master TOC
Return to Section TOC
Return to Master TOC
External DC Ammeter
POWER WAVE 355M/405M
F-39
TROUBLESHOOTING AND REPAIR
Return to Section TOC
Return to Master TOC
Return to Section TOC
Return to Master TOC
F-40
CURRENT TRANSDUCER TEST (continued)
FIGURE F.12 Metal Plate Removal & Plug J8 Location
ST
AT
US
TH
ER
MA
L
LIN
CO
EL L N
EC
TR
IC
WA
RN
ING
RE
MO
TE
PO
WE
R
ON
OF
F
Plug J8
TEST PROCEDURE
Return to Master TOC
Return to Section TOC
1. Remove input power to the POWER WAVE
355M/405M.
2. Using the 5/16” nut driver, remove the case
wraparound cover.
3. Perform the Input Capacitor Discharge
Procedure.
4. Locate plug J8 on the control board. Do not
remove the plug from the P.C. Board.
6. Check for the correct DC supply voltages to
the current transducer at plug J8. See Figure
F.12.
A. Pin 2 (lead 802+) to pin 6 (lead 806-)
should read +15 VDC.
B. Pin 4 (lead 804+) to pin 6 (lead 806-)
should read -15 VDC.
7. If either of the supply voltages are low or missing, the control board may be faulty.
5. Apply the correct input power to the POWER
WAVE 355M/405M.
FIGURE F.13. Plug J8 Viewed From Lead Side of Plug
802
804
Return to Master TOC
801
Return to Section TOC
F-40
Plug J8
806
POWER WAVE 355M/405M
Return to Master TOC
Return to Master TOC
Return to Master TOC
Return to Section TOC
Return to Section TOC
Return to Section TOC
F-41
TROUBLESHOOTING AND REPAIR
AUXILIARY TRANSFORMER TEST (continued)
TABLE F.6
OUTPUT LOAD CURRENT
EXPECTED TRANSDUCER FEEDBACK
VOLTAGE
300
2.4
250
2.0
200
1.6
150
1.2
100
0.8
8. Check the feedback voltage from the current
transducer using a resistive load bank and
with the POWER WAVE 355M/405M in mode
200. Mode 200 is a constant current test
mode. This mode can be accessed using a
wire feeder placed in mode 200 or a laptop
computer and the appropriate software. Apply
the grid load across the output of the POWER
WAVE 355M/405M. Set machine output to
300 amps and enable WELD TERMINALS.
Adjust the grid load to obtain 300 amps on the
external ammeter and check feedback voltages per Table F.6.
A. Pin 1 (lead 801) to Pin 6 (lead 806) should
read 2.4 VDC (machine loaded to 300
amps).
Before replacing the current transducer, check
the leads and plugs between the control board
(J8) and the current transducer (J90). See The
Wiring Diagram. For access to plug J90 and
the current transducer refer to: Current
Transducer Removal and Replacement
Procedure.
11. Remove input power to the POWER WAVE
355M/405M.
12. Replace the control box top and any cable ties
previously removed.
13. Install the case wraparound cover using the
5/16” nut driver.
9. If for any reason the machine cannot be
loaded to 300 amps, Table F.6. shows what
feedback voltage is produced at various current loads.
Return to Master TOC
10. If the correct supply voltages are applied to
the current transducer, and with the machine
loaded, the feedback voltage is missing or not
correct the current transducer may be faulty.
Return to Section TOC
F-41
POWER WAVE 355M/405M
Return to Section TOC
Return to Master TOC
Return to Section TOC
Return to Master TOC
Return to Master TOC
Return to Section TOC
Return to Master TOC
Return to Section TOC
F-42
NOTES
POWER WAVE 355M/405M
F-42
TROUBLESHOOTING AND REPAIR
Return to Master TOC
Return to Section TOC
F-43
FAN CONTROL AND MOTOR TEST
WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician
or machine operator and will invalidate your factory warranty. For your safety and to avoid
electrical shock, please observe all safety notes and precautions detailed throughout this
manual.
Return to Master TOC
Return to Section TOC
If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.
TEST DESCRIPTION
This test will help determine if the fan motor, control board, switch board, or associated
leads and connectors are functioning correctly.
MATERIALS NEEDED
Voltmeter
Return to Section TOC
Return to Master TOC
Return to Section TOC
Return to Master TOC
5/16” Nut Driver
POWER WAVE 355M/405M
F-43
Return to Master TOC
Return to Section TOC
F-44
TROUBLESHOOTING AND REPAIR
F-44
FAN CONTROL AND MOTOR TEST (continued)
TEST PROCEDURE
1. Remove the input power to the POWER WAVE
355M/405M machine.
3. Perform the Input Filter Capacitor Discharge
Procedure.
2. Using the 5/16” nut driver, remove the case
wraparound cover.
4. Locate plug J22 on the main switch board. Do
not remove the plug from the board. See
Figure F.14.
FIGURE F.14 PLUG J22 LOCATION
Return to Master TOC
Return to Section TOC
J22
J21
J20
Return to Master TOC
Return to Master TOC
Return to Section TOC
Return to Section TOC
5. Carefully apply the correct input power to the
machine.
6. Carefully check for 115VAC at plug J22 pin-2
to J22 pin-3. (leads 32A to 31B(C) See Figure
F.15. WARNING: HIGH VOLTAGE IS PRESENT AT THE MAIN SWITCH BOARD.
FIGURE F.15 PLUG J22
207
Fan Lead
1
2
Lead 32A
Lead 31B(C)
3
4
Fan Lead
Plug J22
POWER WAVE 355M/405M
Return to Master TOC
Return to Master TOC
Return to Section TOC
Return to Section TOC
F-45
TROUBLESHOOTING AND REPAIR
FAN CONTROL AND MOTOR TEST (continued)
7. If the 115VAC is low or not present check circuit breaker CB2 located on the front panel. If
the circuit breaker is OK, perform The
Auxiliary Transformer Test. Check plug J22,
circuit breaker CB2 and associated leads for
loose or faulty connections. See the Wiring
Diagram.
8. Energize the weld output terminals with the
PW 355M/405M in mode 200. This mode can
be accessed using a wire feeder placed in
mode 200 or a laptop computer and the appropriate software. Carefully check for 115VAC at
plug J22 pin-1 to J22 pin-4 (fan leads). See
Figure F.15. If the 115VAC is present and the
fan is not running then the fan motor may be
faulty. Also check the associated leads
between plug J22 and the fan motor for loose
or faulty connections. See the Wiring Diagram.
WARNING: HIGH VOLTAGE IS PRESENT AT
THE SWITCH BOARD.
1. Locate plug J20 on the switch board. Do not
remove the plug from the switch board. See
Figure F.14 and F.16.
2. Energize the weld output terminals (Select
Weld Terminals ON) and carefully check for
+15VDC at plug J20 pin-6+ to J20 pin-2(leads 715 to 716). See Figure F.16. If the
15VDC is present and the fan is not running
then the switch board may be faulty. If the
15VDC is not present when the weld terminals
are energized then the control board may be
faulty. Also check plugs J20, J7, and all associated leads for loose or faulty connections.
See the Wiring Diagram.
WARNING: HIGH VOLTAGE IS PRESENT AT
THE SWITCH BOARD.
3. Remove the input power to the POWER WAVE
355M/405M.
Note: The fan motor may be accessed by the
removal of the rear panel detailed in The
Current
Transducer
Removal
and
Replacement Procedure.
9. If the 115VAC is NOT present in the previous
step then proceed to the fan control test.
4. Replace the case wrap-around cover.
FAN CONTROL TEST PROCEDURE
Return to Master TOC
Return to Section TOC
FIGURE F.16 PLUG J20
Lead 716-
1
2
3
4
5
6
7
8
Return to Master TOC
Return to Section TOC
Lead 715+
F-45
Plug J20
POWER WAVE 355M/405M
Return to Section TOC
Return to Master TOC
Return to Section TOC
Return to Master TOC
Return to Master TOC
Return to Section TOC
Return to Master TOC
Return to Section TOC
F-46
NOTES
POWER WAVE 355M/405M
F-46
Return to Master TOC
Return to Section TOC
F-47
TROUBLESHOOTING AND REPAIR
CONTROL BOARD REMOVAL AND REPLACEMENT
WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician
or machine operator and will invalidate your factory warranty. For your safety and to avoid
electrical shock, please observe all safety notes and precautions detailed throughout this
manual.
Return to Master TOC
Return to Section TOC
If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.
DESCRIPTION
The following procedure will aid the technician in removing the control board for maintenance or replacement.
MATERIALS NEEDED
5/16” Nut Driver
3/8” Nut Driver
Flathead Screwdriver
Return to Section TOC
Return to Master TOC
Return to Section TOC
Return to Master TOC
Phillips Head Screwdriver
POWER WAVE 355M/405M
F-47
Return to Master TOC
Return to Section TOC
F-48
TROUBLESHOOTING AND REPAIR
F-48
CONTROL BOARD REMOVAL AND REPLACEMENT (continued)
FIGURE F.17 - CONTROL BOARD LOCATION
STA
TU
S
TH
ER
Return to Master TOC
Return to Master TOC
Return to Master TOC
Return to Section TOC
Return to Section TOC
Return to Section TOC
MA
L
LIN
CO
EL LN
EC
TR
IC
WA
RN
ING
RE
MO
TE
PO
WE
R
ON
OF
F
Control Board
PROCEDURE
1. Remove input power to the POWER WAVE
355M/405M.
4. Locate the control board behind the front panel of
the machine. See Figure F.17.
2. Using a 5/16” nut driver remove the case wraparound cover.
5. Using a 5/16” nut driver remove the two screws
from the bottom of the front of the machine. See
Figure F.18.
3. Perform the Input Filter Capacitor Discharge
Procedure detailed earlier in this section.
FIGURE F.18 CASE FRONT SCREW REMOVAL
ST
STA
ATUS
Phillips Head
Screws
THERMAL
Phillips Head
Screws
_
+
5/16"
Mounting Screws
POWER WAVE 355M/405M
TROUBLESHOOTING AND REPAIR
Return to Master TOC
Return to Section TOC
F-49
F-49
CONTROL BOARD REMOVAL AND REPLACEMENT (continued)
FIGURE F.19 - CONTROL BOARD ALL PLUG LOCATIONS
J6
J5
J7
J8
J9
J4
Return to Master TOC
Return to Section TOC
J2
ST
AT
US
TH
ER
MA
L
J10B
LIN
CO
EL LN
EC
TR
IC
WA
RN
IN
G
RE
MO
J10A
TE
PO
W
ER
ON
Return to Master TOC
Return to Master TOC
Return to Section TOC
Return to Section TOC
OF
F
8. The front of the machine may now gently be pulled
forward to gain access to the Control Board.
Note: The front of the machine cannot be removed
completely, only pulled forward a few inches.
