Lincoln Electric SVM173-A User's Manual

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SVM173-A
April, 2007
POWER WAVE 455M/STT
TM
For use with machines having Code Numbers: 10942 10957
11007 11008
11057 11153
11152
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Safety Depends on You
Lincoln arc welding and cutting
equipment is designed and built
with safety in mind. However,
your overall safety can be increased by proper installation . . .
and thoughtful operation on
your part. DO NOT INSTALL,
OPERATE OR REPAIR THIS
EQUIPMENT WITHOUT
READING THIS MANUAL AND
THE SAFETY PRECAUTIONS
CONTAINED THROUGHOUT.
And, most importantly, think
before you act and be careful.
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SERVICE MANUAL
Copyright © Lincoln Global Inc.
• World's Leader in Welding and Cutting Products •
• Sales and Service through Subsidiaries and Distributors Worldwide •
Cleveland, Ohio 44117-1199 U.S.A. TEL: 1-888-935-3877 WEB SITE: www.lincolnelectric.com
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i
i
SAFETY
WARNING
CALIFORNIA PROPOSITION 65 WARNINGS
Diesel engine exhaust and some of its constituents
are known to the State of California to cause cancer, birth defects, and other reproductive harm.
The Above For Diesel Engines
The engine exhaust from this product contains
chemicals known to the State of California to cause
cancer, birth defects, or other reproductive harm.
The Above For Gasoline Engines
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.
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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.h. To avoid scalding, do not remove the
radiator pressure cap when the engine is
hot.
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.
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
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ii
ELECTRIC SHOCK can kill.
ARC RAYS can burn.
3.a. The electrode and work (or ground) circuits
are electrically “hot” when the welder is on.
Do not touch these “hot” parts with your bare
skin or wet clothing. Wear dry, hole-free
gloves to insulate hands.
4.a. Use a shield with the proper filter and cover
plates to protect your eyes from sparks and
the rays of the arc when welding or observing
open arc welding. Headshield and filter lens
should conform to ANSI Z87. I standards.
3.b. Insulate yourself from work and ground using dry insulation.
Make certain the insulation is large enough to cover your full
area of physical contact with work and ground.
4.b. Use suitable clothing made from durable flame-resistant
material to protect your skin and that of your helpers from
the arc rays.
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.
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.
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.
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ii
SAFETY
3.g. Never dip the electrode in water for cooling.
3.h. Never simultaneously touch electrically “hot” parts of
electrode holders connected to two welders because voltage
between the two can be the total of the open circuit voltage
of both welders.
3.i. When working above floor level, use a safety belt to protect
yourself from a fall should you get a shock.
3.j. Also see Items 6.c. and 8.
FUMES AND GASES
can be dangerous.
5.a. Welding may produce fumes and gases
hazardous to health. Avoid breathing these
fumes and gases.When welding, keep
your head out of the fume. Use enough
ventilation and/or exhaust at the arc to keep
fumes and gases away from the breathing zone. When
welding with electrodes which require special
ventilation such as stainless or hard facing (see
instructions on container or MSDS) or on lead or
cadmium plated steel and other metals or coatings
which produce highly toxic fumes, keep exposure as
low as possible and below Threshold Limit Values (TLV)
using local exhaust or mechanical ventilation. In
confined spaces or in some circumstances, outdoors, a
respirator may be required. Additional precautions are
also required when welding on galvanized steel.
5. b. The operation of welding fume control equipment is affected
by various factors including proper use and positioning of the
equipment, maintenance of the equipment and the specific
welding procedure and application involved. Worker exposure level should be checked upon installation and periodically thereafter to be certain it is within applicable 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.
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5.e. Read and understand the manufacturer’s instructions for this
equipment and the consumables to be used, including the
material safety data sheet (MSDS) and follow your
employer’s safety practices. MSDS forms are available from
your welding distributor or from the manufacturer.
5.f. Also see item 1.b.
AUG ‘06
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iii
WELDING SPARKS can
cause fire or explosion.
6.a. Remove fire hazards from the welding area.
If this is not possible, cover them to prevent
the welding sparks from starting a fire.
Remember that welding sparks and hot
materials from welding can easily go through small cracks
and openings to adjacent areas. Avoid welding near
hydraulic lines. Have a fire extinguisher readily available.
6.b. Where compressed gases are to be used at the job site,
special precautions should be used to prevent hazardous
situations. Refer to “Safety in Welding and Cutting” (ANSI
Standard Z49.1) and the operating information for the
equipment being used.
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6.c. When not welding, make certain no part of the electrode
circuit is touching the work or ground. Accidental contact can
cause overheating and create a fire hazard.
6.d. Do not heat, cut or weld tanks, drums or containers until the
proper steps have been taken to insure that such procedures
will not cause flammable or toxic vapors from substances
inside. They can cause an explosion even though they have
been “cleaned”. For information, purchase “Recommended
Safe Practices for the Preparation for Welding and Cutting of
Containers and Piping That Have Held Hazardous
Substances”, AWS F4.1 from the American Welding Society
(see address above).
6.e. Vent hollow castings or containers before heating, cutting or
welding. They may explode.
6.f. Sparks and spatter are thrown from the welding arc. Wear oil
free protective garments such as leather gloves, heavy shirt,
cuffless trousers, high shoes and a cap over your hair. Wear
ear plugs when welding out of position or in confined places.
Always wear safety glasses with side shields when in a
welding area.
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iii
SAFETY
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.
7.a. Use only compressed gas cylinders
containing the correct shielding gas for the
process used and properly operating
regulators designed for the gas and
pressure used. All hoses, fittings, etc. should be suitable for
the application and maintained in good condition.
7.b. Always keep cylinders in an upright position securely
chained to an undercarriage or fixed support.
7.c. Cylinders should be located:
• Away from areas where they may be struck or subjected to
physical damage.
• A safe distance from arc welding or cutting operations and
any other source of heat, sparks, or flame.
7.d. Never allow the electrode, electrode holder or any other
electrically “hot” parts to touch a cylinder.
7.e. Keep your head and face away from the cylinder valve outlet
when opening the cylinder valve.
7.f. Valve protection caps should always be in place and hand
tight except when the cylinder is in use or connected for
use.
7.g. Read and follow the instructions on compressed gas
cylinders, associated equipment, and CGA publication P-l,
“Precautions for Safe Handling of Compressed Gases in
Cylinders,” available from the Compressed Gas Association
1235 Jefferson Davis Highway, Arlington, VA 22202.
FOR ELECTRICALLY
powered equipment.
8.a. Turn off input power using the disconnect
switch at the fuse box before working on
the equipment.
8.b. Install equipment in accordance with the U.S. National
Electrical Code, all local codes and the manufacturer’s
recommendations.
8.c. Ground the equipment in accordance with the U.S. National
Electrical Code and the manufacturer’s recommendations.
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Mar ‘95
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iv
iv
SAFETY
PRÉCAUTIONS DE SÛRETÉ
Pour votre propre protection lire et observer toutes les instructions
et les précautions de sûreté specifiques qui parraissent dans ce
manuel aussi bien que les précautions de sûreté générales suivantes:
Sûreté Pour Soudage A L’Arc
1. Protegez-vous contre la secousse électrique:
a. Les circuits à l’électrode et à la piéce sont sous tension
quand la machine à souder est en marche. Eviter toujours
tout contact entre les parties sous tension et la peau nue
ou les vétements mouillés. Porter des gants secs et sans
trous pour isoler les mains.
b. Faire trés attention de bien s’isoler de la masse quand on
soude dans des endroits humides, ou sur un plancher metallique ou des grilles metalliques, principalement dans
les positions assis ou couché pour lesquelles une grande
partie du corps peut être en contact avec la masse.
c. Maintenir le porte-électrode, la pince de masse, le câble de
soudage et la machine à souder en bon et sûr état defonctionnement.
d.Ne jamais plonger le porte-électrode dans l’eau pour le
refroidir.
e. Ne jamais toucher simultanément les parties sous tension
des porte-électrodes connectés à deux machines à souder
parce que la tension entre les deux pinces peut être le total
de la tension à vide des deux machines.
f. Si on utilise la machine à souder comme une source de
courant pour soudage semi-automatique, ces precautions
pour le porte-électrode s’applicuent aussi au pistolet de
soudage.
2. Dans le cas de travail au dessus du niveau du sol, se protéger
contre les chutes dans le cas ou on recoit un choc. Ne jamais
enrouler le câble-électrode autour de n’importe quelle partie du
corps.
3. Un coup d’arc peut être plus sévère qu’un coup de soliel, donc:
zones où l’on pique le laitier.
6. Eloigner les matériaux inflammables ou les recouvrir afin de
prévenir tout risque d’incendie dû aux étincelles.
7. Quand on ne soude pas, poser la pince à une endroit isolé de
la masse. Un court-circuit accidental peut provoquer un
échauffement et un risque d’incendie.
8. S’assurer que la masse est connectée le plus prés possible de
la zone de travail qu’il est pratique de le faire. Si on place la
masse sur la charpente de la construction ou d’autres endroits
éloignés de la zone de travail, on augmente le risque de voir
passer le courant de soudage par les chaines de levage,
câbles de grue, ou autres circuits. Cela peut provoquer des
risques d’incendie ou d’echauffement des chaines et des
câbles jusqu’à ce qu’ils se rompent.
9. Assurer une ventilation suffisante dans la zone de soudage.
Ceci est particuliérement important pour le soudage de tôles
galvanisées plombées, ou cadmiées ou tout autre métal qui
produit des fumeés toxiques.
10. Ne pas souder en présence de vapeurs de chlore provenant
d’opérations de dégraissage, nettoyage ou pistolage. La
chaleur ou les rayons de l’arc peuvent réagir avec les vapeurs
du solvant pour produire du phosgéne (gas fortement toxique)
ou autres produits irritants.
11. Pour obtenir de plus amples renseignements sur la sûreté, voir
le code “Code for safety in welding and cutting” CSA Standard
W 117.2-1974.
PRÉCAUTIONS DE SÛRETÉ POUR
LES MACHINES À SOUDER À
TRANSFORMATEUR ET À
REDRESSEUR
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.
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.
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.
3. Avant de faires des travaux à l’interieur de poste, la debrancher à l’interrupteur à la boite de fusibles.
2. Autant que possible, I’installation et l’entretien du poste seront
effectués par un électricien qualifié.
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
Mar. ‘93
v
- MASTER TABLE OF CONTENTS FOR ALL SECTIONS RETURN TO MAIN MENU
Page
Safety .................................................................................................................................................i-iv
Installation.............................................................................................................................Section A
Operation...............................................................................................................................Section B
Accessories ..........................................................................................................................Section C
Maintenance ..........................................................................................................................Section D
Theory of Operation .............................................................................................................Section E
Troubleshooting and Repair ................................................................................................Section F
Electrical Diagrams ..............................................................................................................Section G
Parts Manuals .................................................................................P438 (455M) & P450 (455M/STT)
POWER WAVE 455M/MSTT
v
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Section A
TABLE OF CONTENTS
- INSTALLATION SECTION -
Installation.............................................................................................................................Section A
Technical Specifications.......................................................................................................A-2, A-3
Safety Precautions ......................................................................................................................A-4
Select Suitable Location..............................................................................................................A-4
Lifting ....................................................................................................................................A-4
Stacking ................................................................................................................................A-4
Machine Grounding.....................................................................................................................A-4
High Frequency Protection..........................................................................................................A-4
Input Connection .........................................................................................................................A-5
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Input Fuse and Supply Wire Considerations ........................................................................A-5
Input Voltage Change Over (For Multiple Input Voltage Machines Only).............................A-6
Welding with Multiple Power Waves ...........................................................................................A-6
Electrode and Work Cable Connections .....................................................................................A-7
Negative Electrode Polarity.........................................................................................................A-7
Voltage Sensing ..........................................................................................................................A-8
Work Voltage Sensing ..........................................................................................................A-9
Electrode Voltage Sensing ...................................................................................................A-9
Power Wave / Power Feed Wire Feeder Interconnections.........................................................A-9
Control Cable Specifications ................................................................................................A-9
External I/O Connector .........................................................................................................A-9
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Dip Switch Settings and Locations .....................................................................................A-10
Control Board Dip Switch ...................................................................................................A-10
Feed Head Board Dip Switch .............................................................................................A-10
Devicenet/Gateway Board Dip Switch, Bank (S2)..............................................................A-11
POWER WAVE 455M/MSTT
Section A
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A-2
A-2
INSTALLATION
TECHNICAL SPECIFICATIONS - POWER WAVE 455M (K2202-1, K2202-3)
INPUT AT RATED OUTPUT - THREE PHASE ONLY
AMPS / VOLTS / DUTY CYCLE
INPUT
CURRENT
AMPS
208/230/460/575V - 60HZ.
450A@38V.100%
570A@43V. 60%
58/53/25/22
82/78/37/31
200/220/440/575V - 50HZ.
400A@36V.100%
500A@40V. 60%
49/45/23/18
67/61/31/25
OUTPUT
CONDITIONS
INPUT VOLTSFREQUENCY
IDLE
POWER
POWER FACTOR
@ RATED OUTPUT
EFFICIENCY
@ RATED
OUTPUT
400 Watts
Max.
.95 MIN.
88%
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OUTPUT
OPEN
PULSE
CURRENT
PULSE
CIRCUIT
RANGE FREQUENCY VOLTAGE
AMPS
VOLTAGE
RANGE
75 VDC
5 - 570A
PULSE AND
BACKGROUND
TIME RANGE
0.15 - 1000 Hz 5 - 55 VDC 100 MICRO SEC.
-3.3 SEC.
PROCESS CURRENT RANGE (DC)
AUXILIARY POWER
(CIRCUIT BREAKER PROTECTED)
40 VDC AT
10 AMPS
115VAC AT
10 AMPS
CURRENT
MIG/MAG
FCAW
SMAW
GTAW
Pulse
50-570 Average Amps
40-570 Average Amps
30-570 Average Amps
15-500 Average Amps
5-750 Peak Amps
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RECOMMENDED INPUT WIRE AND FUSE SIZES FOR MAXIMUM RATED OUTPUT
INPUT
VOLTAGE /
FREQUENCY
TYPE 75°C
COPPER WIRE IN
CONDUIT AWG[IEC]
SIZES (MM2)
TYPE 75°C
GROUND WIRE IN
CONDUIT AWG[IEC]
SIZES (MM2)
TYPE 75°C
(SUPER LAG)
OR BREAKER
SIZE (AMPS)
208/50/60HZ
230/50/60HZ
460/50/60HZ
575/50/60HZ
4(25)
4(25)
8(10)
10(6)
6(16)
6(16)
10(6)
10(6)
110
100
50
40
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PHYSICAL DIMENSIONS
HEIGHT
26.10 in
663 mm
WIDTH
19.86 in
505 mm
DEPTH
32.88 in
835 mm
WEIGHT
286 lbs.
130 kg.
TEMPERATURE RANGES
OPERATING TEMPERATURE RANGE
-20°C to +40°C
STORAGE TEMPERATURE RANGE
-40°C to +40°C
POWER WAVE 455M/MSTT
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A-3
A-3
INSTALLATION
TECHNICAL SPECIFICATIONS - POWER WAVE 455M/STT (K2203-1)
INPUT AT RATED OUTPUT - THREE PHASE ONLY
INPUT VOLTS
OUTPUT
CONDITIONS
INPUT
CURRENT
AMPS
208/230/460/575V - 60HZ.
450A@38V.100%
570A@43V. 60%
58/53/25/22
82/78/37/31
200/220/440/575V - 50HZ.
400A@36V.100%
500A@40V. 60%
49/45/23/18
67/61/31/25
IDLE
POWER
POWER FACTOR
@ RATED OUTPUT
EFFICIENCY
@ RATED
OUTPUT
400 Watts
Max.
.95 MIN.
88%
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OUTPUT
OPEN
PULSE
CURRENT
PULSE
CIRCUIT
RANGE/ FREQUENCY VOLTAGE
VOLTAGE
RANGE
STT
75 VDC
PULSE AND
BACKGROUND
TIME RANGE
5-575/5-325 0.15 - 1000 Hz 5 - 55 VDC 100 MICRO SEC.
-3.3 SEC.
PROCESS CURRENT RANGES (DC)
AUXILIARY POWER
(CIRCUIT BREAKER PROTECTED)
40 VDC AT
10 AMPS
115VAC AT
10 AMPS
CURRENT
MIG/MAG
FCAW
SMAW
Pulse
STT
50-570 Average Amps
40-570 Average Amps
30-570 Average Amps
5-750 Peak Amps
40-325 Average Amps
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RECOMMENDED INPUT WIRE AND FUSE SIZES FOR MAXIMUM RATED OUTPUT
INPUT
VOLTAGE /
FREQUENCY
TYPE 75°C
COPPER WIRE IN
CONDUIT AWG
SIZES (mm2)
TYPE 75°C
GROUND WIRE IN
CONDUIT AWG
SIZES (mm2)
TYPE 75°C
(SUPER LAG)
OR BREAKER
SIZE (AMPS)
208/50/60HZ
230/50/60HZ
460/50/60HZ
575/50/60HZ
4(25)
4(25)
8(10)
10(6)
6(16)
6(16)
10(6)
10(6)
110
100
50
40
PHYSICAL DIMENSIONS
HEIGHT
26.10 in
663 mm
WIDTH
19.86 in
505 mm
DEPTH
32.88 in
835 mm
WEIGHT
293 lbs.
133 kg.
TEMPERATURE RANGES
OPERATING TEMPERATURE RANGE
-20°C to +40°C
STORAGE TEMPERATURE RANGE
-40°C to +40°C
POWER WAVE 455M/MSTT
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A-4
A-4
INSTALLATION
SAFETY PRECAUTIONS
CAUTION
Read this entire installation section before you
start installation.
WARNING
ELECTRIC SHOCK can kill.
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.
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• Only qualified personnel should perform this installation.
• Turn the input power OFF at the disconnect switch or fuse box before working on this
equipment. Turn off the input power to any other equipment connected to the welding system at the disconnect switch or fuse box before working on the equipment.
LIFTING
• Do not touch electrically hot parts.
STACKING
• Always connect the Power Wave grounding lug
(located inside the reconnect input access door) to a
proper safety (Earth) ground.
Power Wave machines can be stacked a maximum of
three high.
CAUTION
SELECT SUITABLE LOCATION
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Do not use Power Waves in outdoor environments. The
Power Wave power source should not be subjected to
falling water, nor should any parts of it be submerged
in water. Doing so may cause improper operation as
well as pose a safety hazard. The best practice is to
keep the machine in a dry, sheltered area.
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Lift the machine by the lift bail only. The lift bail is
designed to lift the power source only. Do not attempt
to lift the Power Wave with accessories attached to it.
Place the welder where clean cooling air can freely circulate in through the rear louvers and out through the
case sides and bottom. Dirt, dust, or any foreign material that can be drawn into the welder should be kept at
a minimum. Do not use air filters on the air intake,
because the air flow will be restricted. Failure to
observe these precautions can result in excessive
operating temperatures and nuisance shutdowns.
Machines above code 10500 are equipped with F.A.N.
(fan as needed) circuitry. The fan runs whenever the
output is enabled, whether under loaded or open circuit
conditions. The fan also runs for a period of time
(approximately 5 minutes) after the output is disabled,
to ensure all components are properly cooled.
If desired, the F.A.N. feature can be disabled (causing
the fan to run whenever the power source is on). To
disable F.A.N., connect leads 444 and X3A together at
the output of the solid state fan control relay, located on
the back of the Control PC board enclosure. (See the
Wiring Diagram.)
The bottom machine must always be placed on a firm,
secure, level surface. There is a danger of machines
toppling over if this precaution is not taken.
MACHINE GROUNDING
The frame of the welder must be grounded. A ground
terminal marked with the symbol
is located inside
the reconnect/input access door for this purpose. See
your local and national electrical codes for proper
grounding methods.
HIGH FREQUENCY PROTECTION
Locate the Power Wave away from radio controlled
machinery.
CAUTION
The normal operation of the Power Wave may adversely affect the operation of RF controlled equipment,
which may result in bodily injury or damage to the
equipment.
POWER WAVE 455M/MSTT
A-5
INSTALLATION
. Disconnect input power before
.
inspecting or servicing machine.
VOLTAGE=200-208V
W / L3
V / L2
200-208V
CR1
220-230V
U / L1
380-415V
Do not operate with covers
removed.
'A'
440-460V
ELECTRIC . Do not touch electrically live parts.
SHOCK
Only qualified persons should install,
CAN KILL
use or service this equipment.
.
VOLTAGE=220-230V
VOLTAGE=380-415V
200-208V
200-208V
200-208V
220-230V
220-230V
220-230V
380-415V
'A'
INPUT SUPPLY CONNECTION DIAGRAM
WARNING
WARNING
Disconnect input power before
inspecting or servicing machine.
Do not operate with covers
removed.
ELECTRIC
ELECTRIC
Do not touch electrically live parts.
SHOCK
SHOCK
Only qualified persons should install,
CAN KILL
CAN
KILL use or service this equipment.
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'A'
440-460V
VOLTAGE = 200-208V
W / L3
V / L2
200-208V
CR1
220-230V
U / L1
440-460V
VOLTAGE = 440-460V
VOLTAGE = 550-575V
200-208V
200-208V
200-208V
220-230V
220-230V
550-575V
'A'
'A'
550-575V
220-230V
440-460V
440-460V
'A'
550-575V
440-460V
'A'
550-575V
NOTE: Turn main input power to the machine OFF before performing connection procedure. Failure to do
so will result in damage to the machine.
INPUT FUSE AND SUPPLY WIRE
CONSIDERATIONS
INPUT CONNECTION
WARNING
Only a qualified electrician should connect the input
leads to the Power Wave. Connections should be made
in accordance with all local and national electrical codes
and the connection diagram located on the inside of the
reconnect/input access door of the machine. Failure to
do so may result in bodily injury or death.
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380-415V
A
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'A'
(K1761-2) CONNECTION DIAGRAM ON CONNECTION/INPUT ACCESS DOOR
VOLTAGE = 220-230V
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380-415V
440-460V
440-460V
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VOLTAGE=440-460V
S23847
WARNING
THE LINCOLN ELECTRIC CO.
INPUT SUPPLY CONNECTION DIAGRAM
CLEVELAND, OHIO U.S.A.
FIGURE A.1
(K1761-1) CONNECTION DIAGRAM ON CONNECTION/INPUT ACCESS DOOR
THE LINCOLN ELECTRIC CO. CLEVELAND, OHIO U.S.A.
XA
S25198
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A-5
Use a three-phase supply line. A 1.75 inch (45 mm)
diameter access hole for the input supply is located on
the upper left case back next to the input access door.
Connect L1, L2, L3 and ground according to the Input
Supply Connection Diagram decal located on the
inside of the input access door, or refer to Figure A.1.
Refer to the Technical Specifications at the beginning of this Installation section for recommended fuse
and wire sizes. Fuse the input circuit with the recommended super lag fuse or delay type breakers (also
called “inverse time” or “thermal/magnetic” circuit
breakers). Choose an input and grounding wire size
according to local or national electrical codes. Using
fuses or circuit breakers smaller than recommended
may result in “nuisance” shut-offs from welder inrush
currents, even if the machine is not being used at high
currents.
POWER WAVE 455M/MSTT
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A-6
A-6
INSTALLATION
INPUT VOLTAGE CHANGE OVER
(FOR MULTIPLE INPUT VOLTAGE
MACHINES ONLY)
WELDING WITH MULTIPLE POWER
WAVES
CAUTION
Welders are shipped connected for the highest input
voltage listed on the rating plate. To move this connection to a different input voltage, see the diagram
located on the inside of the input access door. (Figure
A.1.) If the main reconnect switch or link position is
placed in the wrong position, the welder will not produce output power.
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.
If the Auxiliary (A) lead is placed in the wrong position,
there are two possible results. If the lead is placed in
a position higher than the applied line voltage, the
welder may not come on at all. If the auxiliary (A) lead
is placed in a position lower than the applied line voltage, the welder will not come on, and the two circuit
breakers in the reconnect area will open. If this occurs,
turn off the input voltage, properly connect the (A) lead,
reset the breakers, and try again.
Each power source requires a work lead from the work
terminal to the welding fixture. Do not combine all of the
work leads into one lead. The welding travel directions
should be in the direction moving away from the work
lead as shown in Figure A.2. Connect all of the work
sense leads from each power source to the work piece
at the end of the weld.
For the best results when pulse welding, set the wire
size and wire feed speed the same for all the Power
Waves.
FIGURE A.2 – MULTIPLE POWER WAVE CONNECTIONS
TWO POWER WAVES
I ON
I ON
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POWERWAVE 455/R
POWERWAVE 455/R
O OFF
O OFF
SEN
SE L
EAD
ELECTRODE
ELECTRODE
VEL
TRAECTION
DIR
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SENSE LEAD
CONNECT ALL WORK
SENSE LEADS AT THE
END OF THE JOINT
WORK LEAD
WORK LEAD
CONNECT ALL WELDING
WORK LEADS AT THE
BEGINNING OF THE JOINT
POWER WAVE 455M/MSTT
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A-7
When these parameters are identical, the pulsing frequency will be the same, helping to stabilize the arcs.
Every welding gun requires a separate shielding gas
regulator for proper flow rate and shielding gas coverage.
Do not attempt to supply shielding gas for two or more
guns from only one regulator.
If an anti-spatter system is in use, each gun must have
its own anti-spatter system. See Figure A.2.
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ELECTRODE AND WORK CABLE
CONNECTIONS
Connect a work lead of sufficient size and length (per
Table A.1) between the proper output terminal on the
power source and the work. Be sure the connection to
the work makes tight metal-to-metal electrical contact.
To avoid interference problems with other equipment
and to achieve the best possible operation, route all
cables directly to the work or wire feeder. Avoid excessive lengths and do not coil excess cable. Do not tightly bundle the electrode and work cables together.
Use K1796 coaxial welding cables wherever possible.
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Minimum work and electrode cables sizes are as
follows:
TABLE A.1
(Current (60% Duty Cycle)
MINIMUM COPPER
WORK CABLE SIZE AWG
Up To 100 Ft. Length (30 m)
400 Amps
500 Amps
600 Amps
2/0 (67 mm )
3/0 (85 mm2)
3/0 (85 mm2)
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Most welding applications run with the electrode being
positive (+). For those applications, connect one end of
the electrode cable to the positive (+) output terminal
on the power source (located beneath the spring
loaded output cover near the bottom of the case front).
Connect the other end of the electrode cable to the
wire drive feed plate using the stud, lockwasher, and
nut provided on the wire drive feed plate. The electrode
cable lug must be against the feed plate. Be sure the
connection to the feed plate makes tight metal-to-metal
electrical contact. The electrode cable should be sized
according to the specifications given in Table A.1.
Connect a work lead from the negative (-) power
source output terminal to the work piece. The work
piece connection must be firm and secure, especially if
pulse welding is planned.
CAUTION
Excessive voltage drops caused by poor work piece
connections often result in unsatisfactory welding performance.
When welding with the STT process, use the positive
output connection labeled (STT) for STT welding. (If
desired, other welding modes can be used on this terminal; however, their average output current will be limited to 325 amps.) For non-STT processes, use the
positive output connection labeled (Power Wave), so
that the full output range of the machine is available.
CAUTION
2
When using an inverter type power source like the
Power Wave, use the largest welding (electrode and
ground) cables that are practical. At least 2/0 copper
wire - even if the average output current would not normally require it.
CAUTION
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A-7
INSTALLATION
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.
Do not connect the STT and Power Wave terminals
together. Paralleling the terminals will bypass STT circuitry and severely deteriorate STT welding performance.
NEGATIVE ELECTRODE POLARITY
When negative electrode polarity is required, such as
in some Innershield applications, reverse the output
connections at the power source (electrode cable to
the negative (-) terminal, and work cable to the positive
(+) terminal).
When operating with electrode polarity negative, the
Dip switch 7 must be set to ON on the Wire Feed Head
PC Board. The default setting of the switch is OFF to
represent positive electrode polarity.
To set the Negative Polarity switch on Wire Feed Head
PC board, refer to the section DIP SWITCH SETTINGS
AND LOCATIONS.
POWER WAVE 455M/MSTT
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A-8
The sense leads connect to the Power Wave at the
four-pin connector located underneath the output terminal cover. Lead 67 senses electrode voltage. Lead
21 senses work voltage.
VOLTAGE SENSING
The best arc performance occurs when the Power
Wave has accurate data about the arc conditions.
Depending upon the process, inductance within the
electrode and work lead cables can influence the voltage apparent at the terminals of the welder. Voltage
sense leads improve the accuracy of the arc conditions
and can have a dramatic effect on performance.
Enable the voltage sense leads as follows:
TABLE A.2
CAUTION
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If the voltage sensing is enabled but the sense leads
are missing or improperly connected, extremely high
welding outputs may occur.
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A-8
INSTALLATION
Do not tightly bundle the work sense lead to the work
lead.
Process
Electrode Voltage
Sensing 67 lead *
Work Voltage
Sensing 21 lead
GMAW
67 lead required
21 lead optional
GMAW-P 67 lead required
21 lead optional
FCAW
67 lead required
21 lead optional
STT
67 lead required
21 lead required
GTAW
Voltage sense at
terminals
Voltage sense at
terminals
SAW
67 lead required
21 lead optional
* The electrode voltage 67 sense lead is integral to the control cable to the wire feeder.
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FIGURE A.3 – DIP SWITCH LOCATION
/R
55
E4
V
A
RW
WE
O
P
REMOVE
FRONT
COVER
IO
O
N
OF
F
PO
WE
RW
AV
E4
55
/R
WIRE FEED
HEAD BOARD
ON RIGHT
POWER WAVE 455M/MSTT
CONTROL
BOARD
ON LEFT
WORK VOLTAGE SENSING
CONTROL CABLE SPECIFICATIONS
The Power Wave is shipped from the factory with the
work sense lead enabled.
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.
For processes requiring work voltage sensing, connect
the (21) work voltage sense lead from the Power Wave
to the work. Attach the sense lead to the work as close
to the weld as practical. To enable the work voltage
sensing in the Power Wave, refer to the section DIP
SWITCH SETTINGS AND LOCATIONS.
Enabling or disabling electrode voltage sensing is automatically configured through software. Electrode sense
lead 67 must be connected at the wire feeder.
CAUTION
The use of non-standard cables, especially in lengths
greater than 25 feet, can lead to communication problems (system shutdowns), poor motor acceleration
(poor arc starting) and low wire driving force (wire feeding problems).
Lincoln control cables are copper 22 conductor cable in
a SO-type rubber jacket.
3
4
5
6
7
8
9 10 11 12
Reserved for future use
2
Shutdown2 input
1
Shutdown1 input
A work lead must be run from the negative (-) power
source output connection to the work piece. The work
piece connection must be firm and secure, especially if
pulse welding is planned.
+15 for shutdown group
Output connections on some Power Waves are made
via 1/2-13 threaded output terminals located beneath
the spring-loaded output cover at the bottom of the
case front. On machines which carry the CE mark, output connections are made via Twist-Mate receptacles,
also located beneath the spring-loaded output cover at
the bottom of the case front.
Gas Purge Input
The Shutdown Group is always enabled. Shutdown 2 is
used for signaling low flow in the water cooler. Unused
shutdowns must be jumpered. Machines from the factory come with the shutdowns already jumpered. (See
Figure A.4)
FIGURE A.4 – INPUT PORT CONNECTIONS
Cold Inch Reverse
For convenience sake, the electrode and control
cables can be routed behind the left or right strain
reliefs (under the spring loaded output cover), and
along the channels formed into the base of the Power
Wave, out the back of the channels, and then to the
wire feeder.
Cold Inch Forward
The Power Wave is equipped with a port for making simple input signal connections. The port is divided into
three groups: Trigger group, Cold Inch Group and
Shutdown Group. Because the Power Wave is a “slave”
on the DeviceNet network, the Trigger and Cold Inch
Groups are disabled when the DeviceNet/Gateway is
active.
+15 VDC for Cold Inch Group
Connect the control cable between the power source
and wire feeder. The wire feeder connection on the
robotic Power Wave is located under the spring loaded
output cover, near the bottom of the case front. The
control cable is keyed and polarized to prevent improper connection.
4 Step Input
EXTERNAL I/O CONNECTOR
Dual Procedure Input
POWER WAVE / POWER FEED WIRE
FEEDER INTERCONNECTIONS
Trigger Input
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ELECTRODE VOLTAGE SENSING
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A-9
INSTALLATION
+15 VDC for Trigger Group
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A-9
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CAUTION
Excessive voltage drops at the work piece connection
often result in unsatisfactory pulse welding performance.
A
D
B
E
C
POWER WAVE 455M/MSTT
G
H
F
I
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A-10
A-10
INSTALLATION
DIP SWITCH SETTINGS AND LOCATIONS
DIP switches on the PC boards allow for custom configuration of the Power Wave. Access the DIP switches as follows:
WARNING
ELECTRIC SHOCK CAN KILL.
CONTROL BOARD DIP SWITCH:
switch
switch
switch
switch
switch
switch
switch
switch
1
2
3
4
5
6
7
8
=
=
=
=
=
=
=
=
reserved for future
reserved for future
reserved for future
reserved for future
reserved for future
reserved for future
reserved for future
work sense lead
use
use
use
use
use
use
use
• Do not touch electrically live parts or
electrodes with your skin or wet clothing.
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• Insulate yourself from the work and
ground.
• Always wear dry insulating gloves.
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• Remove the top four screws securing the front access
panel.
• Loosen, but do not completely remove, the bottom
two screws holding the access panel.
• Adjust the DIP switches as necessary. Using a pencil or other small object, slide the switch left for the
ON position or to the right for the OFF position, as
appropriate.
off
work sense lead not connected
on
work sense lead connected
switch
switch
switch
switch
switch
switch
switch
switch
1
2
3
4
5
6
7
8
=
=
=
=
=
=
=
=
reserved for future use
reserved for future use
reserved for future use
reserved for future use
reserved for future use
reserved for future use
negative polarity switch
high speed gear
switch 7
electrode polarity
off
positive
on
negative
switch 8
wire drive gear
off
low speed gear
on
high speed gear
• Replace the panel and screws and restore power.
CONTROL BOARD
(LOCATED IN
CONTROL BOX
BEHIND CASE
FRONT)
DEVICENET/
GATEWAY
BOARD
(LOCATED
BEHIND
FRONT
COVER)
FRONT
COVER
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work sense lead
FEED HEAD BOARD DIP SWITCH:
• Turn off power at the disconnect switch.
• Open the access panel, allowing the weight of the
panel to be carried by the bottom two screws. Make
sure to prevent the weight of the access panel from
hanging on the harness.
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switch 8
LEFT
BANK S1
FEED HEAD
BOARD
(LOCATED IN
CONTROL
BOX BEHIND
CASE FRONT)
CASE FRONT
BANK S2
OPENING IN
CASE FRONT
TO ACCESS
CONTROL
BOX
RIGHT
POWER WAVE 455M/MSTT
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A-11
INSTALLATION
DEVICENET/GATEWAY BOARD
DIP SWITCH, BANK (S2):
switch 1,2 = configure the baud rate
for DeviceNET
Prior to S24958-6 software
switch 1
switch 2
baud rate
off
off
-------
on
off
125K
off
on
250K
on
on
500
S24958-6 and later software
switch 1
switch 2
baud rate
off
off
125K
off
on
250K
on
off
500K
on
on
500K
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Programmable value. Consult local Lincoln Technical
representative.
switch
switch
switch
switch
5
6
7
8
=
=
=
=
reserved
reserved
reserved
reserved
for
for
for
for
future
future
future
future
use
use
use
use
POWER WAVE 455M/MSTT
A-11
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A-12
NOTES
POWER WAVE 455M/MSTT
A-12
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Section B-1
TABLE OF CONTENTS
- OPERATION SECTION -
Section B-1
Operation...............................................................................................................................Section B
Safety Precautions ......................................................................................................................B-2
Graphic Symbols.........................................................................................................................B-3
General Description ....................................................................................................................B-4
Design Features and Advantages ........................................................................................B-4
Recommended Processes and Equipment.................................................................................B-5
Recommended Processes....................................................................................................B-5
Recommended Equipment ...................................................................................................B-5
Required Equipment .............................................................................................................B-5
Duty Cycle and Time Period.................................................................................................B-5
Case Front Controls ....................................................................................................................B-6
Welding Mode Descriptions ........................................................................................................B-7
Constant Voltage Welding ....................................................................................................B-7
Pulse Welding.......................................................................................................................B-8
STT Welding .........................................................................................................................B-9
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Limitations.............................................................................................................................B-5
POWER WAVE 455M/MSTT
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B-2
OPERATION
SAFETY PRECAUTIONS
Read this entire section of operating instructions
before operating the machine.
WARNING
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ELECTRIC SHOCK can kill.
• Unless using cold feed feature, when
feeding with gun trigger, the electrode and
drive mechanism are always electrically
energized and could remain energized
several seconds after the welding ceases.
• Do not touch electrically live parts or electrodes with
your skin or wet clothing.
• Insulate yourself from the work and ground.
• Always wear dry insulating gloves.
FUMES AND GASES can be
dangerous.
• Keep your head out of fumes.
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• Use ventilation or exhaust to remove
fumes from breathing zone.
WELDING SPARKS can cause
fire or explosion.
• Keep flammable material away.
• Do not weld on containers that have held
combustibles.
ARC RAYS can burn.
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• Wear eye, ear, and body protection.
Observe additional guidelines detailed in the beginning
of this manual.
POWER WAVE 455M/MSTT
B-2
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B-3
B-3
OPERATION
GRAPHIC SYMBOLS THAT APPEAR ON
THIS MACHINE OR IN THIS MANUAL
INPUT POWER
SMAW
ON
GMAW
OFF
FCAW
HIGH TEMPERATURE
GTAW
MACHINE STATUS
U0
OPEN CIRCUIT
VOLTAGE
CIRCUIT BREAKER
U1
INPUT VOLTAGE
WIRE FEEDER
U2
OUTPUT VOLTAGE
POSITIVE OUTPUT
I1
INPUT CURRENT
NEGATIVE OUTPUT
I2
OUTPUT CURRENT
3 PHASE INVERTER
PROTECTIVE
GROUND
INPUT POWER
WARNING OR
CAUTION
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THREE PHASE
DIRECT CURRENT
POWER WAVE 455M/MSTT
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B-4
OPERATION
B-4
GENERAL DESCRIPTION
DESIGN FEATURES AND ADVANTAGES
The Power Wave power source is designed to be a part
of a modular, multi-process welding system.
Depending on configuration, it can support constant
current, constant voltage, Surface Tension Transfer
and pulse welding modes.
• Designed to the IEC 974-1 Standard.
The Power Wave power source is designed to be used
with the family of Power Feed wire feeders, operating
as a system. Each component in the system has special circuitry to “talk with” the other system components, so each component (power source, wire feeder,
electrical accessories) knows what the other is doing at
all times. The components communicate using ArcLink
protocol.
Robotic systems can communicate with other industrial machines via DeviceNET protocol. The result is a
highly intigrated and flexible welding cell.
The Power Wave 455/R is a high performance, digitally controlled inverter welding power source capable of
complex, high-speed waveform control. Properly
equipped, it can support the GMAW, GMAW-P, FCAW,
GTAW and STT processes. It carries an output rating of
either 450 amps, 38 volts; or 400 amps, 36 volts (both
at 100% duty cycle), depending on input voltage and
frequency. The Surface Tension transfer process (STT)
is supported at currents up to 325 amps, at 100% duty
cycle.
• Power Wave 455 multiple process output ranges:
5 - 570 amps
• Easy access for input connections. Connections are
simple strip and clamp (no lugs required).
• F.A.N. (Fan As Needed). Cooling fan runs only when
necessary (above Code 10500 only, and all STT
machines).
• Modular construction for easy servicing.
• Thermostatically protected.
• Electronic over-current protection.
• Input over-voltage protection.
• Utilizes digital signal processing and microprocessor
control.
• Simple, reliable input voltage change over.
• All system components communicate and transfer
information.
• Auto device recognition simplifies accessory cable
connections.
If the duty cycle is exceeded, a thermostat will shut off
the output until the machine cools to a reasonable
operating temperature.
POWER WAVE 455M/MSTT
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B-5
OPERATION
RECOMMENDED PROCESSES
AND EQUIPMENT
B-5
REQUIRED EQUIPMENT
• PF-10/R Wire Feeder, K1780-1
• Control Cables (22 pin to 22 pin), K1795-10,-25,-50,100
RECOMMENDED PROCESSES
The Power Wave 455/R can be set up in a number of
configurations, some requiring optional equipment or
welding programs. Each machine is factory preprogrammed with multiple welding procedures, typically
including GMAW, GMAW-P, FCAW, GTAW and STT
for a variety of materials, including mild steel, stainless
steel, cored wires, and aluminum. The STT process
supports mild steel and stainless steel welding.
• Control Cables (for use on FANUC robot arm, 22 pin
to 14 pin, 10 ft), K1804-1
The Power Wave 455/R is recommended only for
automatic or mechanized applications such as robotic
welding.
LIMITATIONS
RECOMMENDED EQUIPMENT
• Power Waves are not to be used in outdoor environments.
Automatic Operation
All welding programs and procedures are set through
software for the robotic Power Wave. FANUC robots
equipped with RJ-3 controllers may communicate
directly with the Power Wave. Other pieces of equipment such as PLCs or computers can communicate
with the Power Wave using DeviceNET. All wire welding processes require a robotic Power Feed wire feeder.
• Control Cables (for use on FANUC robot arm, 22 pin
to 14 pin, 18 in), K1805-1
• Control Cables (for use on FANUC robot arm, 22 pin
to 14 pin, 18 in), K1804-2
• The Power Wave 455/R is not suitable for SMAW,
CAC-A or other processes not listed.
• Only ArcLink Power Feed wire feeders and user
interfaces may be used. Other Lincoln wire feeders
or non-Lincoln wire feeders cannot be used.
DUTY CYCLE AND TIME PERIOD
The Power Feed wire feeders are capable of welding at
a 100% duty cycle (continuous welding). The power
source will be the limiting factor in determining system
duty cycle capability. Note that the duty cycle is based
upon a ten minute period. A 60% duty cycle represents
6 minutes of welding and 4 minutes of idling in a ten
minute period.
POWER WAVE 455M/MSTT
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B-6
CASE FRONT CONTROLS
3. HIGH TEMPERATURE LIGHT (thermal overload):
A yellow light that comes on when an over temperature situation occurs. Output is disabled until
the machine cools down. When cool, the light
goes out and output is enabled.
