SVM181-A
January, 2008
POWER WAVE 355M/405M
For use with machine code numbers 11141, 11142
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Lincoln arc welding and cutting
equipment is designed and built
with safety in mind. However,
your overall safety can be
5
5
increased by proper installation
. . . and thoughtful operation on
your part. DO NOT INSTALL,
OPERATE OR REPAIR THIS
EQUIPMENT WITHOUT READ-
ING THIS MANUAL AND THE
SAFETY PRECAUTIONS CON-
TAINED THROUGHOUT. And,
most importantly, think before
you act and be careful.
3
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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: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com
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ii
ii
SAFETY
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.
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.
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:
FUMES AND GASES
can be dangerous.
5.a. Welding may produce fumes and gases
hazardous to health. Avoid breathing these
• Semiautomatic DC Constant Voltage (Wire) Welder.
• DC Manual (Stick) Welder.
fumes and gases.When welding, keep
your head out of the fume. Use enough
• AC Welder with Reduced Voltage Control.
ventilation and/or exhaust at the arc to keep
3.c. In semiautomatic or automatic wire welding, the electrode,
electrode reel, welding head, nozzle or semiautomatic
welding gun are also electrically “hot”.
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.
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.
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
3.g. Never dip the electrode in water for cooling.
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.
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.
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 prod-
ucts.
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.
5.d. Shielding gases used for arc welding can displace air and
cause injury or death. Always use enough ventilation,
especially in confined areas, to insure breathing air is safe.
5.e. Read and understand the manufacturer’s instructions for this
equipment and the consumables to be used, including the
material safety data sheet (MSDS) and follow your
employer’s safety practices. MSDS forms are available from
your welding distributor or from the manufacturer.
5.f. Also see item 1.b.
Aug ‘06
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iii
iii
SAFETY
WELDING SPARKS can
cause fire or explosion.
CYLINDER may explode
if damaged.
6.a. Remove fire hazards from the welding area.
If this is not possible, cover them to prevent
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.
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.
7.b. Always keep cylinders in an upright position securely
chained to an undercarriage or fixed support.
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.
7.c. Cylinders should be located:
•Away from areas where they may be struck or subjected to
physical damage.
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.
•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.
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).
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.
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.
FOR ELECTRICALLY
powered equipment.
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.
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.
6.h. Also see item 1.c.
8.c. Ground the equipment in accordance with the U.S. National
Electrical Code and the manufacturer’s recommendations.
Mar ‘95
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iv
iv
SAFETY
6. Eloigner les matériaux inflammables ou les recouvrir afin de
PRÉCAUTIONS DE SÛRETÉ
prévenir tout risque d’incendie dû aux étincelles.
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 suiv-
antes:
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.
Sûreté Pour Soudage A LʼArc
1. Protegez-vous contre la secousse électrique:
a. Les circuits à l’électrode et à la piéce sont sous tension
quand la machine à souder est en marche. Eviter toujours
tout contact entre les parties sous tension et la peau nue
ou les vétements mouillés. Porter des gants secs et sans
trous pour isoler les mains.
b. Faire trés attention de bien s’isoler de la masse quand on
soude dans des endroits humides, ou sur un plancher met-
allique 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 defonc-
tionnement.
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.
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.
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.
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.
PRÉCAUTIONS DE SÛRETÉ POUR
LES MACHINES À SOUDER À
TRANSFORMATEUR ET À
REDRESSEUR
2. Dans le cas de travail au dessus du niveau du sol, se protéger
contre les chutes dans le cas ou on recoit un choc. Ne jamais
enrouler le câble-électrode autour de n’importe quelle partie du
corps.
3. Un coup d’arc peut être plus sévère qu’un coup de soliel, donc:
a. Utiliser un bon masque avec un verre filtrant approprié ainsi
qu’un verre blanc afin de se protéger les yeux du rayon-
nement de l’arc et des projections quand on soude ou
quand on regarde l’arc.
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.
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.
2. Autant que possible, I’installation et l’entretien du poste seront
effectués par un électricien qualifié.
3. Avant de faires des travaux à l’interieur de poste, la debranch-
er à l’interrupteur à la boite de fusibles.
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, pan-
talons sans revers, et chaussures montantes.
4. Garder tous les couvercles et dispositifs de sûreté à leur place.
5. Toujours porter des lunettes de sécurité dans la zone de
soudage. Utiliser des lunettes avec écrans lateraux dans les
zones où l’on pique le laitier.
Mar ‘93
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v
v
SAFETY
Electromagnetic Compatibility (EMC)
Conformance
Products displaying the CE mark are in conformity with European Community Council Directive of 3 May
1989 on the approximation of the laws of the Member States relating to electromagnetic compatibility
(89/336/EEC). It was manufactured in conformity with a national standard that implements a harmonized
standard: EN 60974-10 Electromagnetic Compatibility (EMC) Product Standard for Arc Welding Equipment.
It is for use with other Lincoln Electric equipment. It is designed for industrial and professional use.
Introduction
All electrical equipment generates small amounts of electromagnetic emission. Electrical emission may be
transmitted through power lines or radiated through space, similar to a radio transmitter. When emissions
are received by other equipment, electrical interference may result. Electrical emissions may affect many
kinds of electrical equipment; other nearby welding equipment, radio and TV reception, numerical controlled
machines, telephone systems, computers, etc. Be aware that interference may result and extra precautions
may be required when a welding power source is used in a domestic establishment.
Installation and Use
The user is responsible for installing and using the welding equipment according to the manufacturer’s
instructions. If electromagnetic disturbances are detected then it shall be the responsibility of the user of the
welding equipment to resolve the situation with the technical assistance of the manufacturer. In some cases
this remedial action may be as simple as earthing (grounding) the welding circuit, see Note. In other cases
it could involve construction an electromagnetic screen enclosing the power source and the work complete
with associated input filters. In all cases electromagnetic disturbances must be reduced to the point where
they are no longer troublesome.
Note: The welding circuit may or may not be earthed for safety reasons according to national
codes. Changing the earthing arrangements should only be authorized by a person who is
competent to access whether the changes will increase the risk of injury, e.g., by allowing
parallel welding current return paths which may damage the earth circuits of other equip-
ment.
Assessment of Area
Before installing welding equipment the user shall make an assessment of potential electromagnetic prob-
lems in the surrounding area. The following shall be taken into account:
a) other supply cables, control cables, signaling and telephone cables; above, below and adjacent to the
welding equipment;
b) radio and television transmitters and receivers;
c) computer and other control equipment;
d) safety critical equipment, e.g., guarding of industrial equipment;
e) the health of the people around, e.g., the use of pacemakers and hearing aids;
f) equipment used for calibration or measurement
g) the immunity of other equipment in the environment. The user shall ensure that other equipment being
used in the environment is compatible. This may require additional protection measures;
h) the time of day that welding or other activities are to be carried out.