CAUTION
Observe static precautions detailed in PC
Board Troubleshooting Procedures at the
beginning of this section.
9. Beginning at the right side of the control board
remove plugs J10A and J10B. Note: Be sure to
label each plugs position upon removal. See
Figure F.19.
6. Using a phillips head screwdriver remove the two
screws and their washers from above and below
the input power switch. See Figure F.18.
10. Working your way across the top of the board
from right to left, label and remove plugs #J9, #J8,
#J7, #J6, and #J5. See Figure F.19.
7. Using a phillips head screwdriver remove the four
screws from around the two welder output terminals on the front of the machine. See Figure F.18.
11. Working your way down the left side of the board,
label and remove plugs #J4 and #J2. See Figure
F.19.
POWER WAVE 355M/405M
TROUBLESHOOTING AND REPAIR
Return to Master TOC
Return to Section TOC
F-50
F-50
CONTROL BOARD REMOVAL AND REPLACEMENT (continued)
12. Using a 3/8” nut driver remove the two mounting
nuts from the top two corners of the control
board. See Figure F.20.
14. Replace the control board.
13. Cut any necessary cable ties.
Return to Master TOC
Return to Section TOC
FIGURE F.20 CONTROL BOARD MOUNTING SCREW LOCATION
e
d
i
S
t
h
g
i
R
Return to Master TOC
Return to Section TOC
Mounting
Nuts (3/8")
15. Replace the two 3/8” mounting nuts at the top
two corners of the control board.
19. Replace the four screws from around the two
welder output terminals on the front of the
machine.
16. Replace any previously removed cable ties.
Return to Master TOC
Return to Section TOC
17. Replace plugs #J2, #J4, #J5, #J6, #J7, #J8, #J9,
#J10B, and #J10A previously removed.
20. Replace the two case front mounting screws at
the bottom of the front of the machine.
21. Replace the case wraparound cover.
18. Replace the two screws and their washers from
above and below the input power switch.
POWER WAVE 355M/405M
Return to Master TOC
Return to Section TOC
F-51
TROUBLESHOOTING AND REPAIR
MAIN SWITCH BOARD REMOVAL & REPLACEMENT
WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician
or machine operator and will invalidate your factory warranty. For your safety and to avoid
electrical shock, please observe all safety notes and precautions detailed throughout this
manual.
Return to Master TOC
Return to Section TOC
If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.
DESCRIPTION
The following procedure will aid the technician in removing the main switch board for
maintenance or replacement.
MATERIALS NEEDED
5/16” Nut Driver
Flathead Screwdriver
7/16” mm Socket
3/16” Allen Wrench
Return to Section TOC
Return to Master TOC
Return to Section TOC
Return to Master TOC
3/8” Nut Driver
POWER WAVE 355M/405M
F-51
Return to Master TOC
Return to Section TOC
F-52
TROUBLESHOOTING AND REPAIR
MAIN SWITCH BOARD REMOVAL & REPLACEMENT (continued)
FIGURE F.21 – MAIN SWITCH BOARD LEAD LOCATIONS
202
207
J22
-
+
-
Return to Master TOC
+
209
201
Return to Section TOC
F-52
204
205
208
J21
J20
-
+
-
+
206
203
Return to Master TOC
Return to Section TOC
PROCEDURE
1. Remove the input power to the POWER WAVE
355M/405M.
2. Using a 5/16” nut driver remove the case wraparound cover.
3. Perform the Input Filter Capacitor Discharge
Procedure detailed earlier in this section.
207
Return to Master TOC
Return to Section TOC
CAUTION
Observe static precautions detailed in PC Board
Troubleshooting Procedures at the beginning of
this section. Failure to do so can result in permanent damage to equipment.
5. Using a 3/8” nut driver, remove the input lead
shield from the area at the bottom of the main
switch board.
6. Using a 7/16” socket, remove leads 201, 202,
203, 204, 205, 206, 207, 208, 209 from the
switch board. Note lead terminal locations and
washer positions upon removal.
7. Locate and disconnect the three harness plugs
associated with the main switch board. Plugs
#J20, #J21, #J22. See Figure F.21.
8. Locate the eight capacitor terminals and
remove the nuts using a 7/16” socket or nut
driver. Note the position of the washers behind
each nut for replacement.
4. Locate the main switch board and all associated plug and lead connections. See figure F.21.
See Wiring Diagram.
POWER WAVE 355M/405M
Return to Master TOC
Return to Section TOC
F-53
TROUBLESHOOTING AND REPAIR
MAIN SWITCH BOARD REMOVAL & REPLACEMENT (continued)
FIGURE F.22 – 3/16” ALLEN BOLT LOCATION
-
+
-
+
Return to Master TOC
Return to Section TOC
3/16" ALLEN BOLTS
-
+
9. Using a 3/16” allen wrench remove four allen
bolts and washers as shown in Figure F.22.
At this point, the board is ready for removal.
Return to Master TOC
Return to Section TOC
10. Carefully maneuver the board out of the
machine.
11. Apply a thin coat of Penetrox A-13 to the
IGBT heatsinks on the back of the new
207
switch boards mating surfaces. Note: Keep
compound away from the mounting holes.
12. Replace the four allen bolts and washers
previously removed.
13. Replace the eight capacitor terminal nuts,
washers, and necessary leads previously
removed.
-
15. Reconnect the nine leads (#201-#209) that
were previously removed.
16. Replace any necessary cable ties previously
removed.
17. Pre-torque all screws to 25 inch lbs. before
tightening to 44 inch lbs.
18. Replace the input lead shield previously
removed.
19. Replace the case wraparound cover.
NOTE: Any instructions that are packaged with
the replacement board will supercede
these instructions.
Return to Master TOC
14. Reconnect the three harness plugs previously removed.
Return to Section TOC
+
POWER WAVE 355M/405M
F-53
Return to Section TOC
Return to Master TOC
Return to Section TOC
Return to Master TOC
Return to Master TOC
Return to Section TOC
Return to Master TOC
Return to Section TOC
F-54
NOTES
POWER WAVE 355M/405M
F-54
Return to Master TOC
Return to Section TOC
F-55
TROUBLESHOOTING AND REPAIR
SNUBBER BOARD REMOVAL AND REPLACEMENT
WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician
or machine operator and will invalidate your factory warranty. For your safety and to avoid
electrical shock, please observe all safety notes and precautions detailed throughout this
manual.
Return to Master TOC
Return to Section TOC
If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.
DESCRIPTION
The following procedure will aid the technician in removing the snubber board for maintenance or replacement.
MATERIALS NEEDED
5/16” Nut Driver
Return to Section TOC
Return to Master TOC
Return to Section TOC
Return to Master TOC
7/16 Socket or Nut Driver
POWER WAVE 355M/405M
F-55
Return to Master TOC
Return to Section TOC
F-56
TROUBLESHOOTING AND REPAIR
SNUBBER BOARD REMOVAL AND REPLACEMENT (continued)
F-56
PROCEDURE
1. Remove input power to the POWER WAVE
355M/405M.
3. Perform the Input Filter Capacitor Discharge
Procedure detailed earlier in this section.
2. Using a 5/16” nut driver remove the case wraparound cover.
4. Locate the snubber board.. See Figure F.23.
Return to Master TOC
Return to Section TOC
FIGURE F.23 – SNUBBER BOARD LOCATION
Snubber
Board
LEFT SIDE
Return to Master TOC
Return to Section TOC
5. Remove small lead #B1 from the board.
Figure F.24.
See
6. Remove the four bolts using a 7/16” socket. Two
of these bolts have leads #30 and #10 connected
to them. Note the position of all leads and associated washers upon removal.
8. Replace the snubber board.
9. Replace the bolts, leads, and washers previously
removed. Torque bolt to 30-40 Inch Lbs.
10. Reconnect small lead B1 previously removed.
11. Replace the case wraparound cover.
7. Carefully remove the snubber board.
FIGURE F.24 – SNUBBER BOARD LEADS (CLOSE UP)
Return to Master TOC
Return to Section TOC
Lead 30
Lead B1
Lead 10
POWER WAVE 355M/405M
Return to Master TOC
Return to Section TOC
F-57
TROUBLESHOOTING AND REPAIR
POWER BOARD REMOVAL AND REPLACEMENT
WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician
or machine operator and will invalidate your factory warranty. For your safety and to avoid
electrical shock, please observe all safety notes and precautions detailed throughout this
manual.
Return to Master TOC
Return to Section TOC
If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.
DESCRIPTION
The following procedure will aid the technician in removing the power board for maintenance or replacement.
MATERIALS NEEDED
5/16” Nut Driver
Return to Section TOC
Return to Master TOC
Return to Section TOC
Return to Master TOC
3/8” Nut Driver
POWER WAVE 355M/405M
F-57
Return to Section TOC
Return to Master TOC
Return to Section TOC
Return to Master TOC
F-58
TROUBLESHOOTING AND REPAIR
POWER BOARD REMOVAL AND REPLACEMENT (continued)
F-58
FIGURE F.25 POWER BOARD LOCATION
Power Board
Return to Master TOC
Return to Section TOC
LEFT SIDE
PROCEDURE
1. Remove input power to the POWER WAVE
355M/405M.
Return to Master TOC
Return to Section TOC
2. Using a 5/16” nut driver remove the case wraparound cover.
3. Perform the Input Filter Capacitor Discharge
Procedure detailed earlier in this section.
4. Locate the power board. See Figure F.25.
POWER WAVE 355M/405M
Return to Master TOC
Return to Section TOC
F-59
TROUBLESHOOTING AND REPAIR
POWER BOARD REMOVAL AND REPLACEMENT (continued)
7. Remove the three nuts at the corners of the board
using a 3/8” nut driver. Board is ready for removal.
CAUTION
8. Replace the power board.
Observe static precautions detailed in PC
Board Troubleshooting Procedures at the
beginning of this section.
Return to Master TOC
Return to Section TOC
5. Locate the three plug connections. J41, J42 and
J43 on the Power Board. See figure F.26.
Return to Section TOC
Return to Master TOC
Return to Master TOC
9. Secure the new power board into its proper position with the three 3/8” nuts previously removed.
10. Reconnect the three plugs previously removed.
Plugs J41, J42 and J43.
11. Replace the case wraparound cover.
6. Carefully disconnect the three plugs from the
Power Board.
FIGURE F.26 – POWER BOARD LEAD LOCATION
J42
Return to Section TOC
F-59
J41
POWER WAVE 355M/405M
J43
Return to Section TOC
Return to Master TOC
Return to Section TOC
Return to Master TOC
Return to Master TOC
Return to Section TOC
Return to Master TOC
Return to Section TOC
F-60
NOTES
POWER WAVE 355M/405M
F-60
Return to Master TOC
Return to Section TOC
F-61
TROUBLESHOOTING AND REPAIR
DC BUS BOARD REMOVAL AND REPLACEMENT
WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician
or machine operator and will invalidate your factory warranty. For your safety and to avoid
electrical shock, please observe all safety notes and precautions detailed throughout this
manual.