All operator controls and adjustments are located on
the case front of the Power Wave. (See Figure B.1)
1. POWER SWITCH: Controls input power to the
Power Wave.
2. STATUS LIGHT: A two color light that indicates system errors. Normal operation is a steady green
light. Error conditions are indicated, per Table B.1.
4. 10 AMP WIRE FEEDER CIRCUIT BREAKER:
Protects 40 volt DC wire feeder power supply.
5. 10 AMP AUXILIARY POWER CIRCUIT BREAKER:
Protects 115 volt AC case front receptacle auxiliary supply.
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NOTE: The robotic Power Waves’ status light will flash
green, and sometimes red and green, for up to
one minute when the machine is first turned on.
This is a normal situation as the machine goes
through a self test at power up.
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6. LEAD CONNECTOR S2 (SENSE LEAD)
7. 5-PIN ARC LINK S1
TABLE B.1
Light
Condition
8. 5-PIN DEVICENET CONNECTOR S5
9. I / O CONNECTOR
Meaning
Steady
Green
System OK. Power source
communicating normally with
wire feeder and its components.
Blinking
Green
Normal for first 1-10 seconds
after power is turned on.
Alternating
Green
and Red
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B-6
OPERATION
Steady
Red
10. NEGATIVE OUTPUT TERMINAL
11. INTERFACE CONNECTOR S6
12. STT TERMINAL
13. POSITIVE OUTPUT TERMINAL
14. AUXILIARY OUTPUT
Non-recoverable system fault.
Must turn power source off, find
source of error, and turn power
back on to reset. See
Troubleshooting Guide.
See Troubleshooting Guide.
FIGURE B.1 – POWER WAVE CASE FRONT CONTROLS
2
I ON
6
POWERWAVE 455/R
3
1
O OFF
7
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8
9
11
10
12
13
5
14
4
POWER WAVE 455M/MSTT
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B-7
OPERATION
WELDING MODE DESCRIPTIONS
CONSTANT VOLTAGE WELDING
For each wire feed speed, a corresponding voltage is
preprogrammed into the machine through special software at the factory. The preprogrammed voltage is the
best average voltage for a given wire feed speed. With
synergic programs, when the wire feed speed changes,
the Power Wave will automatically adjust the corresponding voltage.
Wave control adjusts the inductance of the wave
shape. (This adjustment is often referred to as "pinch".
Inductance is inversely proportional to pinch.) Increasing wave control greater than 0 results in a harsher, colder arc, while decreasing the wave control to less
than 0 provides a softer, hotter arc. (See Figure B.2.)
FIGURE B.2 – CV WAVE CONTROL CHARACTERISTICS
Wave Control +10.0
Wave Control 0.00
Wave Control -10.0
Current
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Time
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B-7
POWER WAVE 455M/MSTT
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B-8
OPERATION
PULSE WELDING
Pulse welding procedures are set by controlling an
overall “arc length” variable. When pulse welding, the
arc voltage is highly dependent upon the waveform.
The peak current, background current, rise time, fall
time and pulse frequency all affect the voltage. The
exact voltage for a given wire feed speed can only be
predicted when all the pulsing waveform parameters
are known. Using a preset voltage becomes impractical, and instead the arc length is set by adjusting “trim.”
The Power Wave utilizes “adaptive control” to compensate for changes in electrical stick-out while welding.
(Electrical stick-out is the distance from the contact tip
to the work piece.) The Power Wave waveforms are
optimized for a 0.75" (19mm) stick-out. The adaptive
behavior supports a range of stickouts from 0.50"
(13mm) to 1.25" (32mm). At very low or high wire feed
speeds, the adaptive range may be less due to reaching the physical limitations of the welding process.
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.
Wave control in pulse programs usually adjusts the
focus or shape of the arc. Wave control values greater
than 0 increase the pulse frequency while decreasing
the background current, resulting in a tight, stiff arc
best for high speed sheet metal welding. Wave control
values less than 0 decrease the pulse frequency while
increasing the background current for a soft arc good
for out-of-position welding. (See Figure B.3.)
Most pulse welding programs are synergic. As the wire
feed speed is adjusted, the Power Wave will automatically recalculate the waveform parameters to maintain
similar arc properties.
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FIGURE B.3 – PULSE WAVE CONTROL CHARACTERISTICS
Current
Wave Control -10.0
Wave Control 0.00
Wave Control +10.0
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Time
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B-8
POWER WAVE 455M/MSTT
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B-9
B-9
OPERATION
STT WELDING
The pictures illustrate the wave shape of current for the
process. They are not drawn to scale, and are intended only for the purpose of showing how the variables
affect the waveform.
Trim in the STT mode adjusts the tailout and background portion of the waveform. Trim values greater
than 1.0 add more energy to the weld and make the
weld puddle hotter; trim values less than 1.0 reduce
energy to weld. A nominal value of 1.0 will work for
most applications. (See Figure B.4.)
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FIGURE B.4 – STT TRIM CONTROL CHARACTERISTICS
Trim 1.50
Current
Trim 1.00
Time
Trim 0.50
For most programs, peak current is adjusted by wave
control values. A value of +10.0 maximizes the peak
current, while a wave control of -10.0 minimizes peak
current. In general, the peak current is proportional to
torch arc length. (See Figure B.5.)
NOTE: The ranges on Wave Control and Trim are
dependent on the weld programs. The values
shown are typical ranges.
FIGURE B.5 – STT WAVE CONTROL CHARACTERISTICS
Wave Control +10.0
Wave Control 0.00
Wave Control -10.0
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Current
Time
POWER WAVE 455M/MSTT
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B-10
NOTES
POWER WAVE 455M/MSTT
B-10
TABLE OF CONTENTS
- ACCESSORIES SECTION -
Optional Equipment ....................................................................................................................C-2
Factory Installed ...................................................................................................................C-2
Field Installed .......................................................................................................................C-2
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Section C-1
Accessories ..........................................................................................................................Section C
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Section C-1
POWER WAVE 455M/MSTT
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C-2
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C-2
OPTIONAL EQUIPMENT
FACTORY INSTALLED
There are no factory installed options available for the
Power Wave 455R.
The water cooler is designed to cool only one welding
gun and should be not used to cool multiple guns or
other devices.
FIELD INSTALLED
•
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ACCESSORIES
Gas Guard Regulator (K659-1)
The Gas Guard regulator is available as an optional accessory for the Power Feed Robotic wire drive
unit. Install the 5/8-18 male outlet on the regulator
to the proper 5/8-18 female gas inlet on the back
panel of the wire drive. Secure the fitting with the
flow adjuster key at the top.
•
Voltage Sense Leads (K940-10, -25 or -50)
The voltage sense leads connect at the front of the
machine. (See Figure A.2.)
•
Power Wave Water Cooler (K1767-1)*
The K1767-1 is the recommended water cooler for
the Power Wave. Incorporated into the cooler is an
automatic flow sensor to detect low coolant flow. In
the event of a low flow condition, a fault signal is
sent to the Power Wave, and welding output automatically stops to protect the torch.
Water cooler manufacturers often specify additives
to the coolant such as fungicides or alkalies. Follow
the manufacturers’ recommendations to achieve
proper operation and long lifetime without clogging.
•
Water Flow Sensor (K1536-1)
Water cooled guns can be damaged very quickly if
they are used even momentarily without water flowing. Recommend practice is to install a water flow
sensor such as on the water return line of the torch.
When fully integrated into the welding system, the
sensor will prevent welding if no water flow is present.
•
Dual Cylinder Undercarriage, K1570-1*
•
Coaxial Welding Cable, K1796
*The Dual Cylinder Undercarriage, K1570-1, is not
compatible in combination with the Power Wave
Water Cooler K1767-1.
POWER WAVE 455M/MSTT
TABLE OF CONTENTS
- MAINTENANCE SECTION -
Safety Precautions......................................................................................................................D-2
Routine and Periodic Maintenance.............................................................................................D-2
Main Assembly (Exploded View) ...............................................................................................D-3
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Section D-1
Maintenance ..........................................................................................................................Section D
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Section D-1
POWER WAVE 455M/MSTT
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D-2
MAINTENANCE
PERFORM THE FOLLOWING DAILY:
SAFETY PRECAUTIONS
1. Check that no combustible materials are in the
welding or cutting area or around the machine.
WARNING
2. Remove any debris, dust, dirt, or materials that
could block the air flow to the machine for cooling.
ELECTRIC SHOCK can kill.
• Only Qualified personnel should
perform this maintenance.
• Turn the input power OFF at the
disconnect switch or fuse box
before working on this equipment.
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•
D-2
Do not touch electrically hot parts.
3. Inspect the electrode cables for any slits or punctures in the cable jacket, or any condition that
would affect the proper operation of the machine.
PERFORM PERIODICALLY:
Clean the inside of the machine with a low pressure air
stream. Clean the following parts. Refer to Figure
D.1.
• Transformer and output rectifier assembly.
ROUTINE AND PERIODIC
MAINTENANCE
• Electrode and work cable connections.
• PC board connections..
1. Disconnect input AC power supply lines to the
machine before performing periodic maintenance,
tightening, cleaning, or replacing parts. See
Figure D.1.
• Intake and outlet louvers on the machine case.
• Any obvious accumulations of dirt within the
machine.
• Fan Assembly.
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NOTE: The fan motor has sealed bearings which
require no maintenance.
POWER WAVE 455M/MSTT
D-3
MAINTENANCE
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D-3
FIGURE D.1 – MAIN ASSEMBLY (EXPLODED VIEW)
7
7
1
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7
3
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4
2
2
6
5
1. CASE FRONT ASSEMBLY
2. TRANSFORMER AND OUTPUT
RECTIFIER ASSEMBLY
3. INPUT ASSEMBLY
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4. CONTROL BOX AND VERTICAL
DIVIDER ASSEMBLY
2
5. BASE, LIFT BAIL AND FAN
ASSEMBLY
6. SWITCH BOARD HEATSINK
ASSEMBLY
7. CASE PARTS
POWER WAVE 455M/MSTT
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D-4
NOTES
POWER WAVE 455M/MSTT
D-4
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Section E-1
Section E-1
TABLE OF CONTENTS
- THEORY OF OPERATION SECTION -
Theory of Operation .............................................................................................................Section E
Block Logic Diagram ...................................................................................................................E-1
General Description ....................................................................................................................E-2
Input Voltage and Precharge ......................................................................................................E-3
Switch Boards and Main Transformer.........................................................................................E-4
DC Bus Board, Power Board, Feed Head Board, Gateway Board
and Voltage Sense Board ...........................................................................................................E-5
Power Wave Communications Diagram .....................................................................................E-6
Control Board ..............................................................................................................................E-7
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Output Rectifier, Output Choke and STT Chopper Board ..........................................................E-8
Thermal Protection, Protective Circuits, Over Current Protection
and Under/Over Voltage Protection ............................................................................................E-9
General Description of STT (Surface Tension Transfer) Process.............................................E-10
Insulated Gate Bipolar Transistor (IGBT) Operation .................................................................E-11
Pulse Width Modulation ............................................................................................................E-12
FIGURE E.1 – BLOCK LOGIC DIAGRAM
IGBT DRIVE
FROM
CONTROL
BOARD
POWER WAVE 455/R
INPUT
RECTIFIER
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+20 VDC FROM
POWER BOARD
IGBT DRIVE
FROM
CONTROL CT CURRENT
TO CONTROL
BOARD
BOARD
SW1
CURRENT
TRANSDUCER
STT CHOPPER
BOARD
STT
ELECTRODE
TERMINAL
+
RIGHT
SWITCH
BOARD
CAP. V/F
FEEDBACK
ELECTRODE
TERMINAL
+
LEFT
SWITCH
BOARD
RECONNECT
SWITCH
STT
DRIVE
CURRENT
TRANSDUCER
OUTPUT
CHOKE
WORK
TERMINAL
67A
INPUT
BOARD
S1
67B
CONTACTOR AND PRECHARGE
CONTROL SIGNALS FROM
CONTROL BOARD
AUX
RECONNECT
MAIN
TRANSFORMER
OUTPUT DIODES
D1 -D4
CAP. V/F
FEEDBACK
CR1
CT CURRENT
TO CONTROL
BOARD
S6
VOLT
SENSE
BOARD
VOLTAGE SENSE
OUTPUT
VOLTAGE SENSE SELECT
ARC LINK
2
4
V
A
C
FROM CONTROL
BOARD
FEED
HEAD
BOARD
40 VDC
115 VAC
FAN
RELAY
DEVICE NET
S5
GATEWAY
BOARD
CONNECTION
TO
ROBOT
TO
LEFT
S.B.
TO
RIGHT
S.B.
C
U
R
R
E
N
T
F
B
S
T
T
F
B
40 VDC
TO FAN RELAY
IGBT
DRIVES
CONTACTOR AND
PRECHARGE
CONTROL SIGNALS
ARC LINK
115 VAC
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+5V RS232
65 VDC
52 VAC
DC
BUS
BOARD
BUS BOARD
RECTIFIER
T1
230 VAC
WATER
COOLER
S6
T2
115 VAC
POWER
BOARD
40 VDC
THERMOSTATS
CONTROL
BOARD
+5V SPI
S2 WORK
SENSE
+15V SPI
S3
RS232
+5 V
+15 V
40 VDC
-15 V
40 VDC
115 VAC
RECP.
CONNECTION
TO WIRE
DRIVE
+5 V ARC LINK
S1
ARC LINK
WIRE
FEEDER
RECP.
LEFT S.B.
CAP. V/F
RIGHT S.B.
CAP. V/F
+20 VDC
TO
CHOPPER
BOARD
POWER WAVE 455M/MSTT
LEFT CT
CURRENT
FB
RIGHT CT
CURRENT
FB
STATUS
LIGHT
THERMAL
LIGHT
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E-2
FIGURE E.2 – INPUT VOLTAGE AND PRECHARGE
IGBT DRIVE
FROM
CONTROL
BOARD
POWER WAVE 455/R
INPUT
RECTIFIER
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+20 VDC FROM
POWER BOARD
IGBT DRIVE
FROM
CONTROL CT CURRENT
TO CONTROL
BOARD
BOARD
SW1
CURRENT
TRANSDUCER
STT CHOPPER
BOARD
STT
ELECTRODE
TERMINAL
+
RIGHT
SWITCH
BOARD
CAP. V/F
FEEDBACK
ELECTRODE
TERMINAL
+
LEFT
SWITCH
BOARD
RECONNECT
SWITCH
STT
DRIVE
CURRENT
TRANSDUCER
OUTPUT
CHOKE
WORK
TERMINAL
67A
INPUT
BOARD
S1
CONTACTOR AND PRECHARGE
CONTROL SIGNALS FROM
CONTROL BOARD
AUX
RECONNECT
MAIN
TRANSFORMER
CT CURRENT
TO CONTROL
BOARD
OUTPUT DIODES
D1 -D4
CAP. V/F
FEEDBACK
CR1
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E-2
THEORY OF OPERATION
67B
S6
VOLT
SENSE
BOARD
VOLTAGE SENSE
OUTPUT
DEVICE NET
S5
VOLTAGE SENSE SELECT
ARC LINK
2
4
V
A
C
FROM CONTROL
BOARD
FEED
HEAD
BOARD
40 VDC
115 VAC
FAN
RELAY
GATEWAY
BOARD
CONNECTION
TO
ROBOT
TO
LEFT
S.B.
TO
RIGHT
S.B.
C
U
R
R
E
N
T
F
B
S
T
T
F
B
40 VDC
TO FAN RELAY
IGBT
DRIVES
CONTACTOR AND
PRECHARGE
CONTROL SIGNALS
ARC LINK
115 VAC
+5V RS232
65 VDC
52 VAC
DC
BUS
BOARD
BUS BOARD
RECTIFIER
T1
230 VAC
WATER
COOLER
S6
CONNECTION
TO WIRE
DRIVE
40 VDC
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T2
115 VAC
+5V SPI
S2 WORK
SENSE
+15V SPI
S3
RS232
+5 V
+15 V
40 VDC
-15 V
40 VDC
115 VAC
RECP.
POWER
BOARD
THERMOSTATS
CONTROL
BOARD
+5 V ARC LINK
S1
ARC LINK
WIRE
FEEDER
RECP.
GENERAL DESCRIPTION
The Power Wave 455M/MSTT power source is
designed to be a part of a modular, multi-process welding system. It is a high performance, digitally controlled inverter welding power source capable of complex, high-speed waveform control. Depending upon
configuration, it can support constant current, constant
voltage, surface tension transfer and pulse welding
modes. Each machine is factory preprogrammed with
multiple welding procedures. Typically these procedures include GMAW, GMAW-P, FCAW, GTAW and
LEFT S.B.
CAP. V/F
RIGHT S.B.
CAP. V/F
+20 VDC
TO
CHOPPER
BOARD
LEFT CT
CURRENT
FB
RIGHT CT
CURRENT
FB
STATUS
LIGHT
THERMAL
LIGHT
STT (Surface Tension Transfer) for a variety of materials such as mild steel, stainless steel, cored wires and
aluminum. The STT process supports mild steel and
stainless steel welding. PW455M/STT only.
The Power Wave 455M/STT has an output rating of
either 450 amps at 38 volts or 400 amps at 36 volts.
The two output ratings are dependent upon input voltage and frequency. Both have a duty cycle of 100%.
The STT process is rated at currents up to 325 amps
at a 100% duty cycle.
NOTE: Unshaded areas of Block Logic Diagram are the subject of discussion.
POWER WAVE 455M/MSTT
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E-3
THEORY OF OPERATION
E-3
INPUT VOLTAGE AND PRECHARGE
The Power Wave 455M can be connected for a variety
of three-phase input voltages. Refer to Figure E.2.
The initial input power is applied to the Power Wave
455M through a line switch located on the front of the
machine. Two phases of the three-phase input power
are applied to the Input Board and both auxiliary transformers. The various secondary voltages developed
by transformer T1 are applied to the Input Board, the
fan motor (via a control relay) and the Bus Board rectifier. The 65VDC produced from the Bus Board rectifier is used by the Bus Board to provide various DC voltages for the Power Board, the Feed Head Board and
the wire feeder receptacle. The 115/230VAC developed on the secondary of auxiliary transformer T2 is
applied to the 115VAC receptacle and to the water
cooler receptacle.
the precharge or "soft start" sequence, these two phases are current limited by the Input Board. The AC input
voltage is rectified, and the resultant DC voltage is
applied through the reconnect switches to the input
capacitors located on the right and left switch boards.
The Control Board monitors the voltage across the
capacitors. When the capacitors have charged to an
acceptable level, the Control Board signals the Input
Board to energize the main input contactor, making all
three phases of input power, without current limiting,
available to the input capacitors. At this point the
Power Wave 455M is in the "Run Mode" of operation.
If the capacitors become undervoltaged, overvoltaged,
or unbalanced, the Control Board will signal the Input
Board to de-energize the main input contactor, and the
Power Wave 455M will be disabled. See Figure E.2.
The two phases that are connected to the Input Board,
through the input line switch SW1, are connected to the
input rectifier through the CR1 precharge relay. During
POWER WAVE 455M/MSTT
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E-4
FIGURE E.3 - SWITCH BOARDS AND MAIN TRANSFORMER
IGBT DRIVE
FROM
CONTROL
BOARD
POWER WAVE 455/R
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CONTACTOR AND PRECHARGE
CONTROL SIGNALS FROM
CONTROL BOARD
67B
S6
VOLT
SENSE
BOARD
+
STT
DRIVE
VOLTAGE SENSE
OUTPUT
DEVICE NET
S5
VOLTAGE SENSE SELECT
ARC LINK
2
4
V
A
C
FROM CONTROL
BOARD
FEED
HEAD
BOARD
40 VDC
CURRENT
TRANSDUCER
OUTPUT
CHOKE
WORK
TERMINAL
115 VAC
FAN
RELAY
GATEWAY
BOARD
CONNECTION
TO
ROBOT
TO
LEFT
S.B.
TO
RIGHT
S.B.
C
U
R
R
E
N
T
F
B
S
T
T
F
B
40 VDC
TO FAN RELAY
IGBT
DRIVES
CONTACTOR AND
PRECHARGE
CONTROL SIGNALS
ARC LINK
115 VAC
+5V RS232
65 VDC
52 VAC
DC
BUS
BOARD
BUS BOARD
RECTIFIER
WATER
COOLER
S6
CONNECTION
TO WIRE
DRIVE
T2
115 VAC
115 VAC
RECP.
POWER
BOARD
THERMOSTATS
CONTROL
BOARD
+5 V ARC LINK
40 VDC
+5V SPI
S2 WORK
SENSE
+15V SPI
S3
RS232
+5 V
+15 V
40 VDC
-15 V
40 VDC
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STT
ELECTRODE
TERMINAL
S1
230 VAC
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CURRENT
TRANSDUCER
STT CHOPPER
BOARD
67A
INPUT
BOARD
T1
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+20 VDC FROM
POWER BOARD
RIGHT
SWITCH
BOARD
CAP. V/F
FEEDBACK
ELECTRODE
TERMINAL
+
IGBT DRIVE
FROM
CONTROL CT CURRENT
TO CONTROL
BOARD
BOARD
SW1
AUX
RECONNECT
MAIN
TRANSFORMER
LEFT
SWITCH
BOARD
INPUT
RECTIFIER
CR1
CT CURRENT
TO CONTROL
BOARD
OUTPUT DIODES
D1 -D4
CAP. V/F
FEEDBACK
RECONNECT
SWITCH
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E-4
THEORY OF OPERATION
ARC LINK
WIRE
FEEDER
RECP.
S1
LEFT S.B.
CAP. V/F
RIGHT S.B.
CAP. V/F
+20 VDC
TO
CHOPPER
BOARD
LEFT CT
CURRENT
FB
RIGHT CT
CURRENT
FB
STATUS
LIGHT
THERMAL
LIGHT
SWITCH BOARDS AND MAIN
TRANSFORMER
There are two switch boards in the Power Wave 455M
machine. Each contains an input capacitor and insulated gate bipolar transistor (IGBT) switching circuitry.
Refer to Figure E.3. When the machine reconnect
switches are configured for a lower input voltage
(below 300VAC), the input capacitors are connected in
parallel. When the machine is configured for higher
input voltages (300VAC and above), the input capacitors are connected in series.
When the input capacitors are fully charged, they act
as power supplies for the IGBT switching circuits. The
insulated gate bipolar transistors switch the DC power
from the input capacitors "on and off," thus supplying
pulsed DC current to the main transformer primary
windings. See IGBT OPERATION DISCUSSION AND
DIAGRAMS in this section.
Each switch board feeds current to a separate, oppositely wound primary winding in the Main Transformer.
The reverse directions of current flow through the main
transformer primaries, and the offset timing of the IGBT
switch boards induce an AC square wave output signal
at the secondary of the main transformer. Current
transformers located on the switch boards monitor the
primary currents. If the primary currents become
abnormally high, the Control Board will shut off the
IGBTs, thus disabling the machine’s output. The firing
of the two switch boards occurs during halves of a 50microsecond interval, creating a constant 20 KHZ output.
NOTE: Unshaded areas of Block Logic Diagram are the subject of discussion.
POWER WAVE 455M/MSTT
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E-5
FIGURE E-4 – DC BUS BOARD, POWER BOARD, FEED HEAD BOARD,
GATEWAY BOARD AND VOLTAGE SENSE BOARD
IGBT DRIVE
FROM
CONTROL
BOARD
POWER WAVE 455/R
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67B
CONTACTOR AND PRECHARGE
CONTROL SIGNALS FROM
CONTROL BOARD
STT
DRIVE
S6
VOLT
SENSE
BOARD
VOLTAGE SENSE
OUTPUT
DEVICE NET
S5
VOLTAGE SENSE SELECT
ARC LINK
2
4
V
A
C
FROM CONTROL
BOARD
FEED
HEAD
BOARD
40 VDC
115 VAC
FAN
RELAY
CURRENT
TRANSDUCER
OUTPUT
CHOKE
GATEWAY
BOARD
CONNECTION
TO
ROBOT
TO
LEFT
S.B.
TO
RIGHT
S.B.
C
U
R
R
E
N
T
WORK
TERMINAL
F
B
S
T
T
F
B
40 VDC
TO FAN RELAY
IGBT
DRIVES
CONTACTOR AND
PRECHARGE
CONTROL SIGNALS
ARC LINK
115 VAC
+5V RS232
65 VDC
DC
BUS
BOARD
BUS BOARD
RECTIFIER
230 VAC
WATER
COOLER
S6
CONNECTION
TO WIRE
DRIVE
T2
115 VAC
115 VAC
RECP.
POWER
BOARD
THERMOSTATS
CONTROL
BOARD
+5 V ARC LINK
40 VDC
+5V SPI
S2 WORK
SENSE
+15V SPI
S3
RS232
+5 V
+15 V
40 VDC
-15 V
40 VDC
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+
S1
T1
S1
ARC LINK
WIRE
FEEDER
RECP.
DC BUS BOARD, POWER BOARD,
AND GATEWAY BOARD
The DC Bus Board receives approximately 65VDC
from the Bus Board rectifier. The DC Bus Board regulates that 65VDC to a +40VDC supply. This regulated
40VDC is applied to the Feed Head Board, the Power
Board, and the wire feeder receptacle.
The switching power supplies on the Power Board supply a variety of regulated DC voltages to the Control
Board and a +20VDC to the STT Chopper Board. The
Control Board uses these regulated voltages to power
the many circuits and communication functions incorporated within the Control Board.
Return to Master TOC
STT
ELECTRODE
TERMINAL
67A
INPUT
BOARD
52 VAC
Return to Section TOC
CURRENT
TRANSDUCER
STT CHOPPER
BOARD
RIGHT
SWITCH
BOARD
CAP. V/F
FEEDBACK
AUX
RECONNECT
+20 VDC FROM
POWER BOARD
IGBT DRIVE
FROM
CONTROL CT CURRENT
TO CONTROL
BOARD
BOARD
SW1
ELECTRODE
TERMINAL
+
LEFT
SWITCH
BOARD
INPUT
RECTIFIER
CR1
MAIN
TRANSFORMER
CT CURRENT
TO CONTROL
BOARD
OUTPUT DIODES
D1 -D4
CAP. V/F
FEEDBACK
RECONNECT
SWITCH
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E-5
THEORY OF OPERATION
LEFT S.B.
CAP. V/F
RIGHT S.B.
CAP. V/F
+20 VDC
TO
CHOPPER
BOARD
LEFT CT
CURRENT
FB
RIGHT CT
CURRENT
FB
STATUS
LIGHT
THERMAL
LIGHT
When the Feed Head Board activates the Voltage
Sense Board, the actual arc voltage is sensed (lead
67), and this information is delivered through the voltage sense board to the Control Board.
The Power Wave 455M uses two digital communication platforms. Internally the PC boards communicate
via ArcLink. Externally the Power Wave 455R communicates using the industry standard Device Net protocols. The Gateway Board makes the translation
between the two platforms possible. The Power Wave
455R does not have a dedicated interface device or
board. The robot (or other input device – PLC, etc.)
acts as the user interface, issuing commands through
the Device Net protocol that are translated by the
Gateway Board to ArcLink compatible messages. The
following block diagram (Figure E.5) depicts the flow of
communication information.
NOTE: Unshaded areas of Block Logic Diagram are the subject of discussion.
POWER WAVE 455M/MSTT
FIGURE E.5 – POWER WAVE 455/R COMMUNICATIONS
A
rc L
ink
Arc
Link
Control
Board
Gateway
Board
Translator
Feed
Head
Board
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Weld Controller /
Sequencer
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E-6
THEORY OF OPERATION
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E-6
PF-10R
PW-455R
D
evice N
et
Device
Net
Robot
Controller
POWER WAVE 455M/MSTT
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E-7
FIGURE E.6 – CONTROL BOARD
IGBT DRIVE
FROM
CONTROL
BOARD
POWER WAVE 455/R
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67B
CONTACTOR AND PRECHARGE
CONTROL SIGNALS FROM
CONTROL BOARD
S6
VOLT
SENSE
BOARD
STT
DRIVE
VOLTAGE SENSE
OUTPUT
DEVICE NET
S5
VOLTAGE SENSE SELECT
ARC LINK
2
4
V
A
C
FROM CONTROL
BOARD
FEED
HEAD
BOARD
40 VDC
CURRENT
TRANSDUCER
OUTPUT
CHOKE
WORK
TERMINAL
115 VAC
FAN
RELAY
GATEWAY
BOARD
CONNECTION
TO
ROBOT
TO
LEFT
S.B.
TO
RIGHT
S.B.
C
U
R
R
E
N
T
F
B
S
T
T
F
B
40 VDC
TO FAN RELAY
IGBT
DRIVES
CONTACTOR AND
PRECHARGE
CONTROL SIGNALS
ARC LINK
115 VAC
+5V RS232
65 VDC
52 VAC
DC
BUS
BOARD
BUS BOARD
RECTIFIER
WATER
COOLER
S6
CONNECTION
TO WIRE
DRIVE
T2
115 VAC
115 VAC
RECP.
POWER
BOARD
THERMOSTATS
CONTROL
BOARD
+5 V ARC LINK
40 VDC
+5V SPI
S2 WORK
SENSE
+15V SPI
S3
RS232
+5 V
+15 V
40 VDC
-15 V
40 VDC
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+
S1
230 VAC
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STT
ELECTRODE
TERMINAL
67A
INPUT
BOARD
T1
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CURRENT
TRANSDUCER
STT CHOPPER
BOARD
RIGHT
SWITCH
BOARD
CAP. V/F
FEEDBACK
AUX
RECONNECT
+20 VDC FROM
POWER BOARD
IGBT DRIVE
FROM
CONTROL CT CURRENT
TO CONTROL
BOARD
BOARD
SW1
ELECTRODE
TERMINAL
+
LEFT
SWITCH
BOARD
INPUT
RECTIFIER
CR1
MAIN
TRANSFORMER
CT CURRENT
TO CONTROL
BOARD
OUTPUT DIODES
D1 -D4
CAP. V/F
FEEDBACK
RECONNECT
SWITCH
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E-7
THEORY OF OPERATION
S1
ARC LINK
WIRE
FEEDER
RECP.
LEFT S.B.
CAP. V/F
RIGHT S.B.
CAP. V/F
+20 VDC
TO
CHOPPER
BOARD
LEFT CT
CURRENT
FB
RIGHT CT
CURRENT
FB
STATUS
LIGHT
THERMAL
LIGHT
CONTROL BOARD
The Control Board performs the primary interfacing
functions to establish and maintain output control of the
Power Wave 455R machine. The function generator
and weld files exist within the Control Board hardware
and software. Digital command signals and feedback
information is received and processed at the Control
Board. Software within the Control Board processes
the command and feedback information and sends the
appropriate pulse width modulation (PWM) signals
(see PULSE WIDTH MODULATION in this section) to
the switch board IGBTs. In this manner, the digitally
controlled high-speed welding waveform is created.
The Control Board also monitors and controls the STT
(Surface Tension Transfer) circuitry incorporated in the
Power Wave 455R. STT output currents and arc voltages are monitored, and the appropriated gate firing
signals are applied (or removed) from the STT
Chopper Board and switch boards to create a low spatter, low fume MIG welding process. See GENERAL
DESCRIPTION OF STT (SURFACE TENSION
TRANSFER PROCESS) in this section.
In addition, the Control Board monitors the thermostats, the main transformer primary currents and
input filter capacitor voltages. Depending on the fault
condition, the Control Board will activate the thermal
and/or the status light and will disable or reduce the
machine output. In some conditions the input contactor will be de-energized.
POWER WAVE 455M/MSTT
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E-8
FIGURE E.7 – OUTPUT RECTIFIER, OUTPUT CHOKE AND STT CHOPPER BOARD
IGBT DRIVE
FROM
CONTROL
BOARD
POWER WAVE 455/R
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INPUT
BOARD
CONTACTOR AND PRECHARGE
CONTROL SIGNALS FROM
CONTROL BOARD
67B
S6
VOLT
SENSE
BOARD
STT
DRIVE
VOLTAGE SENSE
OUTPUT
DEVICE NET
S5
VOLTAGE SENSE SELECT
ARC LINK
2
4
V
A
C
FROM CONTROL
BOARD
FEED
HEAD
BOARD
40 VDC
CURRENT
TRANSDUCER
OUTPUT
CHOKE
WORK
TERMINAL
115 VAC
FAN
RELAY
GATEWAY
BOARD
CONNECTION
TO
ROBOT
TO
LEFT
S.B.
TO
RIGHT
S.B.
C
U
R
R
E
N
T
F
B
S
T
T
F
B
40 VDC
TO FAN RELAY
IGBT
DRIVES
CONTACTOR AND
PRECHARGE
CONTROL SIGNALS
ARC LINK
115 VAC
+5V RS232
65 VDC
52 VAC
DC
BUS
BOARD
BUS BOARD
RECTIFIER
WATER
COOLER
S6
CONNECTION
TO WIRE
DRIVE
T2
115 VAC
115 VAC
RECP.
POWER
BOARD
THERMOSTATS
CONTROL
BOARD
+5 V ARC LINK
40 VDC
+5V SPI
S2 WORK
SENSE
+15V SPI
S3
RS232
+5 V
+15 V
40 VDC
-15 V
40 VDC
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+
S1
230 VAC
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STT
ELECTRODE
TERMINAL
67A
T1
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CURRENT
TRANSDUCER
STT CHOPPER
BOARD
RIGHT
SWITCH
BOARD
CAP. V/F
FEEDBACK
AUX
RECONNECT
+20 VDC FROM
POWER BOARD
IGBT DRIVE
FROM
CONTROL CT CURRENT
TO CONTROL
BOARD
BOARD
SW1
ELECTRODE
TERMINAL
+
LEFT
SWITCH
BOARD
INPUT
RECTIFIER
CR1
MAIN
TRANSFORMER
CT CURRENT
TO CONTROL
BOARD
OUTPUT DIODES
D1 -D4
CAP. V/F
FEEDBACK
RECONNECT
SWITCH
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E-8
THEORY OF OPERATION
S1
ARC LINK
WIRE
FEEDER
RECP.
LEFT S.B.
CAP. V/F
RIGHT S.B.
CAP. V/F
+20 VDC
TO
CHOPPER
BOARD
LEFT CT
CURRENT
FB
RIGHT CT
CURRENT
FB
STATUS
LIGHT
THERMAL
LIGHT
OUTPUT RECTIFIER AND CHOKE
The output rectifier receives the AC output from the
main transformer secondary and rectifies it to a DC
voltage level. Since the outuput choke is in series with
the negative leg of hte output rectifier and also in series
with the welding load, a filtered DC output is applied to
the machine output terminals. Refer to Figure E.7.
When in the STT mode, the control circuit monitors
the voltage conditions at the arc, and turns the STT
chopper module on or of as necessary to generate an
STT output waveform. The STT current transducer in
the STT circuit signals the control board to limit output
to 375 amps maximum.
POWER WAVE 455M/MSTT
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E-9
THEORY OF OPERATION
E-9
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 output rectifier, one on
the DC bus, and one on the output choke. Excessive
temperatures may be caused by a lack of cooling air or
by operating the machine beyond its duty cycle or output rating. If excessive operating temperatures should
occur, the thermostats will prevent output from the
machine. The yellow thermal light, located on the front
of the machine, will be illuminated. The thermostats
are self-resetting once the machine cools sufficiently. If
the thermostat shutdown was caused by excessive
output or duty cycle and the fan is operating normally,
the power switch may be left on and the reset should
occur within a 15-minute period. If the fan is not turning or the intake air louvers are obstructed, the power
must be removed from the machine and the fan condition or air obstruction corrected. On later production
machines (above code 10500) the cooling fan runs
only when necessary. The F.A.N. (fan as needed) system is controlled by the Control Board via a solid state
relay.
If the average current exceeds 570 amps, the peak current will be limited to 100 amps until the average current decreases to under 50 amps or the system is retriggered.
PROTECTIVE CIRCUITS
3. Voltage across a capacitor is under 70 volts. (This
would be due to improper input voltage connections.)
Protective circuits are designed into the Power Wave
455/R to sense trouble and shut down the machine
before damage occurs to the machine’s internal components.
UNDER/OVER VOLTAGE
PROTECTION
A protective circuit is included on the Control Board to
monitor the voltage across the input capacitors. In the
event that a capacitor voltage is too high, too low, or
becomes unbalanced side-to-side, the protection circuit will de-energize the input contactor. Machine output will be disabled, and the "soft start" mode will be
repeated. The protection circuit will prevent output if
any of the following circumstances occur.
1. Capacitor conditioning is required. (This may be
required if the machine has been off for a long period of time and is connected for high input voltage
operation.)
2. Voltage across a capacitor exceeds 390 volts. (This
could result from high line surges or improper input
voltage connections.)
4. Internal component damage.
POWER WAVE 455M/MSTT
E-10
THEORY OF OPERATION
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E-10
FIGURE E.8 – STT WAVEFORMS
Wave Control +10.0
Wave Control 0.00
Wave Control -10.0
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Current
Time
STT Wave control characteristics
Current
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Trim 1.50
Trim 1.00
Time
Trim 0.50
STT Trim control characteristics
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GENERAL DESCRIPTION OF
THE STT (SURFACE TENSION
TRANSFER) PROCESS
The STT process cannot be classified as either a constant current (CC) or a constant voltage (CV) application. The STT function produces current of a desired
waveform to reduce spatter and fumes. The STT
process is optimized for short-circuit GMAW welding
only.
POWER WAVE 455M/MSTT
FIGURE E.9 – IGBT OPERATION
POSITIVE
VOLTAGE
APPLIED
SOURCE
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n+
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E-11
THEORY OF OPERATION
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E-11
GATE
SOURCE
n+
n+
GATE
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
INSULATED GATE BIPOLAR
TRANSISTOR (IGBT) OPERATION
An IGBT is a type of transistor. IGBTs are semiconductors well suited for high frequency switching and
high current applications.
Drawing A shows an IGBT in a passive mode. There is
no gate signal, zero volts relative to the source, and
therefore, no current flow. The drain terminal of the
IGBT may be connected to a voltage supply; but since
there is no conduction, the circuit will not supply current
to components connected to the source. The circuit is
turned off like a light switch in the OFF position.
Drawing B shows the IGBT in an active mode. When
the gate signal, a positive DC voltage relative to the
source, is applied to the gate terminal of the IGBT, it
is capable of conducting current. A voltage supply
connected to the drain terminal will allow the IGBT to
conduct and supply current to circuit components coupled to the source. Current will flow through the conducting IGBT to downstream components as long as
the positive gate signal is present. This is similar to
turning ON a light switch.
POWER WAVE 455M/MSTT
THEORY OF OPERATION
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E-12
E-12
FIGURE E.10 – TYPICAL IGBT OUTPUTS
25
sec
sec
sec
50
sec
sec
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MINIMUM OUTPUT
24 sec
24 sec
1 sec
1 sec
50 sec
MAXIMUM OUTPUT
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PULSE WIDTH MODULATION
The term PULSE WIDTH MODULATION (PWM) is
used to describe how much time is devoted to conduction in the positive and negative portions of the cycle.
Changing the pulse width is known as MODULATION.
Pulse Width Modulation is the varying of the pulse
width over the allowed range of a cycle to affect the
output of the machine.
MAXIMUM OUTPUT
MINIMUM OUTPUT
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By controlling the duration of the gate signal, the IGBT
is turned on and off for different durations during a
cycle. The top drawing below shows the minimum output signal possible over a 50-microsecond time period.
Return to Section TOC
The shaded portion of the signal represents one IGBT
group1, conducting for 1 microsecond. The negative portion is the other IGBT group. The dwell time (off time) is
48 microseconds (both IGBT groups off). Since only 2
microseconds of the 50-microsecond time period are
devoted to conducting, the output power is minimized.
1
By holding the gate signals on for 24 microseconds each
and allowing only 2 microseconds of dwell or off time
(one microsecond during each half cycle) during the 50
microsecond cycle, the output is maximized. The darkened area under the minimum output curve can be compared to the area under the maximum output curve. The
more darkened area, the more power is present.
An IGBT group consists of the sets of IGBT modules grouped onto
one switch board.
POWER WAVE 455M/MSTT
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Section F-1
TABLE OF CONTENTS
- TROUBLESHOOTING & REPAIR SECTION -
Troubleshooting & Repair ...................................................................................................Section F
How to Use Troubleshooting Guide ...........................................................................................F-2
PC Board Troubleshooting Procedures.......................................................................................F-3
Troubleshooting Guide ................................................................................................................F-4
Test Procedures ..........................................................................................................................F-9
Input Filter Capacitor Discharge Procedure .........................................................................F-9
Switch Board Test ...............................................................................................................F-11
Input Rectifier Test .............................................................................................................F-15
Input Contactor Test............................................................................................................F-19
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DC Bus Power Supply PC Board Test................................................................................F-23
Power Board Test ..............................................................................................................F-27
Input Board Test .................................................................................................................F-31
STT Chopper Board Test ....................................................................................................F-35
Power Wave Current Transducer Test ...............................................................................F-39
STT Current Transducer Test ............................................................................................F-43
Output Rectifier Test ..........................................................................................................F-47
Auxiliary Transformer No. 1 Test .......................................................................................F-49
Auxiliary Transformer No. 2 Test .......................................................................................F-53
Component Removal and Replacement Procedures................................................................F-55
Input Rectifier Removal and Replacement ........................................................................F-55
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Input Contactor Removal and Replacement ......................................................................F-57
Auxiliary Transformer No. 1 Removal and Replacement Procedure..................................F-59
Auxiliary Transformer No. 2 Removal and Replacement Procedure..................................F-63
Control, Feed Head, or Voltage Sense PC Board Removal and Replacement .................F-67
Gateway PC Board Removal and Replacement ...............................................................F-71
STT Current Transducer Removal and Replacement ...................................................... F-73
Power Wave Current Transducer Removal and Replacement.......................................... F-77
Output Rectifier, STT Chopper Board and Rectifier Module Removal
and Replacement ........................................................................................................F-81
Switch Board and Filter Capacitor Removal and Replacement .........................................F-85
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Retest after Repair ...................................................................................................................F-88
POWER WAVE 455M/MSTT
Section F-1
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F-2
TROUBLESHOOTING & REPAIR
HOW TO USE TROUBLESHOOTING GUIDE
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 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.
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This Troubleshooting Guide is provided to help
you locate and repair possible machine malfunctions. Simply follow the three-step procedure
listed below.