L10093
3-1-96H
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vi
vi
SAFETY
Electromagnetic Compatibility (EMC)
The size of the surrounding area to be considered will depend on the structure of the building and other
activities that are taking place. The surrounding area may extend beyond the boundaries of the premises.
Methods of Reducing Emissions
Mains Supply
Welding equipment should be connected to the mains supply according to the manufacturer’s recommenda-
tions. If interference occurs, it may be necessary to take additional precautions such as filtering of the
mains supply. Consideration should be given to shielding the supply cable of permanently installed welding
equipment, in metallic conduit or equivalent. Shielding should be electrically continuous throughout its
length. The shielding should be connected to the welding power source so that good electrical contact is
maintained between the conduit and the welding power source enclosure.
Maintenance of the Welding Equipment
The welding equipment should be routinely maintained according to the manufacturer’s recommendations.
All access and service doors and covers should be closed and properly fastened when the welding equip-
ment is in operation. The welding equipment should not be modified in any way except for those changes
and adjustments covered in the manufacturers instructions. In particular, the spark gaps of arc striking and
stabilizing devices should be adjusted and maintained according to the manufacturer’s recommendations.
Welding Cables
The welding cables should be kept as short as possible and should be positioned close together, running at
or close to floor level.
Equipotential Bonding
Bonding of all metallic components in the welding installation and adjacent to it should be considered.
However, metallic components bonded to the work piece will increase the risk that the operator could
receive a shock by touching these metallic components and the electrode at the same time. The operator
should be insulated from all such bonded metallic components.
Earthing of the Workpiece
Where the workpiece is not bonded to earth for electrical safety, not connected to earth because of its size
and position, e.g., ships hull or building steelwork, a connection bonding the workpiece to earth may reduce
emissions in some, but not all instances. Care should be taken to prevent the earthing of the workpiece
increasing the risk of injury to users, or damage to other electrical equipment. Where necessary, the con-
nection of the workpiece to earth should be made by a direct connection to the workpiece, but in some
countries where direct connection is not permitted, the bonding should be achieved by suitable capacitance,
selected according to national regulations.
Screening and Shielding
Selective screening and shielding of other cables and equipment in the surrounding area may alleviate
problems of interference. Screening of the entire welding installation may be considered for special applica-
1
tions.
_________________________
1
Portions of the preceding text are contained in EN 60974-10: “Electromagnetic Compatibility (EMC)
product standard for arc welding equipment.”
L10093
3-1-96H
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I
I
- MASTER TABLE OF CONTENTS FOR ALL SECTIONS -
Page
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .i-vi
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section B
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section C
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section D
Troubleshooting and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section F
Electrical Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section G
Parts Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .P-418 Series
POWER WAVE 355M/405M
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A-1
A-1
TABLE OF CONTENTS - INSTALLATION SECTION
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-1
Technical Specifications 355M . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-2
Technical Specifications 405M . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-3
Tilting..........................................................................................................................................................A-4
Input Grounding Connections....................................................................................................................A-4
Output Cables, Connections and Limitations............................................................................................A-5
Negative Electrode Polarity........................................................................................................................A-5
Welding with Multiple Power Waves........................................................................................................A-11
POWER WAVE 355M/405M
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A-2
A-2
INSTALLATION
TECHNICAL SPECIFICATIONS - POWER WAVE 355
INPUT AC VOLTAGE & DC OUTPUT
Product Ordering
Input AC
Rated DC Output
Output
Range
(continuous)
Weight
with Cord
Dimensions
HxWxD
Name Information Voltage Amps/Volts/Duty Cycle
200-208
220-240
380-415
440-480
575
Power
Wave
355
350A / 34V / 60%
1 & 3 Phase
K2152-1
14.8” x 13.3” x
27.8”*
(373 x 338 x
706*)mm
*Includes
Handles
AMPS
5-425
(81.5 lbs.)
(37.0 kg.)
300A / 32V / 100%
1 & 3 Phase
60/50 HZ
* Overall Length Including Handle, 21.6” (549mm) without handle.
POWER WAVE 355 INPUT CURRENT
Recommended Fuse Sizes Base On The U.S. National Electrical Code And Maximum Machine Outputs
Input 50/60 Hz Output Recommended
Line Cord
300Amps @ Fuse size
Notes
Voltage
200
Phases
350Amps @
34Volts(60%)
Not
32Volts(100%)
Not
AWG
Note 1
1
---
Recommended Recommended
Note 2
Note 2
Note 1
208
230
380
1
1
1
76
69
94
85
2
4
125A
125A
---
Not
Not
Recommended Recommended
Not Not
Recommended Recommended
Note 1
Note 2
400
1
---
---
415
460
575
1
1
1
41
36
31
64
42
37
6
8
8
80A
70A
50A
Note 2
Note 2
200
208
230
380
400
415
460
575
3
3
3
3
3
3
3
3
41
39
36
23
22
22
19
16
50
50
42
28
27
26
23
18
6
6
8
8
8
8
8
8
80A
80A
70A
50A
50A
50A
50A
35A
Note 1. Not rated is indicated by 4-x’s in the box on the rating plate.
Note 2. When operating on these inputs, the line cord should be changed to an input conductor of 6 AWG or larger.
OUTPUT CABLES, CONNECTIONS AND LIMITATIONS
Select The output cable size based upon the following chart.*
Cable sizes for Combined Length of Electrode and Work Cable (Copper) 75C rated:
DUTY CYCLE
100%
CURRENT
300
LENGTH UP 200FT.(61m)
200-250 FT. (61-76m)
1/0
1/0
1/0
2/0
60%
350
*Lincoln Electric recommends using a minimum of 2/0 welding cable for pulse welding.
POWER WAVE 355M/405M
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A-3
A-3
INSTALLATION
TECHNICAL SPECIFICATIONS - POWER WAVE 405
INPUT AC VOLTAGE & DC OUTPUT
Product
Ordering Input AC
Rated DC Output
Output
Range
(continuous)
Weight
with Cord
Dimensions
HxWxD
Name Information Voltage Amps/Volts/Duty Cycle
350A / 34V / 60%
14.7”x12.5”x
27.8”*
(373x318x
706*)mm
Power
Wave
405
200-208 /
3 Phase
K 2152-2
220-240/ 320A / 33V / 60%
AMPS
5-425
86.5lbs
(37.4 kg)
380-415/
3/50/60
1 Phase
60/50 Hz 275A / 31V /100%
1 Phase
300A / 32V / 100%
3 Phase
* Includes
handles
* Overall Length Including Handle, 21.6” (549mm) without handle.