Return to Master TOC
Return to Section TOC
If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.
DESCRIPTION
The following procedure will aid the technician in removing the DC Bus Board for maintenance or replacement.
MATERIALS NEEDED
5/16” Nut Driver
3/8” Open End Wrench
Flat Head Screwdriver
Return to Section TOC
Return to Master TOC
Return to Section TOC
Return to Master TOC
Phillips Head Screwdriver
POWER WAVE 355M/405M
F-61
Return to Master TOC
Return to Section TOC
F-62
TROUBLESHOOTING AND REPAIR
DC BUS BOARD REMOVAL AND REPLACEMENT (continued)
PROCEDURE
1. Remove input power to the POWER WAVE
355M/405M.
2. Using a 5/16” nut driver remove the case wraparound cover.
3. Perform the Input Filter Capacitor Discharge
Procedure detailed earlier in this section.
Return to Section TOC
Return to Master TOC
Return to Section TOC
Return to Master TOC
4. Locate the DC Bus Board. See Figure F.27.
5. Using a 5/16” nut driver remove the two screws
from the bottom of the front of the machine. See
Figure F.28.
6. Using a phillips head screwdriver remove the two
screws and their washers from above and below
the input power switch. See Figure F.28.
7. Using a phillips head screwdriver remove the four
screws mounting the two welder output terminals
on the front of the machine. See Figure F.28.
8. The front of the machine may now gently be pulled
forward to gain access to the DC Bus Board.
Note: The front of the machine cannot be removed
completely, only pulled forward a few inches.
FIGURE F.27 DC BUS BOARD LOCATION
DC BUS BOARD
ST
AT
U
S
TH
ER
MA
L
LIN
CO
EL LN
EC
TR
WA
RN
IN
IC
G
RE
MO
TE
PO
WE
R
ON
Return to Master TOC
OF
Return to Section TOC
F-62
F
POWER WAVE 355M/405M
Return to Section TOC
Return to Master TOC
Return to Section TOC
Return to Master TOC
F-63
TROUBLESHOOTING AND REPAIR
DC BUS BOARD REMOVAL AND REPLACEMENT (continued)
F-63
FIGURE F.28 CASE FRONT SCREW REMOVAL
STA
ATUS
ST
THERMAL
Phillips Head
Screws
Phillips Head
Screws
_
+
5/16"
Mounting Screws
9. Label and remove two thermostat leads and four
leads from the bus rectifier.
13. Reconnect previously removed leads to their proper locations.
10. Using a 3/8” open end wrench, remove the three
DC Bus Board mounting nuts. See Figure F.29.
14. Replace the four phillips head screws mounting
the two welder output terminals to the front of the
machine.
Return to Master TOC
Return to Master TOC
12. Secure the new DC Bus Board in its proper location using the 3/8” mounting nuts.
15. Replace the two phillips head screws from above
and below the input power switch.
FIGURE F.29 CASE FRONT SCREW REMOVAL
J47
Bus
Rectifier
3/8" Mounting
Nuts
L11078-1
Return to Section TOC
Return to Section TOC
11. Replace the DC Bus Board.
J46
POWER WAVE 355M/405M
Thermostat
Return to Master TOC
TROUBLESHOOTING AND REPAIR
DC BUS BOARD REMOVAL AND REPLACEMENT (continued)
16. Replace the two 5/16” mounting screws to the
bottom of the case front.
17. Replace the case wraparound cover.
Return to Master TOC
Return to Master TOC
Return to Master TOC
Return to Section TOC
Return to Section TOC
Return to Section TOC
Return to Section TOC
F-64
POWER WAVE 355M/405M
F-64
Return to Master TOC
Return to Section TOC
F-65
TROUBLESHOOTING AND REPAIR
INPUT RECTIFIER REMOVAL AND REPLACEMENT
WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician
or machine operator and will invalidate your factory warranty. For your safety and to avoid
electrical shock, please observe all safety notes and precautions detailed throughout this
manual.
Return to Master TOC
Return to Section TOC
If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.
DESCRIPTION
The following procedure will aid the technician in removing the input rectifier for maintenance or replacement.
MATERIALS NEEDED
3/16” Allen wrench
5/16” Nut Driver
Flathead Screwdriver
Penetrox A-13 Heatsink Compound
Return to Section TOC
Return to Master TOC
Return to Section TOC
Return to Master TOC
Silicon Sealant
POWER WAVE 355M/405M
F-65
Return to Master TOC
Return to Master TOC
Return to Master TOC
Return to Section TOC
Return to Section TOC
Return to Section TOC
F-66
TROUBLESHOOTING AND REPAIR
INPUT RECTIFIER REMOVAL AND REPLACEMENT (continued)
PROCEDURE
1. Remove input power to the POWER WAVE
355M/405M.
2. Using a 5/16” nut driver remove the case
wraparound cover.
6. Remove the six screws from the terminals using a
flathead screwdriver. Carefully note the position of
all leads and their positions upon removal. See
Figure F.31.
3. Perform the Input Filter Capacitor Discharge
Procedure detailed earlier in this section.
7. Using a 3/16”in. allen wrench remove the two
mounting screws and washers from the input
bridge. See Figure F.31.
4. Locate the input rectifier. See figure F.30.
8. Remove the input bridge.
5. Carefully remove the silicon sealant insulating the
six input rectifier terminals.
NOTE: Any instructions that are packaged with the
replacement board will supercede these
instructions.
FIGURE F.30 – INPUT RECTIFIER LOCATION
INPUT
RECTIFIER
ST
AT
US
TH
ER
MA
L
LIN
CO
EL LN
EC
TR
IC
WA
RN
IN
G
R EM
O TE
Return to Master TOC
PO
Return to Section TOC
F-66
W
ER
ON
O FF
POWER WAVE 355M/405M
Return to Master TOC
Return to Section TOC
F-67
TROUBLESHOOTING AND REPAIR
INPUT RECTIFIER REMOVAL AND REPLACEMENT (continued)
9. Apply a thin coat of Penetrox A-13 heatsink compound to the point of contact between the input
rectifier and the mounting surface.
10. Secure the new input bridge into its proper position with the two 3/16”in. allen mounting screws
previously removed. Torque to 44 inch pounds.
11. Reconnect the previously removed leads to their
proper locations. Torque to 31 inch pounds.
12. Cover the input rectifier and its six terminals with
silicon sealant.
13. Replace the case wraparound cover.
Return to Master TOC
Return to Section TOC
FIGURE F.31 – INPUT RECTIFIER (CLOSE-UP)
Small Lead "H1"
To Auxiliary Transformer
B
C
3/16" ALLEN
BOLTS
#207
Return to Master TOC
Return to Section TOC
#207A
A
#209
Return to Master TOC
Return to Section TOC
FRONT
REAR
F-67
Small Lead "A"
To Circuit Breaker
POWER WAVE 355M/405M
Return to Section TOC
Return to Master TOC
Return to Section TOC
Return to Master TOC
Return to Master TOC
Return to Section TOC
Return to Master TOC
Return to Section TOC
F-68
NOTES
POWER WAVE 355M/405M
F-68
Return to Master TOC
Return to Section TOC
F-69
TROUBLESHOOTING AND REPAIR
OUTPUT RECTIFIER MODULES REMOVAL AND REPLACEMENT
WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician
or machine operator and will invalidate your factory warranty. For your safety and to avoid
electrical shock, please observe all safety notes and precautions detailed throughout this
manual.
Return to Master TOC
Return to Section TOC
If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.
DESCRIPTION
The following procedure will aid the technician in removing the output rectifier modules
for maintenance or replacement.
MATERIALS NEEDED
3/16” Allen wrench
9/64” Allen wrench
5/16” Nut Driver
7/16” Wrench
Flathead Screwdriver
Return to Section TOC
Return to Master TOC
Return to Section TOC
Return to Master TOC
Penetrox A-13 Heatsink Compound
Thin Knife/Screwdriver
POWER WAVE 355M/405M
F-69
TROUBLESHOOTING AND REPAIR
Return to Master TOC
Return to Section TOC
F-70
OUTPUT RECTIFIER MODULES REMOVAL AND REPLACEMENT (con’t)
PROCEDURE
1. Remove input power to the POWER WAVE
355M/405M.
2. Using a 5/16” nut driver remove the case wraparound cover.
3. Perform the Input Filter Capacitor Discharge
Procedure detailed earlier in this section.
Return to Master TOC
Return to Section TOC
4. Locate the output diode modules located behind
the snubber board. See figure F.32.
6. After the snubber board is removed, remove the
four leads connected to the modules using a 3/16”
allen wrench. These leads are #X4, #X2, #20, #40.
Note their positions for reassembly. See Figure
F.33.
7. Remove the copper plates from the tops of the
modules.
NOTE: Any instructions that are packaged with the
replacement part will supercede these instructions.
5. Before the output rectifier modules can be
reached, the Snubber Board Removal
Procedure must be performed.
FIGURE F.32 – OUTPUT RECTIFIER MODULE LEAD LOCATIONS
Return to Master TOC
Return to Section TOC
Output Diode
Modules
Snubber
Board
Return to Master TOC
LEFT SIDE
Return to Section TOC
F-70
POWER WAVE 355M/405M
TROUBLESHOOTING AND REPAIR
Return to Master TOC
Return to Master TOC
Return to Section TOC
Return to Section TOC
F-71
OUTPUT RECTIFIER MODULES REMOVAL AND REPLACEMENT (con’t)
8. Under the copper plate previously removed, there
is an allen bolt. Remove it using a 9/64” allen
wrench. See Figure F.33.
13. The screw threads may catch on the threads of
the heat sink, so be sure to get the face of the
screw into contact with the surface of the module
(using just hand torque).
9. Using a 7/16” socket remove the mounting bolts at
the top and bottom of the modules. See Figure
F.33.
14. Using a 7/16” socket, tighten each mounting bolt
to between 5 and 10 inch pounds.
10. The output rectifier modules are ready for removal
and/or replacement.
15 Tighten the center allen screw to between 12 and
18 inch pounds.
11. Before replacing the diode module, apply a thin
even coat of Penetrox A-13 heatsink compound
to the bottom surface of the diode module. Note:
Keep the compound away from the mounting
holes.
16. Tighten each mounting bolt again (30 to 40 inch
pounds this time).
12. Press the module firmly against the sink while
aligning the mounting holes. Insert each outer
screw through a spring washer and then a plain
washer and into the holes. Start threading all
three screws into the heat sink (2 or 3 turns by
hand).
15. Replace leads #X2, #X4, #20, #40 to their original
terminals in their proper positions. Torque bolts to
30-40 Inch Pounds.
16. Perform the Snubber Board Replacement
Procedure detailed earlier in this section.