Step 1. LOCATE PROBLEM (SYMPTOM). Look
under the column labeled “PROBLEM” (SYMPTOMS). This column describes possible symptoms that the machine may exhibit. Find the listing that best describes the symptom that the
machine is exhibiting. Symptoms are grouped
into two main categories: Output Problems and
Function Problems.
Step 2. PERFORM EXTERNAL TESTS. The
second column, labeled “POSSIBLE AREAS OF
MISADJUSTMENT(S)”, lists the obvious external
possibilities that may contribute to the machine
symptom. Perform these tests/checks in the
order listed. In general, these tests can be conducted without removing the case cover.
Step 3. PERFORM COMPONENT TESTS. The
last column, labeled “Recommended Course of
Action” lists the most likely components that may
have failed in your machine. It also specifies the
appropriate test procedure to verify that the subject component is either good or bad. If there are
a number of possible components, check the
components in the order listed to eliminate one
possibility at a time until you locate the cause of
your problem.
All of the referenced test procedures referred to in
the Troubleshooting Guide are described in detail
at the end of this section.
Refer to the
Troubleshooting and Repair Table of Contents to
locate each specific Test Procedure. All of the
referred to test points, components, terminal
strips, etc., can be found on the referenced electrical wiring diagrams and schematics. Refer to
the Electrical Diagrams Section Table of Contents
to locate the appropriate diagram.
In addition to the troubleshooting information in this manual, Lincoln Electric offers a System Update
Utility to reprogram digital power sources. The utility will examine the welding system allowing you to
upgrade to the current release of the operating system software and welding programs available for the
machine if necessary. This software can be reviewed and downloaded from powerwavesoftware.com
or from mylincolnelectric.com. Download and review the entire user manual before attempting to use
the software.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the test/repairs
safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before
you proceed. Call 1-888-935-3877.
POWER WAVE 455M/MSTT
F-2
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F-3
TROUBLESHOOTING & REPAIR
PC BOARD TROUBLESHOOTING PROCEDURES
WARNING
ELECTRIC SHOCK can kill.
Have an electrician install and service
this equipment. Turn the machine OFF
before working on equipment. Do not
touch electrically hot parts.
Sometimes machine failures appear to be due to PC
board failures. These problems can sometimes be
traced to poor electrical connections. To avoid problems when troubleshooting and replacing PC boards,
please use the following procedure:
1. Determine to the best of your technical ability that
the PC board is the most likely component causing
the failure symptom.
2. Check for loose connections at the PC board to
assure that the PC board is properly connected.
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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:
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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 static-shielding
bag. Wear an anti-static wrist
strap. For safety, use a 1 Meg
ohm resistive cord connected to a
grounded part of the equipment
frame.
• If you don’t have a wrist strap,
touch an unpainted, grounded,
part of the equipment frame. Keep
touching the frame to prevent static build-up. Be sure not to touch
any electrically live parts at the
same time.
• Remove the PC Board from the static-shielding bag
and place it directly into the equipment. Don’t set the
PC Board on or near paper, plastic or cloth which
could have a static charge. If the PC Board can’t be
installed immediately, put it back in the staticshielding bag.
• If the PC Board uses protective shorting jumpers,
don’t remove them until installation is complete.
• If you return a PC Board to The Lincoln Electric
Company for credit, it must be in the static-shielding
bag. This will prevent further damage and allow proper failure analysis.
4. Test the machine to determine if the failure symptom has been corrected by the replacement PC
board.
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
substitution of the original board, then
PC board was the problem. Reinstall
replacement PC board and test
machine.
the
the
the
the
6. Always indicate that this procedure was followed
when warranty reports are to be submitted.
NOTE: Following this procedure and writing on the
warranty
report,
“INSTALLED
AND
SWITCHED PC BOARDS TO VERIFY PROBLEM,” will help avoid denial of legitimate PC
board warranty claims.
• Tools which come in contact with the PC Board must
be either conductive, anti-static or static-dissipative.
POWER WAVE 455M/MSTT
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F-4
TROUBLESHOOTING & REPAIR
TROUBLESHOOTING GUIDE
Observe Safety Guidelines
detailed in the beginning of this manual.
PROBLEMS
(SYMPTOMS)
F-4
POSSIBLE AREAS OF
MISADJUSTMENT(S)
RECOMMENDED
COURSE OF ACTION
OUTPUT PROBLEMS
The input fuses repeatedly fail or
the input circuit breakers keep tripping.
1. Make certain the fuses or breakers are properly sized.
2. Make certain the reconnect
panel is configured properly for
the applied voltage.
3. The welding procedure may be
drawing too much input current
or the duty cycle may be too
high. Reduce the welding current and /or reduce the duty
cycle.
1. Check the reconnect switches
and associated wiring. See the
Wiring Diagram.
2. Perform the Input Rectifier
Test.
3. Perform the Switch Board
Test.
4. Perform the Input Contactor
Test.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call
1-888-935-3877.
POWER WAVE 455M/MSTT
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F-5
TROUBLESHOOTING GUIDE
PROBLEMS
(SYMPTOMS)
Observe Safety Guidelines
detailed in the beginning of this manual.
POSSIBLE AREAS OF
MISADJUSTMENT(S)
1. Make certain the input power
switch SW1 is in the ON position.
2. Check the main input fuses (or
breakers). If open, replace or
reset.
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RECOMMENDED
COURSE OF ACTION
OUTPUT PROBLEMS
The machine is dead—no lights—
no output—the machine appears to
be off.
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F-5
TROUBLESHOOTING & REPAIR
3. Check the 6 amp CB4 breaker
located in the reconnect area.
Reset if tripped.
4. Make certain the reconnect
panel is configured correctly for
the applied input voltage.
1. Check the input power switch
SW1 for proper operation. Also
check the associated leads for
loose or faulty connections.
See the Wiring Diagram.
2. Check circuit breaker CB4 for
proper operation.
3. Perform the DC Bus Board
Test.
4. The power board rectifier may
be faulty. Check rectifier and
associated wiring. See the
Wiring Diagram
5. Perform the Power Board Test.
6. Perform the T1
Transformer Test.
Auxiliary
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7. The Control Board may be
faulty.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call
1-888-935-3877.
POWER WAVE 455M/MSTT
Return to Master TOC
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F-6
TROUBLESHOOTING GUIDE
Observe Safety Guidelines
detailed in the beginning of this manual.
PROBLEMS
(SYMPTOMS)
POSSIBLE AREAS OF
MISADJUSTMENT(S)
1. Turn the input power off and
make certain the reconnect
panel is configured correctly for
the applied input voltage.
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2. Perform the Input Contactor
Test.
3. Perform the Input Board Test.
Auxiliary
5. Perform the Input Rectifier
Test.
6. Perform the Switch Board
Test.
7. Perform the Power Board Test.
8. The Control Board may be faulty.
The thermal light is lit.
The
machine regularly "overheats."
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1. Check status led on case front
evaluate
4. Perform the T1
Transformer Test.
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2. If the Thermal light is lit, See
next.
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RECOMMENDED
COURSE OF ACTION
OUTPUT PROBLEMS
The Power Wave 455M does not
have welding output. The main
input contactor CR1 is not activating. Fan may be running.
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F-6
TROUBLESHOOTING & REPAIR
1. The welding application may be
exceeding the recommended
duty cycle and/or current limits
of the machine.
2. Dirt and dust may have clogged
the cooling channels inside the
machine. Refer to the Maintenance Section of this manual.
1. One of the thermostats may be
faulty. Also check associated
wiring for loose or faulty connections.
See the Wiring
Diagram.
3. Air intake and exhaust louvers
may be blocked due to inadequate clearance around the
machine.
4. Make sure the fan is functioning
correctly. Machines above code
10500 are equipped with F.A.N.
(fan as needed) circuitry. The
fan runs whenever the output is
enabled, whether under load or
open circuit conditions. The fan
also runs for a period of time
(approximately 5 minutes) after
the output is disabled.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call
1-888-935-3877.
POWER WAVE 455M/MSTT
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Return to Section TOC
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F-7
TROUBLESHOOTING GUIDE
PROBLEMS
(SYMPTOMS)
Observe Safety Guidelines
detailed in the beginning of this manual.
POSSIBLE AREAS OF
MISADJUSTMENT(S)
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RECOMMENDED
COURSE OF ACTION
FUNCTION PROBLEMS
The machine often "noodle welds"
when running a particular process.
The output is limited to approximately 100 amps.
1. The machine may be trying to
deliver too much power. When
the average output current
exceeds 570 amps, the
machine will "phase back" to
protect itself. Adjust the procedure or reduce the load to lower
the current draw from the Power
Wave 455R machine.
The machine often "noodle welds"
when running an STT process.
STT work/ Electrode sense lead
routing
1. Perform
the
Transducer Test.
The Power Wave 455R will not produce full output.
1. The input voltage may be too
low, limiting the output capability
of the machine. Make certain
the input voltage is correct for
the machine and the reconnect
panel configuration.
3. If using the STT output terminal,
be aware that the STT output is
limited to 325 amps.
Current
2. The Control Board may be
faulty.
1. Refer to sense lead route recommendations section
2. Perform
the
Transducer Test.
2. Make sure all three phases of
input power are being applied to
the machine.
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F-7
TROUBLESHOOTING & REPAIR
Current
1. Perform the Output Rectifier
Test.
2. Perform the Current Transducer Test.
3. Perform the Power Board Test.
4. The Control Board may be
faulty.
5. If using the STT output terminal,
the STT Chopper Board may be
faulty. See the Wiring Diagram.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call
1-888-935-3877.
POWER WAVE 455M/MSTT
Return to Master TOC
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F-8
TROUBLESHOOTING GUIDE
Observe Safety Guidelines
detailed in the beginning of this manual.
PROBLEMS
(SYMPTOMS)
POSSIBLE AREAS OF
MISADJUSTMENT(S)
RECOMMENDED
COURSE OF ACTION
FUNCTION PROBLEMS
The Auxiliary Receptacle is "dead."
The 120VAC is not present at the
receptacle.
1. Check the 3.5 amp circuit
breaker (CB3) located in the
reconnect area. Reset if necessary.
1. Check the receptacle and associated wiring for loose or faulty
connections. See the Wiring
Diagram.
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2. Perform the T2
Transformer Test.
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F-8
TROUBLESHOOTING & REPAIR
Auxiliary
The Power Wave 455M is "triggered" for output but there is no
welding output.
1. Make sure that the triggering
method and device is correct
and operating properly.
Use troubleshooting software to
find the problem.
When in the STT mode,
the spatter is higher than normal
and the arc is inconsistent.
1. Make certain the work sense
lead (21) is connected properly.
1. Perform the STT Chopper
Board Test.
2. Make certain the electrode
cable is connected only to the
STT output terminal and NOT
the Power Wave positive output
terminal, or both.
2. Perform
the
Current
Transducer (STT) Test.
3. Make sure the welding parameters are correct for the process.
Refer to L.E. setup utility user manual section.
3. Check calibration using L.E.
dianolostic software, and confirm correct wire feed speed to
display
4. The Control Board may be
faulty.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call
1-888-935-3877.
POWER WAVE 455M/MSTT
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F-9
TROUBLESHOOTING & 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
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If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.
DESCRIPTION
This “safety” procedure should be performed before any internal maintenance or repair
procedures are attempted on the Power Wave 455M. Capacitance normally discharges
within 2 minutes of removing input power. This procedure is used to check that the capacitors have properly discharged.
MATERIALS NEEDED
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3/8” Nut driver
Volt-ohmmeter
25-1000 ohms @ 25 watts (minimum) resistor
Electrically insulated gloves and pliers
POWER WAVE 455M/MSTT
F-9
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F-10
TROUBLESHOOTING & REPAIR
INPUT FILTER CAPACITOR DISCHARGE PROCEDURE (CONTINUED)
FIGURE F.1 – CAPACITOR DISCHARGE PROCEDURE
SWITCH
BOARD
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CAPACITOR
TERMINALS
TEST PROCEDURE
1. Remove input power to the Power Wave
455M.
2. Using the 3/8” nut driver, remove the left and
right case sides.
3. Be careful not to make contact with the
capacitor terminals that are located in the
bottom center of the left and right side switch
boards. See Figure F.1.
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4. Carefully check for a DC voltage at the
capacitor terminals on both boards. Note
the polarity is marked on the PC board and
also lead #19 is positive.
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F-10
5. If any voltage is present, proceed to Step #6.
If no voltage is present, the capacitors are
discharged.
6. Using the high wattage resistor (25-1000
ohms @ 25 watts (minimum), electrically
insulated gloves and pliers, connect the
resistor across the two capacitor terminals.
Hold the resistor in place for 10 seconds.
DO NOT TOUCH THE CAPACITOR TERMINALS WITH YOUR BARE HANDS. NEVER
USE A SOLID CONDUCTOR W/LESS
THAN 25 OHM RESISTANCE FOR THIS
PROCEDURE.
7. Repeat procedure for the other capacitor.
8. Recheck the voltage across the capacitor
terminals. The voltage should be zero. If
any voltage remains, repeat the discharge
procedure.
NOTE: Normally the capacitors discharge in
about two minutes after input power is
removed.
POWER WAVE 455M/MSTT
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F-11
TROUBLESHOOTING & REPAIR
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
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If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.
DESCRIPTION
This test will help determine if the “power section” of the switch boards are functioning correctly. This test will NOT indicate if the entire PC board is functional. This resistance test
is preferable to a voltage test with the machine energized because these boards can be
damaged easily. In addition, it is dangerous to work on these boards with the machine
energized.
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MATERIALS NEEDED
3/8” Nut driver
3/8” Wrench
Analog/Digital volt-ohmmeter
Wiring Diagram
POWER WAVE 455M/MSTT
F-11
F-12
TROUBLESHOOTING & REPAIR
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F-12
SWITCH BOARD TEST (CONTINUED)
FIGURE F.2 – RECONNECT SWITCHES
19C
19D
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RECONNECT
SWITCHES
TEST PROCEDURE
1. Remove input power to the Power Wave
455M.
2. Perform
the
Procedure.
Capacitor
Discharge
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3. Locate label and remove leads 19C and 19D
from the reconnect switches with the 3/8”
wrench. Note lead placement for reassembly. Clear leads. Refer to Figure F.2.
4. Using the Analog ohmmeter, perform the following
resistance tests. Refer to Figure F.3 for the test
points. Any readings below 100 ohms can be considered a short circuit. However, readings usually
are below 30 ohms.
Check 11/12 to -20 and 11/12 to +19
Check 13/14 to -20 and +19 to 13/14
5. If any test fails isolate the PC board and
retest, if board still fails, replace switch
board. See Switch Board Removal and
Replacement.
6. If the switch board tests are OK, check the
molex pin connections and associated wiring
from the switch boards to the control board.
See the Wiring Diagram.
POWER WAVE 455M/MSTT
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F-13
SWITCH BOARD TEST (CONTINUED)
FIGURE F.3 – SWITCH BOARD TEST POINTS
13/14
OR
17/18
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SWITCH
BOARD
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F-13
TROUBLESHOOTING & REPAIR
-20 +19
11/12
OR
15/16
8. Reconnect leads 19C and 19D to the reconnect switches. Ensure that the leads are
installed in the same location they were
removed from.
9. Install the right and left case sides and top
using the 3/8” nut driver.
POWER WAVE 455M/MSTT
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F-14
NOTES
POWER WAVE 455M/MSTT
F-14
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F-15
TROUBLESHOOTING & 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
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Return to Master TOC
Return to Section TOC
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If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.
TEST DESCRIPTION
This test will help determine if the input rectifier has “shorted” or “open” diodes.
MATERIALS NEEDED
Analog volt-ohmmeter
Phillips head screw driver
Wiring Diagram
3/8” Nut driver
POWER WAVE 455M/MSTT
F-15
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F-16
INPUT RECTIFIER TEST (CONTINUED)
FIGURE F.4 – INPUT RECTIFIER TEST
INPUT
RECTIFIER
B
NEG (-)
POS (+)
TEST PROCEDURE
1. Remove input power to the Power Wave
455M.
3. Perform
the
Procedure.
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A
C
2. Using the 3/8” nut driver, remove the case
top.
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F-16
TROUBLESHOOTING & REPAIR
Capacitor
Discharge
4. Locate the Input Rectifier and lead locations.
Refer to Figure F.4.
NOTE: Some silicone sealant may have to be
removed from the input rectifier terminals. The G.E. silicone or equivalent
should be replaced when test is complete.
5. With the phillips head screw driver remove
the positive and negative leads from the rectifier.
POWER WAVE 455M/MSTT
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F-17
TROUBLESHOOTING & REPAIR
F-17
INPUT RECTIFIER TEST (CONTINUED)
6. Use the analog ohmmeter to perform the
tests detailed in Table F.1.
7. If the input rectifier does not meet the
acceptable readings outlined in the table,
the component may be faulty. Replace.
NOTE: Before replacing the input rectifier, perform the Switch Board Test.
9. If the input rectifier is good, be sure to
reconnect the positive and negative leads
to the correct terminals and torque to 31
in.-lbs. See the Wiring Diagram.
10. Replace any silicone sealant previously
removed.
11. Reassemble and test.
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8. When installing a new input rectifier, see
Input Rectifier Removal and Replacement
procedure.
TABLE F.1 – INPUT RECTIFIER TEST POINTS AND ACCEPTABLE READINGS
ANALOG METER X100
RANGE
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TEST POINT TERMINALS
+ Probe
- Probe
Acceptable Meter Readings
A
B
C
NEG
NEG
NEG
Greater than 1000 ohms
Greater than 1000 ohms
Greater than 1000 ohms
A
B
C
POS
POS
POS
Approx. 500 ohms or less
Approx. 500 ohms or less
Approx. 500 ohms or less
NEG
NEG
NEG
A
B
C
Approx. 500 ohms or less
Approx. 500 ohms or less
Approx. 500 ohms or less
POS
POS
POS
A
B
C
Greater than 1000 ohms
Greater than 1000 ohms
Greater than 1000 ohms
This test can be performed using a digital volt/ohm meter on the “diode test” setting. Acceptable meter
readings are: open or O.L., For the “Greater than 1000 ohms” and a decimal value less than one (example 0.045) in the approx 500 ohms position.
POWER WAVE 455M/MSTT
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F-18
NOTES
POWER WAVE 455M/MSTT
F-18
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F-19
TROUBLESHOOTING & REPAIR
INPUT CONTACTOR TEST
WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician
or machine operator and will invalidate your factory warranty. For your safety and to avoid
electrical shock, please observe all safety notes and precautions detailed throughout this
manual.
Return to Master TOC
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If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.
TEST DESCRIPTION
This test will help determine if the input contactor is functional and if the contacts are
functioning correctly.
MATERIALS NEEDED
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3/8” Nut driver
Volt-ohmmeter
External 24 VAC supply
POWER WAVE 455M/MSTT
F-19
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F-20
F-20
TROUBLESHOOTING & REPAIR
INPUT CONTACTOR TEST (CONTINUED)
FIGURE F.5 – INPUT CONTACTOR COIL
INPUT
CONTACTOR
601
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X4
TEST PROCEDURE
1. Remove input power to the Power Wave
455.
2. Using the 3/8” nut driver, remove the input
access panel and case top.
4. Using the external 24 VAC supply, apply 24
VAC to the terminals of the input contactor
coil. If the contactor does NOT activate, the
input contactor is faulty. Replace.
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3. Locate, mark, and remove the two leads
(601, X4) that are connected to the input
contactor coil. Refer to Figure F.5.
POWER WAVE 455M/MSTT
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F-21
TROUBLESHOOTING & REPAIR
INPUT CONTACTOR TEST (CONTINUED)
FIGURE F.6 – INPUT CONTACTOR TEST POINTS
L3
T3
L2
T2
L1
T1
5. With the input contactor activated, check the
continuity across the three sets of contacts.
(Zero ohms or very low resistance is normal.) Refer to Figure F.6. If the resistance
is high, the input contactor is faulty. Replace
the input contactor.
7. Reconnect the two leads (601, X4) to the
input contactor coil.
8. Install the input access door and case top
using the 3/8” nut driver.
9. Test.
6. When the contactor is NOT activated, the
resistance should be infinite or very high
across the contacts. If the resistance is low,
the input contactor is faulty.
POWER WAVE 455M/MSTT
F-21
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F-22
NOTES
POWER WAVE 455M/MSTT
F-22
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F-23
TROUBLESHOOTING & REPAIR
DC BUS POWER SUPPLY PC BOARD TEST
WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician
or machine operator and will invalidate your factory warranty. For your safety and to avoid
electrical shock, please observe all safety notes and precautions detailed throughout this
manual.
Return to Master TOC
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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
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3/8” Nut driver
Volt/ohmmeter
Wiring Diagram
POWER WAVE 455M/MSTT
F-23
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F-24
F-24
TROUBLESHOOTING & REPAIR
DC BUS POWER SUPPLY PC BOARD TEST (CONTINUED)
FIGURE F.7 – DC BUS POWER SUPPLY POWER SUPPLY PC BOARD
LED
POWER BOARD
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DC BUS
POWER
SUPPLY
PC BOARD
FAN RELAY
J47
J46
CAPACITOR
C3
CAUTION!
J46
J47
1 2
1 2 3 4
3 4
5 6 7 8
TEST PROCEDURE
WARNING
1. Remove input power to the machine.
ELECTRIC SHOCK can kill.
2. Using the 3/8” nut driver, remove the case
top.
High voltage is present when
input power is applied to the
machine.
3. Locate the DC Bus Power Supply PC Board
and plugs P46 and P47. See Figure F.7.
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4. Carefully apply input power to the Power
Wave 455M.
5. Turn on the Power Wave 455M. The LED on
the DC Bus Power Supply PC Board should
light.
POWER WAVE 455M/MSTT
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F-25
DC BUS POWER SUPPLY PC BOARD TEST(CONTINUED)
6. Check the DC Bus Power Supply PC Board
input and output voltages according to Table
F.3.
See Figure F.7 and the Wiring
Diagram.
If plug P46 pin 1-3 voltage is missing, perform
T1 Auxiliary Transformer Test.
WARNING
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ELECTRIC SHOCK can kill.
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F-25
TROUBLESHOOTING & REPAIR
High voltage is present at the
terminals of Capacitor C3 near
where testing is to be done.
7. If all the voltages are correct, the DC Bus
Power Supply PC Board is operating properly.
8. If any of the output voltages are not correct
and the input voltage is correct, the DC Bus
Power Supply PC Board may be faulty, or
the supplied board may be bad.
9. If the input voltage is not correct, check the
leads between the DC Bus Power Supply
PC Board and the Power PC Board
Rectifier. See the Wiring Diagram.
10. When finished testing, replace the case
top.
TABLE F.2 – 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
Should be same as the
Power PC Board
Rectifier
Plug P47 – Pin 7
Plug P47 – Pin 6
38.0 – 42.0 VDC
Supply to Power PC
Board
Plug P47 – Pin 8
Plug P47 – Pin 6
38.0 – 42.0 VDC
Supply to Power PC
Board
Plug P47 – Pin 4
Plug P47 – Pin 2
38.0 – 42.0 VDC
Supply to Feed Head PC
Board
Plug P47 – Pin 3
Plug P47 – Pin 1
38.0 – 42.0 VDC
Supply to S1 Wire
Feeder Receptacle
POWER WAVE 455M/MSTT
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F-26
NOTES
POWER WAVE 455M/MSTT
F-26
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F-27
TROUBLESHOOTING & 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
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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
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3/8” Nut driver
Volt-ohmmeter
Wiring Diagram
POWER WAVE 455M/MSTT
F-27
TROUBLESHOOTING & REPAIR
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F-28
POWER BOARD TEST (CONTINUED)
FIGURE F.8 – POWER BOARD TEST
J41
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J42
1
4
2
3
5 6
J42
1
J43
2
1
2
3 4
3 4
J41
7
8
9 10 11 12
J43
5
6
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TEST PROCEDURE
1. Remove input power to the Power Wave
455M.
2. Using the 3/8” nut driver, remove the case
top.
3. Perform
the
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 455M.
6. Turn on the Power Wave 455M. Carefully
test for the correct voltages at the Power
Board according to Table F.3.
7. If either of the 40 VDC voltages is low or not
present at plug J41, perform the DC Bus
PC Board Test. See the Wiring Diagram. If
indicated, perform the T1 Auxiliary
Transformer Test.
8. If any of the DC voltages are low or not present at plugs J42 and/or 43, the Power
Board may be faulty.
9. If power board is replaced, reassemble and
test machine.
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WARNING
ELECTRIC SHOCK can kill.
High voltage is present when
input power is applied to the
machine.
POWER WAVE 455M/MSTT
F-28
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F-29
F-29
TROUBLESHOOTING & REPAIR
POWER BOARD TEST (CONTINUED)
TABLE F.3 – POWER BOARD VOLTAGE CHECKS
CHECK POINT
LOCATION
TEST
DESCRIPTION
CONNECTOR
PLUG PIN NO.
LEAD NO. OR
IDENTITY
POWER BOARD
CONNECTOR
PLUG J41
CHECK 40 VDC
INPUT FROM
DC BUS BOARD
2 (+)
1 (-)
477 (+)
475 (-)
38 – 42 VDC
POWER BOARD
CONNECTOR
PLUG J42
CHECK +15
VDC SUPPLY FROM
POWER BOARD
225 (+)
222 (-)
+15 VDC
221 (+)
222 (-)
+5 VDC
222 (+)
223 (-)
-15 VDC
274 (+)
273 (-)
+5 VDC
475
NORMAL
ACCEPTABLE
VOLTAGE
READING
477
1 (+)
5 (-)
225
222
POWER BOARD
CONNECTOR
PLUG J42
CHECK +5 VDC
SUPPLY FROM
POWER BOARD
POWER BOARD
CONNECTOR
PLUG J42
CHECK -15 VDC
SUPPLY FROM
POWER BOARD
3 (+)
5 (-)
221
222
223
2 (+)
5 (-)
222
POWER BOARD
CONNECTOR
PLUG J43
CHECK +5 VDC
ARCLINK SUPPLY
FROM POWER BOARD
5 (+)
10 (-)
POWER BOARD
CONNECTOR
PLUG J43
CHECK +5 VDC
“RS-232” SUPPLY
FROM POWER BOARD
4 (+)
9 (-)
226 (+)
228 (-)
+5 VDC
226
6 (+)
11 (-)
266 (+)
267 (-)
+15 VDC
266
478 (+)
476 (-)
38 – 42 VDC
268A (+)
262 (-)
+5 VDC
345 (+)
346 (-)
+20 VDC
274
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273
228
POWER BOARD
CONNECTOR
PLUG J43
CHECK +15 VDC
SPI SUPPLY FROM
POWER BOARD
267
POWER BOARD
CONNECTOR
PLUG J41
CHECK +40 VDC
INPUT FROM
DC BUS BOARD
4 (+)
3 (-)
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476
POWER BOARD
CONNECTOR
PLUG J43
CHECK +5 VDC
SPI SUPPLY FROM
POWER BOARD
268A
478
3 (+)
12 (-)
262
POWER BOARD
CONNECTOR
PLUG J43
CHECK +20 VDC STT
SUPPLY FROM
POWER BOARD
346
7 (+)
1 (-)
345
POWER WAVE 455M/MSTT
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F-30
NOTES
POWER WAVE 455M/MSTT
F-30
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F-31
TROUBLESHOOTING & REPAIR
INPUT BOARD TEST
WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician
or machine operator and will invalidate your factory warranty. For your safety and to avoid
electrical shock, please observe all safety notes and precautions detailed throughout this
manual.
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If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electric troubleshooting assistance before you proceed. Call 1-888-935-3877.
TEST DESCRIPTION
This test will help determine if the Input Board is sending the correct voltages and also if
the Input Board is regulating and producing the correct DC voltages.
MATERIALS NEEDED
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3/8” Nut driver
Volt-ohmmeter
Wiring Diagram
POWER WAVE 455M/MSTT
F-31
INPUT BOARD TEST (CONTINUED)
FIGURE F.9 – INPUT CONTACTOR CR1
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J60
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J61
601
1
2
3 4
1
2
3 4
5
X4
INPUT
CONTACTOR
5
6 7
J60
8
6
7
8 9 10
J61
TEST PROCEDURE
WARNING
1. Remove input power to the Power Wave
455M.
ELECTRIC SHOCK can kill.
2. Using the 3/8” nut driver, remove the case
top, and input access cover.
High voltage is present when
input power is applied to the
machine.
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3. Remove lead X4 from the coil terminal of
main input contactor CR1. Insulate lead X4.
Refer to Figure F.9.
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F-32
TROUBLESHOOTING & REPAIR
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F-32
4. Carefully apply input power to the Power
Wave 455M.
5. Turn on the Power Wave 455M. Carefully
test for the correct voltages according to
Table F.4.
POWER WAVE 455M/MSTT
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F-33
F-33
TROUBLESHOOTING & REPAIR
INPUT BOARD FUNCTION TEST(CONTINUED)
TABLE F.4 – INPUT BOARD VOLTAGE CHECKS
TEST POINTS
LEAD
NUMBERS
EXPECTED
VOLTAGE
READINGS
J61
SAME AS
INPUT
VOLTAGE
PLUG J61 PIN 8 (H1D)
TO
PLUG J61 PIN 6 (612)
#612
COMMENTS
Present when Input
Switch SW1 is closed.
If not, check input lines and line
switch and wiring.
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H1D
PLUG J60 PIN 3 (238)
TO
PLUG J60 PIN 4 (604)
J60
#238
#604
13 – 15 VDC
J61
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PLUG J61 PIN 10 (T3)
TO
PLUG J61 PIN 2 (T1)
A LITTLE LESS
THAN INPUT
VOLTAGE
T1
T3
J60
PLUG J60 PIN 3 (238)
TO
PLUG J60 PIN 5 (232)
13 – 15 VDC
#238
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#232
POWER WAVE 455M/MSTT
This is the Coil Voltage for the
Pre-Charge Relay. Normally this
DC Voltage will be present 6 seconds after Input Switch SW1 is
activated. This 13 - 15 VDC will
remain for approximately 6 seconds and then be removed. The
Relay is controlled by the Control
Board. See the Wiring Diagram.
This is Pre-Charge Voltage and
will normally be present 6 seconds after activating Input Switch
SW1. The Pre-Charge Voltage
should remain for approximately 6
seconds and then be removed. It
should start at zero and ramp up
to 170 - 200 V.A.C. If zero volts check input board resistors, and
check for a shorted main input
rectifier.
This is the DC Coil Voltage for the
Control Relay. Normally this DC
Voltage will be present approximately 12 seconds after Input
Switch SW1 is activated. The
Relay is controlled by the Control
PC Board. See the Wiring
Diagram. Voltage will not be
applied if capacitor precharge is
incorrect.
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F-34
TROUBLESHOOTING & REPAIR
INPUT BOARD TEST(CONTINUED)
6. Remove input power to the Power Wave
455M. If any of the voltages are low or not
present, perform the Input Contactor Test.
If that checks out, the Input Board may by
faulty.
9. Turn on the Power Wave 455M. Check for
the presence of 24 VAC from lead X4 to
lead 601. See Figure F. 9. If the voltage
is not present, perform the Auxiliary
Transformer #1 Test.
7. Reconnect lead X4 to the main input contactor CR1 coil terminal.
9. This 24 VAC is the coil voltage for main
input contactor CR1. It will normally be
present approximately 12 seconds after
input line switch (SW1) is activated.
8. Carefully apply the correct input voltage to
the Power Wave 455M.
10. When the test is completed, remove input
power from the Power Wave 455M.
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WARNING
ELECTRIC SHOCK can kill.
11. Install the case top and reconnect cover
using the 3/8” nut driver.
High voltage is present when
input power is applied to the
machine.
POWER WAVE 455M/MSTT
F-34
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F-35
TROUBLESHOOTING & REPAIR
STT CHOPPER BOARD TEST
WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician
or machine operator and will invalidate your factory warranty. For your safety and to avoid
electrical shock, please observe all safety notes and precautions detailed throughout this
manual.
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If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electric troubleshooting assistance before you proceed. Call 1-888-935-3877.
TEST DESCRIPTION
This test will help determine if the STT Chopper Board is receiving the necessary voltages
to function and if the related circuitry is correct.
MATERIALS NEEDED
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3/8” Nut driver
Volt-ohmmeter
Wiring Diagram
POWER WAVE 455M/MSTT
F-35
F-36
TROUBLESHOOTING & REPAIR
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F-36
STT CHOPPER BOARD TEST (CONTINUED)
FIGURE F.10 – STT CHOPPER BOARD TEST DETAILS
CONTROL PC BOARD
POWER PC BOARD
J43
J43
J7
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J7
1
2
3
4
5
6
7
8
346
9 10 11 12 13 14 15 16
4W 4R
1
2
3 4
5
6
7
8
9 10 11 12
345
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STT OUTPUT
TERMINAL
POWER WAVE
+ OUTPUT
TERMINAL
TEST PROCEDURE
1. Remove input power to the Power Wave
455M.
+ probe on the Power Wave + output terminal
2. Using the 3/8” nut driver, remove the case
top and the control box cover. See Figure
F.10.
- probe on the STT output terminal
3. Perform the following resistance tests:
+ probe on the STT output terminal
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- probe on the Power Wave + output terminal
The reading should be less than 500 ohms
If both the polarity resistance tests are low,
either the STT Chopper Module is faulty or
diode D6 is shorted. See the Wiring
Diagram.
The reading should be approximately
300,000 ohms
POWER WAVE 455M/MSTT
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F-37
TROUBLESHOOTING & REPAIR
STT CHOPPER BOARD TEST (CONTINUED)
4. Carefully apply input power to the Power
Wave 455M.
WARNING
ELECTRIC SHOCK can kill.
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High voltage is present when
input power is applied to the
machine.
For steps 5 and 6, see Figure F.10.
5. Turn on the Power Wave 455M. Measure
the voltage from Power Board plug J43 lead
345 pin 7 (+) to lead 346 pin 1 (-). The voltage should be approximately 20 VDC. If not
correct, the Power Board may be faulty.
6. Measure the voltage from Control Board
plug J7 lead 4W pin 13 (-) to lead 4R pin 14
(+). The voltage should be 4 – 5 VDC. This
is the pulse width modulation signal to the
STT Chopper Board. If not correct, the
Control Board may be faulty.
7. When the test is completed, remove input
power from the Power Wave 455M.
8. Install the case top and control box cover
using the 3/8” nut driver.
POWER WAVE 455M/MSTT
F-37
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F-38
NOTES
POWER WAVE 455M/MSTT
F-38
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F-39
TROUBLESHOOTING & REPAIR
POWER WAVE CURRENT TRANSDUCER TEST
WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician
or machine operator and will invalidate your factory warranty. For your safety and to avoid
electrical shock, please observe all safety notes and precautions detailed throughout this
manual.
Return to Master TOC
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If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electric troubleshooting assistance before you proceed. Call 1-888-935-3877.
TEST DESCRIPTION
This test will help determine if the Power Wave current transducer and associated wiring
is functioning correctly.
MATERIALS NEEDED
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3/8” nut driver
Volt-Ohmmeter
POWER WAVE 455M/MSTT
F-39
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F-40
TROUBLESHOOTING & REPAIR
POWER WAVE CURRENT TRANSDUCER TEST (CONTINUED)
FIGURE F.11 – POWER WAVE CURRENT TRANSDUCER TEST
CONTROL BOARD
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J8
J8
211 212 213
1
2
3 4
5
6
7 8
216
CURRENT
TRANSDUCER
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1234
P91
TEST PROCEDURE
WARNING
1. Remove input power to the Power Wave
455.
2. Using the 3/8” nut driver, remove the case
top and the control box cover.
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3. Locate the Power Wave current transducer
leads at Control Board plug J8. See Figure
F.11.
4. Carefully apply input power to the Power
Wave 455.
POWER WAVE 455M/MSTT
ELECTRIC SHOCK can kill.
High voltage is present when
input power is applied to the
machine.
F-40
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F-41
POWER WAVE CURRENT TRANSDUCER TEST (CONTINUED)
FIGURE F.12 – RECEPTACLE S7 TRIGGERED
POWER
WAVE
RECEPTACLE
S7
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STT
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F-41
TROUBLESHOOTING & REPAIR
5. Turn on the Power Wave 455. Check for the
correct DC supply voltage to the current
transducer at plug J8. See Figure F.11.
NOTE: The machine can be triggered by
jumpering pin 1 to pin 2 at receptacle
S7. See Figure F.12.
A. Pin 2 (lead 212+) to pin 6 (lead 216-)
should read +15 VDC.
7. With the Power Wave 455 triggered, check
the feedback voltage from the current transducer. The current feedback voltage can be
read at plug J8 on the Control Board.
B. Pin 3 (lead 213-) to pin 6 (lead 216+)
should read -15 VDC.
If the DC supply voltages are not present,
the control board may be faulty.
A. Pin 1 (lead 211) to pin 6 (lead 216)
should read 2.0 VDC (machine loaded
to 250 amps).
6. If both of the supply voltages are low or
missing, check the associated leads
between plug J8 and current transducer plug
P91 and the Control Board.
POWER WAVE 455M/MSTT
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F-42
TROUBLESHOOTING & REPAIR
POWER WAVE CURRENT TRANSDUCER TEST (CONTINUED)
8. If for any reason the machine cannot be
loaded to 250 amps, Table F.5 shows what
feedback voltage is produced at various current loads.
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9. If the correct supply voltages are applied to
the current transducer, and with the machine
loaded, the feedback voltage is missing or
not correct, the current transducer may be
faulty. Also make certain that lead 211
(plug J8 pin 1) has continuity (zero ohms)
between the current transducer and the
control board. See the Wiring Diagram.
10. Install the right side case cover using the
3/8” nut driver.
TABLE F.5 - CURRENT FEEDBACK AT VARIOUS OUTPUT LOADS
OUTPUT LOAD CURRENT
EXPECTED TRANSDUCER FEEDBACK
VOLTAGE
500
450
400
350
300
250
200
150
100
50
4.0
3.6
3.2
2.8
2.4
2.0
1.6
1.2
0.8
0.4
POWER WAVE 455M/MSTT
F-42
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F-43
TROUBLESHOOTING & REPAIR
STT CURRENT TRANSDUCER TEST
WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician
or machine operator and will invalidate your factory warranty. For your safety and to avoid
electrical shock, please observe all safety notes and precautions detailed throughout this
manual.
Return to Master TOC
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If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electric troubleshooting assistance before you proceed. Call 1-888-935-3877.
TEST DESCRIPTION
This test will help determine if the STT current transducer and associated wiring is functioning correctly.
MATERIALS NEEDED
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3/8” nut driver
Volt-Ohmmeter
POWER WAVE 455M/MSTT
F-43
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F-44
F-44
TROUBLESHOOTING & REPAIR
STT CURRENT TRANSDUCER TEST (CONTINUED)
FIGURE F.13 – STT CURRENT TRANSDUCER TEST
CONTROL BOARD
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J8
813
1
2
3 4
5
6
7 8
811
816 812
J8
1234
P90
CURRENT
TRANSDUCER
TEST PROCEDURE
WARNING
1. Remove input power to the Power Wave
455.
2. Using the 3/8” nut driver, remove the case
top and the control box cover.
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3. Locate the STT current transducer leads at
Control Board plug J8. See Figure F.13.
4. Carefully apply input power to the Power
Wave 455M.
POWER WAVE 455M/MSTT
ELECTRIC SHOCK can kill.
High voltage is present when
input power is applied to the
machine.
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F-45
STT CURRENT TRANSDUCER TEST (CONTINUED)
FIGURE F.14 – RECEPTACLE S7 TRIGGERED
POWER
WAVE
RECEPTACLE
S7
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STT
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F-45
TROUBLESHOOTING & REPAIR
5. Turn on the Power Wave 455M. Check for
the correct DC supply voltage to the current
transducer at plug J8.
NOTE: The machine can be triggered by
jumpering pin 1 to pin 2 at receptacle
S7. See Figure F. 14.
A. Pin 8 (lead 812+) to pin 7 (lead 816-)
should read +15 VDC.
7. With the Power Wave 455M triggered, check
the feedback voltage from the current transducer. The current feedback voltage can be
read at plug J8 on the Control Board.
B. Pin 4 (lead 813-) to pin 7 (lead 816+)
should read -15 VDC.
If the DC supply voltages are not present,
the control board may be faulty.
A. Pin 5 (lead 811) to pin 7 (lead 816)
should read 0.4 VDC (machine loaded
to 50 amps).
6. If both of the supply voltages are low or
missing, check the associated leads
between plug J8 and current transducer plug
P90 and the Control Board.
POWER WAVE 455M/MSTT
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F-46
TROUBLESHOOTING & REPAIR
STT CURRENT TRANSDUCER TEST (CONTINUED)
8. If for any reason the machine cannot be
loaded to 50 amps, Table F.6 shows what
feedback voltage is produced at various current loads. S.T.T. stud is limited to 325
amps.
10. Install the right side case cover using the
3/8” nut driver.
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9. If the correct supply voltages are applied to
the current transducer, and with the machine
loaded, the feedback voltage is missing or
not correct, the current transducer may be
faulty. Also make certain that lead 811 (plug
J8 pin 5) has continuity (zero ohms)
between the current transducer and the
control board. See the Wiring Diagram.
POWER WAVE 455M/MSTT
F-46
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F-47
TROUBLESHOOTING & REPAIR
OUTPUT RECTIFIER TEST
WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician
or machine operator and will invalidate your factory warranty. For your safety and to avoid
electrical shock, please observe all safety notes and precautions detailed throughout this
manual.
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If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.
TEST DESCRIPTION
The test will help determine if any of the output rectifiers are shorted.
MATERIALS NEEDED
Analog Volt-Ohmmeter
3/8” Nut driver
5/16” Wrench
POWER WAVE 455M/MSTT
F-47
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F-48
TROUBLESHOOTING & REPAIR
OUTPUT RECTIFIER TEST (CONTINUED)
FIGURE F.15 – OUTPUT RECTIFIER TEST
I ON
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POWERWAVE 455/R
NEGATIVE (-)
OUTPUT
TERMINAL
STT OUTPUT
TERMINAL
POSITIVE (+)
OUTPUT
TERMINAL
TEST PROCEDURE
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1. Remove main input supply power to the
Power Wave 455M.
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O OFF
2. Remove any output load that may be connected to the Power Wave 455M.
3. With the analog ohmmeter, measure the
resistance between the positive and negative output terminals (NOT the STT terminal). Refer to Figure F.15.