POWER WAVE 405 INPUT CURRENT
Recommended Fuse Sizes Based On The U.S. National Electrical Code And Maximum Machine Outputs
Input 50/60 Hz Output Recommended
300Amps@ Line Cord Size Fuse Size
34Volts(60%)
Size mm2
80A
Voltage
Phases
350Amps@
32Volts(100%)
Notes
Note 2
200
220
380
400
415
3
3
3
3
3
41
37
23
22
22
48
48
28
27
26
16
16
10
10
10
80A
50A
50A
50A
Note 2
Voltage
Phases
31Volts(100%)
275Amps@
33Volts(60%)
320Amps@
Line Cord
Fuse Size
Notes
Size mm2
200
220
380
400
415
1
1
1
1
1
Not Recommended Not Recommended
---
20
16
10
10
-----
Note 1
Note 2
Note 2
64
44
40
38
82
55
50
48
125A
80A
80A
80A
1. Not rated is indicated by 4-x's in the box on the rating plate
2. When operating on these inputs, the line cord should be changed to an input conductor of 6 AWG or larger.
OUTPUT CABLES, CONNECTIONS AND LIMITATIONS
Select the output cable size based upon the following chart.
Cable sizes for Combined Length of Electrode and Work Cable (Copper) 75C rated:
DUTY CYCLE
100%
CURRENT
275
350
LENGTH UP 61m (200 FT)
61-76m (200-250 FT)
1/0
1/0
1/0
2/0
60%
POWER WAVE 355M/405M
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A-4
A-4
INSTALLATION
• Open the access panel on the rear of the machine.
• For 200 or 230: Position the large switch to 200-
230.
For higher voltages: Position the large switch to
380-575.
SAFETY PRECAUTIONS
WARNING
ELECTRIC SHOCK can kill.
• Move the "A" lead to the appropriate terminal.
• TURN THE INPUT POWER OFF AT
THE DISCONNECT SWITCH BEFORE
ATTEMPTING TO CONNECT OR DIS-
CONNECT INPUT POWER LINES, OUTPUT
CABLES, OR CONTROL CABLES.
POWER CORD CONNECTION
A power cord is provided and wired into the machine.
Follow the power cord connection instructions.
Machine
PW 355
PW 405
Cord Length
10 Feet
5 Meters
• Only qualified personnel should perform this
installation.
• Connect the green/yellow lead of the power cord
to ground per U.S.National Electrical Code.
----------------------------------------------------------------------
CAUTION
SELECT SUITABLE LOCATION
• Incorrect connection may result in equipment
damage.
In order to assure long life and reliable operation,
the owner of this machine should follow these sim-
ple preventative measures:
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A
A
M
P
S
V
• The machine must be located where there is free cir-
culation of clean air such that air movement in the
back, out the sides and bottom will not be restricted.
V
O
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T
S
A
O
U
T
P
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IN
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3
5
0
-
P
R
O
W
E
R
O
N
F
F
• Dirt and dust that can be drawn into the machine
should be kept to a minimum. Failure to observe
these precautions can result in excessive operating
temperatures and nuisance shutdown.
Single Phase Input (PW 355M)
Connect green lead to ground per National Electrical
Code.
• Keep machine dry. Shelter from rain and snow. Do not
place on wet ground or in puddles.
Connect black and white leads to power.
Wrap red lead with tape to provide 600V insulation.
Three Phase Input (PW 355M)
Connect green lead to ground per National Electric
Code.
CAUTION
• DO NOT MOUNT OVER COMBUSTIBLE SURFACES.
Where there is a combustible surface directly under
stationary or fixed electrical equipment, that surface
shall be covered with a steel plate at least .06”(1.6mm)
thick, which shall extend not less than 5.90”(150mm)
beyond the equipment on all sides.
Connect black, red and white leads to power.
Lead Color Single Phase Three Phase
Connect to
ground per NEC
Connect to
ground per NEC
Green
STACKING
POWER WAVE 355M/405M cannot be stacked.
Black
White
Red
Power Lead
Power Lead
TILTING
Place the machine directly on a secure, level surface or
on a recommended undercarriage. The machine may
topple over if this procedure is not followed.
Power Lead
Power Lead
Power Lead
Tape, provide
600V insulation
INPUT AND GROUNDING CONNECTIONS
• Only a qualified electrician should connect the
POWER WAVE 355M/405M. Installation should be
made in accordance with the appropriate National
Electrical Code, all local codes and the information
detailed below.
Single Phase Input (PW 405M)
Connect green/yellow lead to ground per National
Electrical Code.
Connect blue and brown leads to power.
Wrap black lead with tape to provide 600V insulation.
• When received directly from the factory, multiple volt-
age machines are internally connected for the highest
voltage. Always double-check connections before
powering up the machine.
• Initial 200VAC - 415VAC and 575VAC operation will
require an Input voltage panel setup.
Three Phase Input (PW 405M)
Connect green/yellow lead to ground per National
Electric Code.
Connect black, blue and brown leads to power.
POWER WAVE 355M/405M
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A-5
A-5
INSTALLATION
UNDERCARRIAGE MOUNTINGS
CAUTION
MOUNTING HOLE LOCATIONS
Excessive voltage drops caused by poor work
piece connections often result in unsatisfactory
welding performance.
NOTE: MOUNTING SCREWS CAN NOT PROTR
UDE MORE THAN
CHES INSIDE THE MACHINE.
0.5 IN
3.50
-----------------------------------------------------------------------
NEGATIVE ELECTRODE POLARITY
When negative electrode polarity is required, such as
in some Innershield applications, reverse the output
connections at the power source (electrode cable to
the negative (-) Twist-Mate terminal, and work cable
to the positive (+) Twist-Mate terminal.
1/4-20 NUT (4 PLACES)
5.50
10.00
4/01
11.8
4
M19527
When operating with electrode polarity negative the
"Electrode Sense Polarity" DIP switch must be set to
the "Negative" position on the Wire Drive Feed Head
PC Board. The default setting of the switch is positive
electrode polarity. Consult the Power Feed instruction
manual for further details.
OUTPUT CABLES, CONNECTIONS AND
LIMITATIONS
Connect a work lead of sufficient size and length
between the proper output terminal on the power
source and the work. Be sure the connection to the
work makes tight metal-to-metal electrical contact. To
avoid interference problems with other equipment and
to achieve the best possible operation, route all cables
directly to the work or wire feeder. Avoid excessive
lengths and do not coil excess cable.