17. Replace the case wraparound cover.
FIGURE F.33 – OUTPUT RECTIFIER MODULE MOUNTING BOLT LOCATIONS
Return to Section TOC
Return to Master TOC
Return to Master TOC
40
Return to Section TOC
F-71
20
Mounting
Bolts
X4 X2
3/16" Allen
Bolts
9/64" Allen
Bolts
Mounting
Bolts
POWER WAVE 355M/405M
Return to Section TOC
Return to Master TOC
Return to Section TOC
Return to Master TOC
Return to Master TOC
Return to Section TOC
Return to Master TOC
Return to Section TOC
F-72
NOTES
POWER WAVE 355M/405M
F-72
TROUBLESHOOTING AND REPAIR
Return to Master TOC
Return to Section TOC
F-73
CURRENT TRANSDUCER REMOVAL AND REPLACEMENT
WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician
or machine operator and will invalidate your factory warranty. For your safety and to avoid
electrical shock, please observe all safety notes and precautions detailed throughout this
manual.
Return to Master TOC
Return to Section TOC
If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.
DESCRIPTION
The following procedure will aid the technician in removing the current transducer for
maintenance or replacement.
MATERIALS NEEDED
5/16” Nut Driver
1/4” Nut Driver
1/2” Nut driver
3/8” Nut Driver
Channel Locks
Flathead Screwdriver
Return to Section TOC
Return to Master TOC
Return to Section TOC
Return to Master TOC
Phillips Head Screwdriver
Hammer
Crescent Wrench
Pliers
POWER WAVE 355M/405M
F-73
TROUBLESHOOTING AND REPAIR
Return to Master TOC
Return to Section TOC
F-74
CURRENT TRANSDUCER REMOVAL AND REPLACEMENT (continued)
PROCEDURE
4. Using a 5/16” nut driver remove the four screws
from the bottom and right side of the rear assembly. See Figure F.34.
1. Remove input power to the POWER WAVE
355M/405M.
2. Using a 5/16” nut driver remove the case wraparound cover.
3. Perform the Input Filter Capacitor Discharge
Procedure detailed earlier in this section.
Return to Master TOC
Return to Section TOC
FIGURE F.34 – CASE BACK SCREW LOCATIONS
REAR
OFF
OFF
Return to Master TOC
Return to Section TOC
OFF
Return to Master TOC
Plastic
Nut
Return to Section TOC
F-74
5/16" Mounting Screws
POWER WAVE 355M/405M
TROUBLESHOOTING AND REPAIR
Return to Master TOC
Return to Section TOC
F-75
F-75
CURRENT TRANSDUCER REMOVAL AND REPLACEMENT (continued)
5. Label and remove the four leads connected to the
reconnect panel. Pliers may be necessary.
6. Label and remove the two leads connected to the
CB2 circuit breaker.
7. Using a crescent wrench, remove the large plastic
nut from around the input power line located at bottom of the rear assembly. See Figure F.35.
9. Using a hammer and a flathead screwdriver, firmly
tap the metal nut from the bottom of one of its ribs.
This tapping will loosen the nut. Note: Be sure to
tap from the bottom so the nut loosens in a counter
clockwise fashion if viewed from the front of the
machine.
10. Using a 3/8” nut driver label and remove leads
#202, #203, #206, #207A from the reconnect
switches. See Figure F.35.
FIGURE F.35 LEAD LOCATIONS
Return to Master TOC
Return to Section TOC
8. Locate the steel nut located directly on the other
side of the rear assembly behind the plastic nut
that was previously removed. See Figure F.35.
#206
#202
#207A
Return to Master TOC
Return to Section TOC
#203
ST
AT
US
TH
ER
M
AL
LIN
CO
EL LN
EC
TR
IC
WA
RN
IN
G
R EM
O TE
PO
ON
Return to Master TOC
Return to Section TOC
O FF
W
ER
t
u
ut
N
N
l
a
t
tic
e
s
M Pla
POWER WAVE 355M/405M
TROUBLESHOOTING AND REPAIR
Return to Master TOC
Return to Section TOC
F-76
CURRENT TRANSDUCER REMOVAL AND REPLACEMENT (continued)
11. The back of the machine may now gently be
pulled away to gain access to the current transducer. Note: The rear of the machine cannot be
removed completely.
16. Using a 3/8” wrench, remove the three mounting
screws from the output diode heatsink assembly.
Take note placement of insulation for reassembly.
See Figure F.36.
12. Carefully swing the rear of the machine open to
the left while facing the rear of the machine.
17. Cut any necessary cable ties and carefully remove
the heavy lead from the diode heatsink using a
1/2” nut driver.
Return to Master TOC
Return to Section TOC
13. Perform the
Procedure.
Snubber
Board
Removal
18. Remove the output diode heatsink assembly
through the rear of the machine.
14. Remove leads #X2 and #20 from the output diode
module.
19. Remove plug #J90 from the current transducer.
15. Remove leads #X4 and #40 from the other output
diode module.
20. Using a 3/8” nut driver, remove the two mounting
nuts from the current transducer.
FIGURE F.36 – OUTPUT HEATSINK MOUNTING SCREW LOCATION
Return to Section TOC
Return to Master TOC
Return to Master TOC
3/8"
MOUNTING
BOLTS
Return to Section TOC
F-76
POWER WAVE 355M/405M
Return to Master TOC
Return to Section TOC
F-77
TROUBLESHOOTING AND REPAIR
CURRENT TRANSDUCER REMOVAL AND REPLACEMENT (continued)
29. The rear of the machine may now be placed back
into its original position.
21. Replace the current transducer.
22. Replace the two 3/8” mounting nuts previously
removed.
23. Reconnect plug #J90 to the current transducer.
24. Replace any necessary cable ties previously cut.
Return to Master TOC
Return to Section TOC
25. From the rear of the machine, replace the heavy
flex lead to the bottom of the output diode
heatsink assembly using a 1/2” wrench. Note:
Don’t forget to include all washers.
30. Using a 3/8” wrench, replace leads #202, #203,
#206, and #207A previously removed from the
reconnect switches.
31. Tighten the metal nut previously removed from the
inside of the rear wall on the back of the machine.
Channel locks may be necessary.
32. Replace the large plastic nut from around input
power line located at the back of the machine.
26. Replace the output diode heatsink assembly previously removed using a 3/8” wrench.
33. Replace the four leads to the reconnect panel in
their proper locations.
Note: Be sure to place insulation in its original
location.
34. Replace the two CB2 circuit breaker leads previously removed.
27. Replace leads X2, #20, X4, #40 previously
removed from the two output diode modules.
Torque to 30-40 inch lbs.
35. Using a 5/16” nut driver, replace the four screws
from the rear assembly.
36. Replace the case wraparound cover.
Return to Section TOC
Return to Master TOC
Return to Master TOC
28. Perform the Snubber Board Replacement
Procedure.
Return to Section TOC
F-77
POWER WAVE 355M/405M
TROUBLESHOOTING AND REPAIR
Return to Master TOC
Return to Section TOC
F-78
F-78
RETEST AFTER REPAIR
Retest a machine:
If it is rejected under test for any reason that requires you to remove any part which could affect the machine’s
electrical characteristics.
OR
Return to Master TOC
Return to Section TOC
If you repair or replace any electrical components.
INPUT IDLE AMPS AND WATTS
Input Volts/Hertz
Maximum Idle Amps
Maximum Idle KW
208/60
230/60
400/60
460/60
575/60
4.0
3.3
2.1
2.0
1.8
0.45
0.45
0.45
0.45
0.45
MAXIMUM OUTPUT VOLTAGES
Return to Section TOC
Return to Master TOC
Return to Section TOC
Return to Master TOC
Input Volts/Hertz
208/60
230/60
400/60
460/60
575/60
Output Terminals
- No load
50-70 VDC
X1 - X2
115 Volt Receptacles
OCV
10 Amp Load
115 - 123 VAC
111 - 119 VAC
48.5 - 55 VDC
POWER WAVE 355M/405M
TABLE OF CONTENTS - DIAGRAM SECTION
Return to Master TOC
G-1
G-1
Electrical Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-1
Wiring Diagram (G4131) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-2
Entire Machine Schematic (G4132) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-3
Control PC Board Schematic #1 (G3789-1D0/1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-4
Control PC Board Schematic #2 (G3789-1D0/2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-5
Return to Master TOC
Control PC Board Schematic #3 (G3789-1D0/3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-6
Control PC Board Schematic #4 (G3789-1D0/4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-7
Control PC Board Assembly (S25385-[ ]for 355, S25425-[ ] for 405) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .*
Digital Power Supply PC Board Schematic (G3631) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-8
Digital Power Supply PC Board Assembly (G3632-[ ]) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .*
Switch PC Board Schematic (L11487) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-9
Switch PC Board Assembly (G3830-[ ]) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-10
Snubber PC Board Schematic (S24761) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-11
Snubber PC Board Assembly (M19532-[ ]) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-12
Return to Master TOC
Return to Master TOC
40 VDC Buss PC Board Schematic (M19330) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-13
40 VDC Buss PC Board Assembly (L11832-[ ]) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .*
* NOTE:
Many PC Board Assemblies are now totally encapsulated and are therefore considered to be
unserviceable. The Assembly drawings are provided for reference only.
POWER WAVE 355M/405M
ELECTRICAL DIAGRAMS
RIGHT SIDE OF MACHINE
202
REAR OF MACHINE
CB3
INPUT
BRIDGE
A
H4
380415V
440460V
H5
N.F.
209
H2
200208V
207A
220230V
207
H3
MAIN
TRANSFORMER
+
_
E
_
D
F
A
A
A
TP1
N.E.
COM2
115V
42V
NOTES:
532
CB2
32A
31
31B
31D
PW405
MODEL
30
L2
REACTOR
10
B
TP2
C
H1
C
X2
X4
30
602
2
1
3
4
J47
SNB
COM1A
CB2
S
N
U
B
B
E
R
41
~
41
42
66C
66B
66
65B
CONTROL
RECTIFIER
32A
31B
CURRENT
TRANSDUCER
PW355
MODEL
N.A. 1. FOR MACHINES WITH RED, BLACK AND WHITE POWER CORDSFOR SINGLE PHASE INPUT: CONNECT GREEN LEAD TO GROUND PER NATIONAL ELECTRICAL
CODE. CONNECT BLACK AND WHITE LEADS TO SUPPLY CIRCUIT. WRAP RED LEAD WITH TAPE
TO PROVIDE 600V. INSULATION.
FOR THREE PHASE INPUT; CONNECT GREEN LEAD TO GROUND PER NATIONAL ELECTRICAL
CODE. CONNECT BLACK, RED & WHITE LEADS TO SUPPLY CIRCUIT.
2. FOR MACHINES WITH BROWN, BLACK AND BLUE POWER CORDSFOR SINGLE PHASE INPUT: CONNECT GREEN/YELLOW LEAD TO GROUND PER NATIONAL
ELECTRICAL CODE. CONNECT BLUE AND BROWN LEADS TO SUPPLY CIRCUIT. WRAP BLACK
LEAD WITH TAPE TO PROVIDE 600V. INSULATION.