4. If the reading is approx. 50 ohms, the output
rectifier modules are not shorted. If the
reading is less than 10 ohms, one or more of
the rectifier modules are shorted. Reverse
meter probe and verify low reading. Refer to
the Output Rectifier Module Replacement
procedure.
IMPORTANT: The positive (+) meter probe
must be attached to the positive (+) output terminal and the negative (-) meter probe must be
attached to the negative (-) output terminal.
6. Using the 5/16” wrench, remove and insulate lead 202A from the negative output terminal. Repeat step 4 to confirm.
7. Reconnect lead 202A to the negative output
terminal.
8. Replace the case top and sides.
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5. Remove the case top perform the Input
Filter Capacitor Discharge procedure.
POWER WAVE 455M/MSTT
F-48
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F-49
TROUBLESHOOTING & REPAIR
AUXILIARY TRANSFORMER NO. 1 TEST
WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician
or machine operator and will invalidate your factory warranty. For your safety and to avoid
electrical shock, please observe all safety notes and precautions detailed throughout this
manual.
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If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electric troubleshooting assistance before you proceed. Call 1-888-935-3877.
TEST DESCRIPTION
This test will determine if the correct voltage is being applied to the primary of Auxiliary
Transformer No. 1 and also if the correct voltages are being induced on the secondary
windings of the transformer.
MATERIALS NEEDED
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Volt-ohmmeter (Multimeter)
3/8” Nut driver
Wiring Diagram
POWER WAVE 455M/MSTT
F-49
F-50
TROUBLESHOOTING & REPAIR
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F-50
AUXILIARY TRANSFORMER NO. 1 TEST (CONTINUED)
FIGURE F.16 – AUXILIARY TRANSFORMER NO. 1 TEST
X3
X5
INPUT
CONTACTOR
X1
+
601
FAN MOTOR
LEADS
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X4
-
X2
POWER BOARD
RECTIFIER BRIDGE
TEST PROCEDURE
1. Remove the main input power to the Power
Wave 455 machine.
5. Locate secondary leads X3 and X5 (fan
motor leads).
2. Using the 3/8” nut driver, remove the case
top.
6. Locate secondary lead X4 (at main contactor).
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3. Perform the Capacitor Discharge procedure.
4. Locate secondary leads X1 and X2 (at
power board rectifier bridge). Refer to
Figure F.16.
POWER WAVE 455M/MSTT
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F-51
TROUBLESHOOTING & REPAIR
AUXILIARY TRANSFORMER NO. 1 TEST (CONTINUED)
TABLE F.6 – SECONDARY VOLTAGES
LEAD IDENTIFICATION
NORMAL EXPECTED VOLTAGE
X1 to X2
X3 to X5
X3 to X4
52 VAC
115 VAC
24 VAC
7. Carefully apply the correct input voltage to
the Power Wave 455M.
10. If the correct secondary voltages are present, the T1 auxiliary transformer is functioning properly. If any of the secondary
voltages are missing or low, check to make
certain the primary is configured correctly
for the input voltage applied. See the
Wiring Diagram.
WARNING
ELECTRIC SHOCK can kill.
High voltage is present at primary of the Auxiliary Transformer.
12. Replace any cables ties and insulation
removed earlier.
8. Turn on PW455M.
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9. Check for the correct secondary voltages
according to Table F.6.
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11. If the correct input voltage is applied to the
primary, and the secondary voltage(s) are
not correct, the T1 transformer may be
faulty.
13. Install the case sides and top using the 3/8”
nut driver.
NOTE: The secondary voltages will vary if the
input line voltage varies.
POWER WAVE 455M/MSTT
F-51
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F-52
NOTES
POWER WAVE 455M/MSTT
F-52
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F-53
TROUBLESHOOTING & REPAIR
AUXILIARY TRANSFORMER NO. 2 TEST
WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician
or machine operator and will invalidate your factory warranty. For your safety and to avoid
electrical shock, please observe all safety notes and precautions detailed throughout this
manual.
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 electric troubleshooting assistance before you proceed. Call 1-888-935-3877.
TEST DESCRIPTION
This test will determine if the correct voltage is being applied to the primary of Auxiliary
Transformer No. 2 and also if the correct voltages are being induced on the secondary
windings of the transformer.
MATERIALS NEEDED
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Volt-ohmmeter (Multimeter)
3/8” Nut driver
Wiring Diagram
POWER WAVE 455M/MSTT
F-53
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F-54
F-54
TROUBLESHOOTING & REPAIR
AUXILIARY TRANSFORMER NO. 2 TEST (CONTINUED)
FIGURE F.17 – AUXILIARY TRANSFORMER NO. 2 TEST
H1
3
VIEWED FROM
TRANSFORMER
LEAD SIDE
H6
P50
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5
350 352
1
2
VIEWED FROM
TRANSFORMER
LEAD END
3
4
33A
P52
TEST PROCEDURE
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1. Remove the main input power to the Power
Wave 455M machine.
2. Remove any load that may be connected to
the 115 VAC receptacle.
3. Using the 3/8” nut driver, remove the case
top.
4. Locate plugs P52 and P50 at the Auxiliary
Transformer No. 2. Refer to Figure F.17.
5. Carefully apply the correct input power.
ELECTRIC SHOCK can kill.
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7. If 115 VAC and 230 VAC are present,
Auxiliary Transformer No. 2 is good.
8. If 115 is not present between pins 1 and 4,
and 230 VAC is not present between pins 1
and 2, check the associated leads and
plugs for loose or faulty connections.
9. Carefully test for the correct AC input voltage applied to the primary windings at plug
P50. See the Wiring Diagram.
WARNING
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6. Check for 115 VAC at plug P52 pins 1 and
4 (leads 350 to 33A). Check for 230 VAC
at plug P52 pins 1 and 2 (leads 350 to
352).
High voltage is present at both
plugs.
10. If the correct AC input voltage is applied to
the primary of the Auxiliary Transformer
No. 2 and the secondary voltage is NOT
correct, the transformer may be faulty.
Replace.
11. Replace any cables ties and insulation
removed earlier.
12. Install the case top using the 3/8” nut driver.
POWER WAVE 455M/MSTT
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F-55
TROUBLESHOOTING & 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 electric troubleshooting assistance before you proceed. Call 1-888-935-3877.
DESCRIPTION
This procedure will aid the technician in the removal and replacement of the input rectifier module.
MATERIALS NEEDED
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3/8” nut driver
3/16” Allen wrench
Phillips head screwdriver
POWER WAVE 455M/MSTT
F-55
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F-56
F-56
TROUBLESHOOTING & REPAIR
INPUT RECTIFIER REMOVAL AND REPLACEMENT (CONTINUED)
FIGURE F.18 – INPUT RECTIFIER REMOVAL AND REPLACEMENT
INPUT
RECTIFIER
A
B
C
NEG (-)
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POS (+)
REMOVAL PROCEDURE
REPLACEMENT PROCEDURE
1. Remove input power to the Power Wave
455M.
1. Clean heat sink surfaces.
2. Using the 3/8” nut driver, remove the case
top, and input access panel.
3. Perform the Capacitor Discharge procedure.
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4. Locate and remove the RTV sealant from the
input rectifier connection terminals. See
Figure F. 18.
5. Label and, using the phillips head screwdriver, carefully remove the five leads from the
input rectifier terminals. Note placement for
reassembly. See Figure F.18.
6. Using the 3/16” allen wrench, remove the
two mounting screws and washers from the
rectifier module.
2. Apply an even coating of joint compound
(Penetrox A-13) to both the heat sink and
module
mounting
surfaces.
The joint compound should be 0.002 - 0.005
in. thick per surface.
3. Mount the module to the heat sink and evenly torque the mounting screws (with washers) to 44 in/lbs.
4. Assemble the leads to the correct module
terminals and torque to 26 in/lbs. See Figure
F.18.
5. Apply RTV sealant to the rectifier connection
terminals.
6. Install the case top, sides, and input access
panel using the 3/8” nut driver.
7. Carefully remove the input rectifier module.
POWER WAVE 455M/MSTT
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F-57
TROUBLESHOOTING & REPAIR
INPUT CONTACTOR 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 electric troubleshooting assistance before you proceed. Call 1-888-935-3877.
TEST DESCRIPTION
This procedure will aid the technician in the removal and replacement of the input contactor.
MATERIALS NEEDED
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Return to Section TOC
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3/8” nut driver
5/16” nut driver
Phillips head screwdriver
POWER WAVE 455M/MSTT
F-57
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F-58
F-58
TROUBLESHOOTING & REPAIR
INPUT CONTACTOR REMOVAL AND REPLACEMENT (CONTINUED)
FIGURE F.19 – INPUT CONTACTOR REMOVAL AND REPLACEMENT
INPUT
CONTACTOR
601
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X4
REMOVAL PROCEDURE
REPLACEMENT PROCEDURE
1. Remove input power to the Power Wave
455M.
1. Mount the contactor and tighten the mounting screws.
2. Using the 3/8” nut driver, remove the case
top, and input access panel.
2. Assemble the leads to the correct terminals.
See Figure F.18.
3. Perform the Capacitor Discharge procedure
3. Install the case top, sides, and input access
panel using the 3/8” nut driver.
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4. Locate the input contactor. Label and,
using the phillips head screwdriver, carefully remove the leads from the input contactor terminals. Note placement for reassembly. See Figure F.19.
5. With the 5/16” nut driver, remove the three
mounting screws. See Figure F.19.
6. Carefully remove the input contactor.
POWER WAVE 455M/MSTT
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F-59
TROUBLESHOOTING & REPAIR
AUXILIARY TRANSFORMER NO. 1 REMOVAL AND
REPLACEMENT 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 electric troubleshooting assistance before you proceed. Call 1-888-935-3877.
DESCRIPTION
This procedure will aid the technician in the removal and replacement of auxiliary transformer No. 1.
MATERIALS NEEDED
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Return to Master TOC
Return to Section TOC
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3/8” Nut driver
Wire cutters
Wire splicer or soldering equipment
POWER WAVE 455M/MSTT
F-59
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F-60
AUXILIARY TRANSFORMER NO. 1 REMOVAL AND
REPLACEMENT PROCEDURE (CONTINUED)
FIGURE F.20 – AUXILIARY TRANSFORMER NO. 1 REMOVAL AND REPLACEMENT
X3
X5
H1
CB4
RECONNECT
TERMINALS
H2
H3
H4
H5
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X1
-
INPUT
CONTACTOR
601
FAN MOTOR
LEADS
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F-60
TROUBLESHOOTING & REPAIR
+
X4
X2
POWER BOARD
RECTIFIER BRIDGE
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REMOVAL PROCEDURE
1. Remove input power to the Power Wave
455.
4. Using the 3/8” nut driver, remove the case
back.
2. Using the 3/8” nut driver, remove the case
top, and input access panel.
5. Remove lead X4 from the input contactor
coil terminal.
3. Perform the Capacitor Discharge procedure.
POWER WAVE 455M/MSTT
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F-61
TROUBLESHOOTING & REPAIR
AUXILIARY TRANSFORMER NO. 1 REMOVAL AND
REPLACEMENT PROCEDURE (CONTINUED)
6. Remove leads X1 and X2 from the power
board rectifier bridge. Refer to Figure
F.20.
7. Cut X3 and X5 from the fan motor leads.
Leave enough lead length to splice in the
new transformer leads.
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8. Cut the X3 lead that is connected to the
input board. Leave enough lead length to
splice in the new transformer lead.
9. Locate, label, and remove primary lead H1
from circuit breaker CB4.
10. Label and remove primary leads H2, H3,
H4, and H5 from the reconnect terminals
on the reconnect panel. Note lead placement for reassembly.
6. Splice the new transformer fan leads to
the fan motor leads X3 and X5.
7. Connect lead X4 to the main contactor
coil terminal.
8. Connect leads X1 and X2 to the power
board rectifier bridge.
9. Reposition any wire leads and install
cable ties as necessary.
10. Install the case back using the 3/8” nut
driver.
11. Install the case top, sides, and input
access panel using the 3/8” nut driver.
11. Cut any necessary cable ties and clear the
leads.
12. Using the 3/8” nut driver, remove the two
mounting screws that hold the transformer
to the fan baffle and the machine base.
13. Carefully remove the transformer from the
Power Wave 455.
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REPLACEMENT PROCEDURE
1.
Carefully place the transformer into the
Power Wave 455.
2.
Install the two mounting screws that hold
the transformer to the fan baffle and the
machine base using the 3/8” nut driver.
3.
Install the primary leads H2, H3, H4, and
H5 to the reconnect terminals on the
reconnect panel.
4.
Connect primary lead H1 to circuit breaker
CB4.
5.
Splice the new transformer lead with the
X3 lead connected to the input board.
POWER WAVE 455M/MSTT
F-61
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F-62
NOTES
POWER WAVE 455M/MSTT
F-62
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F-63
TROUBLESHOOTING & REPAIR
AUXILIARY TRANSFORMER NO. 2 REMOVAL AND
REPLACEMENT 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 electric troubleshooting assistance before you proceed. Call 1-888-935-3877.
TEST DESCRIPTION
This procedure will aid the technician in the removal and replacement of auxiliary transformer No. 2.
MATERIALS NEEDED
Return to Section TOC
Return to Master TOC
Return to Section TOC
Return to Master TOC
3/8” Nut driver
Wire cutters
POWER WAVE 455M/MSTT
F-63
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F-64
F-64
TROUBLESHOOTING & REPAIR
AUXILIARY TRANSFORMER NO. 2 REMOVAL AND
REPLACEMENT PROCEDURE (CONTINUED)
FIGURE F.21 – AUXILIARY TRANSFORMER NO. 2 REMOVAL AND REPLACEMENT
INPUT
CONTACTOR
601
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X4
P52
P50
CB4 CIRCUIT
BREAKER &
115V RECEPTACLE
LEADS 33/32
REMOVAL PROCEDURE
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1. Remove input power to the Power Wave
455.
2. Using the 3/8” nut driver, remove the case
top, and input access panel.
3. Perform the Capacitor Discharge procedure.
5. Disconnect plugs P50 and P52.
6. Disconnect leads 33 and 32 to circuit breaker
CB2 and the 115 V receptacle.
7. Using the 3/8” nut driver, remove the two
transformer mounting screws.
4. Using the 3/8” nut driver, remove the case
back.
POWER WAVE 455M/MSTT
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F-65
TROUBLESHOOTING & REPAIR
AUXILIARY TRANSFORMER NO. 2 REMOVAL AND
REPLACEMENT PROCEDURE (CONTINUED)
REPLACEMENT PROCEDURE
1. Carefully place the transformer into the
Power Wave 455.
2. Install the two mounting screws that hold the
transformer to the machine base using the
3/8” nut driver.
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3. Connect leads 33 and 32 to circuit breaker
CB4 and the 115 V receptacle.
4. Connect plugs P50 and P52.
5. Reposition any wire leads and install cable
ties as necessary.
6. Install the case back using the 3/8” nut driver.
7. Install the case top, sides, and input access
panel using the 3/8” nut driver.
POWER WAVE 455M/MSTT
F-65
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F-66
NOTES
POWER WAVE 455M/MSTT
F-66
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F-67
TROUBLESHOOTING & REPAIR
CONTROL, FEED HEAD, OR VOLTAGE SENSE PC BOARD
REMOVAL AND REPLACEMENT
WARNING
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Service and repair should be performed by only Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician
or machine operator and will invalidate your factory warranty. For your safety and to avoid
electrical shock, please observe all safety notes and precautions detailed throughout this
manual.
If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electric troubleshooting assistance before you proceed. Call 1-888-935-3877.
DESCRIPTION
This procedure will aid the technician in the removal and replacement of either the
Control Board the Feed Head Board, or the Voltage Sense Board.
MATERIALS NEEDED
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Return to Master TOC
3/8” Nut driver
Anti-static wrist strap
POWER WAVE 455M/MSTT
F-67
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F-68
TROUBLESHOOTING & REPAIR
CONTROL, FEED HEAD, OR VOLTAGE SENSE PC BOARD
REMOVAL AND REPLACEMENT (CONTINUED)
FIGURE F.22 – CONTROL OR FEED HEAD BOARD REMOVAL AND REPLACEMENT
COMPARTMENT
COVER
POWER
BOARD
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DC BUS
POWER BOARD
CONTROL
BOARD
REMOVAL PROCEDURE
1. Remove input power to the Power Wave
455M.
2. Using the 3/8” nut driver, remove the case
top.
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3. Perform the Capacitor Discharge procedure.
4. Observe all static electricity precautions.
6. Using the 3/8” nut driver, remove the two
screws holding the rear of the Control Box in
place.
7. Clear the leads in the sleeving and the grommets on the sides of the control box.
8. Label and remove the molex plugs from the
Control Board and the Feed Head Board.
5. Using the 3/8” nut driver, remove the PC
board compartment cover. Refer to Figure
F.22.
POWER WAVE 455M/MSTT
F-68
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F-69
TROUBLESHOOTING & REPAIR
CONTROL, FEED HEAD, OR VOLTAGE SENSE PC BOARD
REMOVAL AND REPLACEMENT (CONTINUED)
FIGURE F.23 – VOLTAGE SENSE BOARD REMOVAL AND REPLACEMENT
COMPARTMENT
COVER
POWER
BOARD
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CONTROL
BOARD
VOLTAGE
SENSE
BOARD
9. Tilt back the rear of the control box to
access the PC board mounting nuts. Using
the 3/8” nut driver, remove the self-locking
mounting nuts from the Control and Feed
Head Boards.
Carefully remove the
boards.
REPLACEMENT PROCEDURE
1. Install either the Control or the Feed Head
Board to the back of the control box with the
self-locking nuts. Use the 3/8” nut driver.
10. Remove plugs J1 and J2 from the Voltage
Sense Board. See Figure F.23.
2. Connect the molex plugs to the Control
Board and the Feed Head Board. Be sure
the lead harnesses are securely and properly positioned.
11. Using the needle-nose pliers, carefully
pinch the three plastic standoffs. Remove
the Voltage Sense Board.
3. Secure the rear of the control box in place
using two screws and the 3/8” nut driver.
POWER WAVE 455M/MSTT
F-69
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F-70
TROUBLESHOOTING & REPAIR
CONTROL, FEED HEAD, OR VOLTAGE SENSE PC BOARD
REMOVAL AND REPLACEMENT (CONTINUED)
3. Secure the rear of the control box in place
using two screws and the 3/8” nut driver.
4. Press the Voltage Sense Board onto its
standoffs. Make sure the board snaps into
place on all three standoffs.
5. Connect the two molex plugs to the Voltage
Sense Board.
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6. Install the PC board compartment cover
using the 3/8” nut driver.
7. Install the case top and sides using the 3/8”
nut driver.
POWER WAVE 455M/MSTT
F-70
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F-71
TROUBLESHOOTING & REPAIR
GATEWAY PC BOARD REMOVAL AND REPLACEMENT
WARNING
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Service and repair should be performed by only Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician
or machine operator and will invalidate your factory warranty. For your safety and to avoid
electrical shock, please observe all safety notes and precautions detailed throughout this
manual.
If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electric troubleshooting assistance before you proceed. Call 1-888-935-3877.
DESCRIPTION
This procedure will aid the technician in the removal and replacement of the Gateway PC
Board.
MATERIALS NEEDED
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Return to Master TOC
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Return to Master TOC
Phillips head screw driver
3/8” Nut driver
Anti-static wrist strap
POWER WAVE 455M/MSTT
F-71
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F-72
TROUBLESHOOTING & REPAIR
GATEWAY PC BOARD REMOVAL AND REPLACEMENT (CONTINUED)
FIGURE F.24 – GATEWAY BOARD REMOVAL AND REPLACEMENT
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DEVICENET/
GATEWAY BOARD
(LOCATED BEHIND
FRONT COVER)
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PHILLIPS
SCREW
REMOVAL PROCEDURE
REPLACEMENT PROCEDURE
1. Remove input power to the Power Wave
455.
1. Install the Gateway Board to the case front
cover with the self-locking nuts. Use the 3/8”
nut driver.
2. Using the phillips head screw driver, remove
the six screws from the case front cover. Tilt
open the cover and support it. See Figure
F.24.
3. Observe all static electricity precautions.
2. Connect the four molex plugs to the
Gateway Board.
3. Using the phillips head screw driver, attach
the cover to the case front.
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4. Label and remove the four molex plugs from
the Gateway Board.
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F-72
5. Using the 3/8” nut driver, remove the selflocking mounting nuts from the Gateway
Board. Carefully remove the board. Refer
to Figure F.24.
POWER WAVE 455M/MSTT
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F-73
TROUBLESHOOTING & REPAIR
STT 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 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 electric troubleshooting assistance before you proceed. Call 1-888-935-3877.
DESCRIPTION
This procedure will aid the technician in the removal and replacement of the STT Current
Transducer.
MATERIALS NEEDED
3/8” Nut driver
5/16” Open end wrench
5/16” Socket wrench with extension
Universal adapter
3/4” Wrench
Phillips head screw driver
Wire cutters
Wiring Diagram
POWER WAVE 455M/MSTT
F-73
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F-74
TROUBLESHOOTING & REPAIR
STT CURRENT TRANSDUCER
REMOVAL AND PLACEMENT (CONTINUED)
FIGURE F.25 – STT CURRENT TRANSDUCER REMOVAL AND REPLACEMENT PROCEDURE
RESISTOR
ASSEMBLY
1234
P90
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STT OUTPUT
TERMINAL
(TOP RIGHT)
CURRENT
TRANSDUCER
REMOVAL PROCEDURE
1. Remove input power to the Power Wave
455.
2. Using the 3/8” nut driver, remove the case
top and right side.
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3. Perform the Capacitor Discharge procedure.
4. Using the wire cutters, cut all cable ties to
the transducer lead harness. Unplug the
harness and swing it aside.
5. Label and remove the leads to the resistor
assembly. See Figure F.25. Using the
5/16” socket wrench, extension and universal adapter, remove the resistor assembly.
It may be necessary to remove the plastic
high voltage protection shield. (Use the
3/8” nut driver.) It may also be necessary to
use a 5/16” open end wrench to remove the
inside screws. Carefully swing the resistor
assembly aside.
POWER WAVE 455M/MSTT
F-74
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F-75
TROUBLESHOOTING & REPAIR
STT CURRENT TRANSDUCER
REMOVAL AND REPLACEMENT (CONTINUED)
6. With the 5/16” open end wrench, remove
the small screw from the STT output terminal. Label and remove the small leads.
See the Wiring Diagram.
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7. Using the 3/4” wrench, remove the bolt,
lock washer and flat washer from the STT
output terminal. Remove the double heavy
output leads. Cut any necessary cable
ties.
8. Using the phillips head screw driver,
remove the screws and lock washers that
hold the transducer to the front panel.
9. Remove the STT current transducer, carefully feeding the output leads through it.
3. Attach the double heavy leads to the STT
output terminal with the 3/4” bolt, lock washer and flat washer.
4. Attach the small leads to the STT output terminal with the 5/16” screw.
5. Install the resistor assembly using the 5/16”
socket wrench, extension and universal
adapter. Install the plastic high voltage protection shield with the 3/8” nut driver.
6. Replace all cable ties cut during removal.
7. Install the case top and right side using the
3/8” nut driver.
10. Remove the standoffs from the transducer
and save them for reassembly with the new
transducer.
REPLACEMENT PROCEDURE
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1. Attach the standoffs to the transducer.
2. Position the transducer on the back of the
front panel and attach it with the two
phillips screws and lock washers. Feed the
output leads through the transducer.
POWER WAVE 455M/MSTT
F-75
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F-76
NOTES
POWER WAVE 455M/MSTT
F-76
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F-77
TROUBLESHOOTING & REPAIR
POWER WAVE 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 electric troubleshooting assistance before you proceed. Call 1-888-935-3877.
TEST DESCRIPTION
This procedure will aid the technician in the removal and replacement of the Power Wave
Current Transducer.
MATERIALS NEEDED
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3/8” Nut driver
5/16” Open end wrench
9/16” Wrench
3/4” Wrench
Phillips head screw driver
Wire cutters
Wiring Diagram
POWER WAVE 455M/MSTT
F-77
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F-78
TROUBLESHOOTING & REPAIR
POWER WAVE CURRENT TRANSDUCER
REMOVAL AND REPLACEMENT (CONTINUED)
FIGURE F.26 – POWER WAVE CURRENT TRANSDUCER REMOVAL AND REPLACEMENT PROCEDURE
CURRENT
TRANSDUCER
HEAVY LEAD
BOLTED CONNECTION
(BEHIND CASE FRONT)
REMOVAL PROCEDURE
1. Remove input power to the Power Wave
455.
2. Using the 3/8” nut driver, remove the case
top and sides and the control box cover.
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3. Perform the Capacitor Discharge procedure.
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F-78
4. Using the 3/8” socket wrench or nut driver,
remove the three screws along the bottom
case front. See Figure F.26.
6. Label all leads to all output terminals. Using
the 5/16” wrench and the 3/4” wrench,
remove all leads from the three output terminals. See the Wiring Diagram.
7. Cut any necessary cable ties. Then carefully swing the front panel aside.
8. Remove the insulating tape from the heavy
lead bolted connection. See Figure F.26.
Using the 9/16” wrenches, remove the bolt,
lock washer and nut.
5. Using the 3/8” socket wrench, remove the
four screws that hold the case front to the
machine.
POWER WAVE 455M/MSTT
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F-79
TROUBLESHOOTING & REPAIR
POWER WAVE CURRENT TRANSDUCER
REMOVAL AND REPLACEMENT (CONTINUED)
9. Using the phillips head screw driver,
remove the screws and lock washers that
hold the transducer to the front panel.
10. Remove the Power Wave current transducer.
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11. Remove the standoffs from the transducer
and save them for reassembly with the
new transducer.
4. Using the 5/16” wrench and the 3/4” wrench,
attach all leads to the three output terminals.
See the Wiring Diagram.
5. Replace all cable ties cut during removal.
6. Install the case top and sides using the 3/8”
nut driver.
REPLACEMENT PROCEDURE
1. Attach the standoffs to the transducer.
2. Position the transducer on the back of the
front panel and attach it with the two
phillips screws and lock washers. Feed the
output leads through the transducer.
3. Run the heavy lead through transducer
and secure the bolted connection with the
9/16” bolt, lock washer and nut. Replace
the insulating tape around the connection.
POWER WAVE 455M/MSTT
F-79
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F-80
NOTES
POWER WAVE 455M/MSTT
F-80
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F-81
TROUBLESHOOTING & REPAIR
OUTPUT RECTIFIER, STT CHOPPER BOARD AND RECTIFIER MODULE
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 electric troubleshooting assistance before you proceed. Call 1-888-935-3877.
TEST DESCRIPTION
This procedure will aid the technician in the removal and replacement of the output rectifier assembly and individual rectifier module replacement.
This procedure takes approximately 35 minutes to remove and replace the output rectifier, 5 minutes to remove the STT Chopper Board and 5 minutes to remove and replace the
rectifier module.
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MATERIALS NEEDED
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F-81
3/8” Nut driver
7/16” Wrench
9/16” Wrench
9/64” Allen wrench
3/16” Allen wrench
Needle-nose pliers
Slot head screwdriver
Penetrox A13 Thermal Joint Compound
Wiring Diagram
POWER WAVE 455M/MSTT
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F-82
TROUBLESHOOTING & REPAIR
OUTPUT RECTIFIER, STT CHOPPER BOARD AND RECTIFIER MODULE
REMOVAL AND REPLACEMENT (CONTINUED)
FIGURE F.27 – OUTPUT RECTIFIER, STT CHOPPER BOARD AND RECTIFIER MODULE
REMOVAL AND REPLACEMENT
LEAD 287
(SNUBBER
DIODE)
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F-82
PLUG J10
STT LEAD
RECTIFIER
THERMOSTAT
(LEADS 291 & 292)
LEAD 289B
(STT SNUBBER
CAPACITOR)
TRANSFORMER
LEADS
RECTIFIER
MODULE
POSITIVE
OUTPUT
LEAD
HEATSINK
MOUNT
BOLTS (4X)
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HEATSINK
RECTIFIER ASSEMBLY
REMOVAL PROCEDURE
1. Remove input power to the Power Wave
455.
2. Using the 3/8” nut driver, remove the case
top and sides.
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3. Perform the Capacitor Discharge procedure.
4. Using the 9/16” wrench, remove the Power
Wave positive output lead from the rectifier
heat sink. Note fastener hardware for
reassembly. Refer to Figure F.27.
5. Using the 7/16” wrench, remove the STT
output lead from the rectifier heat sink. Note
fastener hardware for reassembly. Refer to
Figure F.27.
6. Using the 7/16” wrench, remove the eight
transformer leads from the rectifier modules.
Label the leads and take note of lead placement for reassembly. Note that each screw
has two flat washers and one lock washer.
POWER WAVE 455M/MSTT
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F-83
TROUBLESHOOTING & REPAIR
OUTPUT RECTIFIER, STT CHOPPER BOARD AND RECTIFIER MODULE
REMOVAL AND REPLACEMENT (CONTINUED)
7. Using the needle-nose pliers, remove
leads #292 and #291 from the rectifier thermostat.
4. Using the 3/16” allen wrench, remove the
four screws and lock washers holding the
board to the heat sink.
8. Disconnect plug J10 from the STT
Chopper Board.
5. Carefully remove the STT Chopper Board.
9. With the 7/16” wrench, remove lead #287
from the STT Snubber Diode D5.
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10. With the 7/16” wrench, remove lead #289B
from the STT Snubber Capacitor C10.
11. Using the 7/16” wrench, remove the four
nuts and associated washers from the heat
sink mounting bolts. The heat-sink assembly can be removed by carefully sliding the
assembly forward and removing the mounting bolts.
REPLACEMENT PROCEDURE
1. Position the new board on the heat sink,
using the standoffs for the slot head nylon
screws and the allen head screws.
2. Install the four 3/16” allen head screws and
lock washers.
3. Install the two nylon slot head screws.
4. Install the two 7/16” bolts, lock washers and
flat washers.
STT CHOPPER BOARD REMOVAL
AND REPLACEMENT PROCEDURE
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1. Place the output rectifier assembly on a
clean bench surface.
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F-83
2. Using a slot head screw driver, remove the
two nylon screws holding the board to the
heat sink. Save the standoffs for reassembly.
3. Using the 7/16” wrench, remove the two
bolts, lock washers and flat washers. Save
the standoffs for reassembly.
POWER WAVE 455M/MSTT
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F-84
TROUBLESHOOTING & REPAIR
OUTPUT RECTIFIER, STT CHOPPER BOARD AND RECTIFIER MODULE
REMOVAL AND REPLACEMENT (CONTINUED)
RECTIFIER MODULE REMOVAL AND
REPLACEMENT PROCEDURE
RECTIFIER ASSEMBLY REPLACEMENT PROCEDURE
1. Using the 9/64” allen wrench, remove the
cap screw from the center of the rectifier
module that is to be replaced.
1. Position the assembly in place with the
mounting bolts.
2. Using the 7/16” wrench, remove the two
mounting bolts and associated washers
from the rectifier module to be replaced.
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3. Remove the faulty module.
4. This module requires special mounting considerations to prevent warping of the base
plate. The heat sink surfaces must be clean
and flat. Apply a thin, even coating of thermal compound, (Penetrox A13) 0.004 to
0.010 inches thick. Keep the compound
away from the area of the mounting holes.
5. Press the new module firmly against the
heat sink while aligning the mounting holes.
Start all three screws two to three turns by
hand.
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6. Tighten each of the outer screws to between
5 and 10 in-lbs.
7. Tighten the center screw to between 12 and
18 in-lbs.
8. Tighten each of the outer screws again, this
time to between 30 and 40 in/lbs.
2. Assemble the nuts and associated washers to the mounting bolts.
3. Using the 7/16” wrench, tighten the four
nuts on the mounting bolts.
4. Replace leads #292 and #291 to the thermostat.
5. Connect plug J10 to the STT Chopper
Board.
6. With the 7/16” wrench, attach lead #287
from the STT Snubber Diode D5.
7. With the 7/16” wrench, attach lead #289B
from the STT Snubber Capacitor C10.
8. Connect the eight transformer leads to the
correct rectifier modules. Tighten the
screws (with two flat washers and one lock
washer) to between 30 and 40 in/lbs. Do
not stress the terminals when making
these connections.
9. Apply a thin coat of Penetrox A13 to the
heat sink where the Power Wave positive
output lead and the STT output lead attach.
10. Attach the Power Wave positive output
lead to the heat sink using the 9/16”
wrench.
11. Attach the STT output lead to the heat sink
using the 7/16” wrench.
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12. Install the case top and sides using the 3/8”
nut driver.
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F-84
POWER WAVE 455M/MSTT
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F-85
TROUBLESHOOTING & REPAIR
SWITCH BOARD AND FILTER CAPACITOR
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 electric troubleshooting assistance before you proceed. Call 1-888-935-3877.
TEST DESCRIPTION
This procedure will aid the technician in the removal and replacement of the switch
board(s) and/or filter capacitor(s).
MATERIALS NEEDED
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3/8” Nut driver
7/16” Wrench
3/16” Allen wrench
Slot head screwdriver
Penetrox A13 thermal joint compound
POWER WAVE 455M/MSTT
F-85
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F-86
F-86
TROUBLESHOOTING & REPAIR
SWITCH BOARD AND FILTER CAPACITOR
REMOVAL AND REPLACEMENT (CONTINUED)
FIGURE F.28 – SWITCH BOARD AND FILTER CAPACITOR REMOVAL AND REPLACEMENT
MOLEX PLUG
MOUNTING
SCREW (4X)
13/14
OR
17/18
SWITCH
BOARD
19+
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20-
11/12
OR
15/16
REMOVAL PROCEDURE
NOTE: Observe all static electricity precautions.
Lead and plug references below use a slash (/)
to indicate machine right side/left side wire
number differences.
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1. Remove input power to the Power Wave
455.
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NYLON
SCREW
(2X)
4. Using the 5/16” nut driver, remove the three
screws mounting the plastic high voltage
protective shield. Remove the shield.
5. Remove molex plug J40/J50 from the top of
the switch board. Refer to Figure F.28.
6. Remove the mylar insulating shield covering
leads 13/14 or 17/18. Cut the cable tie.
2. Using the 3/8” nut driver, remove the case
top.
3. Perform the Capacitor Discharge procedure.
POWER WAVE 455M/MSTT
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F-87
TROUBLESHOOTING & REPAIR
SWITCH BOARD AND FILTER CAPACITOR
REMOVAL AND REPLACEMENT (CONTINUED)
7. Using the 7/16” wrench, remove leads
13/14 or 17/18 from the switch board.
8. Using the 7/16” wrench, remove leads
11/12 or 15/16 from the switch board.
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9. Using the 7/16” wrench, remove leads
19C/D+ and 20C/D- from the switch board
capacitor connection bolts.
10. With the slot head screwdriver, remove the
two nylon mounting screws at the bottom of
the switch board. Note placement of the
shake-proof washers and fiber spacers.
11. Using the 3/16” allen wrench, carefully
remove the four cap screws that mount the
switch board to the heat sink.
12. Carefully remove the switch board from the
heat sink.
13. If the filter capacitor is to be removed, carefully slide it out of the mounting bracket.
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REPLACEMENT PROCEDURE
1. If the filter capacitor is to be replaced, carefully slide the new capacitor into the mounting bracket. Position the capacitor so the
correct polarity terminal is lined up with the
correct hole on the switch board.
2. All heat sink and IGBT mounting surfaces
must be clean.
5. Mount the new switch board and tighten
the four cap head screws in the following
manner.
Tighten all until snug.
Tighten all from 24 to 28 in-lbs.
Tighten all from 40 to 48 in-lbs.
6. Make sure the capacitor is positioned correctly. Connect leads 19C/D+ and 20C/Dto the correct terminals. Tighten to 55
in/lbs.
7. Position and mount the two nylon screws,
fiber spacers, and washers. Torque from 4
to 8 in-lbs.
8. Connect leads 11/12 or 15/16 to the correct
terminal.
9. Connect leads 13/14 or 17/18 to the correct
terminal.
10. Install the mylar insulating shield covering
leads 11/12 or 15/16. Replace the cable
tie.
11. Connect molex plug J40/J50 to the top of
the switch board.
12. Using the 5/16” nut driver, install the plastic
high voltage protective shield.
13. Install the case top and sides using the 3/8”
nut driver.
3. Apply a thin coat of thermal compound
(Penetrox A13) 0.005 to 0.010 inches thick
to the mating surfaces. Do not apply
around mounting holes.
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4. Apply a thin coat of Penetrox A13 to the
capacitor terminals. Be careful not to apply
compound to screw threads or threaded
area of terminals.
POWER WAVE 455M/MSTT
F-87
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F-88
F-88
TROUBLESHOOTING & REPAIR
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
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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
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MAXIMUM OUTPUT VOLTAGES
Input Volts/Hertz
208/60
230/60
400/60
460/60
575/60
Output Terminals
- No load
50-70 VDC
X1 - X2
Aux. Trans #1
115 Volt Receptacles
OCV
10 Amp Load
115 - 123 VAC
111 - 119 VAC
48.5 - 55 VDC
POWER WAVE 455M/MSTT
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Section G-1
TABLE OF CONTENTS
- ELECTRICAL DIAGRAMS SECTION -
Section G-1
Electrical Diagrams ..............................................................................................................Section G
Wiring Diagram (Code 10942) (G4212)......................................................................................G-2
Wiring Diagram (Codes 10957 - 11311) (G4420).......................................................................G-3
Schematic - Complete Machine (Code 10942) (G4211) ............................................................G-4
Schematic - Complete Machine (Codes 10957 - 11311) PG 1 of 3 (G4421).............................G-5
Schematic - Complete Machine (Codes 10957 - 11311) PG 2 of 3 (G4421).............................G-6
Schematic - Complete Machine (Codes 10957 - 11311) PG 3 of 3 (G4421).............................G-7
Schematic - Chopper PC Board (STT Models only) (L11340-2) ................................................G-8
PC Board Assembly - Chopper PC Board (STT Models only) (G3339-2)..................................G-9
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Schematic - DeviceNet/Gateway PC Board (Robotic Model only) Pg 1 of 2 (G3821-2)..........G-10
Schematic - DeviceNet/Gateway PC Board (Robotic Model only) Pg 2 of 2 (G3821-2) ..........G-11
PC Board Assembly - DeviceNet/Gateway PC Board (Robotic Model only) (L11046-2) .........G-12
Schematic - Control PC Board (All Codes) Pg 1 of 4 (G3789-2) .............................................G-13
Schematic - Control PC Board (All Codes) Pg 2 of 4 (G3789-2) .............................................G-14
Schematic - Control PC Board (All Codes) Pg 3 of 4 (G3789-2) .............................................G-15
Schematic - Control PC Board (All Codes) Pg 4 of 4 (G3789-2) .............................................G-16
PC Board Assembly - Control PC Board (All Codes) (L11088-2).............................................G-17
Schematic - Digital Power Supply PC Board (All Codes) (G3631-3) .......................................G-18
PC Board Assembly - Digital Power Supply PC Board (All Codes) (G3632-3)........................G-19
Schematic - FeedHead PC Board #1 (Robotic Model only) Pg 1 of 3 (G3823-3)....................G-20
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Schematic - FeedHead PC Board #2 (Robotic Model only) Pg 2 of 3 (G3823-3)....................G-21
Schematic - FeedHead PC Board #3 (Robotic Model only) Pg 3 of 3 (G3823-3)....................G-22
PC Board Assembly - FeedHead PC Board (Robotic Model only) (L11087-3) ........................G-23
Schematic - Input PC Board (All Codes) (M19528-2) ..............................................................G-24
PC Board Assembly - Input PC Board (All Codes) (L11396-2) ................................................G-25
Schematic - Switch PC Board (All Codes) (L11385-3) .............................................................G-26
PC Board Assembly - Switch PC Board (All Codes) (G3734-3)...............................................G-27
Schematic - Voltage Sense PC Board (Robotic Model only) (S24779-3) ................................G-28
PC Board Assembly - Voltage Sense PC Board (Robotic Model only) (M19540-3) ................G-29
Schematic - 40 VDC Bus PC Board (All Codes) (M19330-2) ..................................................G-30
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PC Board Assembly - 40 VDC Bus PC Board (All Codes) (L11078-2) ....................................G-31
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 455M/MSTT
LEFT SIDE OF MACHINE
TO TP6
S1
ARCLINK
RECEPTACLE
DEVICENET
CONNECTOR
1
2
+24V
CAN_H
CAN_L
4
5
L5
53A
L2
TO
J75
894
893
892
891
+24V GND 3
J70
A
B
53
54
C
D
67A
67
52
E
51
TO
P73
J2VS
CB1
J47
L6
54A
52A
L7
51A
S6
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J
K
L
M
N
53A
54A
MODULE
INTERFACE
CONNECTOR
L8
539
541
521 L9
522
BLACK
847
WHITE
BLACK
A
B
C
D
E
F
G
H
J71
J16
ROBOTIC/
WIREDRIVE
INTERFACE
RECEPTACLE
51A
67A
52A
1
3
4
5
6
TO
J82 AND J1
OR 73 (IF
MODULE IS
PRESENT)
153B
154B
51B
67B
52B
J72
S2
VOLTAGE
SENSE
RECEPTACLE
3 CONDUCTOR
TWISTED/SHIELDED
SHIELD GROUND TO CASE
1
2
3
4
L4
TO
J9
21A
J74
GND-A
RED
BLACK
GREEN
67C
TO
J83
J84
J2VS
1
2
3
4
5
6
7
S3
RS232
CONNECTOR
253
254
J75
TO
J2
251
J76
20
CB1
52
10A CIRCUIT
BREAKER
TO
L2
BUSS BD
50
743
741
800
840
153B
154B
51B
52B
6B
6W
892
893
TO
J81
TO
S1
J4
TO
S5
891
894
J5
830
J6
I/O
RECEPTACLE
1
2
3
4
5
6
7
8
9
10
11
12
S4
851
852
853
854
855
856
857
858
859
860
861
862
115V
RECEPTACLE
TO
WORK
STT
TP6
TO
J85
31
32
TO
AUX 2
CB2
GND-B
GND-A
VOLTAGE SENSE
SELECT
BOARD
202A
50Ω
J1
CB2
10A CIRCUIT
BREAKER
31
TO
S4
AUX 2
33
67C
511
1
2
J2
206A
512
1
2
3
4
5
6
TO
WORK
ELECTRODE
R
1
J7
67B
TO
S6
TO
J16
J8
D6
+40VDC
DIODE
1W
2B
5W
6W
1B
2W
J9
880
N.D.