VOLTAGE SENSING
The best arc performance occurs when the
PowerWaves have accurate data about the arc condi-
tions. Depending upon the process, inductance within
the electrode and work lead cables can influence the
voltage apparent at the studs of the welder. Voltage
sense leads improve the accuracy of the arc conditions
and can have a dramatic effect on performance.
Sense Lead Kits (K940-10, -25 or -50) are available for
this purpose.
CAUTION
When using inverter type power sources like the
Power Waves, use the largest welding (electrode
and work) cables that are practical. At least 2/0
copper wire - even if the average output current
would not normally require it. When pulsing, the
pulse current can reach very high levels. Voltage
drops can become excessive, leading to poor weld-
ing characteristics, if undersized welding cables
are used.
CAUTION
If the voltage sensing is enabled but the sense
leads are missing, improperly connected, or if the
electrode polarity switch is improperly configured,
extremely high welding outputs may occur.
------------------------------------------------------------------------
Most welding applications run with the electrode being
positive (+). For those applications, connect the elec-
trode cable between the wire feeder and the positive
(+) output Twist-Mate terminal on the power source.
Connect the other end of the electrode cable to the
wire drive feed plate. The electrode cable lug must be
against the feed plate. Be sure the connection to the
feed plate makes tight metal-to-metal electrical con-
tact. The electrode cable should be sized according to
the specifications given in the output cable connections
section. Connect a work lead from the negative (-)
power source output Twist-Mate terminal to the work
piece. The work piece connection must be firm and
secure, especially if pulse welding is planned.
------------------------------------------------------------------------
The ELECTRODE sense lead (67) is built into the con-
trol cable, and is automatically enabled for all semi-
automatic processes. The WORK sense lead (21) con-
nects to the Power Wave at the four pin connector. By
default the WORK voltage is monitored at the output
stud in the POWER WAVE 355/405. For more informa-
tion on the WORK sense lead (21), see"Work Voltage
Sensing” in the following paragraph.
For additional Safety information regarding the elec-
trode and work cable set-up, See the standard "SAFE-
TY INFORMATION" located in the front of the
Instruction Manuals.
POWER WAVE 355M/405M
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A-6
A-6
INSTALLATION
5. Replace the wrap around and screws. The PC board
will “read” the switch at power up, and configure the
work voltage sense lead appropriately.
Enable the voltage sense leads as follows:
TABLE A.1
Process Electrode Voltage
Sensing 67 lead *
GMAW 67 lead required
GMAW-P 67 lead required
FCAW 67 lead required
GTAW Voltage sense at studs Voltage sense at studs
GMAW Voltage sense at studs Voltage sense at studs
SAW
Work Voltage
Sensing 21 lead
21 lead optional
21 lead optional
21 lead optional
ELECTRODE VOLTAGE SENSING
Enabling or disabling electrode voltage sensing is auto-
matically configured through software. The 67 elec-
trode sense lead is internal to the cable to the wire
feeder and always connected when a wire feeder is
present.
67 lead required
21 lead optional
CAC-C Voltage sense at studs Voltage sense at studs
PF10M feeder has user preference features to select
voltage senses temporarily for testing sense leads.
* The electrode voltage 67 sense lead is integral to the
control cable to the wire feeder.
CAUTION
Work Voltage Sensing
The standard POWER WAVE 355M/405M default to
Important: The electrode polarity must be config-
ured at the feed head for all semi-automatic
processes. Failure to do so may result in extreme-
ly high welding outputs.
------------------------------------------------------------------------
POWER WAVETO SEMI-AUTOMATIC POW-
the work stud (work sense lead disabled)
For processes requiring work voltage sensing, connect
the (21) work voltage sense lead (K940) from the
Power Wave work sense lead receptacle to the work
piece. Attach the sense lead to the work piece as close
to the weld as practical, but not in the return current
path. Enable the work voltage sensing in the Power
Wave as follows:
ERFEED WIRE FEEDER INTERCONNEC-
TIONS
The POWER WAVE 355M/405M and semi-automatic
Power Feed family communicate via a 5 conductor
control cable (K1543).The control cable consists of two
power leads, one twisted pair for digital communica-
tion, and one lead for voltage sensing. The cables are
designed to be connected end to end for ease of exten-
sion. The output receptacle on the POWER WAVE
405M is on the case front. The input receptacle on the
Power Feed is typically located at the back of the feed-
er, or on the bottom of the user interface.
WARNING
• Do not touch electrically live parts or
electrodes with your skin or wet
clothing.
• Insulate yourself from the work and
ground.
• Always wear dry insulating gloves.
Due to the flexibility of the platform the configuration
may vary. The following is a general description of the
system. For specific configuration information, consult
the semi-automatic Power Feed instruction manual.
1. Turn off power to the power source at the disconnect
switch.
2. Remove the wrap around cover from the power
source.
3. The control board is on the center assembly facing
the case front. Locate the 8-position DIP switch and
look for switch 8 of the DIP switch.
4. Using a pencil or other small object, slide the switch
to the OFF position if the work sense lead is NOT
connected. Conversely, slide the switch to the ON
position if the work sense lead is present.
O
N
1
2
3
4
5
6
7
8
POWER WAVE 355M/405M
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A-7
A-7
INSTALLATION
From a network perspective, each component in the
system is considered a separate node, regardless of its
physical location. For example, even though a UI and
FH may be physically mounted together, they are still
viewed as separate pieces (nodes) by the network, and
can only communicate via Arclink. The connection is
generally made externally through the Linc-Net Control
Cable, but can also be made internally, as with the PF-
10 bench model feeder.
SYSTEM DESCRIPTION
The POWER WAVE 355M/405M and Power Feed
10/11 family of products utilize a digital communication
system called Arclink. Simply put, Arclink allows large
amounts of information to be passed at very high
speeds between components (nodes) in the system.
The system requires only two wires for communication,
and because of its bus-like structure, the components
may be connected to the network in any order, thus
simplifying the system set-up.
The most common Arclink configuration (called a sim-
ple system) consists of one power source, one user
interface and one feeder. Under these circumstances
the group and feed head ID DIP switches are ignored
and the system will function regardless of their posi-
tion. The same is true for the minimum system consist-
ing of a power source and one UI (Example: a stick
welding system).
Each "system" must contain only one power source.
The power source may be connected to a maximum of
four feeder groups. Each group containing one user
interface (UI), and up to seven Feed Heads (FH). SEE
FIGURE A.1. The UI controls all of the FH’s of that
group. The UI’s and FH’s are assigned to groups by
setting a code on the DIP switches mounted on their
individual control boards. For example all of the FH’s to
be controlled by a given UI must have their "Group ID"
switches set to the same group number as the UI. In
addition, each FH must be assigned a separate FH
number within that group. See the system set-up sec-
tion for further details.