FOR THREE PHASE INPUT: CONNECT GREEN/YELLOW GROUND PER NATIONAL ELECTRICAL
CODE. CONNECT BLUE, BLACK & BROWN LEADS TO SUPPLY CIRCUIT.
N.B.
N.C.
N.D.
N.E.
N.F.
8
802
806
801
2
6
8
16
1
51
7
3
477
6
2
4
1
7
7
2
1
J90
1 234
C5
3
16
6
14
4
12
5
15
13
3
11
1
9
2
4
1
5
3
6
1
3
2
J5
3
5
4
9
3
J4
8
2
10
7
J3
5
1
9
4
J2
8
3
3
4
7
2
1
2
253
251
254
403A
1
WIRE FEEDER
RECEPTACLE
L3
4
J41
7
2
8
J43
3
9
4
10
5
53
A
54
B
903
LEFT SIDE OF MACHINE
SINCE COMPONENTS OR CIRCUITRY OF A PRINTED CIRCUIT BOARD MAY CHANGE WITHOUT AFFECTING
THE INTERCHANGEABILITY OF A COMPLETE BOARD, THIS DIAGRAM MAY NOT SHOW THE EXACT
COMPONENTS OR CIRCUITRY HAVING A COMMON CODE NUMBER.
PLACE "A" LEAD ON APPROPRIATE CONNECTION FOR INPUT VOLTAGE. CONNECTION SHOWN IS FOR
550-575V OPERATION (PW405 ONLY GO TO 415VAC)
INPUT POWER LINE FILTER IS PRESENT ONLY ON PW405.
TOP CENTER
ON PW405, MOV'S ARE IN THE INPUT POWER LINE FILTER.
PANEL
220VWINDING IS ONLY PRESENT ON PW405.
901
52
VOLTAGE SENSE
RECEPTACLE
51
3
1
2
4
( )COLORS FOR PW405
L4
G(G/Y)
R1
903B
901B
W(N)
W
R(B)
V
B(U)
U
C
B
A
LEGEND
ALL MACHINES
OPTION
COMPONENT OUTLINE
COLOR CODE:
B = BLACK
G = GREEN
R = RED
W = WHITE
U = BLUE
N = BROWN
Y = YELLOW
FRONT VIEW OF MACHINE
FAN SHROUD CASE FRONT BASE
PROTECTIVE BONDING CIRCUIT
ELECTRICAL SYMBOLS PER E1537
C
D
_
6
11 12
E
67
L5
POWER
R2
10
403
401A 401
405
402
403 406
1
14
1
401
403A 401A
408 407
405 410
412 411
402
2
FLAT SIDE OF LED
ALIGNED WITH
WHITE LEAD
25
251
254
253
J6
406
407 410
477
412 411 408 475
J42
1B
2 10
502
503
STATUS
RED/GREEN
LED
13
52
4
1W
J1
8
6
475
1
J11
4
CONTROL
BOARD
J7
12 11 10
65C
65
2W
3
THERMAL
YELLOW
LED
2B
1104
2
1
2
J10A J10B
5
15
54 53
4
7
605
610
612
611
J8
1
1103 1104
~
+
CB1
J46
DC BUS
BOARD
5
8
20
40
COM1
609
502
65C66C
65
66
4
608
616
607
615
505
506
503
OUTPUT
RECTIFIER
1
3
J9
5
4
1B
1W
B
1 5 8
31 42
532
X4 40
20
L1
REACTOR
CHOKE
10
T
OS
BO
T
OS
BO
6
2
1002 1020
1103
1001 1010
+
5201
J52-11
J52-3
X3
X2
3
804
2B
716
2W
715
504
10
J52
B
TP3
H1 H2 H3 H4 H5 H6
220V
X1
C
SE
L6
C
SE
7
901
67
201
2
PR
I-O
UT
208
A
A
N.C.
3
204
202
AUXILIARY
TRANSFORMER
Return to Master TOC
505
FAN
( 380-575VAC POSITION )
CB4
Return to Master TOC
+C2,C4
205
FAN FAN
207A
H6
Return to Section TOC
504
6
PRIMARY
RECONNECT
550575V
Return to Section TOC
3200/300 207
903
21
PR
I-IN
Return to Master TOC
Return to Section TOC
FAN
FAN
32A
31B
206
201
204
2
4
6
5
xxxxxxx
3
2
1
J22
1
203
J21
4
7
+
8
3
1010
1020
610
605
608
616
1001
1002
8
802
804
801
806
3
4
N
7
208
209
2
6
205
PR
I-I
1
FLAT SIDE OF LED
ALIGNED WITH
BLACK LEAD
203
PR
I-O
UT
5
C1,C3
3200/300
-
N.D.
J20
607
615
716
715
611
612
609
602
206
xxxxxxx
SWITCH
J52-1
G-2
WIRING DIAGRAM - POWER WAVE 355/405
xxxxxxx
INPUT
PER
N.A.
+
Return to Master TOC
WIRING DIAGRAM - POWERWAVE 355/405 - G4131
}
Return to Section TOC
G-2
1
6
J52
5
1
10
9
J1,J6,J7
8
16
J2,J5,J11,
J22, J41, J46
1
2
3
4
J9, J42
J8,J20,
J21, J47
1
3
1
4
1
4
6
5
8
7
CONNECTOR CAVITY NUMBERING SEQUENCE
(VIEWEDFROM COMPONENT SIDE OF BOARD)
J4, J43
6
J10A,
J10B
1
12
2
A
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The wiring diagram specific to your code is pasted inside one of the enclosure panels of your machine.
G4131
POWER WAVE 355M/405M
ELECTRICAL DIAGRAMS
ENGINEERING CONTROLLED CHANGE DETAIL: Released from "X"
MANUFACTURER: No
42V
42
15A
J20-7
615
J20-3
J20-5
607
715
612
66B
J46-2
66
66C
J46-3
J46-4
B-OUT
S
X3
0
X2
0
X2
2
BK-IN
X4
0
506
SNB
503
250 Ohms
FR-IN
X3
X1
X4
S
3
506
R1
903B
TP3
150V
80J
THERMOSTAT
C1/TP1 320V
.05uF 160J
600V
-
611
502
477
COMMON J47-6
52
+40VDC J47-8
FEEDER
COMMON J47-1
51
DC BUS
BOARD
(Sch. M19330)
J42-4
J42-1
J42-3
J42-5
J42-2
+5 SPI (b) J43-3
SPI
+15 SPI (b) J43-6
POWER
SUPPLY SPI GND (b) J43-12
+5 RS232 (e) J43-4
RS232
GND (e) J43-9
SUPPLY
J43-11
+20 (c) J43-8
CHOPPER GND (c) J43-2
POWER
SUPPLY +20 (d) J43-7
GND (d) J43-1
CAN
J8-1
J8-2
J8-4
J8-6
32A
2.5A
PW405
MODEL
9
16
3
4
J9,J42
1
3
J8,J20,
J21,J47
4
1
1
4
5
7
6
8
J4, J43
CONNECTOR CAVITY NUMBERING SEQUENCE
(VIEWED FROM COMPONENT SIDE OF BOARD)
6
12
J10A,
J10B
1
2
1
6
J52
10
2W
3J7
VOLTAGE / FREQUENCY CONVERTER #2 (+)
VOLTAGE / FREQUENCY CONVERTER #2 (-)
PRIMARY CURRENT SENSE #2 (-)
PRIMARY CURRENT SENSE #2 (+)
GND (a)
SOFT START CONTROL
PULSE TRANSFORMER GATE DRIVE
PULSE TRANSFORMER GATE DRIVE
+ 15 (a)
FAN CONTROL
408
410
407
412
408
410
J4-7
J4-12
J4-8
J4-10
POWERDOWN SIGNAL (HIGH=RUN)
+15V (a)
403
403A
411
411
402
401
406
405
401A
R2
10 Ohms
+5 J43-5
GND J43-10
405
21
67
54
53
1104
1103
GND (a)
-15V (a)
J4-2
+15V SPI (b)
RED/GREEN
LED
FLAT SIDE OF LED
ALIGNED WITH WHITE LEAD
+5V SPI (b)
GND SPI (b)
+5V RS232 (e)
J4-5
GND (e)
J9-6
J9-4
J11-1
J11-2
J11-4
J11-3
N.A. PC BOARD COMPONENTS SHOWN FOR REFERENCE
ONLY. ALL COMPONENTS ARE NOT SHOWN.
N.B. INPUT POWER LINE FILTER IS PRESENT ONLY ON PW405.
N.C. ON PW405, MOV's ARE IN THE INPUT POWER LINE FILTER.
N.D. PLACE "A" LEAD ON APPROPRIATE CONNECTION FOR
INPUT VOLTAGE. CONNECTION SHOWN SI FOR 550-575V
OPERATION (PW405 ONLY GO TO 415 VAC).
STATUS
+5V (a)
J4-11
J4-1
J4-6
L3
1W
THERMOSTAT
J4-3
402
401A
406
YELLOW
LED
1B
4J7
J6-5
J6-10
J10B-1
J10B-2
J6-11
J6-12
J6-15
J6-7
J7-15
J7-16
NOTES :
5
7J7
605
610
1010
1020
611
612
615
607
715
716
L4
8
THERMAL LED
THERMOSTAT
J2-1
J2-3
VOLTAGE SENSE
LINCNET
LINCNET
67
52
J1,J6,J7
2B
STATUS LED (HI FOR GREEN)
31
1
8J7
502
407
412
THERMAL
THERMAL LED
J5-3
J5-2
53
54
J2,J5,J11,
J22,J41,J46
2
1
FLAT SIDE OF LED
ALIGNED WITH BLACK LEAD
(+) STUD VOLTAGE SENSE
(-) STUD VOLTAGE SENSE
STATUS LED (HI FOR RED)
L5
31D
CURRENT FEEDBACK ( 4V=500A )
+15V
-15V
CONTROL BOARD COMMON
NEGATIVE
31B
CB4
J9-1
J9-3
901
903
503
POWER DOWN SIGNAL
+15 (a)
+5 (a)
GND (a)
SUPPLY
-15 (a)
J41-2
+40 VDC
J41-1
475
801
802
804
806
+15V
MAIN RELAY CONTROL
VOLTAGE / FREQUENCY CONVERTER #1 (+)
VOLTAGE / FREQUENCY CONVERTER #1 (-)
PRIMARY CURRENT SENSE #1 (-)
PRIMARY CURRENT SENSE #1 (+)
C2/TP2
320V
.05uF 160J
600V
505
POWER MACHINE
BOARD CONTROL
(Sch. G3631) POWER
J6-9
J6-2
J6-16
J6-8
J10A-1
J10A-2
J52-11
J52-3
CB2
532 2.5A
B1
901B
POSITIVE
504
+40VDC POWER J47-3
32A
MAIN CHOKE
+
505
J46-1
65
65C
PW355
MODEL
SEE BELOW
FOR PW405
J52-1
REACTOR
504
C5
41
SOFT
START
801
802
804
806
CURRENT
TRANSDUCER
1010
1020
31B
65B
42
201
(+)
J20-1
FAN
32A
COM1A
J21-4
J21-8
+15
I OUT J90-3
+15V J90-1
-15V J90-2
GND J90-4
609
602
616
608
1001
1002
CONTROL BOARD
(Sch. G3789)
51
21
251
253
254
J2-4
13
WIRE FEEDER
RECEPTACLE
25
251
254
253
A LINCNET -
B LINCNET +
C ELECTRODE SENSE
14
1
D +40 VDC
E 0VDC
VOLTAGE SENSE
RECEPTACLE
1
2
3
4
ELECTRICAL SYMBOLS PER E1537
LEGEND
ALL MACHINES
OPTION
COMPONENT OUTLINE
DOCUMENT CONTAINS PROPRIETARY INFORMATION OWNED BY LINCOLN GLOBAL, INC. AND MAY NOT BE DUPLICATED, COMMUNICATED
PROPRIETARY& CONFIDENTIAL:THIS
TO OTHER PARTIES OR USED FOR ANY PURPOSE WITHOUT THE EXPRESS WRITTEN PERMISSION OF LINCOLN GLOBAL, INC.