STATUS LED (R/G)
TO J7
AC
AC
TO
J83
886
J10A
J10B
N.A.
THERMAL LED (Y)
TO J7
J11
TO J9
206
5B
6B
251
253
254
TO
S3
J84
J42
TO
J16
J41
1
2
3
4
5
6
539
541
521
522
886
880
TO
S6
D6
1
2
3
4
5
6
7
8
WHITE
RED
BLACK
BLACK
BLACK
GREEN
TO
S6
J43
847
225
223
221
227
222
228
226
227
221
222
223
225
224
220
TO
J42
J43
R5
J85
TO
RECT
THERM
231
232
J86
504
503
406
405
238
505
TO
J20
J40
J50
604
506
403
404
J87
1W
1B
2W
2B
4W
4R
3R
3W
211
212
213
813
811
216
816
812
206
202
67
21A
414
418
514
518
54
53
273
274
+
+
ELECTRODE
289D
R2
TO TP3
TO RECONNECT PANEL
A
TO J61
H1D
(TOP)
288E
STT
LOAD LINE TO CONTACTOR
L3A
2Ω
289E
R3
288F
2Ω
289F
R4
2Ω
SW1
STT SNUBBER
RESISTOR BANK
POWER
TO CB3
612B
TO CONTACTOR
L1A
TO FAN
X3A
TO AUX #1
224A
TO
SSR
J10CH
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
851
852
853
854
855
856
857
858
859
860
861
862
512
511
5W
5B
291
MAIN CHOKE
TO J8
216
211
213
212
P91
4
3
2
1
+
DC BUS BOARD
TO C3
1
2
3
4
1
2
3
4
5
6
7
8
J46
TO
S7
J47
TO
J1VS
220
H5
H4A
H3
(220-230)
H2
(200-208)
H1
220A
POS
POS
NEG
NEG
H3A
H3
51
50
475
476
477
478
THIS AREA VIEWED FROM
REAR OF MACHINE
4R
346
4W
TO
SWITCH
BD #2
F4
18
287
TO
SWITCH BD #2
POS
13
14
.022
SEC
800V (BOTTOM
TO D5
LEFT)
TO
PRI
(BOTTOM SWITCH
LEFT)
BD #1
20D
TO
SWITCH BD #2
F3
TO
AUX #2
289B
TO C10
TO
MAIN TRANSFORMER
14
15 16 11 12
F3
TO RECONNECT SWITCH
20
TO
ROBOT
IFACE
268
268A
TO
J4
J43
.022
800V
AC
AC
SEC
(BOTTOM
RIGHT)
X2
TO
P90
P91
TO
C3
AUX. #1
TO
J40,J50
TO J6, J10B
2.7 10W SEC
(TOP
.022 RIGHT)
800V
D1
POS
POS
POS
F1
287
-
STT CURRENT
TRANSDUCER
812
813
811
816
TO
J43
S1
P90
1
2
3
4
288B
D5
C10
20uF
400V
STT SNUBBER
CAPACITOR BANK
1
2
3
4
5
6
7
8
18
J60
13
J50
STT SNUBBER
DIODE
C5
288A
TO C10
TO C8
J61
3500µ F
500V
15 16
20D 19D
+
601
X3
238
604
232
TO
CR1
J6
AUX #1
POS
NEG
AC
3
231
1
2
3
4
5
6
7
8
9
10
SWITCH BOARD
#2
RIGHT SIDE
AC
2
AC
1
T1
T2
612
TO
CR1
SW1
CB4
TO J61
TO J60
H1D
T3
T2
T1
L3
L2
L1
601
T3
CR1
X4
NOTES:
N.A. PIN NEAREST THE FLAT EDGE OF LED LENS (CATHODE)
ALIGNS WITH BLACK LEAD OF LED SOCKET.
20uF C8
400V
17
TO
SWITCH
BD #1
F1
+
TO J8
PRI
(TOP
RIGHT)
INPUT
RECTIFIER
INPUT BOARD
11
TO J46
POWER BD RECT
POS
19D
F2
NEG
NEG
NEG
2400µF
100V
TO J1 VOLTAGE SENSE
WORK
ELECTRODE
S2
3
4
NEG
17
TP7
C3
33A
S8
WATER
COOLER
RECEPTACLE
TO
RECONNECT
SWITCH
HARMONIC
FILTER 19
20C
F2
NEG
TO
J73
1
2
TO
PRI
(BOTTOM SWITCH
RIGHT) BD #2
D2
POS
TO
D6
J47
S1
J11
350
352
15
2.7 10W
POWER BD
RECTIFIER
200-208V
220-230V
440-460V
550-575V
'A
'
TO
20
HARMONIC
FILTER
20C 19C
D3
EMITTER
R5
TO AUX #1
H2
H3
H5
H6
TO
SWITCH BD #1
NEG
3500µ F
500V
C4
TO SW1
N.C.
19
J40
12
TO C8
289A
262
RECONNECT
PANEL
TO
SWITCH BD #1
TO
HARMONIC
FILTER
SWITCH BOARD
#1
2.7 10W
COLLECTOR
1
2
3
J10
4
5
6
345
PRI
(TOP
LEFT)
TO RECT
THERM
292
N.B.
RECONNECT SWITCH
D4
X1
289A
289C
288B
288C
288D
288E
289B
289C
289D
289E
X5
TO AUX#1
TO J6,J10B
F4
220A
TO SOLID STATE RELAY
444
19C
SEC
(TOP
LEFT)
CIRCUIT
BREAKER
JUMPER (H1A)
H1
TO AUX #1
X3A
TO SOLID STATE RELAY
16
291
TO
CB1
J41
J82
S1
CB4
6A
FAN
CURRENT
TRANSDUCER
292
TO J61
CB3
612A
612
H2A
H2
H1
TO FAN
TO
CR1
J60
RECT
THERM
TO
CHOKE
THERM
H1A
TO
AUX. #2
TO
AUX #2
CB4
RECONNECT PANEL
H4
MAIN
TRANSFORMER
LEFT SIDE
OUTPUT
RECT
224A
CHOPPER BOARD
TO
SSR, J10 CHOPPER BD.
288A
288C
H5A
TO J5
1
2
3
4
5
6
7
8
9
10
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
CHOKE
THERM
TO RECT
THERM
L1
TO
J4
J11
R5
228
273
267
262
TO D5
TP5
288D
TO R1
206A
TP4
TO POWER BD.
RECTIFIER
X3
W
X3
(24V) N
X4
(115V) R
X5
CIRCUIT
BREAKER
TO CB4
612A
H6A
H6
TO
RECONNECT
SWITCH
TO
MAIN
TRANSFORMER
N.C. PLACE "A" LEAD ON APPROPRIATE CONNECTION FOR
INPUT VOLTAGE. CONNECTION SHOWN IS FOR 550-575V
OPERATION.
N.D. PIN NEAREST THE FLAT EDGE OF LED LENS (ANODE)
ALIGNS WITH WHITE LEAD OF LED SOCKET.
RIGHT SIDE OF MACHINE
TO AUX #1
TO SW1
L3A
P50 JUMPER
N.B. PLACE SWITCH IN APPROPRIATE POSITION FOR INPUT
VOLTAGE. CONNECTION SHOWN IS FOR 440-575V
OPERATION.
C6
.05/600V
TP2
444
H6
(550-575)
H5
(440-460)
H4
(380-415)
1
224
267
266
268
W
(51V)
U
X2
TO
J47
TO SW1
612B
AUXILIARY TRANSFORMER #1
X1
346
268A
226
274
266
345
-
TO
J4
2
475
477
476
478
TO TP6
C2
.05/600V
Return to Master TOC
J83
153B
154B
51B
52B
1
2
3
4
5
6
1
2
3
4
1
2
3
4
5
6
7
8
9
10
11
12
TO
J72
CB3
10A
3W
4
REAR OF MACHINE
FRONT OF MACHINE
S7
Return to Master TOC
J3
TO
WORK
ELECTRODE
TP3
Return to Section TOC
J73
J2
1
2
3
4
J82
743
741
800
840
SOLID 3R
STATE
RELAY + 3
414
418
403
404
405
406
TP1
J1
1
2
3
4
J81
DIGITAL POWER
SUPPLY BOARD
1
2
3
4
5
6
C1
.05/600V
FEED HEAD
BOARD
514
518
503
504
505
506
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
1
2
3
4
5
6
7
8
9
10
1
2
3
4
1
2
3
4
1
2
1
2
3
4
5
6
1
2
3
4
WORK
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
1
2
3
4
1
2
3
4
5
6
7
8
9
10
1
2
3
4
5
6
7
8
9
10
11
12
1
2
3
4
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
1
2
3
4
5
6
7
8
1
2
3
4
5
6
1
2
1
2
1
2
3
4
TO
J7
1
2
3
4
5
6
DEVICE NET
GATEWAY
BOARD
TO
CB1
J47
+
TO TP3
202A
TO R1
-
CONTROL BOARD
TO J9
202
+
Return to Master TOC
WIRING DIAGRAM - ENTIRE MACHINE - CODE 10942 (G4212)
S5
Return to Section TOC
G-2
ELECTRICAL DIAGRAMS
+
Return to Section TOC
G-2
32
1
33
4
350
33A
352
2
TO
S4
CB2
P52
1
4
2
(115V) R
(230V)
H6
(550-575)
H5
(440-460)
H4
(380-415)
H3
(220-230)
H2
(200-208)
H1
5
H6A
5
H6A
6
6
H5A
3
3
H4A
2
2
H3A
4
4
H2A
1
H1A
1
H1A
W
LEAD COLOR CODING
B=BLACK
COMPONENT VALUES:
G=GREEN
CAPACITORS=MFD/VOLTS
N=BROWN
RESISTORS=OHMS/WATTS
R=RED
LEGEND
U=BLUE
DASHED "
" = STT MACHINE ONLY
W=WHITE
" = OPTION
J10,J2VS
J74
1
2
J2,J5,J11,
J41,J46,J72
J73,J76,J81
J82
1 2
3
4
J1VS,J9,J10CH,
J14,J40J42,
J50,J75,J83
1
TO
CB3
AUX #1
4
3
6
5
U
G
TO A SYSTEM GROUND PER
NATIONAL ELECTRICAL CODE.
J8,
J47,J60
J84
1
V
TO SUPPLY LINES
AUXILIARY TRANSFORMER #2
ELECTRICAL SYMBOLS PER E1537
PHANTOM "
W
TO SW1
L1A
J3,
J61,J86
4
1
8
6
J4,J13,
J43,J71
5
1
6
1
10
7
12
8
CONNECTOR CAVITY NUMBERING SEQUENCE (VIEWED FROM COMPONENT SIDE OF BOARD)
7
1
14
9
J1,J6,J7
J10,J70,J85
J87
8
16
B
G4212
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The wiring diagram specific to your code is pasted inside one of the enclosure panels of your machine.
POWER WAVE 455M/MSTT
LEFT SIDE OF MACHINE
CONTROL BOARD
253
254
TO TP6
TO J9
202
6B
N.D.
J72
S5
L2
1
+24V 2
CAN_H
CAN_L
J73
6B
6W
892
893
894
893
892
891
+24V GND 3
4
5
1
2
1
2
3
4
5
6
1
2
3
4
891
894
S9
830
ETHERNET
CONNECTOR
RJ 45 TYPE
743
741
800
840
153B
154B
51B
52B
TO R1
202A
WORK
N.M.
J3
-
J74
J4
J76
ETHERNET
PORT
L10
J5
J710
N.M.
N.M.
J712
ONLY PRESENT IF FEEDHEAD
MODULE IS NOT PRESENT
J16
52B
J16
J81
GND-A
RED
BLACK
GREEN
67C
J82
3 CONDUCTOR
TWISTED/SHIELDED
SHIELD GROUND TO CASE
S7
851
852
853
854
855
856
857
858
859
860
861
862
Return to Master TOC
1
2
3
4
5
6
7
8
9
10
11
12
VOLTAGE SENSE
SELECT
BOARD
J1
J2
539
541
521
522
886
880
1
2
3
4
5
6
WHITE
RED
BLACK
BLACK
BLACK
GREEN
1
2
3
4
5
6
7
8
847
I/O
RECEPTACLE
1
2
3
4
5
6
512
1
2
67B
1
2
3
4
851
852
853
854
855
856
857
858
859
860
861
862
512
511
5W
5B
53A
153B
154B
51B
52B
53
54
C
D
67A
67
52
E
51
54A
L5
CB1
52
10A CIRCUIT
BREAKER
50
228
226
227
221
TO
J42
J43
R5
222
223
225
S2
268A
226
274
266
345
TO
J47
444
TO
RECT
THERM
224
220
504
503
406
405
238
505
TP4
TO FAN
TO
J4
J11
R5
224A
MAIN CHOKE
TO J8
P91
4
3
2
1
216
211
213
212
220
TO C3
1
2
3
4
1
2
3
4
5
6
7
8
J46
J47
220A
POS
POS
NEG
NEG
2W
2B
TO
THERMAL
LED
50
345
4R
346
4W
F4
D3
F3
289B
TO C10
F3
2.7
10W
TO
J4
J43
POWER BD
RECTIFIER
AC
2B
TO J61
H1D
20
POWER
HARMONIC
FILTER 19
17
1
2
3
4
S8
WATER
COOLER
RECEPTACLE
TO
RECONNECT
SWITCH
N.G.
POS
INPUT
RECTIFIER
19D
TO J6, J10B
POS
NEG
SEC
(TOP
RIGHT)
PRI
(TOP
RIGHT)
17
TO
SWITCH
BD #1
1
2
3
4
5
6
7
8
18
J60
13
J50
STT CURRENT
TRANSDUCER
J61
3500µ F
500V
C5
15 16
20D 19D
+
288A
TO C8
D5
601
X3
238
604
232
AC
2
C
N.F.
TO
CR1
J6
AUX #1
AC
1
B
A
LOAD
INPUT
LINE
FILTER
231
LINE
1
2
3
4
5
6
7
8
9
10
SWITCH BOARD
#2
RIGHT SIDE
+
AC
3
INPUT BOARD
T1
T2
612
TO
CR1
SW1
CB4
TO J61
TO J60
H1D
T3
T2
T1
L3
L2
L1
N.K.
601
T3
CR1
X4
STT SNUBBER
DIODE
TO MAIN
TRANSFORMER
288B
TO C10
TO
RECONNECT
SWITCH
TO AUX #1
P50
N.E.
N.A.
THERMAL LED (Y)
TO J7
32
P51
1
33
4
352A
6
TO
S4
CB2
(TOP)
H6
(550-575)
350
P52
1
33A
4
352
2
5
H6A
W
TO
CB3
AUX #1
(115V) R
(230V)
H1
1
L1B
L3B
L3A
C6
H1A
AUXILIARY TRANSFORMER #2
W
L3
V
U
TO SUPPLY LINES
.0047 µF
440
LOAD LINE TO CONTACTOR
L3A
TO SW 1
SW1
TO CB4
612B
350
352
33A
NEG
F1
287
TO J46
POWER BD RECT
N.D.
STATUS LED (R/G)
TO J7
TO RECONNECT PANEL
A
TO
J2
251
20
PRI
TO
(BOTTOM SWITCH
RIGHT) BD #2
F1
L4
253
254
TO
AUX #2
TO RECONNECT
SWITCH
D1
P90
1
2
3
4
200-208V
220-230V
440-460V
550-575V
TO
20
HARMONIC
FILTER
11 12
2.7
10W
.022
800V
812
813
811
816
TO SW1
'A
'
TO
MAIN TRANSFORMER
11
21A
1
2
3
4
5
6
7
20D
TO
SWITCH BD #2
3500µ F
500V
C4
TO AUX #1
H2
H3
H5
H6
TO
SWITCH BD #1
NEG
20C
POS
POS
POS
C3 2400µ F
100V
N.C.
N.J.
19
F2
NEG
NEG
NEG
J10B
RECONNECT
PANEL
20C 19C
F2
NEG
J10A
TO
SWITCH BD #1
TO
HARMONIC
FILTER
D2
TO
C3
AUX. #1
X2
TP7
1B
TO
PRI
(BOTTOM SWITCH
LEFT)
BD #1
15
POS
AC
13
14
SWITCH BOARD
#1
14
.022
800V
X1
2W
N.B., N.G., N.H.
TO
SWITCH BD #2
POS
J40
2.7 10W
SEC
(BOTTOM
RIGHT)
TO J8
1W
TO
SWITCH
BD #2
12
TO D5
268
268A
R5
TO
P90
P91
J11
X5
TO AUX#1
RECONNECT SWITCH
F4
TO C8
289A
TO AUX #1
THIS AREA VIEWED FROM
REAR OF MACHINE
18
SEC
.022 (BOTTOM
LEFT)
800V
FUSE
TO SOLID STATE RELAY
444
19C
PRI
(TOP
LEFT)
N.L.
10A
H1
D4
287
H1
H1B
TO INPUT SWITCH
TO J61
H2
EMITTER
TO
SSR
211
212
213
813
811
216
816
812
N.J.
H3
TO J6,J10B
16
SEC
(TOP
LEFT)
TO RECT
THERM
COLLECTOR
1
2
3
J10
4
5
6
612
TO
AUX #2
CB3
RECONNECT PANEL
X3A
TO SOLID STATE RELAY
MAIN
TRANSFORMER
LEFT SIDE
291
TO
CB1
J41
J82
S1
475
476
477
478
262
4W
4R
3R
3W
H4B
FAN
CURRENT
292
CHOPPER BOARD
TO
STATUS
LED
612B
H4
TO FAN
TO
CR1
J60
+ TRANSDUCER
OUTPUT
RECT
J9
S3
291
H1A
CIRCUIT
BREAKER
TO AUX #2
H6A
H6
H5
H3
(220-230)
H2
(200-208)
H1
RECT
THERM
TO
CHOKE
THERM
51
220A
J1 & J3
ARE NOT USED
RS232
CONNECTOR
CHOKE
THERM
292
1W
1B
TO POWER BD.
RECTIFIER
X3
W
X3
(24V) N
X4
(115V) R
X5
X3A
TO AUX #1
TO RECT
THERM
224A
604
506
403
404
H6
(550-575)
H5
(440-460)
H4
(380-415)
TO J5
231
232
TO
J20
J40
J50
W
(51V)
U
1
224
R1
50Ω
L1A
TO CONTACTOR
J
N.F.
C7
G
SWITCH LEAD
FILTER
TO A SYSTEM GROUND PER
NATIONAL ELECTRICAL CODE.
S4
115V
RECEPTACLE
(NEUTRAL BONDED)
S4
NOTES:
220V RECEPTACLE
N.D.
TO
J83
351
N.A. PIN NEAREST THE FLAT EDGE OF LED LENS (CATHODE)
ALIGNS WITH BLACK LEAD OF LED SOCKET.
N.B. PLACE SWITCH IN APPROPRIATE POSITION FOR INPUT
VOLTAGE. CONNECTION SHOWN IS FOR 440-575V
OPERATION.
TO WORK
CB2
5A CIRCUIT
BREAKER
34
CB2
352A
32
TP6
CE Model
N.C. PLACE "A" LEAD ON APPROPRIATE CONNECTION FOR
INPUT VOLTAGE. CONNECTION SHOWN IS FOR 550-575V
OPERATION.
N.D. PIN NEAREST THE FLAT EDGE OF LED LENS (ANODE)
ALIGNS WITH WHITE LEAD OF LED SOCKET.
10A CIRCUIT
BREAKER
CASEFRONT
PANEL
33
TO D5
288D
206
TO J9
OR
206A
TO R1
STT
288E
2Ω
288F
2Ω
C6
.05/600V
+
ELECTRODE
TP5
C2
.05/600V
31
289E
R3
TO TP3
32
289D
R2
+
(EARLIER MODEL)
115V
RECEPTACLE
(NEUTRAL FLOATING)
Return to Master TOC
AUXILIARY TRANSFORMER #1
X1
X2
228
273
267
262
206A
1
2
3
4
-
TO
J4
346
DC BUS BOARD
202A
VOLTAGE
SENSE
RECEPTACLE
J85
J43
TO ELECTRODE
32
886
TO
J43
21A
414
418
514
518
54
53
273
274
TP3
TO J47
GND-B
CASEFRONT
TO
J40
J50
L7
TO WORK
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
202
67
67
67C
511
880
GND-A
L6
J83
J84
1
2
3
4
5
6
1
2
1
2
1
2
3
4
206
51A
C11
.0047/3KV
+40VDC
DIODE
AC
A
B
52A
D6
AC
J8
ARCLINK
RECEPTACLE
743
741
800
840
1
2
3
4
N.M.
51A
67A
52A
S1
FEEDHEAD
BOARD
539
541
521 L9
522
BLACK
847
WHITE
BLACK
53A
54A
1
3
4
5
6
153B
154B
51B
67B
52B
ROBOTIC/WIREDRIVE
INTERFACE RECEPTACLE
A
B
C
D
E
F
G
H
J7
MODULE
INTERFACE
CONNECTOR
WIRE DRIVE INTERFACE
MODULE
L8
1
3
4
5
6
153B
154B
51B
OR
OR
S6
J6
267
266
268
475
477
476
478
CB3
3.5A
3W
4
2
+
J77
J
K
L
M
N
Return to Section TOC
ONLY PRESENT IF FEEDHEAD
MODULE IS PRESENT
1
2
3
4
5
6
7
8
9
10
1
2
3
4
5
6
7
8
THE ETHERNET CONNECTION
IS ONLY PRESENT IN THE
ETHERNET / DEVICENET MODULE
FRONT OF MACHINE
Return to Master TOC
Return to Section TOC
J70 & J71
ARE NOT USED
J41
225
223
221
227
222
TO
J7
REAR OF MACHINE
1
2
3
4
5
6
7
8
9
10
11
12
1
2
3
4
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
1
2
3
4
5
6
7
8
C1
.05/600V
TP1
J75
1
2
3
4
5
6
1
2
3
4
1
2
3
4
5
6
7
8
9
10
11
12
J42
1
2
3
4
5
6
7
8
9
10
TO TP3
1
2
3
4
1
2
3
4
J2
414
418
403
404
405
406
6W
SOLID 3R
STATE
RELAY + 3
DIGITAL POWER
SUPPLY BOARD
1
2
3
4
251
1
2
3
4
5
6
DEVICENET MODULE
514
518
503
504
505
506
OR
1
2
3
4
5
6
ETHERNET / DEVICENET
MODULE
+
Return to Master TOC
WIRING DIAGRAM - ENTIRE MACHINE - CODES 10957 - 11311 (G4420)
DEVICENET
CONNECTOR
Return to Section TOC
G-3
ELECTRICAL DIAGRAMS
+
Return to Section TOC
G-3
289F
R4
2Ω
STT SNUBBER
RESISTOR BANK
288A
288C
289A
289C
288B
288C
288D
288E
289B
289C
289D
289E
TP2
CB2
RIGHT SIDE OF MACHINE
10A CIRCUIT
BREAKER
33
C8
20µF
400V
STT SNUBBER
CAPACITOR BANK
C10
20µF
400V
N.E. LEAD 33 IS PRESENT IN MODELS WITH 115V RECEPTACLE
ON THE CASE FRONT. LEAD 352A IS PRESENT ONLY IN
MODELS WITH 220V RECEPTACLE ON THE CASE FRONT.
N.F. ONLY PRESENT ON "CE" MODELS.
N.G. ONLY PRESENT ON NON-CE MODELS.
N.H. "CE" MODELS DO NOT HAVE A RECONNECT SWITCH. POS LEAD
CONNECTS DIRECTLY TO (+) OF C4. LEAD C CONNECTS
(-) OF C4 TO (+) C5 AND NEG LEAD CONNECTS TO (-) OF C5.
N.J. THE "CE" MODELS DO NOT HAVE A RECONNECT PANEL. INSTEAD
LEAD H4B CONNECTS H4 TO SW1.
N.K. ON CE MODELS LEADS T1, T2 AND T3 ARE REPLACED BY LEADS
A, B AND C. LEADS A, B AND C ARE CONNECTED TO THE INPUT
RECTIFIER TERMINALS RATHER THAN CR1.
N.L. 10 AMP CIRCUIT BREAKER IS USED IN PLACE OF FUSE ON CODES
BELOW 11150.
N.M. ON SYNCHRONIZED TANDEM MIG APPLICATIONS J77, J712 OF THE
ETHERNET BOARD AND J3, J7 OF THE CONTROL BOARD ARE USED,
SEE S26631 FOR DETAILS.
REAR
FAN
FRONT
RECONNECT RECONNECT
HORIZONTAL HORIZONTAL SHROUD SHELL
BRACKET
BAFFLE
BAFFLE
CASE
FRONT
REAR
UPPER
BASE
FRONT
UPPER
BASE
AUX.
2
N.F.
AUX.
1
PROTECTIVE BONDING CIRCUIT
LEGEND
DASHED "
PHANTOM "
" = STT MACHINEONLY
" = OPTION
LEAD COLOR CODING
B=BLACK
G=GREEN
N=BROWN
R=RED
U=BLUE
W=WHITE
COMPONENT VALUES:
CAPACITORS=MFD/VOLTS
RESISTORS=OHMS/WATTS
COMPONENT VALUE UNITS:
CAPACITOR: MFD/VOLTS
RESISTOR: OHMS/WATTS
CONNECTOR PIN NUMBERS:
EX. 12 PIN CONNECTOR
1 2
6
7
12
LATCH
ELECTRICAL SYMBOLS PER E1537
VIEW OF CONNECTOR ONPC BOARD
J
G4420
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The wiring diagram specific to your code is pasted inside one of the enclosure panels of your machine.
POWER WAVE 455M/MSTT
CHANGE DETAIL: Released from "X"
MAIN TRANSFORMER T1
SWITCH BOARD #1 (LEFT)
N.A.
RECONNECT
SWITCH
208-230V
POS
19D
19
20C
414
NEG
L1A
3J40
IGBT DRIVE (+)
404
4J40
V/F (+)
405
5J40
V/F (-)
+13V
232
5J60
522
4J83
SOLENOID INPUT
539
1J83
MOTOR "+"
541
2J83
MOTOR "-"
WHITE
1J84
6J40
N.A.,
N.B.
GND
I OUT
-15V
D6
886
P91
IGBT DRIVE (-)
N.C.
C10
SWITCH BOARD #2 (RIGHT)
CURRENT
TRANSDUCER
C8
D5
C
H2
200-208V
H3
220-230V
H5
440-460V
H6
550-575V
4J60
T2
4J61
3J60
238
SINGLE PHASE DETECT
8J60
(LOW=1 PHASE)
231
S6 ROBOTIC
INTERFACE
RECEPTACLE
17
TACH COMMON
BLACK
5J84
TACH 2A DIFF. INPUT
GREEN
6J84
TACH 2B DIFF. INPUT
847
7J84
SINGLE TACH INPUT
851
1J85
TRIGGER +15VDC
852
2J85
TRIGGER INPUT
BLACK
847
WHITE
BLACK
3J85
4J85
4 STEP INPUT
855
5J85
COLD INCH +15VDC
CT CURRENT (+)
503
3J50
IGBT DRIVE (+)
504
4J50
V/F (+)
505
5J50
V/F (-)
6J50
16
856
6J85
857
7J85
GAS PURGE INPUT
859
9J85
860
10J85
851
852
853
854
855
856
857
858
859
860
861
862
861
11J85
SHUTDOWN 2 INPUT
12J85
INPUT B
5B
16J85
+40VDC
ARCLINK H
0V
STATUS LED (Hi for RED)
STATUS LED (Hi for GREEN)
+
24V
115V
H2
6J10
4W
3J10
4R
886
5J83
2J82
X4
N.A.
1J73
1J82
153B
2J73
3J82
51B
3J73
4J82
52B
741
ARCLINK L
1J81
743
COMMON
3J81
800
+40VDC
4J81
840
2J72
1J72
ARCLINK L
ARCLINK H
COMMON
+ 40VDC
3J72
VOLTAGE SENSE SELECT (-)
14J85
511
VOLTAGE SENSE SELECT (+)
13J85
512
894
893
612B
612A
H5A
6
H4A
3
(440-460)
POS
65VDC
291
2
H3
CB3
H2A
4
H1A
1
4J72
+40VDC
5J75
OUTPUT RECTIFIER
THERMOSTAT
6W
2J74
2
352
230V
352A
33A
2
4
CB2
115V
1J1
512
VOLTAGE SENSE OUTPUT
3J1
67C
DC BUS
THERMOSTAT
2J75
1J75
CAN_H
891
4J75
CAN_L
262
+15V
WORK VOLTAGE SENSE
10A
33
4
S8 WATER COOLER
RECEPTACLE
1
3
1
4W
13J7
STT CHOPPER DRIVE (-)
4R
14J7
STT CHOPPER DRIVE (+)
503
6J6
YELLOW
THERMAL
LED
THERMAL LED
10J6
506
14J6
S4
110V
RECEPTACLE
2W
7J7
V/F (+)
5J6
505
2B
8J7
THERMAL LED
IGBT DRIVE (+)
3J7
1W
V/F (-)
RED/GREE
STATUS
LED
IGBT DRIVE (-)
514
1J10B
CT CURRENT (-)
518
2J10B
CT CURRENT (+)
403
15J6
IGBT DRIVE (+)
404
16J6
V/F (+)
405
8J6
V/F (-)
7J6
4J7
1B
1J10A
1J2
345
7J43
346
1J43
POS
1J46
POS
2J46
31
N.A. PC BOARD COMPONENTS SHOWN FOR
REFERENCE ONLY. ALL COMPONENTS
ARE NOT SHOWN.
N.B. WIRING FOR OPTIONAL MODULES MAY NOT
BE PRESENT IF MODULE IS NOT INSTALLED.
NEG
NEG
3J46
224
2J5
THERMOSTAT
220
3J5
THERMOSTAT
3W
16J7
3R
15J7
FAN CONTROL (+)
3J4
+5V SPI
9J6
604
12J6
PRECHARGE CONTROL
231
1J6
SINGLE PHASE DETECT
(LOW=1 PHASE)
232
2J6
MAIN CONTACTOR CONTROL
+13V
6J43
266
2J4
+15V SPI
11J43
267
1J4
SPI COMMON
ARCLINK +
1J11
ARCLINK -
2J11
53
4J9
67
VOLTAGE SENSE
6J16
52B
51A
4J16
51B
67B
54
L7
52A
STT COMMON
262
12J43
SPI COMMON
4J42
227
7J4
53A
54A
POWER DOWN INTERUPT
67
+15V
1J42
225
12J4
+15V
+5V
3J42
221
8J4
+5V
SPI +5V
CONTROL BOARD COMMON
5J42
222
10J4
CONTROL BOARD COMMON
-15V
2J42
223
11J4
-15V
67B
3J43
51A
L6
67A
1J41
ARCLINK +5V
+40V COMMON
5J43
274
4J11
475
+5V ARCLINK +5V
ARCLINK COMMON
2J41
+40V
10J43
273
3J11
477
ARCLINK COMMON
L5
S1 ARCLINK
RECEPTACLE
53
A ARCLINK -
54
B ARCLINK +
67
C ELECTRODE SENSE
52
D +40VDC
51
E 0VDC
S5 DEVICENET
CONNECTOR
RS232 +5V
4J43
226
6J4
RS232 +5V
894
2
RS232 COMMON
9J43
228
5J4
RS232 COMMON
893
3 +24V GND
892
4 CAN_H
891
5 CAN_L
COMMON
6J47
476
3J41
+40V COMMON
+40VDC POWER
8J47
478
4J41
+40V
COMMON
1J47
L2
51
+24VDC
52
50
CB1
10A
ELECTRICAL SYMBOLS PER E1537
N.C. R2, R3 AND R4 ARE 2 W / 300.
C8 AND C10 ARE 20 mfd / 400V.
N.D. IF FEED HEAD BOARD IS NOT PRESENT,
INSERT P82 INTO J73.
52A
(NORMALLY CLOSED)
238
7J47
4J46
5J16
J16
}
5J47
3J47
153B
67A
FAN CONTROL (-)
COMMON
+40VDC FEEDER
154B
1J16
CT CURRENT (+)
2J10A
STT +20V
POWER DOWN INTERUPT
268A
3J16
53A
CT CURRENT (-)
418
268
54A
IGBT DRIVE (-)
+40VDC POWER
NOTES :
32
3
POWER BOARD
33
350
32
21A
6J9
4
268A
SPI COMMON
DC BUS BD
N.A.
0V
H2
H1
-15V
8J8
511
4J1
VOLTAGE SENSE SELECT (+)
WIRE FEEDER VOLTAGE SENSE
220A
292
6B
1J74
R5
10Ω
892
N.A.
C3
NEG
(200-208)
10A
4J8
812
ARCLINK L
24000uF/100V
(220-230)
EN-170
Return to Master TOC
Return to Section TOC
H3A
813
1
2
L4
X2
H4
(380-415)
STT FEEDBACK
224A
CHOKE
THERMOSTAT
COMMON
+24VDC
+24V GND
VOLT SENSE BD
-
X5
H6
(550-575)
H5
CONTROL BOARD COMMON
5J8
414
ARCLINK H
P80
5
7J8
811
406
TRANSFORMER T2
H6A
816
3J76
COMMON
2J81
830
1J76
154B
ARCLINK H
RED/GREEN
STATUS
LED
+15V SPI
52V
H1
S2 VOLTAGE SENSE
RECEPTACLE
GND
GATEWAY BD
3W
X1
(200-208)
H1
N.D.
3R
FAN
H3
(220-230)
H2A
N.A.,
N.B.
880
6J83
POWER BD. RECT.
X3
H4
H4A
346
ARCLINK L
VOLTAGE SENSE SELECT (-)
X3
+15
COMMON
TP4
(380-415)
H3A
1J10
4J10
STATUS LED(Hi for GREEN)
444
H5
(440-460)
2J8
STATUS LED (HI FOR RED)
STATUS LED(Hi for RED)
SOLID STATE RELAY
H6
(550-575)
212
+20V STT
4J73
X3A
H5A
345
SHUTDOWN 1 INPUT
862
15J85
-15V
STATUS LED (HI FOR GREEN)
COLD IN. REVERSE
SHUTDOWN +15VDC
5W
TP5
320V
160J
C6
.05uF
600V
IGBT DRIVE (-)
COLD IN. FORWARD
8J85
5B
CURRENT FEEDBACK
3J8
16
5W
RED/GREEN
STATUS
LED
1J8
213
504
15
C5
(CAP "B")
3500uF
500V
211
7
20
CONTROL BOARD COMMON
STT
D
18
+40VDC
67C
S
F
+
+40VDC
AUXILIARY
TRANSFORMER T1
612
CT CURRENT (-)
2J50
6J8
251
1J2
DUAL PROC. INPUT
853
854
858
H6A
6A
1J50
518
GND-A
RED
BLACK
GREEN
TRIGGER +15VDC 1
TRIGGER INPUT 2
DUAL PROC. INPUT 3
4 STEP INPUT 4
COLD INCH +15VDC 5
COLD IN. FORWARD 6
COLD IN. REVERSE 7
GAS PURGE INPUT 8
SHUTDOWN +15VDC 9
SHUTDOWN 1 INPUT 10
SHUTDOWN 2 INPUT 11
INPUT B 12
CB4
514
506
L9
S7 I/O
RECEPTACLE
Return to Master TOC
4J84
L8
539
541
521
522
A
B
C
D
E
F
G
H
J
TACH 1A DIFF SIGNAL K
TACH 1B DIFF SIGNAL L
TACH 2B DIFF SIGNAL M
VOLTAGE SENSE N
604
PRECHARGE RELAY
+13V
MOTOR "+"
MOTOR "-"
SOLENOID 40VDC
SOLENOID INPUT
TACH 2A DIFF SIGNAL
SINGLE TACH INPUT
TACH +15VDC
TACH COMMON
BLACK
T1
+13V
AUX. RECONNECT
A
2J61
812
6J61
612
P90
F
-15V
CHOPPER BOARD
S
A
15
+15V
TACH 1B DIFF. INPUT
I OUT
3J84
+
R4
3J90
BLACK
T3
TACH 1A DIFF. INPUT
811
10J61
2J84
216
816
8J61
- ELECTRODE VOLTAGE SENSE
+
N.C.
R2
+15VDC TACH
TP1
320V
160J
TP6
150V
80J
2J90
A
612B
3J9
RS232 COMMON
C1
.05uF
600V
880
1J90
RED
3
A
MAIN
CHOKE
L1
813
MAIN CONTACTOR CONTROL
2
254
4
202
202A
R3
H1D
253
4J2
6
C4
(CAP "A")
3500uF
500V
SOLENOID +40VDC
X3
2J60
OFF
3J83
406
INPUT BOARD
1J60
FEED HD BD
521
N.A.
601
L3A
403
3J2
RS232 TRANSMIT
+ELECTRODE VOLTAGE SENSE
5
+
12
RS232 RECEIVE
1J9
LEGEND
DASHED = "
PHANTOM= "
" STT MACHINE ONLY
" OPTION
THIS DOCUMENT CONTAINS PROPRIETARY INFORMATION OWNED BY LINCOLN GLOBAL, INC. AND MAY NOT BE DUPLICATED, COMMUNICATED
PROPRIETARY & CONFIDENTIAL:
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
ON 2 PLACE DECIMALS IS ± .02
ON 3 PLACE DECIMALS IS ± .002
DRAWN BY:
F.Valencic
ON ALL ANGLES IS ± .5 OF A DEGREE
MATERIAL TOLERANCE (" t ") TO AGREE
WITH PUBLISHED STANDARDS.
ENGINEER:
S.Poole
DO NOT SCALE THIS DRAWING
APPROVED: J.O'Connor
REFERENCE:
G3791
SCALE:
NONE
EQUIPMENT TYPE:
SUBJECT:
MATERIAL
DISPOSITION:
UF
INVERTER WELDERS
PW455M MACHINE SCHEMATIC
APPROVAL
DATE:
3/4/03
PROJECT
NUMBER:
CRM33689
1
1 OF ___
PAGE ___
DOCUMENT
NUMBER:
G4211
DOCUMENT
REVISION:
A
SOLID EDGE
N.A.,
N.B.
X4
Return to Master TOC
CT CURRENT (+)
TP2
320V
160J
C2
.05uF
600V
TP3
150V
80J
CURRENT
TRANSDUCER
212
G
ON
2J40
20D
CR1
SW1
POWER
418
S3 RS232
CONNECTOR
ELECTRODE
20
NEG
R1
50Ω
2.7Ω
10W
CT CURRENT (-)
1J40
+
AC1
T3
L3
.022u
800V
11
4J91
NEG
T2
206A
OUTPUT DIODES
D1-D4
B
S
216
AC2
L2
HARMONIC
FILTER
POS
CONTROL BOARD
ELECTRODE
206
2.7Ω
10W
+15V
AC3
T1
F
14
19C
L1
U
.022u
800V
2J91
380-460V
+
1J91
CR1
S
13
2.7Ω
10W
3J91
INPUT
RECTIFIER
W
Return to Section TOC
N.A.
.022u
800V
A
2.7Ω
10W
.022u
800V
F
211
ENGINEERING CONTROLLED
MANUFACTURER: No
213
Return to Master TOC
SCHEMATIC - ENTIRE MACHINE - CODE 10942 (G4211)
V
Return to Section TOC
G-4
ELECTRICAL DIAGRAMS
G4211
Return to Section TOC
G-4
STRP
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
POWER WAVE 455M/MSTT
ENGINEERING CONTROLLED CHANGE DETAIL: CONTROL BOARD, CHANGED 2J4 TO 3J4
MANUFACTURER: No
15
S
2.7Ω
10W
.022u
800V
C
Located on rear
horizontal baffle
P91
F
Located behind
Electrode stud
18 F
514
RED(-)
518
WHITE(+)
D5
R3
P90
H3
N.A.
52V
H1
H6A
5
H6
230V
(550-575)
612A
EX. 12 PIN CONNECTOR
33
6
12
LATCH
VIEW OF CONNECTOR ON PC BOARD
CB3
0V
located on
reconnect panel
252A
2J52
352
2
33A
4J52
1J52
33A
350
4
350
115V
32
4J51
located on
case front
H1A
1
H1
3
4J51
CB2
S4
115V
RECEPTACLE
32
34
GND
-15V
SPI COM
+ 5V SPI
3J4
268A
262
11J43
COM
CB2
located on
front case
10A
5A
1J51
31
32
3J9
THERMOSTAT
Additional input / outputs are
illustrated on schematic page 2.
LEDS - 10 TOTAL
DIP Switch -1, Bank of 8
(See page 3 for detail)
262
DC BUS BD
Located on rear of control box (center)
6J43
2J41
NTC
+
1J41
477
7J47
+40VDC POWER
478
475
8J47
5J47
+40VDC POWER
COMMON
476
6J47
COMMON
3J41
POS
65VDC
C3
(earlier version)
115V
RECEPTACLE
(Neutral Floating)
NOTES:
N.A. CE MACHINE ONLY.
N.B. NON-CE MACHINE ONLY.
POS
1J46
POS
2J46
24000uF/100V
Located behind DC Bus board
Located on center baffle left of lift bale
NEG
3J46
NEG
4J46
Located on rear of control
box (right)
Additional outputs are
illustrated on schematic page 2.
POWER BD. RECT.
LEDS - 2 TOTAL
(See page 3 for detail)
SPI
N.A.
351
6J51
33
1J51
1J9
3J5
6J8
2J5
2J8
1J8
812
8J8
+15V
-15V
STT FEEDBACK
CONTROL BOARD COMMON
3J8
811
813
816
7J8
4J8
4W
13J7
5J8
4R
14J7
STT CHOPPER DRIVE (+)
+15V SPI
2J4
1J4
266
RS232 COM
POWER DOWN
7J4
6J4
5J4
228
227
ARCLINK COM
RS232 +5V
3J11
226
+5V ARCLINK +5V
THERMOSTAT
POWER BD. RECT.
LEDS - 1 TOTAL
(See page 3 for detail)
V in
+72 VDC
+
V out
+40 VDC
N.C. ON CE MODELS LEADS T1, T2 AND T3 ARE REPLACED BY LEADS
A, B AND C. LEADS A, B AND C ARE CONNECTED TO THE INPUT
RECTIFIER TERMINALS RATHER THAN CR1.
N.D. FOR SYNCHRONIZED TANDEM MIG APPLICATIONS SEE S26631 FOR
DETAILS.
THIS DOCUMENT CONTAINS PROPRIETARY INFORMATION OWNED BY LINCOLN GLOBAL, INC. AND MAY NOT BE DUPLICATED, COMMUNICATED
Schematic numbers are given for reference only.