FIGURE A.1
System Model
Maximum
Configuration
POWER WAVE 355M/405M
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A-8
A-8
INSTALLATION
SYSTEM SET-UP
Basic Rules
• Each group is required to have one user interface. No
group may have more than one user interface.
• Each group can have up to seven Feed Heads.
Exception: Group 3 is limited to a maximum of six
Feed Heads.
• Each system has only one power source. For network
purposes, the PS belongs to Group 3, which is why
group 3 is only allowed 6 feed heads in addition to it’s
user interface.
• No two feed heads can have identical Group and
Feed Head numbers.
• Group and Feed Head ID numbers must be set on the
appropriate dip switches at each node. Consult the
PF-10/11 Instruction Manual for specific details
regarding dip switch settings.
• Feed head “0” not allowed. Exception: Simple sys-
tem ignores all ID numbers, therefore “FH0” will func-
tion.
• Each node must be connected to the Linc-Net com-
munication network. The order of connection is not
important, as each node is identified by it’s unique
Group and Feed Head ID number as defined on it’s
dip switches. See Figures A.2 thru A.5.
Simple System
FIGURE A.2
Group and Feed
Head ID numbers are
ignored in a simple
system.
POWER WAVE 355M/405M
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A-9
A-9
INSTALLATION
Multiple Group System
No “FH0 Allowed!
FIGURE A.3
Single Group Multi-Head System
FIGURE A.4
No “FH0 Allowed!
The Dual Head option
allows the ability to
maintain 2 sets of
procedures. If more
then 2 heads are
used, odd #’s use
FH1 settings, even #’s
use FH2 settings.
POWER WAVE 355M/405M
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A-10
Single Group Multi-Head System (Alternate Method)
A-10
INSTALLATION
No “FH0 Allowed!
When standard
FIGURE A.5
a
User Interface is used
in a group with multi-
ple Feed Heads, all of
the Feed Heads use a
single set of proce-
dures.
POWER WAVE 355M/405M
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A-11
A-11
INSTALLATION
CONTROL CABLE SPECIFICATIONS
WELDING WITH MULTIPLE POWER
WAVES
It is recommended that genuine Lincoln control cables
be used at all times. Lincoln cables are specifically
designed for the communication and power needs of
the Power Wave / Power Feed system.
CAUTION
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.
CAUTION
The use of non-standard cables, especially in
lengths greater than 25 feet, can lead to communi-
cation problems such as: system shutdowns, poor
motor acceleration, poor arc starting) and low wire
driving force (wire feeding problems).
------------------------------------------------------------------------
The K1543 series of control cables can be connected
end to end for ease of extension. Do not exceed more
than 100 feet (30.5 m) total control cable length.
Each power source requires a work lead from the work
stud to the welding fixture. Do not combine all of the
work leads into one lead. The welding travel directions
should be in the direction moving away from the work
lead as shown below. Connect all of the work sense
leads from each power source to the work piece at the
end of the weld.
For the best results when pulse welding, set the wire
size and wire feed speed the same for all the Power
Waves. When these parameters are identical, the puls-
ing 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 cover-
age.
Do not attempt to supply shielding gas for two or more
guns from only one regulator.
If an anti-spatter system is in use then each gun must
have its own anti-spatter system. (See Figure A.6)
FIGURE A.6
POWER WAVE 355/405
POWER WAVE 355/405
TWO POWER WAVES
Travel
Direction
Connect All Work
Sense Leads at the End
of the Joint
Connect All Welding
Work Leads at the
Beginning of the Joint
POWER WAVE 355M/405M
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A-12
A-12
INSTALLATION
MULTIPLE ARC UNSYNCHRONIZED SENSE LEAD AND WORK LEAD PLACEMENT GUIDELINES
POWER WAVE 355M/405M
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A-13
A-13
INSTALLATION
CONTROL BOARD DIP SWITCH:
switch 1 = reserved for future use
switch 2 = reserved for future use
switch 3 = reserved for future use
switch 4 = reserved for future use
switch 5 = reserved for future use
switch 6 = reserved for future use
switch 7 = reserved for future use
switch 8* = work sense lead
I / O RECEPTACLE SPECIFICATIONS
TABLE A.2
WIRE FEEDER RECEPTACLE
PIN
A
B
C
D
LEAD#
53
FUNCTION
Communication Bus L
Communication Bus H
Electrode Voltage Sense
+40vdc
54
67A
52
E
51
0vdc
TABLE A.3
VOLTAGE SENSE RECEPTACLE
switch 8*
work sense lead
work sense lead not connected
work sense lead connected
off
on
PIN
LEAD#
FUNCTION
3
21A
Work Voltage Sense
*Factory setting for Switch 8 is OFF.
TABLE A.4
RS232 RECEPTACLE
PIN
2
3
4
5
LEAD#
253
254
#
FUNCTION
RS232 Receive
RS232 Transmit
Pin5
FIGURE A.7
CONTROL BOARD (DIP Switch Location)
#
Pin4
6
20
7
# #
# #
251
Pin20
Pin6
RS232 Common
DIP SWITCH SETTINGS AND
LOCATIONS
DIP switches on the P.C. Boards allow for custom con-
figuration of the Power Wave.To access the DIP switch-
es:
WARNING
1. Turn off power to the power source at the dis-
connect switch.
------------------------------------------------------------------------
2. Remove the wrap around cover from the power
source.
NOTE: For PF10M Dual Boom Feeder set/up and op-
eration. The Power Wave 355M/405M control
board dip switches must be set with 3, 4, 7 to
the “ON” position (Power Wave 355M/405M
input on/off switch must be cycled to enable
any change of dip switches).
3. The control board is on the center assembly facing
the case front. Locate the 8-position DIP switch and
look for switch 8 of the DIP switch.
4. Using a pencil or other small object, slide the switch
to the OFF position if the work sense lead is NOT
connected. Conversely, slide the switch to the ON
position if the work sense lead is present.
5. Replace the wrap around and screws. The PC board
will “read” the switch at power up, and configure the
work voltage sense lead appropriately.
O
N
1
2
3
4
5
6
7
8
POWER WAVE 355M/405M
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A-14
A-14
INSTALLATION
Most welding applications run with the electrode being
positive (+). For those applications, connect the elec-
trode cable between the wire feeder and the positive
(+) output Twist-Mate terminal on the power source.