UNLESS OTHERWISE SPECIFIED TOLERANCE
MANUFACTURING TOLERANCE PER E2056 DESIGN INFORMATION
REFERENCE:
ON ALL ANGLES IS ± .5 OF A DEGREE
MATERIAL TOLERANCE (" t ") TO AGREE
WITH PUBLISHED STANDARDS.
SCALE:
ON 2 PLACE DECIMALS IS ± .02
EN-170
ON 3 PLACE DECIMALS IS ± .002
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
DO NOT SCALE THIS DRAWING
DRAWN BY:
ENGINEER:
F.Valencic
L.Petrila
APPROVED: J.O'Connor
G4093
NONE
EQUIPMENT TYPE:
SUBJECT:
MATERIAL
DISPOSITION:
RW
APPROVAL
DATE:
POWERWAVE 355/405
MACHINE SCHEMATIC
7/15/02
PROJECT
NUMBER:
CRM33683
1
1 OF ___
PAGE ___
DOCUMENT
NUMBER:
G4132
DOCUMENT
REVISION:
A
SOLID EDGE
J20-2
FAN CONTROL
J20-6
J22-4
J22-1
J22-2
FAN POWER
J22-3
(200-208)
(220-230)
(380-415)
(440-460)
(550-575)
H1
H2
H3
H4
H5
H6
COM2
COM1
FAN
J52-8
115V
J52-5
220V
J52-1
-
716
610
J21-3
xxxxxxx
Return to Master TOC
FAN
115 VAC
605
xxxxxxx
CB2
2.5A
4200 uF
(-)
CB1
5201
Return to Master TOC
207
Shown connected for
200 - 240 Volt Input Voltage
532
V/F CONVERTER # 2
PULSE
TRANSFORMER
Dashed lines represent
copper bus connections.
31B
J21-7
B-IN S
CB3
N.D.
AUXILIARY
TRANSFORMER
-
X1
0
4200 uF
OUTPUT
DIODES
S
6.0A
204
A-OUT
NEG
MAIN TRANSFORMER
202
A
GND
208
+
Return to Master TOC
A
AC2
AC1
-
203
REACTOR
S
TP1
J21-2 608
J21-1 1001
J21-5 1002
SNUBBER
BOARD
(Sch. S24761)
S
B
4200 uF
POS
AC3
J21-6 616
V/F CONVERTER # 1
+
( ) COLOR FOR PW405
TP3 TP2
-
+
G GREEN
(GREEN/YELLOW)
H1
C
31
Return to Section TOC
205
6
4200 uF
L1
W WHITE
(BROWN)
INPUT
L2
LINES V RED
(BLACK)
L3
U BLACK
(BLUE)
Return to Section TOC
N.C.
N.B.
602
J20-8
CR1
206
609
J20-4
S
7
209
RECONNECT SWITCH
+15
MAIN
CR1
INPUT
RELAY
A-IN
SWITCH BOARD
(Sch. L11487)
INPUT SWITCH
Return to Section TOC
G-3
xxxxxxx
G4132
Return to Master TOC
SCHEMATIC - COMPLETE MACHINE
+
Return to Section TOC
G-3
POWER WAVE 355M/405M
Return to Master TOC
SCHEMATIC - DIGITAL CONTROL PC BOARD #1
ELECTRICAL DIAGRAMS
G-4
Return to Master TOC
Return to Master TOC
Return to Master TOC
Return to Section TOC
Return to Section TOC
Return to Section TOC
Return to Section TOC
G-4
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
POWER WAVE 355M/405M
Return to Master TOC
SCHEMATIC - DIGITAL CONTROL PC BOARD #2
ELECTRICAL DIAGRAMS
G-5
Return to Master TOC
Return to Master TOC
Return to Master TOC
Return to Section TOC
Return to Section TOC
Return to Section TOC
Return to Section TOC
G-5
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
POWER WAVE 355M/405M
Return to Master TOC
SCHEMATIC - DIGITAL CONTROL PC BOARD #3
ELECTRICAL DIAGRAMS
G-6
Return to Master TOC
Return to Master TOC
Return to Master TOC
Return to Section TOC
Return to Section TOC
Return to Section TOC
Return to Section TOC
G-6
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
POWER WAVE 355M/405M
Return to Master TOC
SCHEMATIC - DIGITAL CONTROL PC BOARD #4
ELECTRICAL DIAGRAMS
G-7
Return to Master TOC
Return to Master TOC
Return to Master TOC
Return to Section TOC
Return to Section TOC
Return to Section TOC
Return to Section TOC
G-7
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
POWER WAVE 355M/405M
ELECTRICAL DIAGRAMS
Return to Master TOC
Return to Section TOC
G-8
SCHEMATIC - POWER SUPPLY PRINTED CIRCUIT BOARD
G-8
+5V
Machine Control Power Supply
R50
D18
R9
D22
1.0A
30V
11
VCC
OUT
6
8
VREF
VFB
2
4
RT/CT
COMP 1
5
GND
CS
R5
100K
100K
IN
X8
5
R15
R16
OCI1
1
OUT
CNY17-3
2
6
4
C11
22
35V
T1
475
C14
0.1
50V
C47
1.0
35V
1.21K
.33W
Vfb1
R52
1.82K
221K
R14
OV1
R46
D21
1.0A
30V
R3
6.19K
7
4
6
C7
0.1
50V
C6
4.7
35V
C8
820p
50V
R39
R12
56.2K
5.62K
C45
150p
100V
3W
0.05
C32
10p
100V
J41
3
C42
R13
2700p
50V
10.0K
1
GND
C44
0.1
50V
C38
4.7
35V
C40
1.0
35V
8
DZ1
24V
3W
30.1
30.1
R36
R35
IN
R26
1.00K
D2
1A
600V
1
CNY17-3
2
R34
C26
1
200V
150p
100V
OUT
6
VREF
VFB
2
4
RT/CT
COMP 1
5
GND
CS
G
R32
15.0
D20
1.0A
30V
Vfb2
75K
C53
.1
OV2
C4
820p
50V
S
R31
3
X4
C2
0.1
50V
C3
4.7
35V
Overvoltage
Shutdown
D10
R29
Q2
21A
200V
J43
DZ7
18V
3W
3
R28
56.2K
5.62K
249
3W
0.05
J43
R40
3
+t
.13
60V
D16
16A
200V
LED1
2
+5Volts, 3 Amps
150
.33W
X7
IN
5
OUT
1A
600V
1
C5
0.1
50V
C30
1.0
35V
R44
GND
C1
4.7
35V
T2
150
.33W
+5Volts, .100 Amp
OCI3
CNY17-3
8
6
J43
+t
D7
1A
600V
10
9
2
.24
C17
4.7
35V
T2
C18
4.7
35V
C21
0.1
50V
2.49K
.33W
C46
150p
100V
.24
150
.33W
T2
8
RS232
C20
4.7
35V
C19
4.7
35V
C22
0.1
50V
R23
+5Volts, .100 Amp
R25
10
7
C29
1.0
35V
2700p
50V
10.0K
+t
D6
1A
600V
GND
C9
0.1
50V
C16
R22
7
4
OUT
1.82K
R20
J43
R24
J43
X6
C10
4.7
35V
Vfb2
R21
J43
D1
1A
600V
4
475K
2
5
6
+20Volts
.200 Amps
Gate Drive
D12
IN
5
J43
R17
CAN
11
T2
SPI
J43
D15
4
15
2.49K
.33W
R42
332
C33
4.7
35V
Vref 2
44.2K
150
.33W
R18
150
.33W
43.2K
C34
0.1
50V
R43
C35
100
16V
R41
C36
100
16V
13
R63
C37
100
16V
T2
D13
Return to Master TOC
15Volts, .250Amps
SPI
C28
10p
100V
D17
DZ4
3.3V
3W
1.21K
.33W
12
OV1
D14
C23
1.0
35V
C25
0.1
50V
C24
4.7
35V
T2
> 55 VDC
OV2
6
OUT
ADJ
100K
C52
150p
R38
X3
IN
D9
1A
600V
R19
5.62K
R45
gnd_mcps
VCC
8
15.0K
C27
DZ3
27V
.5W
R1
221K
7
R62
10.0K
R56
Vref 2
6
R30
6
2
D25
D
4
C49
.022
R33
J42
4
5
J42
J42
gnd_mcps
1
C31
.0015
2000V
D23
1.0A
30V
6
J42
OUT
X9
R64
5
OCI2
-15Volts, .100Amp
D8
1A
600V
T2
Operation
30-55 VDC
1.21K
.33W
ADJ
14
+5V
Undervoltage
Detect
<30VDC
8
X1
TL431 REF
5
T1
R37
1
R48
J41
DC Input (-)
DZ2
27V
.5W
Return to Section TOC
.750 Amp
1
3A
600V
J42
ADJ
T1
Machine Control
Shut Down
Capacitor
R10
D24
D19
DZ8
18V
3W
Vfb1
3
+15Volts
Q1
21A
200V
9
R55
Return to Master TOC
Return to Section TOC
+t
S
10.0
X5
4
Vref 1
R51
7
J41
12
33.2
R11
2
33.2
332
D
G
R8
DC Input (+)
Vref 1
D3
1A
600V
C39
0.1
50V
44.2K
R60
R61
C13
1
200V
C41
100
16V
10.0
10.0
J41
C43
100
16V
3
43.2K
10.0K
+5Volts, .750 Amp
10
T1
C12
.0015
2000V
R49
10.0K
R27
R2
R4
10.0K
+t
.13
60V
LED2
T1
10-55 VDC
Operation
J42
3
6A
200V
R53
R6
R7
2
47.5
R57
47.5
R58
47.5
D4
6A
200V
47.5
1
1
+20Volts
.200 Amps
Gate Drive
8
X2
TL431 REF
6
J43
11
J43
J43
9
J43
1
12
FILENAME: G3631-2D2
GENERAL INFORMATION
LAST NO. USED
ELECTRICAL SYMBOLS PER E1537
MFD ( .022/50V
CAPACITORS =
UNLESS OTHERWISE SPECIFIED)
RESISTORS = Ohms (
1/4W UNLESS OTHERWISE SPECIFIED)
1A, 400V
DIODES =
(UNLESS OTHERWISE SPECIFIED)
NOTES :
N.A. SINCE COMPONENTS OR CIRCUITRY ON A PRINTED CIRCUIT BOARD MAY CHANGE
WITHOUT AFFECTING THE INTERCHANGEABILITY OF A COMPLETE BOARD, THIS DIAGRAM MAY
NOT SHOW THE EXACT COMPONENTS OR CIRCUITRY OF CONTROLS HAVING A COMMON CODE
NUMBER.