1J51
10A
3.5 A
N.B.
+ELECTRODE
VOLTAGE SENSE
- ELECTRODE
VOLTAGE SENSE
-15V
NEG
CB2
1
33
206
202
CONTROL BOARD COMMON
(NORMALLY CLOSED)
6J51
352A
CONNECTOR PIN NUMBERS:
RS232
S8 WATER COOLER
RECEPTACLE
AUXILIARY
TRANSFORMER T2
COMPONENT VALUE UNITS:
CAN
CONTROL
X2
(right, rear)
CAPACITOR: MFD/VOLTS
RESISTOR: OHMS/WATTS
I OUT
518
2J10B
CT CURRENT (+)
CT CURRENT (-)
H2
H1
10 ohms
224A
CHOKE
THERM
CURRENT FEEDBACK
+15V
325A Max STT output
570A Max Output
Fold Back = 100A
268
268A
291
292
DC BUS OUTPUT
THERM
RECTIFIER
THERM
220
4J41
X5
(200-208)
10 A
12J43
1J43
+15V
X4
346
X1
(220-230)
220A
32
S4
220V
RECEPTACLE
(Neutral Bonded)
located on case front
PROPRIETARY & CONFIDENTIAL:
TO OTHER PARTIES OR USED FOR ANY PURPOSE WITHOUT THE EXPRESS WRITTEN PERMISSION OF LINCOLN GLOBAL, INC.
THE INFORMATION ON THIS
PRINT IS FOR REFERENCE
ONLY. COMPONENTS AND
CIRCUITRY MAY BE DIFFERENT
FROM AN ACTUAL MACHINE.
DESIGN INFORMATION
DRAWN BY:
F.Valencic
ENGINEER:
S.Poole
APPROVED:
.
REFERENCE:
G4050
SCALE:
NONE
INVERTER WELDERS
455M MACHINE SCHEMATIC
EQUIPMENT TYPE:
SUBJECT:
MATERIAL
DISPOSITION:
UF
APPROVAL
DATE:
2/1/2007
PROJECT
CRM22115-GC
NUMBER:
3
1 OF ___
PAGE ___
DOCUMENT
REVISION:
DOCUMENT
NUMBER:
G4421
F
SOLID EDGE
115V
7J43
COM
24V
H4
(380-415)
612
224A
Schematic: M19330
345
9J43
X3
H5
(440-460)
Located in Rear of
FAN PowerSource
POWER BOARD
Schematic: G3631
Located on rear of control box (left)
4J42
(550-575)
H6A
-
SOLID STATE
RELAY
X3
0V
811
418
514
1J10B
414
2J10A
406
1J10A
403
506
15J6
FAN CONTROL (+15 VDC)
FAN CONTROL (-)
COM
H6
EARTH GROUND
EN-170
15J7
16J7
POWER DOWN INTERUPT
612B
FRAME GROUND
7
3R
3W
273
444
(left, rear)
CB4
(Max Output = 325A)
4J43
AUXILIARY
TRANSFORMER T1
COMMON
1 2
PRECHARGE CONTROL
MAIN CONTACTOR CONTROL
550-575V
located on
reconnect panel
LABELS:
2J6
10J43
LEAD COLOR CODE:
B-BLACK
G-GREEN
O-ORANGE
R-RED
U-BLUE
W-WHITE
Y-YELLOW
+
X3A
TP4
232
SINGLE PHASE DETECT (LOW=1 PHASE)
+5V
" STT MACHINE ONLY
" OPTION
Located in rear of machine
behnid reconnect panel.
1J6
12J6
Schematic: G3789
Located on left side of control box
+13V
+15V
LEGEND
DASHED = "
PHANTOM= "
220-230V
224
CONTROL BOARD
COM
H6
200-208V
440-460V
231
604
8 Hertz per Volt
325 Volts = 2600 Hertz
221
H3
H5
9J6
}
222
H2
A
Located behind control board
(left side)
238
V/F (-)
V/F (+)
4J11
N.B.
SW1
POWER
Located on top
right of case front OFF
16J6
274
AUX. RECONNECT
404
V/F (+)
V/F (-)
225
H1D
8J6
5J43
X3
ON
5J6
10J6
405
+5V
2J60
504
505
-15V
1J60
4R
CONTROL BOARD COMMON
11J4
601
10J4
223
.0047uF
440
232
5J60
+13V
4W
3J10
+15V
2J42
MAIN CONTACTOR CONTROL
12J4
-15V
225A
222A
L1A L3A
C6
CT CURRENT (-)
604
1J42
N.A.
X4
CT CURRENT (+)
6J61
+5V
8J61
612
4J60
601
C7
H1D
8J4
N.B.
6J10
COMMON
0
-15
5J42
3J42
L3
(Located right
of Contactor)
+13V
CR1
COM
+5V
L3B
SWITCH
LEAD
FILTER
Return to Master TOC
T3
L3
W
10J61
frequency = 20 kHz
+15
IGBT DRIVE (+)
T3
PRECHARGE
RELAY
7J6
2J61
4J61
4J10
220
T2
V
1J10
346
211
+20V STT
224
IGBT DRIVE (-)
T1
T2
231
IGBT DRIVE (+)
L2
238
503
L1B
3J60
8J60
6J6
T1
14J6
N.C.
L1
U
IGBT DRIVE (-)
Schematic: M19528
Located in reconnect
cavity in rear of machine
+13V
SINGLE PHASE DETECT
(LOW=1 PHASE)
345
212
213
816
812
216
INPUT BOARD
CR1
TP5
320V
160J
-15
Located on rear
horizontal panel
Located behind
reconnect panel
(Located upper left
from electrode stud)
STT
C6
.05uF
600V
A.04
0
}
IGBT DRIVE (+)
6J50 IGBT DRIVE (-)
+15V
CHOPPER BOARD
+15
3J50
3J90
}
+
R4
3J43
V/F (-)
V/F (+)
+
R2
+5V
5J50
4J50
Located under
Power Switch
CURRENT
TRANSDUCER
125:1
C8
2J90
1J50
2J50
CT
C10
Located above
Main Transformer
frequency = 20 kHz
G
Return to Master TOC
TP6
150V
80J
D
8 Hertz per Volt
325 Volts = 2600 Hertz
503
506
TP1
320V
160J
C1
.05uF
600V
(Located Behind
Work Stud)
+
N.A.
505
504
MAIN
CHOKE
L1
1J90
Return to Master TOC
16 S
INPUT LINE
FILTER
202
WORK
(Located bottom
left side)
-
17
C6
3500uF
500V
202A
813
20D
Located behind
reconnect panel
+
2.7Ω
10W
-15
Schematic:L11385
Located on right side of machine
N.B.
.022u
800V
F
TP3
150V
80J
267
20
12
0
SWITCH BOARD #2
20C
NEG
+15
}
TP2
320V
160J
C2
.05uF
600V
STT CHOPPER DRIVE (-)
6J40 IGBT DRIVE (-)
I OUT
406
GND
4J40 V/F (+)
5J40 V/F (-)
3J40 IGBT DRIVE (+)
R1
CURRENT
50Ω
TRANSDUCER
125:1
(Located right of Work stud)
2.7Ω
10W
.022u
800V
-15V
}
404
405
403
S
B
4J91
19C
NEG
14
216
AC1
19
NEG
CT 2J40
frequency = 20 kHz
+15V
HARMONIC
FILTER
206A
2J91
AC2
1J40
8 Hertz per Volt
325 Volts = 2600 Hertz
208-230V
POS
(Located bottom
right side)
F
3J91
380-575V
11
414
RED(-)
418
WHITE(+)
1J91
RECONNECT
SWITCH
OUTPUT DIODES
D1-D4
(Located above Main transformer)
.022u
2.7Ω
800V
10W
A
212
INPUT
RECTIFIER
+
ELECTRODE
+
S
213
N.B.
C6
3500uF
500V
206
T1
13
POS
Return to Section TOC
( Located Front Center of Machine)
Schematic: L11385
(Located on left side of Machine)
211
Undervoltage = 200V
Overvoltage = 467V
AC3
Return to Section TOC
MAIN
TRANSFORMER
SWITCH BOARD #1
}
Return to Master TOC
SCHEMATIC - ENTIRE MACHINE - CODES 10957 - 11311 PG 1 OF 3 (G4421)
N.C.
Return to Section TOC
G-5
ELECTRICAL DIAGRAMS
G4421
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 455M/MSTT
SCHEMATIC - ENTIRE MACHINE - CODES 10957 - 11311 PG 2 OF 3 (G4421)
ENGINEERING CONTROLLED CHANGE DETAIL: CONTROL BOARD, CHANGED 2J4 TO 3J4
MANUFACTURER: No
ETHERNET/DEVICENET OR DEVICENET BOARD
(ETHERNET/DEVICENET BOARD SHOWN)
CONTROL BOARD
Schematic: G3893
Located on rear, left side of front door
see page 3 for details
Schematic: G3789
Located on left side of control box
2B
2B
8J7
THERMAL LED
YELLOW
THERMAL
LED
2W
2W
7J7
ETHERNET/DEVICENET
DEVICENET
LEDS - 12 TOTAL
DIP SWITCH - 4 BANKS OF 8
LEDS - 9 TOTAL
DIP SWITCH - 2 BANKS OF 8
SEE PAGE 3 FOR DETAILS
SEE PAGE 3 FOR DETAILS
ETHERNET
CONNECTOR
(Ethernet Board only)
THERMAL LED
Located by power switch.
See page 3 for details
Located under spring loaded cover
1W
1W
3J7
L10
STATUS LED (HI FOR RED)
RED/GREEN
STATUS
LED
1B
1B
4J7
3J76
S3 RS232
CONNECTOR
2
253
253
3J2
RS232 RECEIVE
3
254
254
4J2
RS232 TRANSMIT
ETHERNET/DEVICENET BOARD
ONLY
DEVICENET CONFIGURATION
MUST BE IN FOR
DEVICENET
1J76
830
DIP SWITCH - 1 BANK OF 8
SEE PAGE 3 FOR DETAILS
Return to Master TOC
+24VDC
5J75
894
0 VDC
2J75
893
CAN_H
1J75
892
CAN_L
4J75
891
S5 DEVICENET
CONNECTOR
STATUS LED (HI FOR GREEN)
LEDS - 10 TOTAL
RED/GREEN
STATUS
LED
6B
1J74
(HIGH for RED)
6W
2J74
(HIGH for GREEN)
L2
4
Located under spring loaded cover
see page 3 for details
5
ARCLINK L
3J73
ARCLINK H
4J73
4
CAN_H
891
5 CAN_L
Located under spring loaded cover
See page 3 for details
ARCLINK L
1J73
ARCLINK H
2J73
0 VDC
6
1J2
RS232 COMMON
3J72
251
1J72
251
7
4J72
+40VDC
20
743
ARCLINK +
CONTROL BOARD
154B
VOLT SENSE BD
741
4J9
VOLTAGE SENSE
67
Schematic:S24779
Located on rear, right side of front door
see page 3 for details
VOLTAGE SENSE OUTPUT
800
840
153B
ELECTRODE SENSE
Located behind front
door panel.
54A
1J16
53A
67B
5J16
67A
52B
6J16
52A
51B
4J16
51A
+40VDC
0 VDC
3J16
N.D.
N.E.
L7
52A
1
1J11
ARC LINK H
Located under spring loaded cover
See page 3 for details
2
3
WIRE FEEDER VOLTAGE SENSE
L4
21A
21A
6J9
ARC LINK L
WORK VOLTAGE SENSE
2J11
1J2
51A
J16
54
67B
ROBOTIC VOLTAGE SENSE 3J1
Return to Master TOC
C422-1
3J6
C422-2
11J6
512
VOLTAGE SENSE SELECT (-)
4J1
511
FEED HD BD
Schematic: G3823
Located on rear, right side
of front door
see page 3 for details
Additional input /
outputs are
illustrated on
schematic # 1.
DC BUS BD
840
4J81 +40VDC
800
3J81
0 VDC
741
2J81
ARCLINK H
743
1J81
ARCLINK L
Schematic: M19330
Located on rear of control box (right)
Additional input /
outputs are
illustrated on
schematic # 1.
154B
2J82
153B
1J82
ARCLINK H
ARCLINK L
RED/GREEN
STATUS
LED
0 VDC
1J47
51
3J47
50
51B
3J82 0 VDC
52B
4J82 +40VDC
5W
15J85
10A
located on lower left
case front
C ELECTRODE SENSE
52
D +40VDC
51
E 0 VDC
14J85
VOLTAGE SENSE SELECT (+)
13J85
512
+15VDC TACH
1J84
841
TACH COMMON
4J84
844
841
A TACH +15VDC
844
B TACH COMMON
C TACH 1A DIFF SIGNAL
TACH 1A DIFF. INPUT
2J84
842
842
TACH 1B DIFF. INPUT
3J84
843
843
D TACH 1B DIFF SIGNAL
TACH 2A DIFF. INPUT
5J84
845
845
E TACH 2A DIFF SIGNAL
TACH 2B DIFF. INPUT
6J84
846
846
F TACH 2B DIFF SIGNAL
SINGLE TACH INPUT 7J84
847
847
G SINGLE TACH INPUT
MOTOR "+" 1J83
539
67C
539
I VOLTAGE SENSE
J MOTOR "+"
MOTOR "-"
2J83
541
541
K MOTOR "-"
SOLENOID +40VDC
3J83
521
521
N SOLENOID +40VDC
SOLENOID INPUT
4J83
522
522
Located under spring loaded cover
See page 3 for details
TACH signals are selected
by software ( standard or Diff type )
N.D. COMMUNICATION INTERFACE MODULE.
TRIGGER +15VDC 1J85
851
851
1 TRIGGER +15VDC
TRIGGER INPUT 2J85
852
852
2 TRIGGER INPUT
DUAL PROC. INPUT 3J85
853
853
3 DUAL PROC. INPUT
854
4 4 STEP INPUT
855
5 COLD INCH +15VDC
(HIGH for GREEN)
COLD IN. FORWARD 6J85
856
856
6 COLD IN. FORWARD
857
8J85
858
SHUTDOWN +15VDC 9J85
859
SHUTDOWN 1 INPUT 10J85
860
857
858
859
860
861
862
7 COLD IN. REVERSE
8 GAS PURGE INPUT
9 SHUTDOWN +15VDC
10 SHUTDOWN 1 INPUT
11 SHUTDOWN 2 INPUT
12 INPUT B
886
5J83
+40VDC
880
Located on rear of control box (center)
6J83
+40VDC
COLD IN. REVERSE 7J85
GAS PURGE INPUT
DIP SWITCHES
(see other sheet for use )
NOTES:
N.C. IF FEEDHEAD BOARD IS NOT PRESENT, INSERT
P82 INTO J73.
S7 I/O
RECEPTACLE
P SOLENOID INPUT
T
854
16J85
jumper 9,10,11 for
welder to operate
Located under spring loaded cover
See page 3 for details
S6
WIREFEEDER
INTERFACE
RECEPTACLE
511
855
5B
D6
67
4 STEP INPUT 4J85
52
CB1
B ARCLINK +
COLD INCH +15VDC 5J85
(HIGH for RED)
Blocking Diode for Motor
+40VDC FEEDER
EN-170
VOLTAGE SENSE SELECT (-)
GND-A
LEDS - 1 TOTAL
SEE PAGE 3 FOR DETAILS
A ARCLINK -
54
L6
GROUND CURRENT SENSE
Located on vertical panel near lift
bale
N.F.
1J1
L5
GROUND CURRENT SENSE
53
67C
VOLTAGE SENSE SELECT (+)
CURRENT SENSOR CLOSED
IS THE FAULT CONDITION
GROUND LEAD
CURRENT SENSOR
S1 ARCLINK
RECEPTACLE
53A
54A
53
4
Return to Master TOC
0 VDC
892
+24VDC
ARCLINK L
S2 VOLTAGE SENSE
RECEPTACLE
Return to Section TOC
2
3
N.C.
ARCLINK -
Return to Section TOC
894
893
ARCLINK H
2J72
Return to Section TOC
RJ45 type
J710
ETHERNET PORT
SHUTDOWN 2 INPUT 11J85
861
INPUT B 12J85
862
Schematic numbers are given for reference only.
PROPRIETARY &
N.E. ROBOTIC WIRE DRIVE INTERFACE MODULE.
N.F. K2202-4 MACHINES ONLY.
COMPONENTVALUE UNITS:
LEAD COLOR CODE:
B-BLACK
G-GREEN
O-ORANGE
R-RED
U-BLUE
W-WHITE
Y-YELLOW
Located under spring loaded cover
See page 3 for details
CAPACITOR: MFD/VOLTS
RESISTOR: OHMS/WATTS
CONNECTORPIN NUMBERS:
EX. 12 PIN CONNECTOR
1 2
6
7
12
LABELS:
LEGEND
DASHED = "
PHANTOM= "
COMMON
" STT MACHINE ONLY
" OPTION
FRAME GROUND
LATCH
EARTH GROUND
VIEW OF CONNECTORON PC BOARD
THIS DOCUMENT CONTAINS PROPRIETARY INFORMATION OWNED BY LINCOLN GLOBAL, INC. AND MAY NOT BE DUPLICATED, COMMUNICATED
CONFIDENTIAL:
TO OTHER PARTIES OR USED FOR ANY PURPOSE WITHOUT THE EXPRESS WRITTEN PERMISSION OF LINCOLN GLOBAL, INC.
THE INFORMATION ON THIS
PRINT IS FOR REFERENCE
ONLY. COMPONENTS AND
CIRCUITRY MAY BE DIFFERENT
FROM AN ACTUAL MACHINE.
DESIGN INFORMATION
DRAWN BY:
F.Valencic
ENGINEER:
S.Poole
APPROVED:
.
REFERENCE:
G4050
SCALE:
NONE
INVERTER WELDERS
455M MACHINE SCHEMATIC
EQUIPMENT TYPE:
SUBJECT:
MATERIAL
DISPOSITION:
UF
APPROVAL
DATE:
2/1/2007
PROJECT
CRM22115-GC
NUMBER:
3
2 OF ___
PAGE ___
DOCUMENT
REVISION:
DOCUMENT
NUMBER:
G4421
F
SOLID EDGE
Return to Master TOC
G-6
ELECTRICAL DIAGRAMS
G4421
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 455M/MSTT
Troubleshooting the PowerWave
DEVICENET MODULE
Using the Status LED
(OPTIONAL K2206)
ETHERNET MODULE
S1
LED6
LED5
(OPTIONAL K2207)
LED4
LED3
MEANING
LED8
CONTROL BOARD
LED7
S2
J70
J4
J70
LED2
Return to Master TOC
Return to Section TOC
J75
COLOR
11
12
Green
Green
Green
Green
Green
Red
Green
Red
Green
Red
Green
Green
Indicates Isolated Module Section Supply is ON
Indicates DeviceNet Supply is ON
ArcLink Status Indicators (Main System Slave ArcLink Connection)
Solid Green only when functional (See software for error codes)
Reserved For Future Use
DeviceNet Status Indicators (See software group for coding)
Indicates Isolated ArcLink Section Supply is ON
10Base-T Link Status ON indicates functional ethernet link has been
established
Receiver Polarity ON indicates proper ethernet signal polarity
Indicates I/O+5V Supply is ON This is used by differential I/O pair 4
circuitry, J712 pins 1 and 2.
Description
Object Instance LSB (see Table 1)
Object Instance MSB (see Table 1)
Equipment Group 1 Select
Equipment Group 2 Select
Equipment Group 3 Select
Equipment Group 4 Select
Reserved for future use
Reserved for future use
Bank (S1)
Switch
1
2
3
4
5
6
7
8
Description
DeviceNet Baud Rate
DeviceNet Mac ID
Default ID=62
Return to Master TOC
Description
1-2
Devicenet Baud Rate
3-4
Devicenet Mac ID
LED6
Configuring the DIP switches
on the Devicenet Board
O
N
O
N
1 2 3 4 5 6 7 8
'Bank S1 Default'
1 2 3 4 5 6 7 8
LED 10
'Bank S2 Default'
J10A
Control Board DIP Switch:
Switch
1
2
3
4
5
6
7
off
8
on
Description
Indication
CAN communication bus off.
12
User Interface time out error.
21
Unprogrammed Weld Mode.
22
Empty Weld Table.
23
Weld Table checksum error.
31
Primary overcurrent error.
Comments
Object Instance LSB
Object Instance MSB
Equipment Group 1 Select
Used for Arclink configuration
Equipment Group 2 Select
Equipment Group 3 Select
Equipment Group 4 Select
Reserved for future use
work sense lead not connected
Used for configuring work sense lead
work sense lead connected
Low voltage on the main capacitors. May be caused by
improper input configuration, or an open/short circuit
in the primary side of the machine.
Excess voltage on the main capacitors. May be caused
by improper input configuration, or an open/short
circuit in the primary side of the machine.
Indicates over temperature. Usually accompanied by
Thermal LED. Check fan operation. Be sure process
does not exceed duty cycle limit of the machine.
Capacitor precharge failed. Usually accompanied by
codes 32-35.
The secondary (weld) current limit has been exceeded.
When this occurs the machine output will phase back
to 100 amps, typically resulting in a condition refered
to as “noodle welding”
36
Thermal error
37
Softstart error
41
Secondary overcurrent error
42
Ground lead Current Shutdown
(On K2202-4 machines only)
43
Capacitor delta error
49
Single phase error
J81
J85
Description of LED functions on the Power Wave 455M
For reference only
NO P.C. BOARD MOUNTED LED's
LED #
1
2
3
4
5
6
7
8
9
10
Comments
J86
S1
COLOR
Green
Green
Green
Green
Green
Green
Red
Green
Green
Red
L11088 Digital Control PC Board
FUNCTION
Indicates +15VDC from power supply board is present
Indicates –15VDC from power supply board is present
Indicates +5VDC for +5SPI from power supply board is present
Indicates +15VDC for +15SPI from power supply board is present
Indicates +5VDC for +5V from power supply board is present
Indicates +5VDC for +5VRS232 from power supply board is present
FAULT Signal (See software group for coding)
Indicates +5VDC for +5CAN from power supply board is present
ArcLink Status Indicators (Main System Master ArcLink Connection) Solid
Green only when functional (See software for error codes)
Other
6
19
20
17
18
Probably due to excessive number of communication
errors.
UI is no longer responding to the Power Source. The
most likely cause is a fault/bad connection in the
communication leads or control cable.
Contact the Service Department for instructions on
reloading the Welding Software.
Contact the Service Department for instructions on
reloading the Welding Software.
Contact the Service Department for instructions on
reloading the Welding Software.
Excessive Primary current present. May be related to a
switch board or output rectifier failure.
32 Capacitor “A” under voltage
(Left side facing machine)
33 Capacitor “B” under voltage
(Right side facing machine)
34 Capacitor “A” over voltage
(Left side facing machine)
35 Capacitor “B” over voltage
(Right side facing machine)
LED 8
Indicates Isolated ArcLink Section Supply is ON
J82
J10B
S1
11
LED7
DeviceNet Status Indicators (See software group for coding)
J83
LED 4
J11
L11046 DeviceNet Gateway PC Board
FUNCTION
Indicates Isolated Module Section Supply is ON
Indicates DeviceNet Supply is ON
ArcLink Status Indicators (Main System Slave ArcLink Connection) Solid
Green only when functional (See software for error codes)
Module Status Indicators (See software group)
COLOR
Green
Green
Green
Red
Green
Red
Green
Red
Green
Error codes for the PowerWave
The following is a list of possible error codes that the Power Wave can output via the status light
J1
Description of LED functions on Power-Wave type systems
LED #
1
2
3
4
5
6
7
8
9
J84
Used for DeviceNet
configuration
Error Code interpretation through the Status light is detailed in the Service
Manual. Individual code digits are flashed in red with a long pause between
digits. If more than one code is present, the codes will be separated by a green
light.
LED 5
J2
(OPTIONAL K2205)
Bank S1
Switch
Description
Comments
1
Object Instance LSB
2
Object Instance MSB
3
Equipment Group 1 Select
Used for Arclink
Configuration
4
Equipment Group 2 Select
5
Equipment Group 3 Select
6
Equipment Group 4 Select
7
Reserved for future use
8
Reserved for future use
Table 15
Non-recoverable system fault. If the PS Status light is flashing any combination
of red and green, errors are present in the Power Wave. Read the error code
before the machine is turned off.
Error Code #
WIRE DRIVE MODULE
Ethernet Board DIP Switch :
Bank S2
Switch
J71
J76 J74 J71
Bank (S1)
LED
#
1
2
3
4
5
6
7
8
9
10
Alternating
Green and Red
To clear the error, turn power source off, and back on to reset.
LED 3
J3
J74
J76
Devicenet Board DIP Switch
For reference only
Occurs during a reset, and indicates the Power Wave 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
J73
LED1
J75
G3894 Ethernet Gateway PC Board
FUNCTION
LED 9
J9
J8
System OK. Power source communicating normally with wire feeder and its
components.
LED 2
LED9
Description of LED functions on the Power Wave 455M
J7
LED 1
J72
J73
Switch
1
2
3
4
5
6
7
8
J6
J5
Steady Green
Blinking Green
The K2202-4 has a special circuit installed that
monitors current flowing on the input ground lead.
When current is sensed, the machine will turn the
welding output off. The machine will need to be turned
off for several seconds and then back on to clear this
error.
The maximum voltage difference between the main
capacitors has been exceeded. May be accompanied by
errors 32-35.
Indicates machine is running on single phase input
power. Usually caused by the loss of the middle leg
(L2).
Error codes that contain three or four digits are defined
as fatal errors. These codes generally indicate internal
errors on the PS Control Board. If cycling the input
power on the machine does not clear the error, try
reloading the operating system. If this fails, replace the
control board.
3
2
7
J87
1
8
14
POWER BOARDS
M19540
J1
Description of LED functions on the Power Wave 455M
For reference only
J2
99/08/04@11:34:37
Diode Detail
R2
TP2
L1
R1
D1
R3
OCI1
C1
Switch
1
2
3
4
5
6
off
7
on
off
8
Voltage Sense Board
Description
Object Instance LSB
Object Instance MSB
Equipment Group 1 Select
Equipment Group 2 Select
Equipment Group 3 Select
Equipment Group 4 Select
Electrode polarity positive (default)
Electrode polarity negative
Low speed gear (default)
COLOR
Red
Red
G3632 Digital Power Supply Board
FUNCTION
Indicates +5VDC SPI supply is present
Indicates +5VDC control supply is present
COLOR
Red
L11078 +40 Volt DC Bus Board
FUNCTION
Indicates +40 VDC supply is present
OCI2
TP1
Feed Head Board DIP Switch:
EN-170
Return to Master TOC
Return to Section TOC
VOLTAGE SENSE SELECT
99/08/04@11:28:10
LED #
1
2
LED #
1
16
9
12
11
13
4
Comments
Used for Arclink Configuration
Used for configuring electrode polarity
Used for confi guring wirefeeder gear ratio
15
Case Front Detail
10
5
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
Power Switch
Status Light
High Temperature Light
10 Amp Wire Feeder Circuit Breaker
Auxiliary Power Circuit Breaker
Work Sense Lead Connector
Arclink Receptacle
DeviceNET Connector (not shown)*
I/O Connector*
RS232 Connector
Work Stud
STT Stud
Electrode Stud
Robotic Interface Connector*
Auxiliary Output (110V or 220V)
Ethernet Connector*
Wire Drive Interface Module (not shown)*
Wire Drive Status LED*
Communication Interface Module (not shown)*
Communication Status LED*
* Not Standard in Base Model
Power Wave 455M/STT CE
(shown with Wire Drive Interface Module
& Ethernet communication Module)
THIS DOCUMENT CONTAINS PROPRIETARY INFORMATION OWNED BY LINCOLN GLOBAL, INC. AND MAY NOT BE DUPLICATED, COMMUNICATED
PROPRIETARY & CONFIDENTIAL:
TO OTHER PARTIES OR USED FOR ANY PURPOSE WITHOUT THE EXPRESS WRITTEN PERMISSION OF LINCOLN GLOBAL, INC.
THE INFORMATION ON THIS
PRINT IS FOR REFERENCE
ONLY. COMPONENTS AND
CIRCUITRY MAY BE DIFFERENT
FROM AN ACTUAL MACHINE.
DESIGN INFORMATION
DRAWN BY:
F.Valencic
ENGINEER:
S.Poole
APPROVED:
.
REFERENCE:
G4050
SCALE:
NONE
INVERTER WELDERS
455M MACHINE SCHEMATIC
EQUIPMENT TYPE:
SUBJECT:
MATERIAL
DISPOSITION:
UF
APPROVAL
DATE:
2/1/2007
PROJECT
CRM22115-GC
NUMBER:
3
3 OF ___
PAGE ___
DOCUMENT
REVISION:
DOCUMENT
NUMBER:
G4421
F
SOLID EDGE
ENGINEERING CONTROLLED CHANGE DETAIL: CONTROL BOARD, CHANGED 2J4 TO 3J4
MANUFACTURER: No
G4421
Return to Master TOC
SCHEMATIC - ENTIRE MACHINE - CODES 10957 - 11311 PG 3 OF 3 (G4421)
J72
Return to Section TOC
G-7
ELECTRICAL DIAGRAMS
GATEWAY
L11046
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 455M/MSTT
Return to Master TOC
ELECTRICAL DIAGRAMS
G-8
SCHEMATIC - CHOPPER PC BD - (STT MODELS ONLY) (L11340-2)
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-8
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
POWER WAVE 455M/MSTT
Return to Master TOC
PC BOARD ASSEMBLY - CHOPPER PC BD - (STT MODELS ONLY) - (G3339-2)
ENGINEERING CONTROLLED
MANUFACTURER: No
CHANGE DETAIL: REVISED MAKE SPECIFICATION
NOTES :
N.A. CAUTION: THIS DEVICE IS SUBJECT TO DAMAGE BY STATIC
ELECTRICITY. SEE E2454 BEFORE HANDLING.
N.B. DO NOT COAT WITH ENCAPSULATION MATERIAL.
N.A.,N.J.
N.C. THIS AREA TO BE COVERED ON BOTH SIDES OF BOARD WITH
SEALANT PRIOR TO ENCAPSULATION.
N.D. INJECT SEALANT ITEM 4 THROUGH THE PC BOARD HOLES (6 HOLES)
TO SEAL MODULE LEADS. CAVITY BETWEEN BOARD AND MODULE TO
BE COMPLETELY FILLED WITH ITEM 4 SEALANT MATERIAL AS PER
APPROPRIATE MANUFACTURING WORK INSTRUCTIONS. COVER ALL
MODULE LEADS THAT PROTRUDE FROM THE NON-MODULE SIDE OF
THE BOARD WITH ITEM 4 SEALANT.
N.E. FEMALE EYELET TO BE AGAINST THE OPPOSITE COMPONENT SIDE AS
SHOWN. EYELET MUST NOT SPIN AFTER CLINCHING.
P.C. BOARD BLANK INFORMATION
BUY COMPLETE AS G3339-D (2 LAYER BOARD PER E3281)
(SEE ELECTRONIC FILE FOR ADDITIONAL INFORMATION)
N.B.
N.F. SOLDER EYELET SO THAT SOLDER COVERS ENTIRE EYELET AND ALL
AROUND EYELET ON OPPOSITE COMPONENT SIDE ONLY. NO ICICLES OR
SOLDER BLOBS PERMITTED.
N.G. ELECTRONIC MODULES TO BE ASSEMBLED AND ENCAPSULATED
PER E3875.
N.H. THIS DIMENSION APPLIES TO THESE TWO OF THE FOUR EYELETS AS SHOWN.
N.J. ELECTRONIC MODULES ON A COMMON P.C. BOARD ASSEMBLY TO
HAVE VGE(TH) WITHIN 5 SORT CODES (0.5VSPAN) FOR THE SAME
VCE(SAT) CODE AND MANUFACTURING CODE.
e.g. M21214-1 X XX XX ........
Return to Master TOC
Return to Section TOC
G-9
ELECTRICAL DIAGRAMS
G3339-2
Return to Section TOC
G-9
N.A.
N.A.
N.A.
VENDOR CODE
ITEM (USED WITH)*
QTY PART NUMBER
1
1 G3339-D
2 (X4)*
1 S20590-1
3 (B48,B49,B53,B55)*
4 T9147-11
4
2 oz. E2861
REFERENCES
QTY PART NO.
A1, A2
2 M21214-1
B48, B49, B53, B55
4 T9147-15
C1
1 T11577-49
C2
1 S13490-8
C3, C7, C9, C10, C21
5 S16668-11
C6, C8, C20
3 S13490-173
C11, C14
2 S16668-10
C12, C17
2 S16668-7
C13, C15, C16
3 S16668-3
C18, C19
2 S20500-2
C22
1 S16668-9
C23
1 S13490-25
D1, D2, D3, D4, D7
5 T12199-1
D5, D6
2 T12705-23
DZ1
1 T12702-29
J10
1 S20351-6
OCI1
1 S15000-10
R1
1 S18380-5
R2
1 S19400-3320
R3, R4, R27
3 S19400-3321
R5
1 S19400-4752
R6
1 S19400-4750
R8, R23
2 S19400-4751
R9, R10, R11, R12, R13, R14,
14 S19400-3010
R15, R16, R17, R18, R19, R20,
R21, R22
R25
1 S19400-2213
R26
1 S19400-3323
X1
1 S15018-9
X2
1 S15018-21
X3
1 S15018-15
X4
1 S15128-6
DESCRIPTION
PC BOARD BLANK
HEAT SINK, TO-220
EYELET, FEMALE
SEALANT
DESCRIPTION
ELECTRONIC MODULE,7 IGBT(T12704-85)
EYELET, MALE
500/50
50/25
.1/50
CAPACITOR,MPF,1.0 uF,63VDC
4700pF/50
820pF/50
100pF/100
.47/630
150pF/100
4.7/35
1N4004
1N5818
1N4744A
HEADER
OPTO ISOLATOR
THERMISTOR,PTC,0.5-1.17 OHMS,0.5A
332 1/4W
3.32K 1/4W
47.5K 1/4W
475 1/4W
4.75K
301 1/4W
221K 1/4W
332K 1/4W
IC,CMOS,MULTIVIBRATOR,MONOSTABLE,DUAL,4538 (SS)
IC,DRIVER,9A LOW-SIDE MOSFET (SS)
IC,CMOS,GATE,NAND,2-INPUT,QUAD,SCHM (SS)
IC,SMD,VOLT REG,FIXED,3-TERMINAL,POS VOLT,1A,15V
VCE(SAT)
VGE(TH)
N.G.
CAPACITORS = MFD/VOLTS
RESISTORS = OHMS
N.K. BEFORE ENCAPSULATION, APPLY A .19 WIDE BEAD OF ITEM 4 SEALANT IN
AREAS SHOWN TO ANCHOR CAPACITORS C18 AND C19 (2 PLACES).
.490 ±.005
(RESTRAINED)
N.H.
N.C.
1
5.50 ±.04
B49
N.D.
R15
R23
R8
R16
C10
D6
C6
DZ1
D5
R14
R26
X2
C9
X1
C8
R13
C3
R12
C13
R27
C15
C1
C2
X4
.275
.285
R .045
.116
MAX.
CRIMP HEIGHT
OPPOSITE COMPONENT SIDE
N.K.
EYELET DETAIL
R11
R19
R3
R4
C12
X3
xx x x x x x x xx
x
x
x
x
x
x
x
x
x
x
x
C18
x
x
x
x
x
x
x
x
x
x
xxx x x x x x x xx
3
R21
R10
R25
2
R6
C14
R18
C16
C20
D7
C23
C17
R20
xx x x x x x x x
x
x
x
x
x
x
x
x
x
x
x C19
x
x
x
x
x
x
x
x
x
x
x
xxx x x x x x x xx
C21
R5
R17
C7
N.E., N.F.
STT CHOPPER G3339-2
Return to Master TOC
Return to Section TOC
B48
D3
D1
D2
R1
R9
R2
R22
N.H.
D4
C22
C11
OCI1
N.H.
MAKE PER E1911-ROHS
ENCAPSULATE WITH E1844 (1 COAT)
J10
B55
B53
.45
TEST PER E3647-CH
0
SCHEMATIC REFERENCE: L11340-2D0
N.B.
1.30
4.00
MANUFACTURED AS:
1.30
7.50 ±.04
ALL COMPONENTS AND MATERIALS USED IN THIS
ASSEMBLY ARE TO BE RoHS COMPLIANT PER E4253.
G3339-2D0
Return to Master TOC
IDENTIFICATION CODE
FOR PARTS ORDERS AND SUBSIDIARY ORDERS:
INCLUDE (1) S25191PRINT AND (1) T12837-1.
THIS DOCUMENT CONTAINS PROPRIETARY INFORMATION OWNED BY LINCOLN GLOBAL, INC. AND MAY NOT BE DUPLICATED, COMMUNICATED
PROPRIETARY & CONFIDENTIAL:
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
ON 2 PLACE DECIMALS IS ± .02
ON 3 PLACE DECIMALS IS ± .002
DRAWN BY:
ON ALL ANGLES IS ± .5 OF A DEGREE
MATERIAL TOLERANCE (" t ") TO AGREE
WITH PUBLISHED STANDARDS.
ENGINEER:
DO NOT SCALE THIS DRAWING
APPROVED:
FEI
REFERENCE:
G3339-1
SCALE:
-
1:1
EQUIPMENT TYPE:
SUBJECT:
MATERIAL
DISPOSITION:
UF
INVERTER WELDERS
CHOPPER P.C. BOARD ASSEMBLY
APPROVAL
DATE:
10/2/2006
PROJECT
NUMBER:
CRM34409
1
1 OF ___
PAGE ___
DOCUMENT
NUMBER:
G3339-2
DOCUMENT
REVISION:
A
SOLID EDGE
Return to Section TOC
0
STRP
NOTE:
Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your factory warranty. Individual Printed Circuit Board Components are not available from Lincoln Electric. This information is 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
455M/MSTT
Return to Master TOC
ELECTRICAL DIAGRAMS
G-10
SCHEMATIC - DEVICENET/GATEWAY PC BOARD (ROBOTIC MODEL ONLY) PG 1 OF 2 (G3821-2)
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-10
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
POWER WAVE 455M/MSTT
Return to Master TOC
ELECTRICAL DIAGRAMS
G-11
SCHEMATIC - DEVICENET/GATEWAY PC BOARD (ROBOTIC MODEL ONLY) PG 2 OF 2 (G3821-2)
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
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
POWER WAVE 455M/MSTT
PC BOARD ASSEMBLY - DEVICENET/GATEWAY PC BOARD (ROBOTIC MODEL ONLY) (L11046-2)
ENGINEERING CONTROLLED
MANUFACTURER: Yes
CHANGE DETAIL: NEW
ITEM
N.E.
3
PART NO.
QTY
PC BOARD REFERENCE
DESCRIPTION
DESIGNATORS
1
L11046-F
1
GATEWAY PC BOARD BLANK
2
S24671
1
PLUG, KEYING PLUG
3
M19436-5
1
POTTING TRAY
4
S8025-80
2
SELF TAPPING SCREW
5
E2527
195g.
(6.87OZ) EPOXY ENCAPSULATING RESIN
6
E3539
AS REQ.
ELECTRICAL INSULATING COMPOUND
7
S24824-3
1
X11
SOFTWARE CPLD
N.F.
N.G.
8
S24825-1
1
X13
SOFTWARE, FLASH
FOR ITEMS LISTED BELOW REFER TO ELECTRONIC COMPONENT DATABASE FOR COMPONENT SPECIFICATIONS
5.84
N.D.
Return to Master TOC
Return to Section TOC
2
6.34
N.A.
N.B.
Return to Master TOC
Return to Section TOC
4
CAUTION: THIS DEVICE IS SUBJECT TO DAMAGE BY STATIC
ELECTRICITY. LINCOLN ELECTRIC TO SEE E2454 BEFORE
HANDLING.
Return to Master TOC
PLACE CONNECTOR KEYING PLUG, OVER HEADER PIN, IN
LOCATION SHOWN. PLUG SHOULD BE INSERTED BELOW
CONNECTOR TOP SURFACE.
N.C.
SECURE PC BOARD ASSEMBLY IN PLACE WITH ITEM (4).
(2 PLACES, 5.3 +/- .5 IN. LBS)
N.D.
NO COMPONENTS ON BOTTOM SIDE OF PC BOARD.
PLACE BARCODED ASSEMBLY NUMBER IDENTIFICATION AND
BARCODED SERIAL NUMBER IDENTIFICATION IN AREA SHOWN.
N.E.
Return to Section TOC
REVISION CONTROL
L11046-2F0
NOTES:
N.B.
N.F.
PROGRAM ITEM 60 WITH ITEM 7 .
N.G.
PROGRAM ITEM 61 WITH ITEM 8 .
N.J.
MUST BE COVERED BY ITEM 5 .