Connect the other end of the electrode cable to the
wire drive feed plate. The electrode cable lug must be
against the feed plate. Be sure the connection to the
feed plate makes tight metal-to-metal electrical con-
tact. The electrode cable should be sized according to
the specifications given in the output cable connec-
tions section. Connect a work lead from the negative
(-) power source output Twist-Mate terminal to the
work piece. The work piece connection must be firm
and secure, especially if pulse welding is planned.
CABLE INDUCTANCE, AND ITS EFFECTS
ON PULSE WELDING
For Pulse Welding processes, cable inductance will
cause the welding performance to degrade. For the
total welding loop length less than 50 ft.(15.24m), tradi-
tional welding cables may be used without any effects
on welding performance. For the total welding loop
length greater than 50 ft.(15.24m)), the K1796 Coaxial
Welding Cables are recommended. The welding loop
length is defined as the total of electrode cable length
(A) + work cable length (B) + work length (C) (See
Figure A.3).
FIGURE A.3
POWER
WAVE
A
For additional Safety information regarding the elec-
trode and work cable set-up, See the standard "SAFE-
TY INFORMATION" located in the front of the
Instruction Manuals.
C
WORK
B
For long work piece lengths, a sliding ground should be
considered to keep the total welding loop length less
than 50 ft.(15.24m). (See Figure A.4.)
FIGURE A.4
POWER
WAVE
A
A
C
WORK
C
B
B
SLIDING WORK
K1796 COAXIAL CABLE
MEASURE FROM END
OF OUTER JACKET OF
CABLE
POWER WAVE 355M/405M
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B-1
B-1
TABLE OF CONTENTS - OPERATION SECTION
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-1
Recommended Processes and Equipment.................................................................................................B-2
Limitations....................................................................................................................................................B-3
Duty Cycle and Time Period........................................................................................................................B-3
Welding Adjustments...................................................................................................................................B-4
Tig (GTAW) ...................................................................................................................................................B-6
Special Welding Processes Available..........................................................................................................B-6
Pulse-on-Pulse (GMAW-PP)......................................................................................................................B-10
POWER WAVE 355M/405M
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B-2
B-2
OPERATION
SAFETY PRECAUTIONS
GENERAL DESCRIPTION
The Power Wave semi-automatic power source is
designed to be a part of a modular, multi-process weld-
ing system. Depending on configuration, it can support
constant current, constant voltage, and pulse welding
modes.
Read this entire section of operating instructions
before operating the machine.
WARNING
The Power Wave power source is designed to be used
with the semi automatic family of Power Feed M wire
feeders, operating as a system. Each component in the
system has special circuitry to "talk with" the other sys-
tem components, so each component (power source,
wire feeder, user interface) knows what the other is
doing at all times. These components communicate
with Arclink.
ELECTRIC SHOCK can kill.
• Unless using cold feed feature, when
feeding with gun trigger, the elec-
trode and drive mechanism are
always electrically energized and
could remain energized several sec-
onds after the welding ceases.
The POWER WAVE 355M/405M is a high perfor-
mance, digitally controlled inverter welding power
source capable of complex, high-speed waveform con-
trol. Properly equipped, it can support the GMAW,
GMAW-P, FCAW, SMAW, GTAW, and CAC-A process-
es. It carries an output rating of 350 Amps, 34 Volts at
60% duty cycle and 300 Amps, 32 volts at 100% duty
cycle.
• 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.
RECOMMENDED PROCESSES
AND EQUIPMENT
• Use ventilation or exhaust to remove fumes from
breathing zone.
RECOMMENDED PROCESSES
-----------------------------------------------------------
The POWER WAVE 355M/405M can be set up in a
number of configurations, some requiring optional
equipment or welding programs. Each machine is fac-
tory preprogrammed with multiple welding procedures,
typically including GMAW, GMAW-P, FCAW, GTAW,
and CAC-A for a variety of materials, including mild
steel, stainless steel, cored wires, and aluminum.
WELDING SPARKS can cause
fire or explosion.
• Keep flammable material away.
• Do not weld on containers that have
held combustibles.
-----------------------------------------------------------
The POWER WAVE 355M/405M is recommended for
semi-automatic welding, and may also be suitable for
basic hard automation applications.
ARC RAYS can burn.
• Wear eye, ear, and body protection.
• This Power Wave is not recommended for processes
other than those listed.
-----------------------------------------------------------
Observe additional guidelines detailed in the
beginning of this manual.
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B-3
B-3
OPERATION
POWER WAVE 355M/405M – Semi-Automatic
Operation
NOTE: The POWER WAVE 355M/405M status light
will flash green, and sometimes red and green, for up
to one minute when the machine is first turned on. This
is a normal situation as the machine goes through a
self test at power up.
Semi Automatic Power Waves can only be used with
Arclink compatible Power Feed semi-automatic wire
feeders. In addition, the Power Feed semi-automatic
wire feeders may require optional equipment to access
certain weld modes in the Power Wave. Other models
of Lincoln feeders, or any models of non-Lincoln wire
feeders, cannot be used.
TABLE B.1
Light
Condition
Meaning
Steady Green System OK. Power source communicating
normally with wire feeder and its components
if other feeder & components show they are
powered up.
All welding programs and procedures are selected
through the Power Feed semi-automatic user interface
Blinking
Green
Occurs during a reset, and indicates the
POWER WAVE 355M/405M is mapping
(identifying) each component in the system.
Normal for first 1-10 seconds after power is
turned on, or if the system configuration is
changed during operation
REQUIRED EQUIPMENT
Any Arclink compatible semi-automatic wire feeding
equipment. Specifically, the semi-automatic Power
Feed family (PF10M Series, Power Feed 15M and
Power Feed 25M).
Alternating
Green and
Red
Non-recoverable system fault. If the PW
Status light is flashing any combination of red
and green, errors are present in the POWER
WAVE 355M/405M. Read the error code
before the machine is turned off.
LIMITATIONS
• Only Arclink compatible Power Feed semi-automatic
wire feeders and users interfaces may be used.
Other Lincoln wire feeders or non-Lincoln wire feed-
ers cannot be used.
Error Code interpretation through the Status
Individual code digits are flashed in red with
a long pause between digits. If more than
one code is present, the codes will be sepa-
rated by a green light.
• POWER WAVE 355M/405M Output Limitations
The POWER WAVE 355M/405M will support maxi-
mum average output current of 350 Amps @ 60%
duty cycle.
To clear the error, turn power source off, and
back on to reset.
DUTY CYCLE AND TIME PERIOD
The duty cycle is based upon a ten minute period. A
60% duty cycle represents 6 minutes of welding and 4
minutes of idling in a ten minute period.
Non recoverable hardware fault. Generally
indicates nothing is connected to the
POWER WAVE 355M/405M wire feeder
receptacle. See Trouble Shooting Section.