RC-
LABELS
D-
SUPPLY
VOLTAGE NET
POWER SUPPLY SOURCE POINT
COMMON CONNECTION
FRAME CONNECTION
ON 2 PLACE DECIMALS IS ± .02
ON 3 PLACE DECIMALS IS ± .002
ON ALL ANGLES IS ± .5 OF A DEGREE
MATERIAL TOLERANCE (" t ") TO AGREE
WITH PUBLISHED STANDARDS.
"X" INFO.
Chg. Sheet No.
6-2-2000A
10-27-2000E
DO NOT SCALE THIS DRAWING
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
DESIGN INFORMATION
REFERENCE:
DRAWN BY: JP\TK
ENGINEER:
APPROVED:
SUPERSEDING:
EQUIPMENT TYPE:
SUBJECT:
SCALE: NONE
Digital Systems
Schematic, Digital Power Supply
DATE: 11-30-98 DRAWING No.:
G 3631
SOLID EDGE
UNLESS OTHERWISE SPECIFIED TOLERANCE
MANUFACTURING TOLERANCE PER E2056
EN-170
Return to Master TOC
Return to Section TOC
EARTH GROUND CONNECTION
THIS SHEET CONTAINS PROPRIETARY INFORMATION OWNED BY THE LINCOLN ELECTRIC COMPANY AND IS NOT TO BE REPRODUCED, DISCLOSED OR USED WITHOUT THE EXPRESS WRITTEN PERMISSION OF THE LINCOLN ELECTRIC COMPANY, CLEVELAND, OHIO U.S.A.
POWER WAVE 355M/405M
Return to Master TOC
SCHEMATIC - SWITCH PC BOARD
ELECTRICAL DIAGRAMS
G-9
Return to Master TOC
Return to Master TOC
Return to Master TOC
Return to Section TOC
Return to Section TOC
Return to Section TOC
Return to Section TOC
G-9
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
POWER WAVE 355M/405M
ELECTRICAL DIAGRAMS
R122
C14
DZ16
DZ15
R78
B211
R97
R87
1
2
R59
R45
DZ10
Q3
C23
R49
R48
R50
R33
A1
R68
D14
C11
B212
Q5
Q4
B204
DZ12
D12
R67
C28
R61
R69
R70
DZ18
DZ19
DZ7
DZ13
R27
DZ20
R100
Q1
DZ8
DZ5
DZ6
B206
C24
R82
R28
1
R79
R22
R26
C6
D4
R129
R53
R52
B205
N.D.
(16 PLACES)
X3
R46
R47
R134
R32
B216
R105
C16
R58
TP1
B209
N.L.
CR2
T1
J22
R138
R137
OCI1
CR1
R140
R139
C25
2
N.H.
(2 PLACES)
OCI4
D18
C27
R141
Q6
R109
D19
D7
J20
N.P.
N.N.
(2 PLACES)
N.K.
(4 PLACES)
TRI1
R30
Return to Master TOC
MANUFACTURED AS:
R132
R57
R56
R55
R36
C8
R12
R10
R11
C26
G3830-1B1
PART NO.
IDENTIFICATION CODE
NOTES:
N.A. CAUTION: THIS DEVICE IS SUBJECT TO DAMAGE BY
STATIC ELECTRICITY. LINCOLN ELECTRIC TO SEE E2454
BEFORE HANDLING.
N.B. SNAP POWER TERMINALS INTO COMPONENT SIDE OF BOARD.
N.C. THIS AREA TO BE COVERED ON BOTH SIDES OF BOARD (WHERE
POSSIBLE) WITH SEALANT PRIOR TO ENCAPSULATION.
N.D. INJECT SEALANT ITEM 8 THROUGH THE PC BOARD TO SEAL MODULE LEADS
(16 PLACES), AND ALL COMPONENT LEADS ON THE NONO-COMPONENT
SIDE OF THE BOARD, THAT ARE COVERED BY MODULE CASE.
N.E. FEMALE EYELET TO BE AGAINST THE NON-COMPONENT SIDE AS SHOWN
EYELET MUST NOT SPIN AFTER CLINCHING.
N.F. SOLDER EYELET SO THAT SOLDER COVERS ENTIRE EYELET
AND ALL AROUND EYELET ON COPPER SIDE ONLY.
NO ICICLES OR SOLDER BLOBS PERMITTED.
N.G. AFTER SOLDERING, INSPECT POWER TERMINAL CONNECTIONS
TO ENSURE SOLDER HAS PROPERLY WET COMPONENT SIDE PAD
ON A MINIMUM OF 3 OF THE 4 LEGS OF THE POWER TERMINAL.
N.H. BAR MUST BE FREE OF ENCAPSULATION MATERIAL ON BOTH SURFACES
AROUND MOUNTING HOLES AND ENTIRE LENGTH OF MOUNTING SURFACE.
ENCAPSULATION MATERIAL MUST NOT EXTEND BEYOND THE MOUNTING
SURFACE PLANE. (2 PLACES)
N.J. DO NOT COAT WITH ENCAPSULATION MATERIAL, TOP AND BOTTOM, .80 +/- .05” DIA.
N.K. PC BOARD HOLES TO BE FREE OF ENCAPSULATION MATERIAL AND SEALANT
FOR A DIAMETER OF .50” FOR THE LARGER HOLES, AND .25 FOR THE SMALLER
HOLES, BOTH SIDES OF BOARD. (4 PLACES).
N.L. THIS AREA TO BE COVERED ON COMPONENT SIDE OF BOARD WITH SEALANT
PRIOR TO ENCAPSULATION. MATERIAL MUST BE APPLIED FROM TOP TO
COMPLETELY FILL TO UNDERSIDE OF DEVICE. THEN APPLY SEALANT AROUND
BASE OF DEVICE.
N.M. THIS AREA TO BE COVERED ON OPPOSITE COMPONENT SIDE OF BOARD WITH
ITEM 8 PRIOR TO ENCAPSULATION. DO NOT COAT WITH ENCAPSULATION
MATERIAL ON THE TOP SURFACES NOR THE THREADS.
N.N. THESE SURFACES MUST BE MAINTAINEDCO-PLANAR WITHIN .010” THROUGH
ENTIRE SOLDERING AND SEALING PROCESS.
N.P. SEALANT HEIGHT BETWEEN MODULES NOT TO EXCEED .17” MAX.
REQ'D
PART NO.
IDENTIFICATION
2
2
2
2
2
2
2
4
9
S20500-4
S13490-130
S20500-7
T11577-57
S13490-93
S16668-7
S20500-1
S16668-6
S16668-5
CAPACITOR,PPMF,.0047,1000V,BOX
CAPACITOR,PCF,0.27,50V,5%
CAPACITOR,PPMF,.047,1600V,BOX,10%
CAPACITOR,PEF,0.1,400V,10%
CAPACITOR,TAEL,27,35V,10%
CAPACITOR,CEMO,820p,50V,5%
CAPACITOR,PPMF,0.1,1000V,10%,BOX
CAPACITOR,CEMO,4700p,50V,10%
CAPACITOR,CEMO,.022, 50V,20%
3
2
4
9
S16668-9
S14293-18
T12705-59
T12199-1
CAPACITOR,CEMO,150p, 100V,5%
RELAY,DPST,12VDC,AG-CDO
DIODE,AXLDS,3A,600V,UFR
DIODE,AXLDS,1A,400V
10
T12702-29
ZENER DIODE, 1W,15V,5% 1N4744A
2
4
1
4
2
1
3
1
1
4
1
16
T12702-4
T12702-40
T12702-19
T12702-45
S24016-8
S24016-4
S15000-22
S15000-29
T12704-75
T12704-73
T12704-69
T14648-5
ZENER DIODE, 1W,20V,5% 1N4747A
ZENER DIODE, 1W,6.2V,5% 1N4735A
ZENER DIODE, 1W,12V,5% 1N4742A
ZENER DIODE, 1W,18V,5% 1N4746A
CONNECTOR,MOLEX,MINI,PCB,RT-L,8-PIN
CONNECTOR,MOLEX,MINI,PCB,RT-L,4-PIN
OPTOCOUPLER,PHOTO-Q,70V,CNY17-3/VDE
OPTOCOUPLER,TRIAC,DRV,RANDOM,600V
TRANSISTOR,NMF,T247,4A,900V(SS)
MOSFET,4-PIN DIP,1A,100V,RFD110(SS)
TRANSISTOR,PNP,TO226,0.5A, 40V,2N4403
RESISTOR,WW,5W,3.3K,5%,SQ
4
6
1
1
1
2
1
12
S19400-1503
S19400-3321
S19400-3570
S19400-1500
S19400-4750
S19400-1652
S19400-39R2
S19400-10R0
RESISTOR,MF,1/4W,150K,1%
RESISTOR,MF,1/4W,3.32K,1%
RESISTOR,MF,1/4W,357,1%
RESISTOR,MF,1/4W,150,1%
RESISTOR,MF,1/4W,475,1%
RESISTOR,MF,1/4W,16.5K,1%
RESISTOR,MF,1/4W,39.2,1%
RESISTOR,MF,1/4W,10.0,1%
4
16
S19400-1000 RESISTOR,MF,1/4W,100,1%
S19400-1003 RESISTOR,MF,1/4W,100K,1%
4
3
14
S19400-6191 RESISTOR,MF,1/4W,6.19K,1%
S19400-2213 RESISTOR,MF,1/4W,221K,1%
S19400-1002 RESISTOR,MF,1/4W,10.0K,1%
2
2
2
2
9
S19400-4752
T12300-79
S19400-3322
S19400-2000
S19400-1001
RESISTOR,MF,1/4W,47.5K ,1%
RESISTOR,WW, 1W,1.0,1%
RESISTOR,MF,1/4W,33.2K,1%
RESISTOR,MF,1/4W,200,1%
RESISTOR,MF,1/4W,1.00K,1%
4
2
2
2
1
2
1
1
2
2
S24376-3
S19400-8251
S19400-2001
S16296-5
S13000-46
M19612
T13640-24
S15161-27
S15128-10
S15128-18
RESISTOR,WW,10W,100,5%
RESISTOR,MF,1/4W,8.25K,1%
RESISTOR,MF,1/4W,2.00K,1%
TRIMMER,MT,1/2W,10K, 10%,LINEAR
TRANSFORMER,PCB;
CURRENT-TRANSDUCER,125-TURN
MOV,175VRMS,120J,20MM
TRIAC,T220,8A,800V
VOLTAGE REF,ADJ, PRECISION,431I
OP-AMP,QUAD, HIGH-PERF,33074
CAPACITORS = MFD/VOLTS
INDUCTANCE = HENRIES
RESISTOR = OHMS
N.A.