S25020-13SMT
S25024-8SMT
S13490-179
S25024-5SMT
S25024-6SMT
S25024-2SMT
S25020-3SMT
2
5
1
4
4
4
30
C2,C7
C3,C4,C5,C6,C8
C9
C10,C13,C27,C30
C11,C12,C43,C60
C14,C16,C20,C25
C15,C17,C18,C19,C21,C22
C23,C24,C26,C28,C31,C32
C33,C35,C36,C37,C38,C41
C42,C44,C45,C46,C47,C48
C49,C50,C51,C53,C54,C58
CAPACITOR,SMD,CERAMIC,150pF,100V,5%,C
CAPACITOR,SMD,TANTALUM,10MF,16V,10%,S
CAPACITOR,ALEL,1000,35V,20%
CAPACITOR,SMD,TANTALUM,4.7MF,35V,10%,
CAPACITOR,SMD,TANTALUM,22MF,16V,10%,S
CAPACITOR,SMD,TANTALUM,1.0MF,35V,10%,
CAPACITOR,SMD,CERAMIC,0.1MF,50V,10%,X
16
17
18
19
20
21
22
23
S25020-15SMT
S13490-182
S13490-181
S25040-10SMT
S25040-9SMT
S25040-2SMT
S25040-11SMT
S25040-4SMT
3
1
1
2
1
3
3
8
CAPACITOR,SMD,CERAMIC,22PF,50V,5%,COG
CAP,ALEL,3300,63V,20%
CAP,ALEL,22,63V,20%
DIODE,SMD,3A,400V,D0-214AB
DIODE,SMD,3A,200V,D0-214AB,ULTRA-FAST
DIODE,SMD,1A,400V,DO-214BA/AC
DIODE,SMD,1A,600V,S403A,ULTRA-FAST RE
DIODE,SMD,DUAL,0.200A,70V,UFR
24
25
26
27
28
29
S25049-3SMT
S25049-4SMT
S25040-5SMT
S25046-1SMT
S25046-3SMT
S25044-9SMT
1
1
6
1
4
7
30
31
32
33
34
35
S18248-16
S18248-10
S24020-4
S24020-2
S24020-6
S25080-2SMT
1
1
3
1
1
6
36
37
38
39
40
41
42
43
S25080-1SMT
S15000-28SMT
S15000-32SMT
S25050-2SMT
S25051-4SMT
S25000-4750SMT
S25003-2000SMT
S25000-1002SMT
3
4
2
5
6
6
2
25
C29,C39,C40
C56
C59
D1,D5
D2
D3,D6,D21
D4,D16,D20
D7,D8,D9,D10,D12,D13,D14
D15
D17
D19
D22,D23,D24,D25,D26,D27
DZ1
DZ2,DZ3,DZ4,DZ5
DZ6,DZ7,DZ8,DZ10,DZ11,DZ12
DZ13
J70
J71
J72,J73,J76
J74
J75
LED1,LED2,LED3,LED5,LED7
LED9
LED4,LED6,LED8
OCI1,OCI2,OCI3,OCI4
OCI5,OCI6
Q2,Q4,Q5,Q12,Q13
Q6,Q7,Q8,Q9,Q10,Q11
R1,R2,R39,R40,R66,R67
R3,R4
R5,R8,R9,R10,R11,R12,R13
R14,R15,R16,R17,R19,R20
R21,R22,R23,R24,R25,R29
R34,R35,R42,R60,R61,R69
44
45
46
47
48
49
50
51
S25000-4751SMT
S25000-1001SMT
S25001-1002SMT
S25000-1501SMT
S25001-3320SMT
S25000-7500SMT
S25001-1211SMT
S25001-2670SMT
5
6
2
1
6
3
2
7
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
70
71
72
73
74
75
S25000-1000SMT
S25001-24R9SMT
S25001-2000SMT
S18380-5
S19869-8
S20375-8
S20353-1SMT
S15128-25SMT
S25068-6SMT
S15128-5SMT
S24841-1
S25068-7SMT
S25069-2SMT
M15101-14SMT
S25070-3SMT
S25069-3SMT
S17900-11SMT
M15104-15
S20353-5SMT
S20353-4SMT
S25068-4SMT
S17900-24SMT
S25065-2SMT
S25082-1SMT
6
3
3
1
2
1
1
1
2
1
1
2
1
1
1
1
1
1
2
2
1
1
1
1
N.C.
2
N.A.
9
10
11
12
13
14
15
PART NO. IDENTIFICATION
CODE
TEST PER E3856-G
POT WITH E2527
SCHEMATIC REFERENCE: G3821-2F0
N.J.
N.A.
BUY DETAIL
MAKE DETAIL
BUY PER E3867
MANUFACTURE PER E1911
BUY BLANK COMPLETE
(4 BOARDS PER PANEL)
N.A.
N.A.
N.A.
N.A.,N.F.
N.A.,N.G.
N.A.
N.A.
N.A.
N.A.
N.A.
N.A.
N.A.
4 LAYER BOARD BLANK PANEL
SEE ELECTRONIC FILE FOR ADDITIONAL INFORMATION.
UNLESS OTHERWISE SPECIFIED:
RESISTANCE = OHMS
R6,R38,R43,R45,R101
R18,R37,R41,R65,R68,R100
R27,R28
R30
R31,R32,R33,R46,R47,R72
R36,R44,R76
R48,R49
R50,R51,R52,R53,R57,R58
R59
R54,R55,R56,R80,R81,R82
R73,R74,R75
R77,R78,R79
R83
S1,S2
T1
X2
X3
X4,X24
X5
X6
X7,X9
X8
X10
X11
X13
X14
X15
X16,X18
X17,X22
X20
X23
X31
Y1
DIODE,SMD,3A,40V,SCHOTTKY,CASE 403-3
DIODE,SMD,DUAL,200MA,30V,SCHOTTKY,SOT
DIODE,SMD,DUAL,0.200A,70V,UFR
ZENER DIODE,SMD,0.5W,5.1V, 5%,SOD123
ZENER DIODE,SMD,0.5W,18V, 5%,SOD123
ZENER DIODE,SMD,3W,6.2V,5%, SMB
CONNECTOR,MOLEX,MINI,PCB,16-PIN
CONNECTOR,MOLEX,MINI,PCB,10-PIN
CONNECTOR,MOLEX,MINI,PCB,4-PIN,TIN
CONNECTOR,MOLEX,MINI,PCB,2-PIN,TIN
CONNECTOR,MOLEX,MINI,PCB,6-PIN,TIN
LED,SMD,GREEN,CLEAR,S1206
LED,SMD,RED,CLEAR,S1206
OPTOCOUPLER,SMD,TTL-OUT,HI-SPD,HI-CMR
OPTOCOUPLER,SMD,CMOS,HIGH SPEED,HIGH
TRANSISTOR,SMS,PNP,SOT23,0.5A, 40V,MM
TRANSISTOR,SMD,NMF,SOT-23,0.115A,60V,
RESISTOR,SMD,METAL FILM,1/10W,475OHMS
RESISTOR,SMD,1W,200OHMS,1%
RESISTOR,SMD,METAL FILM,1/10W,10.0K,1
RESISTOR,SMD,METAL FILM,1/10W,4.75K,1
RESISTOR,SMD,METAL FILM,1/10W,1.00K,1
RESISTOR,SMD,10K,1/4W,1206,1%,TR
RESISTOR,SMD,METAL FILM,1/10W,1.50K,1
RESISTOR,SMD,332OHMS,1/4W,1206,1%,TR
RESISTOR,SMD,METAL FILM,1/10W,750OHMS
RESISTOR,SMD,1.21K,1/4W,1206,1%,TR
RESISTOR,SMD,267OHMS,1/4W,1206,1%,TR
RESISTOR,SMD,METAL FILM,1/10W,100OHMS
RESISTOR,SMD,24.9OHMS,1/4W,1206,1%,TR
RESISTOR,SMD,200OHMS,1/4W,1206,1%,TR
THERMISTOR,PTC,0.5-1.17 OHMS,0.5A
SWITCH,DIP,SPST,8-CIRCUITS
TRANSFORMER,PCB,PWM,FLYBACK
IC,SMD,CMOS,DRIVER,RECEIVER,EIA232,14
IC,SMD,VOLTAGE REGULATOR,FIXED,POSITI
IC,SMD,VOLT REG,FIXED,3-T,(+),0.1A,5V
IC,VOLT REG,SMD,FIXED,3-T,(+),1A,5V
IC,MODULE,CONVERTER,DC-DC,+5V/3A OUT
IC,SMD,CMOS,UNDERVOLT-SENSING,RESET,M
IC,SMD,CMOS,EEPROM,SERIAL,SPI,64Kx8,S
IC,SMD,CMOS,MCU,32-BIT,2K-RAM,TPU,25M
CPLD,PROGRAMMABLE,XC9536,44-PIN,VQFP(
IC,SMD,CMOS,EEPROM,FLASH,16-BIT,512K
IC,SMD,CMOS,TRANCEIVER,BUS,3-STATE,OC
RAM,STATIC,16-BIT,64K,44-PIN,TSOP
IC,CMOS,CONTROLLER,COMMUNICATION,SERI
IC,CMOS,SMD,XCVR,EIA485(SS)
IC,SMD,TRANSCEIVER,CAN,UC5350,S0IC-8
IC,SMD,CMOS,GATE,NAND,2-INPUT,QUAD,SC
IC,SMD,ACT,LATCH,OCTAL,3-STATE,TSSOPCRYSTAL,SMD,QUARTZ,16MHZ
ALL COMPONENTS AND MATERIALS USED IN THIS
ASSEMBLY ARE TO BE RoHS COMPLIANT PER E4253
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 2 PLACE DECIMALS IS ± .02
DRAWN BY:
JIMJ
ON ALL ANGLES IS ± .5 OF A DEGREE
MATERIAL TOLERANCE (" t ") TO AGREE
WITH PUBLISHED STANDARDS.
ENGINEER:
ILD
L11046-1
SCALE:
DO NOT SCALE THIS DRAWING
APPROVED:
-
1:1
ON 3 PLACE DECIMALS IS ± .002
EQUIPMENT TYPE:
SUBJECT:
MATERIAL
DISPOSITION:
NA
COMMON DIGITAL CONTROLS
GATEWAY PC BOARD ASSEMBLY
APPROVAL
DATE:
9-18-2006
PROJECT
NUMBER:
CRM37943-B
1
1 OF ___
PAGE ___
DOCUMENT
NUMBER:
L11046-2
DOCUMENT
REVISION:
A
SOLID EDGE
Return to Master TOC
G-12
ELECTRICAL DIAGRAMS
L11046-2
Return to Section TOC
G-12
STRP
NOTE:
Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your factory warranty. Individual Printed Circuit Board Components are not available from Lincoln Electric. This information
is 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 455M/MSTT
Return to Master TOC
ELECTRICAL DIAGRAMS
G-13
SCHEMATIC - CONTROL PC BOARD (ALL CODES) PG 1 OF 4 (G3789-2)
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 455M/MSTT
Return to Master TOC
ELECTRICAL DIAGRAMS
G-14
SCHEMATIC - CONTROL PC BOARD (ALL CODES) PG 2 OF 4 (G3789-2)
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-14
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
POWER WAVE 455M/MSTT
Return to Master TOC
ELECTRICAL DIAGRAMS
G-15
SCHEMATIC - CONTROL PC BOARD (ALL CODES) PG 3 OF 4 (G3789-2)
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-15
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
POWER WAVE 455M/MSTT
Return to Master TOC
ELECTRICAL DIAGRAMS
G-16
SCHEMATIC - CONTROL PC BOARD (ALL CODES) PG 4 OF 4 (G3789-2)
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-16
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
POWER WAVE 455M/MSTT
ENGINEERING CONTROLLED
MANUFACTURER: Yes
CHANGE DETAIL: ADDED MANUFACTURE SPECIFICATION
9
N.J.
9
ITEM
1
2
3
4
5
6
7
9
N.J.
3
2
N.A.
Return to Master TOC
Return to Section TOC
6.34
9
2
N.M.
8.09
COMPONENT SIDE
N.A.
N.A.
N.A.
N.A.
N.A.
Return to Master TOC
N.E.
TE
AS
P
N
ND D'S I
A
T
R
CU BOA
1
1
2
6.01 oz.
0.01 oz.
1
1
3
DESCRIPTION
E3868-4
S25020-15SMT
S25024-10SMT
S25024-5SMT
S25020-23SMT
S13490-183
S13490-173
2
4
4
9
1
1
2
LAB,THT-53-423-3,BRADY,PLY
SCAP,22pF,0805,50V,COG,5%,TR,N
SCAP,22uF,TAN,7343,25V,10%
SCAP,4.7uF,7343,35V,10%,TR,NP
SCAP,1200pF,CER,1206,50V,X7R,10%
SCAP,120MF,25V,20%,RADIAL,AE
CAP,1uF,RA,63V,10%,NP
S25020-3SMT
69
SCAP,0.1uF,0805,50V,X7R,10%,TR
S25020-14SMT
S25020-12SMT
S25020-18SMT
S25020-4SMT
S25020-10SMT
S13490-179
S24833-1
S25020-13SMT
S25024-8SMT
S25020-2SMT
S25024-2SMT
S25044-4SMT
S25044-10SMT
1
5
1
11
2
1
2
7
4
2
8
2
3
SCAP,330pF,100V
SCAP,100pF,0805,COG,100V,5%
SCAP,10pF,CER,0805,100V,5%
SCAP,820pF,0805,50V,COG,5%,TR,
SCAP,4700pF,0805,50V,X7R,10%
CAP,1000uF,ALU,35V,20%,NP
CAP,0.27uF,MF,50V,5mm,5%,TR,NP
SCAP,150pF,0805,100V,COG,5%,TR,
SCAP,10uF,TAN,6032,TR,NP
SCAP,0.022uF,0805,50V,X7R,10%,
SCAP,1uF,TAN,3528,35V,TR,NP
SDIO,B5929,15V,1.5W,ZENER,TR,N
SDIO,B5930,16V,1.5W,ZENER,TR,N
S25046-1SMT
19
SDIO,MMSZ5231BT1,5.1V,NP
S25044-5SMT
S25049-4SMT
S25040-12SMT
S25046-3SMT
S25044-9SMT
9
8
8
4
7
SDIO,1SMB5931BT3,3W,18V,5%
SDIO,BAT54S,DUAL,30V,200mA
SDIO,MURS320T3,3A,200V,ULTRAFAST
SDIO,MMSZ5248B,18V,ZENER,TR,NP
SDIO,1SMB5920BT3,6.2V,NP
S25040-5SMT
13
SDIO,BAV99LT1,SOT23,DUAL SWITC
S25040-2SMT
13
SDIO,1A,400V,DO-214BA,GLS
S25049-2SMT
S25040-6SMT
T12702-59
T12702-60
S25083-1SMT
S18248-16
S24020-2
S18248-10
S24020-12
S24020-4
S24020-16
S24020-8
S24020-6
S25080-1SMT
S25080-2SMT
S15000-28SMT
N/A
S25051-7SMT
S25050-1SMT
S25050-2SMT
S25051-4SMT
S25051-6SMT
S25001-4753SMT
S25000-2802SMT
S25001-2671SMT
S25001-1501SMT
S25001-1503SMT
S25001-3321SMT
S25001-6811SMT
S25003-2000SMT
4
6
2
2
1
1
2
1
1
3
2
1
1
2
8
4
1
1
9
5
2
2
1
1
1
7
2
6
2
2
SDIO,MBRA130LT3,1A,30V,SCHOTKY
SDIO,BAV70
DIO,1N5333B
DIO,1N5358B
SIND,FERRITEBEAD,TR,NP
CON,16P,MINI,NP
CON,2P,TIN,MINI,NP
CON,10P,MINI,NP
CON,12P,TIN,MINI,NP
CON,4P,TIN,MINI,NP
CON,16P,TIN,MINI,NP
CON,8P,TIN,MINI,NP (or TH600-265)
CON,6P,TIN,MINI,NP
SLED,RED,1206,TR,NP
SLED,GRN,1206,TR,NP
SICS,HCPL-0601,OPTOCOUPLER
1E0 ARTWORK
SICS,IRF7103,NP
STRA,MMBT4401LT,NPN,SOT-23
STRA,2N4403,SO23,TR,(500475),N
STRA,2N7002,TR,NP
STRA,IRLR120N,10A,100V,MOSFET,
SRES,475K,1206,1%,1/8W,TR,NP
SRES,28K,0805,1%,1/10W,TR
SRES,2.67K,1206,1%,1/8W,TR,NP
SRES,1.5K,TKF,1206,1%,1/4W,TR
SRES,150K,1206,1%,1/8W,TR
SRES,3.32K,1206,1%,1/8W,TR
SRES,6.81K,1206,1%,1/4W,TR
SRES,200,2512,5%,1W,TR,NP
S25006-10ROSMT
10
SRES,10,
S25001-1001SMT
33
SRES,1K,1206,1%,1/4W,TR
S25001-1002SMT
REFERENCE-DESIGNATOR
PART NO.
DIGITAL CONTROL P.C. BD. BLANK (REF. ONLY)
POTTING TRAY
SELF TAPPING SCREW
EPOXY ENCAPSULATION RESIN
ELECTRICAL INSULATING COMPOUND
FLASH SOFTWARE
CPLD FIRMWARE
PLUG, KEYING PLUG
47
SRES,10K,MF,1206,1%,1/8W
S25001-7500SMT
S25001-2672SMT
1
4
SRES,750,1206,1%,1/4W,TR
SRES,26.7K,THK,1206,1%,1/8W,10
S25001-4751SMT
15
SRES,4.75K,1206,1%,1/8W,TR
S25001-4750SMT
24
SRES,475,1206,1%,1/8W,TR,NP
S25001-1500SMT
S25001-1004SMT
2
2
SRES,150,1206,1%,1/8W,TR,NP
SRES,1M,1206,1%,1/8W,TR
Barcode Labels
C118 C116 C128 C130
C119 C110 C49 C54
C12 C102 C1 C9 C10 C39 C40 C16 C61
C126
C13
C136 C135
C7 C138 C134 C133 C125 C55 C96 C98 C100 C28 C82
C14 C11 C83 C103 C121 C101 C117 C115 C111 C113
C85 C90 C48 C93 C109 C120 C127 C106 C95 C105
C73 C68 C8 C114 C108 C99 C77 C76 C75 C84 C79
C67 C88 C80 C50 C78 C23 C21 C91 C51 C92 C58 C57
C52 C60 C59 C131 C123 C122 C124
C30 C129 C139 C140 C137 C141 C142 C42
C143
C15, C18, C22, C25, C27
C32
C43 C4 C74 C3 C71 C19 C70 C5 C72 C6 C17
C44 C69
C45
C56 C34
C64 C89 C26 C35 C36 C38 C37
C66 C62 C65 C63
C86 C87
C94 C97 C104 C107 C47 C81 C2 C46
D10 D11
D18 D15 D43
D25 D45 D44 D17 D9 D6 D2 D5 D7 D8 D35 D36 D38
D37 D42 D41 D40 D39 D69
D27 D32 D26 D30 D31 D29 D24 D14 D16
D34 D54 D28 D47 D80 D81 D82 D83
D51 D55 D56 D57 D98 D99 D100 D101
D53 D52 D58 D59
D62 D61 D60 D13 D12 D1 D46
D66 D50 D33 D49 D19 D78 D79 D102 D103 D104 D105
D106 D107
D68 D67 D4 D3 D75 D63 D64 D65 D70 D72 D71 D73
D74
D76 D77 D114 D115
D84 D85 D86 D89 D90 D91
DZ1 DZ2
DZ3 DZ4
E1
J1
J10A J10B
J3
J4
J5 J11 J2
J6 J7
J8
J9
LED7 LED10
LED8 LED1 LED5 LED3 LED2 LED4 LED6 LED9
OCI1 OCI2 OCI3 OCI4
PCB
Q11
Q12 Q4 Q7 Q5 Q6 Q1 Q18 Q19 Q20
Q17 Q16 Q15 Q13 Q14
Q3 Q2
Q9 Q10
R100
R107
R109
R113 R118 R122 R74 R76 R80 R78
R117 R125
R123 R128 R129 R179 R246 R251
R127 R130
R132 R133
R151 R154 R157 R160 R148 R161 R158 R155 R152
R149
R171 R178 R177 R193 R231 R167 R61 R34 R89 R82
R163 R135 R136 R169 R131 R112 R60 R56 R126 R71
R54 R69 R68 R143 R144 R58 R206 R213 R214 R90
R168 R255 R256
R173 R191 R181 R164 R170 R172 R189 R186 R180
R91 R92 R93 R94 R95 R96 R97 R98 R22 R174 R201
R185 R104 R87 R33 R99 R260 R261 R139 R140 R121
R200 R199 R103 R221 R229 R204 R242 R241 R216
R217 R218 R252 R253 R254 R257 R258 R259
R183
R187 R114 R120 R72
R190 R192 R182 R184 R137 R146 R209 R210 R222
R42 R43 R46 R47 R51 R67
R195 R194 R41 R11 R83 R86 R166 R165 R21 R15 R20
R88 R81 R17 R19 R18 R141 R138 R119 R116 R85 R84
R40 R36
R196 R198
R212 R211
OPPOSITE COMPONENT
SIDE (BACKSIDE)
IDENTIFICATION CODE
DESCRIPTION
REFERENCE-DESIGNATOR
6
9
2
10
6
2
6
SRES,100,0805,1%,1/10W
SRES,47.5K,1206,1%,1/8W,TR
SRES,511,MF,1206,1%,1/8W,TR
SRES,2.21K,1206,1%,1/8W,TR
SRES,332,1206,1%,1/4W
SRES,47.5,TKF,1206,1%,1/4W,TR
SRES,22.1K,1206,1%,1/8W,TR,NP
R223, R224, R240, R226, R227, R228
R230 R27 R28 R26 R53 R29 R110 R57 R65
R24 R23
R25 R13 R12 R32 R1 R31 R134 R66 R268 R269
R262 R263 R264 R265 R266 R267
R3 R2
R37 R38 R35 R203 R8 R39
S25001-1003SMT
10
SRES,100K,1206,1%,1/8W,200PPM,
R55 R111 R49 R108 R115 R124 R142 R208 R207 R106
S25001-2210SMT
13
SRES,221,1206,1%,1/8W,TR
S25001-1000SMT
S25001-3322SMT
S25001-1213SMT
S20620-1003
N.C. S19869-8
N.A. S15128-13SMT
N.A. S25065-3SMT
N.A. S25069-2SMT
N.A. M15105-9SMT
N.A. S25067-3SMT
N.A. S25067-2SMT
N.A. S20353-1SMT
N.A.,N.G. S25070-3SMT
N.A. S25070-4SMT
N.A. S25066-2SMT
N.A. S15018-21SMT
N.A. S25065-2SMT
N.A. S25070-23SMT
N.A. S25068-7SMT
N.A. M15101-14SMT
N.A.,N.F. S25069-24SMT
N.A. S25069-7SMT
N.A. S20353-5
N.A. S20353-4SMT
N.A. S17900-11SMT
N.A. S25068-8SMT
N.A. S15128-21SMT
N.A. S25057-3SMT
N.A. S15128-18SMT
N.A. S25082-1SMT
4
2
1
4
1
1
2
1
1
2
1
1
1
1
1
2
1
1
1
1
1
1
1
1
1
1
2
2
3
1
SRES,100,1206,1%,1/8W,TR,NP
SRES,33.2K,1206,1%,1/8W,TR,NP
SRES,121K,1206,MF,1%,1/4W
RES,100K,AX,5%,1/2W,HI VOLT,TR
SWT,78B08S,DIP,SPST,8P,NP
SICS,OP-27G,OPAMP,SO8,TR,NP
SICS,74VHC14,NP
SICS,25128,SERIAL EEPR,NP
SICS,7945 (old package)
SICS,ADG417,SPST,CMOS,SWT,SO8
SICS,ADG409BR
SICS,MC145407,RECEIVER/DRVR,RS
ICS,XC9536-15 VQ44
SICS,XCS20,FPGA
SICS,AD7862,DUAL,12BIT,250kSPS
ICS,MIC4451BM
SICS,74ACT573,OCTAL,TRANS.,LAT
SICS,TMS320F240PQA,NP
SICS,4.6V,2%,VOLT. DETECTOR,SO
SICS,MC68332
SICS,28F800B5-90,FLASH RO,90n
SICS,128Kx16,20nS,TSOP
SICS,AN82527
SICS,MAX485ESA,NP
74HC245, NEW PACKAGE
SICS,MC79L05ABD
SICS,LT1016,COMPARATOR
SICS,AD8403ARU10
SICS,MC33074,QUAD,OPAMP,SO14,T
SXTL,16MHZ,HC40,20PF,NP
R59 R48 R102 R197 R45 R9 R10 R14 R16 R101 R50
R64 R105
R62 R44 R52 R30
R63 R233
R70
R73 R79 R75 R77
S1
X1
X10 X30
X11
X12
X13 X31
X15
X16
X17
X18
X19
X2 X3
X21
X22
X23
X24
X25
X27
X28
X29
X33
X4
X5 X7
X6 X32
X8 X14 X20
Y1
NOTES:
N.A. CAUTION: THIS DEVICE IS SUBJECT TO DAMAGE BY
STATIC ELECTRICITY. LINCOLN ELECTRIC TO SEE E2454
BEFORE HANDLING.
N.B. SECURE P.C. BOARD ASSEMBLY IN PLACE WITH (ITEM 3)
(2 PLACES, 4.8-5.8 IN. LBS.)
N.C. TOP OF THESE COMPONENTS MUST BE FREE OF POTTING
MATERIAL.
N.D. PLACE BARCODED ASSEMBLY NUMBER IDENTIFICATION AND
BARCODED SERIAL NUMBER IDENTIFICATION IN AREA SHOWN.
N.E. THERE ARE COMPONENTS ON BOTTOM SIDE OF P.C. BOARD.
N.F. PROGRAM X25 WITH ITEM 6.
N.G. PROGRAM X17 WITH ITEM 7.
N.J. PLACE CONNECTOR KEYING PLUG (ITEM 9) OVER HEADER PIN,
IN LOCATION SHOWN. PLUG SHOULD BE INSERTED BELOW
CONNECTOR TOP SURFACE.
N.K. ALL CONNECTORS MUST BE GREASED WITH (ITEM 5) PRIOR
TO ENCAPSULATION.
N.L. ENCAPSULATION PER E1911-E TO A MINIMUM DEPTH, SUCH
THAT ALL COMPONENT LEADS ARE COVERED.
N.M. SOLDER A #30 INSULATED COPPER WIRE FROM PIN 23 OF X27 TO
POSITIVE TERMINAL ON C119 AS SHOWN.
CAPACITORS = MFD/VOLTS
INDUCTANCE = HENRIES
RESISTANCE = OHMS
MANUFACTURE PER E1911-ROHS
SCHEMATIC REF. G3789-2F0
BUY PER E3867
TEST PER E3856-C
ALL COMPONENTS AND MATERIALS USED IN THIS
ASSEMBLY ARE TO BE RoHS COMPLIANT PER E4253.
L11088-2F0
PART NO.
REQ'D
S25000-1000SMT
S25001-4752SMT
S25001-5110SMT
S25001-2211SMT
S25001-3320SMT
S25001-47R5SMT
S25001-2212SMT
BUY AS
THIS DOCUMENT CONTAINS PROPRIETARY INFORMATION OWNED BY LINCOLN GLOBAL, INC. AND MAY NOT BE DUPLICATED, COMMUNICATED
PROPRIETARY & CONFIDENTIAL:
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
ON 2 PLACE DECIMALS IS ± .02
EN-170
Return to Master TOC
Return to Section TOC
REQ'D
1
N.D.
N.J.
PART NO.
L11088-F
M19436-1
S8025-80
E2527
E3539
S26082-4
S24804-3
S24671
ON 3 PLACE DECIMALS IS ± .002
DRAWN BY:
ON ALL ANGLES IS ± .5 OF A DEGREE
MATERIAL TOLERANCE (" t ") TO AGREE
WITH PUBLISHED STANDARDS.
ENGINEER:
DO NOT SCALE THIS DRAWING
APPROVED:
FEI
REFERENCE:
L11088-1
SCALE:
.
NONE
EQUIPMENT TYPE:
SUBJECT:
MATERIAL
DISPOSITION:
UF
INVERTER WELDERS
CONTROL P.C. BOARD AS'BLY
APPROVAL
DATE:
PROJECT
NUMBER:
CRM34409
1
1 OF ___
PAGE ___
DOCUMENT
NUMBER:
L11088-2
DOCUMENT
REVISION:
F.01
SOLID EDGE
Return to Master TOC
PC BOARD ASSEMBLY - CONTROL PC BOARD (ALL CODES) (L11088-2)
N.B.
Return to Section TOC
G-17
ELECTRICAL DIAGRAMS
L11088-2
Return to Section TOC
G-17
STRP
NOTE:
Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your factory warranty. Individual Printed Circuit Board Components are not available from Lincoln Electric. This information is
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
455M/MSTT
Return to Master TOC
ELECTRICAL DIAGRAMS
G-18
SCHEMATIC - DIGITAL POWER SUPPLY PC BOARD (ALL CODES) (G3631-3)
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-18
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
POWER WAVE 455M/MSTT
PC BOARD ASSEMBLY - DIGITAL POWER SUPPLY PC BOARD (ALL CODES) (G3632-3)
ENGINEERING CONTROLLED
MANUFACTURER: Yes
CHANGE DETAIL: REVISED IDENTIFICATION CODE, BLANK PART NIMBER, SCHEMATIC REFERFENCE AND UPDATED GRAPHICS
N.A.
N.A.
N.A.
8
7
1
N.G.
R50
J42
G3632-3
POWER
SUPPLY
J41
J43
R24
D7
C11
R17
T1
C26
C13
D8
D24
C18
C20
D6
D25
R40
C38
C19
C17
T2
X8
6
X3
X7
X6
D10
D13
D12
C23
D15
C29
C1
C10
3.64
C40
C47
C12
C33
D18
D22
DZ4
C31
DZ2
X1
C3
OCI1
QTY
1
2
2
AS REQ
2
2
1
2
115g
AS REQ
PART NUMBER
G3632-F
CF000003
E106A-13
E1868
S18104-5
S25128-1SMT
M19436-3
S8025-80
E2527
E2861
D1
LED1
DZ7
D20
D2
C37
R62
R63
D16
X2
R64
N.A.
6
N.B.
N.B.
N.B.
6.14
N.A.
REFERENCES
C1, C3, C6, C10, C17,
C18, C19, C20, C24, C33,
C38
C2, C5, C7, C9, C14, C21,
C22, C25, C34, C39, C44,
C53
C4, C8
C11, C43
C12, C31
C13, C26
C16, C42
C23, C29, C30, C40, C47
C28, C32
C36, C37
C45, C46, C52
D1, D2, D3, D6, D7, D8,
D9, D15, D25
D10, D12, D13, D17, D24
D16
D18
D19
D20, D21, D22, D23
DZ2, DZ3
DZ4
DZ7, DZ8
J41
J42
J43
LED1, LED2
OCI1, OCI3
Q1, Q2
R1
R2, R4, R13, R22, R27
R3
R5, R10, R29
R6, R7, R57, R58
R8
R9, R60, R61
R11, R30
R12, R28, R45
R14, R20
R15, R16
R17, R24
R18, R49
R19, R23
R21
R25, R44, R62, R63, R64
R31
R32, R43
R33
R35, R36
R37, R46, R48
R38, R39
R40
R41, R53
R42, R51
R50
R52
T1
T2
X1, X2
X3
X4, X5
X6, X7
X8
X9
QTY
PART NUMBER
DESCRIPTION
11
S13490-197
CAPACITOR,ALEL,82,35V,20%,LOW-ESR
12
S25020-3SMT
CAPACITOR,SMD,CERAMIC,0.1MF,50V,10%,X7R,S0805
2
2
2
2
2
5
2
2
3
S25020-4SMT
S13490-198
S20500-5
T11577-62
S25020-5SMT
S25024-2SMT
S25020-18SMT
S13490-202
S25020-13SMT
CAPACITOR,SMD,CERAMIC,820pF,50V,5%,COG,S0805
CAPACITOR,ALEL,1000,35V,20%,LOW-ESR
CAPACITOR,PPMF,.0015,2000V,BOX
CAPACITOR,PEMF,1.0,200V,10%
CAPACITOR,SMD,CERAMIC,2700pF,50V,5%,X7R,S0805
CAPACITOR,SMD,TANTALUM,1.0MF,35V,10%,S3528
CAPACITOR,SMD,CERAMIC,10pF,100V,5%,COG,S0805
CAPACITOR,ALEL,470MF,10V,20%
CAPACITOR,SMD,CERAMIC,150pF,100V,5%,COG,S0805
9
S25040-11SMT
DIODE,SMD,1A,600V,S403A,ULTRA-FAST RECOVERY
5
1
1
1
4
2
1
2
1
1
1
2
2
2
1
5
1
3
4
1
3
2
3
2
2
2
2
2
1
5
1
2
1
2
3
2
1
2
2
1
1
1
1
2
1
2
2
1
1
S25040-2SMT
S25040-13SMT
S25040-3SMT
S25040-8SMT
S25049-2SMT
S25046-5SMT
S25044-12SMT
S25044-5SMT
S24020-4
S24020-6
S24020-12
S25080-1SMT
S15000-10
T12704-93
S25001-1502SMT
S25001-1002SMT
S25001-6191SMT
S25001-1003SMT
S25002-47R5SMT
S25001-4750SMT
S25000-10R0SMT
S25005-1SMT
S25001-5621SMT
S25001-1821SMT
S25001-33R2SMT
S25084-2SMT
S25001-4322SMT
S25002-2491SMT
S25001-4753SMT
S25002-1500SMT
S25001-7502SMT
S25001-15R0SMT
S25001-2490SMT
S25002-30R1SMT
S25002-1211SMT
S25001-5622SMT
S18380-15
S25001-3320SMT
S25001-4422SMT
S25084-1SMT
S25001-2213SMT
S20375-13
S20375-10
S15128-10SMT
S25068-9SMT
S25071-2SMT
S25068-1SMT
S15128-6SMT
S25068-10SMT
DIODE,SMD,1A,400V,DO-214BA/AC
DIODE,SMD,DUAL,16A,200V,D2PAK,CC,ULTRA-FAST RECOVERY
DIODE,SMD,DUAL,6A,200V,DPAK,CC,ULTRA-FAST RECOVERY
DIODE,SMD,3A,600V,D0-214AB,ULTRA-FAST RECOVERY
DIODE,SMD,SCHOTTKY,1A,30V,SMA
ZENER DIODE,SMD,0.5W,27V,5%,SOD-123
ZENER DIODE,SMD,3W,3.3V,5%, SMB
ZENER DIODE,SMD,3W,18V,5%, SMB
CONNECTOR,MOLEX,MINI,PCB,4-PIN,TIN
CONNECTOR,MOLEX,MINI,PCB,6-PIN,TIN
CONNECTOR,MOLEX,MINI,PCB,12-PIN,TIN
LED,SMD,RED,CLEAR,S1206
OPTOCOUPLER,PHOTO-Q,70V,CNY17-3
TRANSISTOR,NMF,T220,21A,200V,BUZ30A
RESISTOR,SMD,15K,1/4W,1206,1%,TR
RESISTOR,SMD,10K,1/4W,1206,1%,TR
RESISTOR,SMD,6.19K,1/4W,1206,1%,TR
RESISTOR,SMD,100K,1/4W,1206,1%,TR
RESISTOR,SMD,47.5OHMS,1/3W,MF,1%,S1210
RESISTOR,SMD,475OHMS,1/4W,1206,1%,TR
RESISTOR,SMD,METAL FILM,1/10W,10.0OHMS,1%,S0805
RESISTOR,SMD,METAL STRIP,3W,0.05OHMS,1%
RESISTOR,SMD,5.62K,1/4W,1206,1%,TR
RESISTOR,SMD,1.82K,1/4W,1206,1%,TR
RESISTOR,SMD,33.2OHMS,1/4W,1206,1%,TR
THERMISTOR,SMD,PTC,0.35./1.4OHMS,2.0A
RESISTOR,SMD,43.2K,1/4W,1206,1%,TR
RESISTOR,SMD,2.49K,1/3W,MF,1%,S1210
RESISTOR,SMD,475K,1/4W,1206,1%,TR
RESISTOR,SMD,150OHMS,1/3W,MF,1%,S1210
RESISTOR,SMD,75.0K,1/4W,1206,1%,TR
RESISTOR,SMD,15.0OHMS,1/4W,1206,1%,TR
RESISTOR,SMD,249OHMS,1/4W,1206,1%,TR
RESISTOR,SMD,30.1OHMS,1/3W,MF,1%,S1210
RESISTOR,SMD,1.21K,1/3W,MF,1%,S1210
RESISTOR,SMD,56.2K,1/4W,1206,1%,TR
THERMISTOR,PTC,0.01/0.03OHMS,4.0A
RESISTOR,SMD,332OHMS,1/4W,1206,1%,TR
RESISTOR,SMD,44.2K,1/4W,1206,1%,TR
THERMISTOR,SMD,PTC,0.06/.25OHMS,1.5A
RESISTOR,SMD,221K,1/4W,1206,1%,TR
TRANSFORMER,PCB,PWM,FLYBACK
TRANSFORMER,PCB,PWM,FLYBACK
IC,SMD,VOLTAGE REF,ADJ, PRECISION,431I,SOIC-8
IC,SMD,VOLTAGE REGULATOR,FIXED,3-TERMINAL,0.5A,+15V
IC,SMD,PWM-CONTROLLER,SOIC8(SS)
IC,SMD,VOLTAGE REGULATOR,FIXED,3-TERMINAL,0.5A,+5V
IC,SMD,VOLTAGE REGULATOR,FIXED,3-TERMINAL,1A,+15V
IC,SMD,VOLTAGE REGULATOR,FIXED,3-TERMINAL,0.5A,-15V
NOTES:
N.A. SEE HEAT SINK MOUNTING DETAILS.
N.E.
N.B. ALL CONNECTORS MUST BE GREASED WITH ITEM 10 PRIOR
TO ENCAPSULATION.
5
2
N.H.
Q1 OR Q2
N.C. ATTACH ITEM 1 TO ITEM 7 (2 PLACES) WITH ITEM 8
(TORQUE = 5.3 +/- .05 IN-LB). ITEM 1 SHOULD
BE ALLIGNED SO THAT THE DISTANCE BETWEEN ITEM 1's
CONNECTORS AND ITEM 7 IS AS LARGE AS POSSIBLE.
G3632-3F0
N.E . TIGHTEN TO 6-8 in. lbs. WITHOUT APPLYING ANY PRESSURE
TO PLASTIC CASE OF Q1 AND Q2.
SCHEMATIC REFERENCE: G3631-3F0
N.H. PLACE A HEAVY FILM OF ITEM 4 ON HEAT SINK SURFACE.
DO NOT GET ON THREADS.
BUY PER E3867
TEST PER E3856-P
HEATSINK MOUNTING DETAIL
THIS DOCUMENT CONTAINS PROPRIETARY INFORMATION OWNED BY LINCOLN GLOBAL, INC. AND MAY NOT BE DUPLICATED, COMMUNICATED
PROPRIETARY & CONFIDENTIAL:
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
ON 2 PLACE DECIMALS IS ± .02
EN-170
Return to Master TOC
IDENTIFICATION CODE
PART NO.
N.G. PLACE BARCODED ASSEMBLY NUMBER IDENTIFICATION
AND BARCODED SERIAL NUMBER IDENTIFICATION IN
AREA SHOWN.
3
CAPACITORS = MFD/VOLTS
INDUCTANCE = HENRIES
RESISTANCE = OHMS
BUY AS
N.D. ENCAPSULATION PER E1911-E TO A MINIMUM DEPTH SO
ALL OF THE COMPONENTS LEADS ARE COVERED.
Return to Section TOC
DESCRIPTION
PC BOARD BLANK
6-32 X .375 ROUND HEAD MACHINE SCREW
# 6 LOCK WASHER
THERMO JOINT COMPOUND
HEAT SINK,ALUMINUM,EXTRUDED,FOR 1 TO-220,1.0
SMD HEAT SINK FOR D2PAK TO-263
POTTING TRAY
SELF TAPPING SCREW
EPOXY ENCAPSULTION RESIN
ELECTRICAL INSULATION COMPOUND
ON 3 PLACE DECIMALS IS ± .002
DRAWN BY:
ON ALL ANGLES IS ± .5 OF A DEGREE
MATERIAL TOLERANCE (" t ") TO AGREE
WITH PUBLISHED STANDARDS.
ENGINEER:
DO NOT SCALE THIS DRAWING
APPROVED:
REFERENCE:
G3632-2
SCALE:
.
NONE
EQUIPMENT TYPE:
SUBJECT:
MATERIAL
DISPOSITION:
UF
INVERTER WELDERS
DIGITAL POWER P.C. BOARD AS'BLY
APPROVAL
DATE:
9/30/2004
PROJECT
NUMBER:
CRM35510-B
1
1 OF ___
PAGE ___
DOCUMENT
REVISION:
DOCUMENT
NUMBER:
G3632-3
B
SOLID EDGE
Return to Master TOC
Return to Master TOC
D23
Q1
R11
C30
Q2
LED2
C43
Return to Section TOC
DZ8
D9
C36
R30
X4
C2
D17
C7
C24
DZ3
D21
C6
OCI3
X9
D3
X5
Return to Section TOC
ITEM (USED WITH)
1
2 (Q1, Q2)
3 (Q1, Q2)
4 (Q1, Q2)
5 (Q1, Q2)
6 (D16, X8)
7
8
9
10
REFER TO ELECTRONIC COMPONENT DATABASE FOR SPECIFICATIONS ON ITEMS LISTED BELOW
D19
Return to Master TOC
G-19
ELECTRICAL DIAGRAMS
G3632-3
Return to Section TOC
G-19
STRP
NOTE:
Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your factory warranty. Individual Printed Circuit Board Components are not available from Lincoln Electric.
This information is 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 455M/MSTT
Return to Master TOC
ELECTRICAL DIAGRAMS
G-20
SCHEMATIC - FEEDHEAD PC BOARD #1 (ROBOTIC MODEL ONLY) PG 1 OF 3 (G3823-3)
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-20
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
POWER WAVE 455M/MSTT
Return to Master TOC
ELECTRICAL DIAGRAMS
G-21
SCHEMATIC - FEEDHEAD PC BOARD #2 (ROBOTIC MODEL ONLY) PG 2 OF 3 (G3823-3)
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-21
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
POWER WAVE 455M/MSTT
Return to Master TOC
ELECTRICAL DIAGRAMS
G-22
SCHEMATIC - FEEDHEAD PC BOARD #3 (ROBOTIC MODEL ONLY) PG 3 OF 3 (G3823-3)
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-22
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
POWER WAVE 455M/MSTT
Return to Master TOC
PC BOARD ASSEMBLY - FEEDHEAD PC BOARD (ROBOTIC MODEL ONLY) (L11087-3)
ENGINEERING CONTROLLED
MANUFACTURER: Yes
CHANGE DETAIL: REVISED MAKE SPECIFICATION
2
ITEM
N.B.
3
N.D.
Return to Master TOC
N.E.
Return to Section TOC
G-23
ELECTRICAL DIAGRAMS
L11087-3
Return to Section TOC
G-23
N.C.