Steady Red
Blinking Red
CASE FRONT CONTROLS
All operator controls and adjustments are located on
Not applicable.
1. POWER SWITCH: Controls input power to the
Power Wave.
3. HIGH TEMPERATURE LIGHT (thermal overload):
A yellow light that comes on when an over temper-
ature situation occurs. Output is disabled and the
fan continues to run, until the machine cools down.
When cool, the light goes out and output is enabled.
2. STATUS LIGHT: A two color light that indicates sys-
tem errors. Normal operation is a steady green light.
Error conditions are indicated, per table B.1.
4. CB1 WIRE FEEDER CIRCUIT BREAKER: Protects
40 volt DC wire feeder power supply.
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B-4
B-4
OPERATION
The steps for operating the Power Wave will vary
depending upon the options installed in the user inter-
face (control box) of the welding system. The flexibility
of the Power Wave system lets the user customize
operation for the best performance.
FIGURE B.1
2
3
7
First, consider the desired welding process and the
part to be welded. Choose an electrode material, diam-
eter, shielding gas and process (GMAW, GMAW-P,
etc.)
4
1
6
Second, find the program in the welding software that
best matches the desired welding process. The stan-
dard software shipped with the Power Waves encom-
passes a wide range of common processes and will
meet most needs. If a special welding program is
desired, contact the local Lincoln Electric sales repre-
sentative.
8
9
10
5
To make a weld, the Power Wave needs to know the
desired welding parameters. The Power Feed (PF)
family of feeders communicate settings to the Power
Wave through control cable connection. Arc length,
wire feed speed, arc control, etc. are all communicated
digitally via the control cable.
CASE FRONT LAYOUT
POWER WAVE 355M/405M
5. Internal POWER CIRCUIT BREAKER: Protects 115
volt AC circuit.
6. LEAD CONNECTOR (SENSE LEAD)
7. DIAGNOSTIC CONNECTOR (RS-232)
8. WIRE FEEDER RECEPTACLE (5-PIN)
9. NEGATIVE TWIST- MATE TERMINAL
10. POSITIVE TWIST- MATE TERMINAL
WELDING ADJUSTMENTS
All adjustments are made on the system component
known as the User Interface (Control Box), which con-
tains the switches, knobs, and digital displays neces-
sary to control both the Power Wave and a Power Feed
wire feeder. Typically, the Control Box is supplied as
part of the wire feeder. It can be mounted directly on
the wire feeder itself, the front of the power source, or
mounted separately, as might be done in a welding
boom installation.
NOMINAL PROCEDURES
The Power Wave is designed to operate with 3/4" elec-
trode stick-out for CV and Pulse processes.
FRINGE PROCEDURES
Excessively short or long electrode stick-outs may
function only on a limited basis, if at all.
MAKING A WELD
Because the Control Box can be configured with many
different options, your system may not have all of the
following adjustments. Regardless of availability, all
controls are described below. For further information,
consult the Power Feed wire feeder instruction manual.
WARNING
The serviceability of a product or structure utiliz-
ing the welding programs is and must be the sole
responsibility of the builder/user. Many variables
beyond the control of The Lincoln Electric
Company affect the results obtained in applying
these programs. These variables include, but are
not limited to, welding procedure, plate chemistry
and temperature, weldment design, fabrication
methods and service requirements. The available
range of a welding program may not be suitable for
all applications, and the build/user is and must be
solely responsible for welding program selection.
------------------------------------------------------------------------
• WFS / AMPS:
In synergic welding modes (synergic CV, pulse GMAW)
WFS (wire feed speed) is the dominant control para-
meter, controlling all other variables. The user adjusts
WFS according to factors such as weld size, penetra-
tion requirements, heat input, etc. The Power Wave
then uses the WFS setting to adjust its output charac-
teristics (output voltage, output current) according to
pre-programmed settings contained in the Power
Wave.
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B-5
B-5
OPERATION
In non-synergic modes, the WFS control behaves more
like a conventional CV power source where WFS and
voltage are independent adjustments. Therefore to
maintain the arc characteristics, the operator must
adjust the voltage to compensate for any changes
made to the WFS.
CONSTANT VOLTAGE WELDING
Synergic CV:
For each wire feed speed, a corresponding voltage is
preprogrammed into the machine through special soft-
ware at the factory. The nominal preprogrammed volt-
age is the best average voltage for a given wire feed
speed, but may be adjusted to preference. When the
wire feed speed changes, the Power Wave automati-
cally adjusts the voltage level correspondingly to main-
tain similar arc characteristics throughout the WFS
range.
In constant current modes (stick, TIG) this control
adjusts the output current, in amps.
• VOLTS / TRIM:
In constant voltage modes (synergic CV, standard CV)
the control adjusts the welding voltage.
Non Synergic CV:
This type of CV mode behaves more like a convention-
al CV power source.Voltage and WFS are independent
adjustments. Therefore to maintain the arc characteris-
tics, the operator must adjust the voltage to compen-
sate for any changes made to the WFS.
In pulse synergic welding modes (pulse GMAW only)
the user can change the Trim setting to adjust the arc
length. It is adjustable from 0.500 to 1.500. A Trim set-
ting of 1.000 is a good starting point for most condi-
tions.
All CV Modes:
• WELDING MODE
Arc Control, often referred to as wave control, adjusts
the inductance of the wave shape. The wave control
adjustment is similar to the "pinch" function in that it is
inversely proportional to inductance. Therefore,
increasing wave control greater than 0.0 results in a
harsher, colder arc while decreasing the wave control
to less than 0.0 provides a softer, hotter arc.
(See Figure B.2)
May be selected by name (CV/MIG, CC/Stick Crisp,
Gouge, etc.) or by a mode number (10, 24, 71, etc.)
depending on the Control Box options. Selecting a
welding mode determines the output characteristics of
the Power Wave power source. A more complete
description of all modes can be found in this section.
• ARC CONTROL
Also known as Inductance or Wave Control. Allows
operator to vary the arc characteristics from "soft" to
"harsh" in all weld modes. It is adjustable from -10.0 to
+10.0, with a nominal setting of 00.0 (The nominal set-
ting of 00.0 may be displayed as OFF on some Power
Feed wire feeder control panels). See the Welding
Mode descriptions for a more detailed explanations of
how the Arc Control affects each mode.
FIGURE B.2
CURRENT WAVE FORM (CV)
Current
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B-6
B-6
OPERATION
TIG GTAW
NOTE: Later versions of weld software
eliminated the Arc Control Function
in TIG mode and only allow for
“Touch Start” operation.
The TIG mode features continuous control from 5 to
425 amps. The TIG mode can be run in either the
Touch Start TIG or Scratch start mode.