ITEM
1
2
3
4
5
6
7
8
PART NO.
G3831-B
M16100-44
S23006
M19612
S24866
T9147-11
T9147-15
E2861
DESCRIPTION
P.C. BOARD BLANK
ELECTRONIC MODULE (A1, A2)
TERMINAL (B211,B218,B204,B205,B209)
CURRENT TRANSDUCER (T2, T3)
POWER TERMINAL (B201, B208)
EYELET-FEMALE
EYELET-MALE
SEALANT
QTY
1
2
5
2
2
8
8
5.0oz
MAKE PER E1911
ENCAPSULATE WITH E1844, 3 COATS
TEST PER E3817-SW
UNLESS OTHERWISE SPECIFIED TOLERANCE
MANUFACTURING TOLERANCE PER E2056
NOTE:
ON 2 PLACE DECIMALS IS ± .02
ON 3 PLACE DECIMALS IS ± .002
ON ALL ANGLES IS ± .5 OF A DEGREE
MATERIAL TOLERANCE (" t ") TO AGREE
WITH PUBLISHED STANDARDS.
DO NOT SCALE THIS DRAWING
Chg. Sheet No.
6-2-2000A
"X" INFO.
XM5626
XA
DESIGN INFORMATION
REFERENCE:
EQUIPMENT TYPE:
ENGINEER:
SUPERSEDING:
SCALE: FULL
DRAWN BY: F.V./JB
APPROVED:
SUBJECT:
INVERTER WELDERS
SWITCH P.C. BOARD ASSEMBLY
DATE:5-11-2000 DRAWING No.:
G 3830-1B1
Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your factory warranty. Individual Printed Circuit Board Components are not available from Lincoln Electric. This information is provided for reference only. Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician. Improper PC board repairs could result in damage to the
machine.
SOLID EDGE
THIS SHEET CONTAINS PROPRIETARY INFORMATION OWNED BY THE LINCOLN ELECTRIC COMPANY AND IS NOT TO BE REPRODUCED, DISCLOSED OR USED WITHOUT THE EXPRESS WRITTEN PERMISSION OF THE LINCOLN ELECTRIC COMPANY, CLEVELAND, OHIO U.S.A.
EN-170
Return to Master TOC
R133
R130
R131
R31
R7
N.B., N.G., N.M.
(5 PLACES)
B202
R101
R9
C30
R142
R143
Return to Section TOC
R8
3
D17
R106
R29
N.K.
(4 PLACES)
EYELET DETAIL
DZ23
A2
C2
NON-COMPONENT
SIDE
R128
DZ1
R6
.275
.285
N.J.
(8 PLACES)
C21
R81
R80
R66
D20
C7
R51
R34
C13
C20
R5
B217
D16
C31
R35
R60
C4
C1
∅
N.C.
Q2
R44
C10
DZ2
R93
C15
4
B207
R99
R86
D9
B201
R98
DZ17
R41
R43
DZ9
D1
R85
C12
DZ3
B218
C29
R77
R75
R63
D8
R40
R42
DZ4
R21
R19
C5
.105
CRIMP
HEIGHT
MAX.
R84
R62
R76
R64
R74
R73
R120
B208
X2
R15
R .045
R135
R72
C32
R39
R38
R20
B213
X4
C18
OCI2
R125
R65
T2
T3
R4
Return to Master TOC
R92
R107
R14
R13
R3
C3
C1,C23
C10,C11
C2,C24
C25,C26
C3,C18
C31,C32
C4,C21
C5,C6,C15,C16
C7,C12,C13,C14,C20,C27,C28
C29,C30
C8,C9,C22
CR1,CR2
D1,D4,D16,D17
D7,D8,D9,D12,D14,D18,D19
D20,D21
DZ1,DZ2,DZ3,DZ5,DZ6,DZ15
DZ16,DZ18,DZ19,DZ23
DZ11,DZ22
DZ4,DZ7,DZ17,DZ20
DZ8
DZ9,DZ10,DZ12,DZ13
J20,J21
J22
OCI1,OCI2,OCI3
OCI4
N.A. Q1
N.A. Q2,Q3,Q4,Q5
Q6
R1,R2,R3,R4,R7,R8,R9,R10
R124,R125,R126,R127,R130
R131,R132,R133
R11,R12,R30,R31
R13,R39,R43,R60,R81,R92
R137
R138
R139
R14,R107
R140
R15,R20,R21,R22,R27,R28
R97,R98,R99,R100,R101,R106
R29,R83,R122,R141
R32,R33,R34,R48,R49,R50
R51,R62,R63,R74,R75,R85
R86,R87,R134,R135
R35,R52,R73,R84
R36,R37,R123
R38,R40,R42,R45,R53,R59
R66,R69,R70,R72,R80,R82
R142,R143
R41,R67
R44,R68
R46,R76
R47,R64
R5,R6,R19,R26,R93,R105
R109,R128,R129
R55,R56,R57,R58
R61,R77
R65,R120
R78,R79
T1
T2,T3
TP1
TRI1
X1,X4
X2,X3
6
7
R124
DZ11
R37
C9
OCI3
N.E., N.F.
R127
R126
R83
DZ22
R123
C22
X1
5
Return to Section TOC
J21
D21
B203
G38301
V35
0
SWITCH
R2
R1
Return to Section TOC
G-10
ITEM
2
Return to Master TOC
PC BOARD ASSEMBLY - SWITCH PC BOARD
1
Return to Section TOC
G-10
POWER WAVE 355M/405M
Return to Master TOC
Return to Master TOC
Return to Master TOC
Return to Master TOC
Return to Section TOC
Return to Section TOC
Return to Section TOC
Return to Section TOC
G-11
SCHEMATIC - SNUBBER PC BOARD
ELECTRICAL DIAGRAMS
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
G-11
6-2-2000
S24761
POWER WAVE 355M/405M
ELECTRICAL DIAGRAMS
PC BOARD ASSEMBLY - SNUBBER PC BOARD
M195321
2
R1
1
B10
R .045
.105
CRIMP
HEIGHT
MAX.
BOXCP4
2
R4
T14710
T14710
RW5F
R2
B30
1
B20
C4
B40
Return to Master TOC
0
0
.60
1.75
2.90
3.50
PART NO.
M19532-A
T13157-16
T9147-11
T9147-15
DESCRIPTION
P.C. BOARD BLANK
TAB TERMINAL
EYELET-FEMALE
EYELET-MALE
QTY
1
1
4
4
NOTES:
N.A. FEMALE EYELET TO BE AGAINST THE COPPER SIDE AS SHOWN
EYELET MUST NOT SPIN AFTER CLINCHING.
N.B. SOLDER EYELET SO THAT SOLDER COVERS ENTIRE EYELET
AND ALL AROUND EYELET ON COPPER SIDE ONLY.
NO ICICLES OR SOLDER BLOBS PERMITTED.
COPPER
SIDE
MANUFACTURED AS:
M19532-1A0
MAKE PER E1911
ENCAPSULATE WITH E1844, 2 COATS
TEST PER E3817-SN
IDENTIFICATION CODE
THIS SHEET CONTAINS PROPRIETARY INFORMATION OWNED BY THE LINCOLN ELECTRIC COMPANY AND IS NOT TO BE REPRODUCED, DISCLOSED OR USED WITHOUT THE EXPRESS WRITTEN PERMISSION OF THE LINCOLN ELECTRIC COMPANY, CLEVELAND, OHIO U.S.A.
MANUFACTURING TOLERANCE PER E2056
ON 2 PLACE DECIMALS IS ± .02
ON 3 PLACE DECIMALS IS ± .002
ON ALL ANGLES IS ± .5 OF A DEGREE
MATERIAL TOLERANCE (" t ") TO AGREE
WITH PUBLISHED STANDARDS.
EN-166
Return to Master TOC
.275
.285
+.04
UNLESS OTHERWISE SPECIFIED TOLERANCE
Return to Section TOC
∅
EYELET DETAIL
1
BOXCP4
RW5F
2
QC1
6
T14710
RW5F
T14710
BOXCP4
B1
R3
PART NO.
DESCRIPTION
S20500-4 CAPACITOR,PPMF,.0047,1000V,BOX
T14648-20 RESISTOR,WW,5W,150,5%,SQ
T14648-25 RESISTOR,WW,5W,10,5%,SQ
ITEM
1
2
3
4
BOXCP4
C1
C2
SNUBBER
4
2
.55
REQ'D
4
2
2
3
RW5F
Return to Master TOC
C3
2
Return to Section TOC
N.A., N.B.
2.90 +.04
1.92
ITEM
C1,C2,C3,C4
R1,R3
R2,R4
1
Return to Section TOC
1
G-12
DO NOT SCALE THIS DRAWING
NOTE:
Chg. Sheet No.
6-2-2000
"X" INFO.
XM5626
XC-UF
DESIGN INFORMATION
REFERENCE:
ENGINEER:
SUPERSEDING:
DRAWN BY:
APPROVED:
F.V.
EQUIPMENT TYPE:
SUBJECT:
SCALE: NONE
INVERTER WELDERS
SNUBBER P.C. BOARD ASSEMBLY
DATE: 10-6-99
DRAWING No.:
M 19532-1
Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your factory warranty. Individual Printed Circuit Board Components are not available from Lincoln Electric. This information is provided for reference only. Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician. Improper PC board repairs could result in damage to the
machine.
POWER WAVE 355M/405M
SOLID EDGE
Return to Master TOC
Return to Section TOC
G-12
Return to Master TOC
SCHEMATIC - 40 VDC BUSS PC BOARD
ELECTRICAL DIAGRAMS
G-13
Return to Master TOC
Return to Master TOC
Return to Master TOC
Return to Section TOC
Return to Section TOC
Return to Section TOC
Return to Section TOC
G-13
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
POWER WAVE 355M/405M