6.34
74
75
76
S25001-3320SMT
S25005-1SMT
S25001-4751SMT
6
2
4
77
S25000-4751SMT
12
78
79
80
81
82
83
84
85
86
87
88
89
90
91
92
93
94
95
96
97
98
99
100
101
102
103
104
105
106
107
108
S25001-1503SMT
S25000-1211SMT
S25000-2002SMT
S25007-9091SMT
S19869-8
S20375-8
S25068-7SMT
M15101-14SMT
S25069-2SMT
S20353-1SMT
S25070-6SMT
S17900-24SMT
S25069-24SMT
S25066-2SMT
S25057-3SMT
M15105-9ASM
S15128-21SMT
S15128-18SMT
S15128-16SMT
S15018-20SMT
M15104-15
S20353-5
S25065-2SMT
S20353-4SMT
S25068-8SMT
S25068-6SMT
S15128-25SMT
S17900-11SMT
S24841-1
S25082-1SMT
S25000-1000SMT
1
1
3
2
1
1
1
1
1
1
1
2
1
1
1
1
1
2
1
1
1
1
1
3
1
2
1
1
1
1
6
R139,R140,R141,R142,R143,R144
R97,R98
R99,R114,R132,R137
R101,R104,R125,R126,R127,
R128,R129,R130,R131,R133,
R134,R145
R115
R135
R146,R147,R76
R90,R109
S1
T1
X1
X2
X3
X4
X5
X7,X29
X9
X10
X11
X12
X13
X14,X20
X15
X16
X17
X18
X19
X21,X26,X27
X22
X23,X24
X25
X28
X30
Y1
R155,R156,R157,R158,R159,R160
RESISTOR,SMD,332ohms,1/4W,1206,1%
SRES,0.05,3W,1% ,TR,NP
SRES,4.75K,1206,1% ,1/8W,NP,(SM
N.D.
N.E.
SRES,4.75K,0805,1% ,TR,NP
SRES,150K,1206,1% ,1/8W,NP
SRES,1.21K,0805,1% ,1/10W,TR,NP
SRES,20K,TKF,0805,1% ,01/10W,TR
RESISTOR,SMD,9.09K,1/10W,0805,0.1%
SWT,78B08S,DIP,SPST,8P,NP
TFM,L5936,Noreast,Switching Pwr
SICS,4.6V,2% ,VOLT. DETECTOR
SICS,MC68332,MICRCONTROLLER,TQ
SICS,25128,SERIAL EEPR,NP
SICS,MC145407,RECEIVER/DRVR,RS
SICS,XC9572-15,CPLD,TQ100,NP
SICS,74HC132,NP
SICS, FLASH ROM, 16 x 256K, 70 NS
SICS,AD7862,DUAL,12BIT,250kSPS
SICS,AD8403ARU10,DIGITAL POT,NP
SICS,AD7945,12BIT,PARALLEL,DAC
SICS,LT1016,COMPARATOR,NP
SICS,MC33074,QUAD,OPAMP,S014,T
ICS,SMD,OP-AMP,QUAD,HIGH PERFORMANCE 1014
SICS,HIP4082,H-BRIDGE,FET DRIVE
IC,SMD,CMOS,RAM,STATIC,16-BIT,64K X 16
SICS,AN82527,CAN CONTROLLER,PL
SICS,74ACT573,OCTAL,TRANS. LAT
SICS,MAX485,TRANSCEIVER,NP
SICS,79L05,V-REG,-5V,SO8
SICS,78L05,V-REG,+5V,SO8
SICS,LM2576HVS-5.0,VREG,60V,SWI
SICS,74HC245,SOL20,HCMOS,NP
ICS,DC/DC,5V 3A OUT,36-75V IN
SXTL,16MHz,HC40,20pF,NP
RESISTOR,SMD,100,1/10W,0805,1%
UNLESS OTHERWISE SPECIFIED:
RESISTANCE = OHMS
Return to Master TOC
Return to Section TOC
N.F.
5.84
3
ALL COMPONENTS AND MATERIALS USED IN THIS
ASSEMBLY ARE TO BE RoHS COMPLIANT PER E4253
REVISION CONTROL
N.B.
L11087-3E0
NOTES:
N.A.
CAUTION: THIS DEVICE IS SUBJECT TO DAMAGE BY STATIC ELECTRICITY. LINCOLN ELECTRIC TO SEE
E2454 BEFORE HANDLING.
N.B.
SECURE PC BOARD ASSEMBLY IN PLACE WITH ITEM 4. (2 PLACES) TIGHTEN SCREWS TO A TORQUE OF
5.3±0.5 IN-LBS.
N.C.
PLACE BARCODED ASSEMBLY NUMBER IDENTIFICATION AND BARCODED SERIAL NUMBER
IDENTIFICATION IN AREA SHOWN.
PROGRAM ITEM 88 WITH ITEM 6 .
PROGRAM ITEM 90 WITH ITEM 7 .
PARTS INDICATED MUST BE COMPLETELY COVERED WITH ENCAPSULATION.
N.D.
N.E.
N.F.
PART NO. IDENTIFICATION
CODE
TEST PER E3856-FH
POT WITH E2527
SCHEMATIC REFERENCE: G3823-3E0
BUY DETAIL
BUY PER E3867
MAKE DETAIL
MANUFACTURE PER E1911-ROHS
BUY BLANK COMPLETE
(4 BOARDS PER PANEL)
4 LAYER BOARD BLANK PANEL
SEE ELECTRONIC FILE FOR ADDITIONAL INFORMATION.
PART NO.
PC BOARD REFERENCE
DESIGNATORS
QTY
1
2
3
L11087-E
M19436-5
S8025-80
1
1
2
195g
6.88 OZ.
AS REQ.
1
1
4
E2527
5
6
7
E3539
Y00552-5
S24823-5
8
S25024-2SMT
4
9
S25020-3SMT
47
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
S25024-8SMT
S25020-13SMT
S25024-5SMT
S25024-10SMT
S25020-2SMT
S25020-10SMT
S25020-9SMT
S25020-15SMT
S24833-1
S13490-179
S13490-182
S13490-184
S25020-4SMT
S25040-12SMT
S25040-2SMT
5
2
6
3
1
3
2
3
2
1
1
1
2
2
4
25
S25040-5SMT
10
26
27
28
29
30
31
32
33
S25049-4SMT
S25040-4SMT
S25040-11SMT
S25040-9SMT
S25040-10SMT
S25046-3SMT
S25046-1SMT
S25044-9SMT
4
5
4
1
1
4
3
6
DESCRIPTION
FEED HEAD PC BOARD BLANK
POTTING TRAY
SELF TAPPING SCREW
EPOXY ENCAPSULATING RESIN
ELECTRICAL INSULATING COMPOUND
SOFTWARE,CPLD
SOFTWARE,FLASH
X5
X9
FOR ITEMS LISTED BELOW REFER TO ELECTRONIC COMPONENT DATABASE FOR COMPONENT SPECIFICATIONS
34
S25044-1SMT
9
35
36
S25046-2SMT
S18380-5
4
2
37
S18380-14
12
38
39
40
41
42
43
44
45
46
47
S24020-4
S24020-6
S24020-8
S24020-16
S18248-10
S18248-16
S15000-28SMT
S15000-26SMT
S25051-4SMT
S25050-2SMT
2
1
1
1
1
1
4
1
5
5
48
S25050-1SMT
9
49
50
S25051-16SMT
S23060-1SMT
4
1
51
S25000-1002SMT
24
52
53
54
S25001-1002SMT
S25011-9092SMT
S25003-2000SMT
6
4
2
55
S25001-4750SMT
9
56
S25000-1001SMT
8
57
S25000-4750SMT
2
58
S25004-2430SMT
12
59
S25000-3320SMT
9
60
S25000-2210SMT
9
61
S25001-2000SMT
8
62
63
64
65
66
67
68
69
70
71
72
73
S25001-7500SMT
S25000-2213SMT
S25000-4752SMT
S25000-1003SMT
S25001-1001SMT
S25000-9092SMT
S25000-3921SMT
S25001-4753SMT
S25001-4752SMT
S25001-1000SMT
S25001-15R0SMT
S25001-1500SMT
1
1
2
6
1
2
1
2
2
3
2
4
C1,C2,C7,C50
C3,C4,C5,C6,C8,C9,C12,C14,
C15,C19,C20,C22,C25,
C26,C27,C28,C29,C30,C31,
C32,C34,C35,C38,C39,C41,
C43,C45,C46,C47,C48,C49,
C51,C54,C56,C57,C59,C60,
C64,C65,C69,C72,C75,C76,
C77,C78,C81,C82
C10,C11,C17,C18,C80
C13,C16
C23,C63,C66,C67,C68,C71
C24,C36,C73
C37
C40,C42,C44
C52,C79
C55,C58,C83
C61,C62
C70
C74
C84
C85,C86
D1,D12
D2,D17,D20,D27
D3,D4,D5,D6,D9,D18,D21,D28,D29,
D31
D7,D8,D10,D19
D11,D13,D14,D15,D16
D22,D23,D24,D25
D26
D30
DZ1,DZ2,DZ3,DZ4
DZ5,DZ28,DZ29
DZ6,DZ7,DZ8,DZ9,DZ26,DZ27
DZ10,DZ11,DZ12,DZ13,DZ14,
DZ15,DZ16,DZ17,DZ18
DZ20,DZ21,DZ22,DZ23
F1,F2
F3,F4,F5,F6,F7,F8,F9,F10,
F11,F12,F13,F14
J81,J82
J83
J84
J85
J86
J87
OCI1,OCI2,OCI3,OCI4
OCI5
Q1,Q12,Q13,Q15,Q16
Q2,Q3,Q7,Q14,Q17
Q4,Q5,Q6,Q19,Q20,Q21,Q22,Q23,Q
24
Q8,Q9,Q10,Q11
Q18
R2,R3,R4,R5,R6,R7,R9,R16,
R17,R18,R19,R20,R21,R22,
R23,R53,R54,R77,R80,R106,
R116,R138,R148,R149
R8,R10,R13,R83,R100,R118
R84,R85,R86,R152
R11,R12
R14,R15,R62,R68,R78,R102,
R103,R107,R112
R24,R25,R55,R105,R113,
R136,R153,R154
R26,R27
R28,R29,R30,R31,R32,R33,
R34,R35,R36,R37,R38,R39
R41,R42,R48,R49,R50,R51,
R52,R121,R123
R43,R44,R45,R46,R47,R65,
R108,R122,R124
R56,R57,R58,R61,R64,R66,
R110,R111
R1
R63
R67,R72
R69,R71,R73,R75,R82,R117
R70
R74,R81
R79
R87,R120
R88,R119
R89,R93,R96
R91,R92
R94,R95,R150,R151
SCAP,1uF,TAN,3528,35V,TR,NP
SCAP,0.1uF,0805,50V,X7R,10% ,TR
SCAP,10uF,TAN,6032,16V,10% ,TR,NP
SCAP,150pF,CER,0805,100V,COG,5% ,TR,NP
SCAP,4.7uF,TAN,7343,35V,10% ,TR,NP
SCAP,22uF,TAN,7343,25V,10% ,POLAR,TR
SCAP,0.022uF,0805,50V,X7R,10% ,
SCAP,4700pF,0805,50V,X7R,10% ,T
SCAP,47pF,0805,50V,COG,5% ,TR,N
SCAP,22pF,0805,50V,COG,5% ,TR,N
CAP,0.27uF,PCF,63V,5% ,TR,NP
CAP,1000uF,ALU,35V,20% ,NP
CAP,3300uF,ALU,63V,20% ,NP
CAP,330uF,100V
CAPACITOR ,SMD CERAMIC,820PF,50V,5% COG,S0805
SDIO,MURS320T3,3A,200V,ULTRAFA
SDIO,400V,0.8A,NP
SDIO,BAV99LT1,SOT23,DUAL SWITC
SDIO,BAT54S,DUAL/SERIES,30V,20
SDIO,BAW56LT1,SOT23,DUAL SWT,T
SDIO,MURS160,1A,600V,FAST RECO
SDIO,3A,200V,D0-214AB,UFR
DIODE,SMD,3A,400V
SDIO,MMSZ5248B,18V,ZENER,TR,NP
SDIO,MMSZ5231BT1,5.1V,NP
SDIO,1SMB5920BT3,6.2V,NP
SDIO,1SMB5918BT3,3W,5.1V,5% ,TR,NP
SDIO,MMSZ5240BT1,10V,500mW,ZEN
RES,50,VAR,PTC,NP
RES,500,PTC,265V
CON,MOLEX,15-97-7042,MINI,PCB,4 PIN,TIN
CON,MOLEX,15-97-7062,MINI,PCB,6 PIN,TIN
CON,MOLEX,15-97-7082,MINI,PCB,8 PIN,TIN
CON,MOLEX,15-97-7162,MINI,PCB,16 PIN,TIN
CON,10P,MINI,NP
CON,MOLEX,39-28-1163,PCB,16 PIN,TIN
SICS,Optocoupler, HCPL-0601 (SO-8)
SICS,HCPL-0201,OPTOCOUPLE
STRA,2N7002,TR,NP, (SM400-020)
STRA,2N4403,SO23,TR,(500475),N
STRA,2N4401,SOT-23,NPN,TR,
STRA,75A,55V,0.007 OHM FET,N-CHAN
IC,SMD,SWITCH,LO-SIDE,2.2A60V,
SRES,10K,0805,1% ,1/10W,TR,NP
SRES,10K,MF,1206,1% ,1/8W,TR
RESISTOR,SMD,90.9K,1/4W,1206,0.1%
SRES,200,2512,5% ,1W,TR,NP
SRES,475,1206,1% ,1/8W,TR,NP
SRES,1K,0805,1% ,1/10W,TR,NP
SRES,475,0805,1% ,TR,NP
SRES,243,WSC-1,1% ,1W,TR,NP
SRES,332,0805,1% ,1/10W,TR,NP
SRES,221,TKF,0805,1% ,1/10W,TR
SRES,200,1206,1% ,1/8W,TR,NP
RESISTOR,SMD,750ohms,1/4W,1206,1%
SRES,221K,TKF,0805,1% ,01/10W,TR
SRES,47.5K,TKF,0805,1% ,01/10W,TR
SRES,100K,TKF,0805,1% ,01/10W,TR
SRES,1K,1206,1% ,1/8W,TR,NP,(09
SRES,90.9K,TKF,0805,1% ,1/10W
SRES,3.92K,TKF,0805,1% ,1/10W,TR
SRES,475K,1206,1% ,1/8W,TR,NP
SRES,47.5K,1206,1% ,1/8W,TR,NP
SRES,100,1206,1% ,1/8W,TR,NP
SRES,15,1206,1% ,1/8W,TR,NP
SRES,150,1206,1% ,1/8W,TR,NP
DO NOT SEND THIS ASSEMBLY.
SEND THE APPROPRIATE
HARDWARE/SOFTWARE ASSEMBLY ONLY
Return to Master TOC
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 2 PLACE DECIMALS IS ± .02
L11087-2
SCALE:
DRAWN BY:
JIMJ
ON ALL ANGLES IS ± .5 OF A DEGREE
MATERIAL TOLERANCE (" t ") TO AGREE
WITH PUBLISHED STANDARDS.
ENGINEER:
DRS
DO NOT SCALE THIS DRAWING
APPROVED:
ON 3 PLACE DECIMALS IS ± .002
-
1:1
EQUIPMENT TYPE:
SUBJECT:
MATERIAL
DISPOSITION:
UF
COMMON DIGITAL CONTROLS
FEED HEAD PC BOARD ASSEMBLY
APPROVAL
9/18/2006
DATE:
PROJECT
NUMBER:
CRM34409
1
1 OF ___
PAGE ___
DOCUMENT
NUMBER:
L11087-3
DOCUMENT
REVISION:
C.01
SOLID EDGE
Return to Section TOC
FOR PARTS ORDERS ONLY:
STRP
NOTE:
Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your factory warranty. Individual Printed Circuit Board Components are not available from Lincoln Electric.
This information is 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 455M/MSTT
Return to Master TOC
ELECTRICAL DIAGRAMS
G-24
SCHEMATIC - INPUT PC BOARD (ALL CODES) (M19528-2)
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-24
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
POWER WAVE 455M/MSTT
Return to Master TOC
G-25
ELECTRICAL DIAGRAMS
PC BOARD ASSEMBLY - INPUT PC BOARD (ALL CODES) (L11396-2)
L11396-2
Return to Section TOC
G-25
CHANGE DETAIL: REVISED MAKE SPECIFICATION
ENGINEERING CONTROLLED
MANUFACTURER: No
REFERENCES
C1
CR1, CR2
D1, D3
D2
N.C. J60
N.C. J61
OCI1
R1, R2, R3, R6, R7, R8, R9, R10
R4
R5
R11,
R17,
R23,
TP1,
P.C. BOARD BLANK INFORMATION
BUY COMPLETE AS L11396-B
( 2 LAYER BOARD PER E3281)
Return to Master TOC
N.D.
4.50 ±.04
XXXXXXXX
INPUT
J61
J60
Return to Master TOC
TP1
XXX X
X
X
X
R9
X
X
X
X
XXX X
X
N.B.
S19400-2673
S19400-4750
S19400-3011
267K 1/4W
475 1/4W
3.01K 1/4W
T13640-23
MOV,250J,660V
REQ'D
1
1.0 OZ.
2
PART NO.
IDENTIFICATION
SEE BLANK INFO. P.C. BD. BLANK
E2861
SEALANT
S14020-7
PLASTIC EXPANSION NUT
R5
C1
4
DESCRIPTION
.022/50
DPST RELAY
1N4004
DIODE,1.0A,1500V
HEADER,VERTICAL
HEADER,VERTICAL
OPTO ISOLATOR
100/1OW
D2
TP2
1
R4
TP4
TP3
Return to Section TOC
ITEM
1
2
3
XXXXXXX
D1
R22
1
1
15
R13, R14, R15, R16,
R19, R20, R21, R22,
R25
TP3, TP4
PART NO.
S16668-5
S14293-18
T12199-1
T12705-58
S24020-8
S24020-10
S15000-22
S24376-3
3
N.D.
N.A.
D3
Return to Section TOC
(MAKES 8 BOARDS PER PANEL, SEE ELECTRONIC FILE
FOR ADDITIONAL INFORMATION)
R12,
R18,
R24,
TP2,
QTY
1
2
2
1
1
1
1
8
R24
R25
R23
R21
R20
R19
R18
R11
R12
R13
R14
R15
R16
R17
R7
R6
R8
R3
R10
OCI1
CAPACITORS = MFD / VOLTS
X
X
X
X
X
X
X
X
X
X
RESISTORS = OHMS/WATTS
CR1
CR2
X
X
X
X
R1
R2
X
X
X
X
N.A.
THIS AREA TO BE COVERED ON BOTH SIDES OF BOARD WITH ITEM 2 PRIOR TO
ENCAPSULATION. MATERIAL MUST BE APPLIED THRU SLOTS FROM BOTTOM
SIDE TO COMPLETELY FILL TO UNDERSIDE OF DEVICE ON COMPONENT SIDE.
N.B.
P.C. BOARD HOLES TO BE FREE OF ENCAPSULATION MATERIAL.
N.C.
DO NOT COAT WITH ENCAPSULATION MATERIAL.
N.D.
APPLY ITEM 2 AS SHOWN, ALL EXPOSED LEADS MUST BE COVERED. MATERIAL
MUST BE APPLIED PRIOR TO ENCAPSULATION.
N.E.
APPLY ITEM 2 ON NON-COMPONENT SIDE OF BOARD PRIOR TO
ENCAPSULATION. ALL EXPOSED PINS MUST BE COVERED.
L11396-2
0
0
N.D.
N.D.
6.00 ±.04
MAKE PER E1911-ROHS
ENCAPSULATE WITH E1844
TEST PER E3647-I
SCHEMATIC REFERENCE: M19528-2B0
MANUFACTURED AS:
L11396-2B0
Return to Master TOC
ALL COMPONENTS AND MATERIALS USED IN THIS
ASSEMBLY ARE TO BE RoHS COMPLIANT PER E4253.
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 2 PLACE DECIMALS IS ± .02
L11396-1
SCALE:
ON 3 PLACE DECIMALS IS ± .002
DRAWN BY:
ON ALL ANGLES IS ± .5 OF A DEGREE
MATERIAL TOLERANCE (" t ") TO AGREE
WITH PUBLISHED STANDARDS.
ENGINEER:
DO NOT SCALE THIS DRAWING
APPROVED:
FEI
-
1:1
EQUIPMENT TYPE:
SUBJECT:
MATERIAL
DISPOSITION:
UF
INVERTER WELDERS
INPUT P.C. BOARD ASSEMBLY
APPROVAL
DATE:
PROJECT
NUMBER:
CRM34409
1
1 OF ___
PAGE ___
DOCUMENT
NUMBER:
L11396-2
DOCUMENT
REVISION:
B.01
SOLID EDGE
Return to Section TOC
IDENTIFICATION CODE
STRP
NOTE:
Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your factory warranty. Individual Printed Circuit Board Components are not available from Lincoln Electric.
This information is 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 455M/MSTT
Return to Master TOC
ELECTRICAL DIAGRAMS
G-26
SCHEMATIC - SWITCH PC BOARD (ALL CODES) (L11385-3)
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-26
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
POWER WAVE 455M/MSTT
Return to Master TOC
G-27
ELECTRICAL DIAGRAMS
PC BOARD ASSEMBLY - SWITCH PC BOARD (ALL CODES) (G3734-3)
G3734-3
Return to Section TOC
G-27
ENGINEERING CONTROLLED
MANUFACTURER: No
CHANGE DETAIL: REVISED MAKE SPECIFICATION
ITEM (USED WITH)*
1
N.D. 2 (B11, B19, B20)*
N.X. 3
4
P.C. BOARD BLANK REFERENCE INFORMATION
NOTES :
BUY COMPLETE AS G3734-E (4 LAYER BOARD PER E3281)
N.A. CAUTION: THIS DEVICE IS SUBJECT TO DAMAGE BY STATIC
ELECTRICITY. SEE E2454 BEFORE HANDLING.
N.D.
N.A.,N.J.,N.R.
2
N.E. SOLDER EYELET SO THAT SOLDER COVERS ENTIRE EYELET AND
ALL AROUND EYELET ON COPPER SIDE ONLY. NO ICICLES OR
SOLDER BLOBS PERMITTED. MUST BE SMOOTH AND EVEN WITHIN .020" OVER SURFACE.
N.H. MOLEX CAVITIES AND AREA AROUND LOCKING TAB TO BE FREE OF ENCAPSULATION MATERIAL.
MASK PER APPROPRIATE MANUFACTURING WORK INSTRUCTIONS.
N.J. ELECTRONIC MODULES TO BE ASSEMBLED, SOLDERED, AND SEALED TO PC BOARD PER E3875.
.116
N.Q.
N.Q.
.275
.285
R .045
MAX.
CRIMP HEIGHT
N.M. DO NOT COAT THE TOP SURFACES OR THE THREADS WITH ENCAPSULANT MATERIAL (1 TERMINAL).
MASK PER APPROPRIATE MANUFACTURING WORK INSTRUCTIONS.
COPPER SIDE
N.Q. BRACKET MUST HAVE FULL MATING CONTACT WITH POWER TERMINAL AND HAVE HOLES ALIGNED.
EYELET DETAIL
N.R. ELECTRONIC MODULES ON A COMMON P.C. BOARD ASSEMBLY TO
HAVE THE SAME VENDOR CODE.
VGE(TH)
N.S. AFTER SOLDERING, INSPECT TERMINAL CONNECTIONS PER E1880.
N.T. ENCAPSULATE COMPONENT SIDE OF P.C. BOARD TO A THICKNESS OF .30 +.12/-.00 IN AREA SHOWN.
N.U. ENCAPSULATE NON COMPONENT SIDE OF P.C. BOARD TO A THICKNESS OF .25 +.12/-.00.
N.V. ENCAPSULATION MATERIAL MUST EXTEND BEYOND EDGES OF P.C. BOARD .12 +.12/-.00.
N.W. ENCAPSULATE OPPOSITE COMPONENT SIDE OF P.C. BOARD IN AREAS SHOWN TO A MAXIMUM THICKNESS OF .20.
N.X.
N.W.
N.X.
N.X.
3
N.X.
6.00 ±.04
SH1
Return to Master TOC
VENDOR CODE
VCE(SAT)
C5
C1
C8
C9
X2
DESCRIPTION
PC BOARD BLANK
CONNECTOR,EYELET,POWER,FEMALE
PC BOARD SHIELD
EPOXY ENCAPSULATING RESIN
REFERENCES
A1, A2
B11, B19, B20
B13
B14
C1
C2
C3
C4, C6, C7
C5
C8, C9, C10, C11, C12,
C13, C14, C15, C16, C17
D1, D2
D3, D4, D5, D6, D7, D8,
D9, D10, D11, D12
DZ1
DZ2, DZ3, DZ5, DZ6
DZ4, DZ7
J40
L1, L2, L3, L4, L5, L6, L7,
L8, L9, L10
OCI1
R1
R2
R3, R8
R4, R13, R14, R17, R18,
R19, R20, R21, R23, R24,
R25, R26, R27
R5, R9
R6
R7
R10, R12, R15
R11
R16, R22
R28, R29, R30, R31, R32
SH1
T1
T2
X1
X2
QTY
2
3
1
1
1
1
1
3
1
PART NUMBER
M21214-2
T9147-15
S24866
S23006
S20500-14
S16668-11
S16668-5
S16668-6
S13490-93
DESCRIPTION
ELECTRONIC MODULE,5-T12704-84 IGBT'S
CONNECTOR,EYELET,POWER,MALE
BRACKET,POWER-HOLDER
CONNECTOR,TERMINAL,POWER
CAPACITOR,PPMF,.022,100V,BOX,5%
CAPACITOR,CEMO,0.1, 50V,10%
CAPACITOR,CEMO,.022,50V,20%
CAPACITOR,CEMO,4700pF,50V,10%
CAPACITOR,TAEL,27,35V,10%
10
S20500-1
CAPACITOR,PPMF,0.1,1000V,10%,BOX
2
T12705-44
DIODE,AXLDS,1A,1000V,FR, 818
10
T12705-32
DIODE,TO220,15A,600V,FR,MUR1560
1
4
2
1
T12702-4
T12702-29
T12702-40
S24020-6
ZENER DIODE,1W,20V,5%,1N4747A
ZENER DIODE,1W,15V,5%,1N4744A
ZENER DIODE,1W,6.2V,5%,1N4735A
CONNECTOR,MOLEX,MINI,PCB,6-PIN,TIN
10
T12218-15
CHOKE,RF,FERRITE BEAD,180 OHM
1
1
1
2
S15000-22
S16296-5
S19400-6811
S19400-1002
OPTOCOUPLER,PHOTO-Q,70V,CNY17-3/VDE
TRIMMER,MT,1/2W,10K, 10%,LINEAR
RESISTOR,MF,1/4W,6.81K,1%
RESISTOR,MF,1/4W,10.0K,1%
13
S19400-10R0
RESISTOR,MF,1/4W,10.0,1%
2
1
1
3
1
2
5
1
1
1
1
1
S19400-2001
S19400-2213
S19400-1000
S19400-1003
S19400-6191
S19400-1001
T14648-9
S24869-1
T12737-7
M19612
M13552-3
S15128-10
RESISTOR,MF,1/4W,2.00K,1%
RESISTOR,MF,1/4W,221K,1%
RESISTOR,MF,1/4W,100,1%
RESISTOR,MF,1/4W,100K,1%
RESISTOR,MF,1/4W,6.19K,1%
RESISTOR,MF,1/4W,1.00K,1%
RESISTOR,WW,5W,2.5K,5%,SQ
PC BOARD SHIELD,0.75 X 1.35
TRANSFORMER,PULSE,3-WINDING
CURRENT-TRANSDUCER,125-TURN
IC,CONVERTER,V/F,654
VOLTAGE REF,ADJ, PRECISION,431I
.30 +.12
-.00
C2
D1
R4
C10
C11
C12
B11
11/12
OR
15/16
Return to Section TOC
e.g. M21214-2 X XX XXX......
N.X. BOTH P.C. BOARD SHIELDS SOLDER INTO THE SAME MOUNTING HOLES. ITEM 3 IS MOUNTED ON NON-COMPONENT SIDE
OF P.C. BOARD.
PART NUMBER
G3734-E
T9147-11
S24869-2
E2527
REFER TO ELECTRONIC COMPONENT DATABASE FOR SPECIFICATIONS ON ITEMS LISTED BELOW
(SEE ELECTRONIC FILE FOR ADDITIONAL INFORMATION)
N.D. FEMALE EYELET TO BE AGAINST THE COPPER SIDE AS SHOWN.
EYELET MUST NOT SPIN AFTER CLINCHING.
QTY
1
3
1
280 g.
X1
R9
R2
R8
D3
D4
D5
D6
D7
R10
R1
R3
R11
C3
R12
A1
R5
R15
DZ3
OCI1
DZ2
C6
DZ4
L4
L3
L2
R16
L1
N.H.
R13
R17
C4
R18
R6
R19
R7
R20
DZ1
B20
20
L5
R21
DZ5
R 1.62
C7
T1
DZ6
3.00
R30
R29
R28
R14
R26
R25
R24
L10
L9
L8
L7
N.M., N.S.,N.Q.
N.E.
(3 PLACES)
J40
R23
L6
R22
D2
B14
SWITCH
G3734-3
1
A2
T2
B13
D8
D9
D10
D11
D12
R32
N.Q.
C13
C14
C15
C16
C17
Return to Master TOC
R27
2
R31
B19
19
Return to Section TOC
DZ7
.30 +.12
-.00
0
N.W.
N.W.
.00
1.20
1.38 +.12
-.00
N.T.,N.U.,N.V.
2.00 ±.12
11.15 ±.04
MAKE PER E1911-ROHS
POT PER E1911-E
TEST PER E3901-SW
NON COMPONENT
SIDE ENCAPSULATION
SCHEMATIC REFERENCE: L11385-3E0
MANUFACTURED AS:
G3734-3E0
{
ALL COMPONENTS AND MATERIALS USED IN THIS
ASSEMBLY ARE TO BE RoHS COMPLIANT PER E4253.
P.C. BOARD
FOR PARTS ORDERS OR SUBSIDIARY ORDERS
INCLUDE ONE G3010PRINT, ONE M19661PRINT,
ONE S25254PRINT AND ONE T12837-1.
N.W.
COMPONENT SIDE
ENCAPSULATION
THIS DOCUMENT CONTAINS PROPRIETARY INFORMATION OWNED BY LINCOLN GLOBAL, INC. AND MAY NOT BE DUPLICATED, COMMUNICATED
PROPRIETARY & CONFIDENTIAL:
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
ON 2 PLACE DECIMALS IS ± .02
ON 3 PLACE DECIMALS IS ± .002
DRAWN BY:
ON ALL ANGLES IS ± .5 OF A DEGREE
MATERIAL TOLERANCE (" t ") TO AGREE
WITH PUBLISHED STANDARDS.
ENGINEER:
DO NOT SCALE THIS DRAWING
APPROVED:
FEI
REFERENCE:
G3734-2
SCALE:
-
1:1
INVERTER WELDERS
SWITCH P.C. BD ASSEMBLY
EQUIPMENT TYPE:
SUBJECT:
MATERIAL
DISPOSITION:
UF
APPROVAL
DATE:
PROJECT
NUMBER:
CRM34409
1
1 OF ___
PAGE ___
DOCUMENT
NUMBER:
G3734-3
DOCUMENT
REVISION:
B.01
SOLID EDGE
Return to Master TOC
Return to Section TOC
IDENTIFICATION CODE
STRP
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
POWER WAVE 455M/MSTT
Return to Master TOC
ELECTRICAL DIAGRAMS
G-28
SCHEMATIC - VOLTAGE SENSE PC BOARD (ROBOTIC MODEL ONLY) (S24779-3)
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-28
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
POWER WAVE 455M/MSTT
Return to Master TOC
PC BOARD ASSEMBLY - VOLTAGE SENSE PC BOARD (ROBOTIC MODEL ONLY) (M19540-3)
CHANGE DETAIL: REVISED MAKE SPECIFICATION
ENGINEERING CONTROLLED
MANUFACTURER: No
N.A.
N.A.
P.C. BOARD BLANK INFORMATION
BUY COMPLETE AS M19540-C
( 2 LAYER BOARD PER E3281)
Return to Master TOC
Return to Section TOC
G-29
ELECTRICAL DIAGRAMS
M19540-3
Return to Section TOC
G-29
ITEM
REQD
C1
D1
1
1
S20500-4
T12199-1
.0047 1000V
1N4004
J1
J2
L1
1
1
1
S24020-6
S24020-2G
T12218-7
HEADER
HEADER
330uH
OCI1,OCI2
R1,R2
R3
TP1,TP2
2
2
1
2
S15000-20
S19400-4750
S18380-1
T13640-18
PHOTO FET
475 1/4W
THERMISTOR,PTC
160J
PART NO.
IDENTIFICATION
CAPACITORS = MFD/VOLTS
RESISTORS = OHMS
INDUCTANCE = HENRYS
(MAKES 54 BOARDS PER PANEL, SEE ELECTRONIC FILE
FOR ADDITIONAL INFORMATION)
ITEM
1
REQD
1
PART NO.
SEE BLANK INFO
DESCRIPTION
P.C. BOARD BLANK
SCHEMATIC REFERENCE: S24779-3CO
N.A. DO NOT COAT WITH ENCAPSULATION MATERIAL.
.20
N.B. DO NOT COAT WITH ENCAPSULATION MATERIAL
.23 MIN. DIA. (3 PLACES) ON NON COMPONENT SIDE.
1.80
N.A.
1.75
1.55
M19540-3
0
J2
TP1
R2
TP2
C1
L1
R1
1.00
MAKE PER E1911-ROHS
ENCAPSULATE WITH E1844 (2 DIPS)
TEST PER E3689-VS
D1
R3
MANUFACTURED AS
OCI1
.20
0
VOLTAGE SENSE SELECT
J1
OCI2
Return to Master TOC
Return to Section TOC
±.04
N.B.
±.04
2.00
M19540-3CO
}
IDENTIFICATION CODE
ALL COMPONENTS AND MATERIALS USED IN THIS
ASSEMBLY ARE TO BE RoHS COMPLIANT PER E4253.
UNLESS OTHERWISE SPECIFIED TOLERANCE
MANUFACTURING TOLERANCE PER E2056 DESIGN INFORMATION
REFERENCE:
ON 2 PLACE DECIMALS IS ± .02
FEI
M19540-2
SCALE:
-
1:1
ON 3 PLACE DECIMALS IS ± .002
DRAWN BY:
ON ALL ANGLES IS ± .5 OF A DEGREE
MATERIAL TOLERANCE (" t ") TO AGREE
WITH PUBLISHED STANDARDS.
ENGINEER:
DO NOT SCALE THIS DRAWING
APPROVED:
EQUIPMENT TYPE:
SUBJECT:
MATERIAL
DISPOSITION:
UF
COMMON DIGITAL CONTROLS
VOLTAGE SENSE PC BRD AS'BLY
APPROVAL
DATE:
PROJECT
NUMBER:
CRM34409
1
1 OF ___
PAGE ___
DOCUMENT
NUMBER:
M19540-3
DOCUMENT
REVISION:
C.01
SOLID EDGE
Return to Master TOC
Return to Section TOC
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.
STRP
NOTE:
Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your factory warranty. Individual Printed Circuit Board Components are not available from Lincoln Electric.
This information is 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 455M/MSTT
Return to Master TOC
ELECTRICAL DIAGRAMS
G-30
SCHEMATIC - 40 VDC BUS PC BOARD (ALL CODES) (M19330-2)
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-30
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
POWER WAVE 455M/MSTT
ENGINEERING CONTROLLED
MANUFACTURER: No
CHANGE DETAIL: REVISED MAKE SPECIFICATION
P.C. BOARD BLANK INFORMATION
BUY COMPLETE AS L11078-C (4 LAYER BOARD PER E3281)
MAKES 12 BOARDS PER PANEL. PANEL SIZE PER E1911.
(SEE ELECTRONIC FILE FOR ADDITIONAL INFORMATION)
Return to Master TOC
Return to Section TOC
.37 MIN.
POTTING DIMENSIONS
.13 TYP.
N.C.
N.F.
3.85 ±.04
N.C.
DC BUSS
4.30
L11078-2
REFERENCE
N.A., N.B., N.D. A1
C1
C2, C3, C5
C6
C7, C8, C9, C10
C11, C17
C13
C14
C15
C16
D1
D2
D3
D4
D5
DZ4
DZ5, DZ6
J46
J47
L1
LED1
MOV1
R3, R4, R5, R7, R8
R9, R10, R11
R12, R13
R14, R22
R15, R16
R19
R20, R21
R23
R25
R26, R27
R28
R29
N.A. X1
N.A. X2
3.65
J47
ITEM
1
3
4
C13
L1
C2
R20
C16
DZ5
R16
R15
C7
C8
R29
D4
0 .20
C5
N.E.
4.50 ±.04
1
PART NO.
DESCRIPTION
SEE BLANK INFO. P.C. BOARD BLANK
E2527
EPOXY ENCAPSULATION RESIN
E2861
SEALANT
MANUFACTURED AS:
ALL COMPONENTS AND MATERIALS USED IN THIS
ASSEMBLY ARE TO BE RoHS COMPLIANT PER E4253.
L11078-2C0
}
MAKE PER E1911-ROHS
POT PER E1911-E
TEST PER E3862
SCHEMATIC REFERENCE - M19330-2C0
DZ4
C6
D2
X2
C10
R12
C9
X1
R14
R13
R25
R10
C11
R21
C14
R9
D3
R23
C17
DZ6
C1
C3
.20
0
REQ'D
1
100 g.
.75 oz.
N.A. CAUTION: THIS DEVISE IS SUBJECT TO DAMAGE BY STATIC ELECTRICITY.
SEE E2454 BEFORE HANDLING.
N.B. COVER EXPOSED BOTTOM SURFACE OF ELECTRONIC MODULE TO AVOID
POTTING MATERIAL BUILD UP.
N.C. MOLEX CAVITIES AND AREA AROUND TAB TO BE FREE OF POTTING
MATERIAL. MASK PER APPROPRIATE MANUFATURING WORK INSTRUCTIONS.
N.D. ELECTRONIC MODULES TO BE ASSEMBLED AND ENCAPSULTED PER E3875.
N.E. COMPLETELY COVER EXPOSED LEADS AND BODY OF R25 RESISTOR WITH
ITEM 4 SEALANT.
N.F. COVER EXPOSED LEADS OF C15 CAPACITOR WITH ITEM 4 SEALANT.
D1
R27
D5
DESCRIPTION
ELECTRONIC MODULE,2 MOSFETS(T12704-71)WITH 1DIO
CAPACITOR,TAEL,27,35V,10%
CAPACITOR,TAEL,4.7,35V 10%
CAPACITOR,TAEL,47,35V 10%
CAPACITOR,CEMO,0.1, 50V,10%
CAPACITOR,CEMO,4700P, 50V,2%
CAPACITOR,PPMF,0.47,630V,10%,BOX
CAPACITOR,CEMO,100P, 100V,5%
CAPACITOR,ALEL,470,100V,+50/-10%, LOW PROFILE
CAPACITOR,TAEL,1.0,35V,10%
DIODE,AXLDS,1A,1000V
DIODE,AXLDS,1A,400V
DIODE,AXLDS,3A,600V,UFR
DIODE,SCHOTTKY,AXLDS,1A,30V,1N5818
DIODE,AXLDS,1A,400V,FR,1N4936
ZENER DIODE,5W,20V,5% 1N5357B
ZENER DIODE, 1W,18V,5% 1N4746A
CONNECTOR,MOLEX,MINI,PCB,4-PIN,TIN
CONNECTOR,MOLEX,MINI,PCB,8-PIN,TIN
CHOKE,HIGH-CURRENT,100UH,10A,10%, LOW PROFILE
LED,T-1,3/4,RED,HLMP-3003
MOV,50VRMS,15J,14MM
RESISTOR,MF,1/4W,10.0K,1%
RESISTOR,MF,1/4W,8.25K,1%
RESISTOR,MF,1/4W,100,1%
RESISTOR,MF,1/4W,1.82K,1%
RESISTOR,MF,1/4W,47.5,1%
RESISTOR,MF,1/4W,56.2K,1%
RESISTOR,MF,1/4W,26.7K,1%
RESISTOR,MF,1/4W,221K,1%
RESISTOR,WW,5W,270,5%,SQ
RESISTOR,WW,3W,0.05,1%
RESISTOR,MF,1/4W,47.5K ,1%
RESISTOR,MF,1/4W,332K,1%
IC,PWM-CONTROLLER,IMODE,2842A
IC,CMOS,DRIVER,MOSFET,2110(SS)
1A
R11
R3
R22
R19
Return to Master TOC
Return to Section TOC
R26
C15
MOV1
R7
R8
R28
PART NO.
M21214-6
S13490-93
S13490-25
S13490-66
S16668-11
S16668-10
S20500-2
S16668-3
S13490-174
S13490-42
T12199-2
T12199-1
T12705-59
T12705-23
T12705-34
T12702-25
T12702-45
S24020-4
S24020-8
T12218-16
T13657-2
T13640-15K
S19400-1002
S19400-8251
S19400-1000
S19400-1821
S19400-47R5
S19400-5622
S19400-2672
S19400-2213
T14648-17
T12300-86
S19400-4752
S19400-3323
M15458-4
S15018-16
CAPACITOR = MFD/VOLTS
RESISTORS = OHMS, 1/4 WATT (UNLESS OTHERSIDE SPECIFIED)
J46
LED1
R4
R5
QTY
1
1
3
1
4
2
1
1
1
1
1
1
1
1
1
1
2
1
1
1
1
1
5
3
2
2
2
1
2
1
1
2
1
1
1
1
IDENTIFICATION CODE
Return to Master TOC
FOR PARTS ORDERS ONLY:
INCLUDE (1) S25191PRINT AND (1) T12837-1
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 2 PLACE DECIMALS IS ± .02
L11078-1
SCALE:
ON 3 PLACE DECIMALS IS ± .002
DRAWN BY:
ON ALL ANGLES IS ± .5 OF A DEGREE
MATERIAL TOLERANCE (" t ") TO AGREE
WITH PUBLISHED STANDARDS.
ENGINEER:
DO NOT SCALE THIS DRAWING
APPROVED:
FEI
-
NONE
EQUIPMENT TYPE:
SUBJECT:
MATERIAL
DISPOSITION:
UF
MULTI-WELD 350
40V DC BUS P.C. BOARD ASSEMBLY
APPROVAL
DATE:
PROJECT
NUMBER:
CRM34409
1
1 OF ___
PAGE ___
DOCUMENT
NUMBER:
L11078-2
DOCUMENT
REVISION:
B.01
SOLID EDGE
Return to Master TOC
PC BOARD ASSEMBLY - 40 VDC BUS PC BOARD (ALL CODES) (L11078-2)
.50 MAX.
Return to Section TOC
G-31
ELECTRICAL DIAGRAMS
L11078-2
Return to Section TOC
G-31
STRP
NOTE:
Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your factory warranty. Individual Printed Circuit Board Components are not available from Lincoln Electric.
This information is 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 455M/MSTT