The Arc Control level selects the starting mode.
SMAW
In SMAW (STICK mode), the arc control adjusts the
arc force. It can be set to the lower range (0 to -10) for
a soft and less penetrating arc characteristic or to the
higher range (0 to +10) for a crisp and more penetrat-
ing arc. Normally, when welding with cellulosic types of
electrodes (E6010, E7010, E6011), a higher energy
arc is required to maintain arc stability. This is usually
indicated when the electrode sticks to the work-piece
or when the arc pops-out during manipulative tech-
nique. For low hydrogen types of electrodes (E7018,
E8018, E9018, etc.) a softer arc is usually desirable
and the lower end of the Arc Control suits these types
of electrodes. In either case the arc control is available
to increase or decrease the energy level delivered to
the arc.
Between –10 and 0, the Touch Start TIG mode is
selected. The OCV is controlled below 10V and the
short circuit "TIG touch" current is maintained at
approximately 25 amps, independent of the preset
current. When the tungsten is lifted, an arc is initiated
and the output is regulated at the preset value. A set-
ting of 0, results in the most positive arc initiation. A
setting of -10 reduces the start procedure to start the
weld, and from there, to ramp to the welding proce-
dure over a specified amount of time.
A setting above 0 selects a Scratch Start. Full OCV is
available when the arc initiates the output is regulated
to the preset value
Typically starting procedure on a higher “+” setting is
known as a “Hot Start”. Setting a starting procedure
on a lower setting is known as a “Cold Start”.
Recommended Welding Procedures for Power Mode
TABLE B.2
MATERIAL
WIRE
Aluminum 4043 Aluminum 5356
Mild Steel
L56
Mild Steel
L56
Mild Steel
L56
Mild Steel
L56
Mild Steel
L56
Mild Steel
L56
Stainless Steel Stainless Steel
E4043
0.035
E5356
0.035
E308L
0.030
E308L
0.035
WIRE SIZE
GAS
0.025
0.025
0.030
0.030
0.035
0.035
100% Agr.
100% Agr.
100% CD
75/25 Ar/CO
100 / 0.8
120 / 1.0
140 / 1.5
190 / 2.0
260 / 3.0
330 / 4.5
100% CD
75/25 Ar/CO
90 / 1.0
100% CD
75/25 Ar/CO
2
Tri-mix
Tri-mix
2
2
2
2
2
Not
Not
22 ga.
recommended
recommended
20 ga.
18 ga.
16 ga.
14 ga.
12 ga.
10 ga.
3/16
120 / 1.0
140 / 1.7
190 / 2.0
260 / 3.0
330 / 5.0
100 / 0.7
100 / 1.0
110 / 1.5
125 / 2.0
160 / 2.3
230 / 3.5
300 / 6.0
400 / 7.0
80 / 1.5
110 / 2.0
140 / 2.5
210 / 3.0
270 / 5.0
325 / 6.5
50 / 0.5
110 / 2.0
130 / 2.7
190 / 3.5
230 / 6.0
300 / 7.0
110 / 1.5
125 / 2.0
160 / 2.3
230 / 3.5
300 / 6.0
400 / 7.5
100 / 2.5
125 / 3.0
160 / 3.8
200 / 5.0
240 / 6.5
100 / 2.5
125 / 3.0
160 / 3.5
200 / 4.5
240 / 7.0
400 / 2.0
400 / 2.5
500 / 7.0
570 / 90
500 / 7.0
600 / 7.8
1/4
700 / 9.1
Not
700 / 8.5
Not
Recommended Recommended
COMMENTS
below 400
WFS
below 400
WFS
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B-7
B-7
OPERATION
ARC GOUGING
Power Mode™ is a method of high speed regulation of
the output power whenever an arc is established. It
provides a fast response to changes in the arc. The
higher the Power Mode Setting, the longer the arc. If a
welding procedure is not established, the best way to
determine the Power Mode Setting is by experimenta-
tion until the desired output result is established.
Gouging is basically removing metal to form a bevel or
groove in a piece of steel with controlled forced air and
a carbon rod.
The common procedures for Arc Gouging metal are:
• Removing poor welds from a weldment so that new
welds can be made.
In the Power Mode variables need to be set:
• Creating a welding groove or grooves in two pieces
of steel butted together. (See Example below)
• Wire Feed Speed
• Output
• Arc Control
WELD GROOVES CREATED BY ARC GOUGING
Setting up a Power Mode procedure is similar to set-
ting a CV MIG procedure. Select a shielding gas
appropriate for a short arc process.
STEEL BUTTED TOGTHER
• For steel, use 75/25 Ar/CO2 shield gas.
• For Stainless, select a Helium blend Tri-Mix.
• For Aluminum, use 100% Ar.
Mode 9 in the POWER WAVE 355M is specifically for
gouging. Gouging can also be done in the stick soft
and crisp modes. Setting the output of the Stick Soft
mode to 425 amps will enable the arc-gouging mode.
The actual output current will depend on the size of
carbon used.The recommended maximum size carbon
is 5/16".
Start by setting the wire feed speed based upon mate-
rial thickness and appropriate travel speed. Then
adjust the Output knob as follows:
• For steel, listen for the traditional “frying egg”
sound of a good short-arc MIG procedure to know
you have the process set correctly.
POWER MODE™
The Power Mode™ process was developed by Lincoln
to maintain a stable and smooth arc at low procedure
settings which are needed to weld thin metal without
pop-outs or burning-through. For Aluminum welding, it
provides excellent control and the ability to maintain
constant arc length. This results in improved welding
performance in two primary types of applications.
• For aluminum, simply adjust the Output knob until
the desired arc length is obtained.
Note the Volts display is simply a relative number and
DOES NOT correspond to voltage.
• Short Arc MIG at low procedure settings.
• Aluminum MIG welding.
Some Power Mode procedure recommendations
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B-8
B-8
OPERATION
Pulsed MIG is an advanced form of welding that takes
the best of all the other forms of transfer while mini-
mizing or eliminating their disadvantages. Unlike short
circuit, pulsed MIG does not create spatter or run the
risk of cold lapping. The welding positions in pulsed
MIG are not limited as they are with globular or spray
and its wire use is definitely more efficient. Unlike the
spray arc process, pulsing offers controlled heat input
that allows better welding on thin materials. Pulsing
allows for lower wire feed speeds which leads to less
distortion and improved overall quality and appear-
ance. This is especially important with stainless, nick-
el and other alloys that are sensitive to heat input.
SPECIAL WELDING PROCESSES
AVAILABLE ON THIS MACHINE
PULSE WELDING (GMAW-P)
The pulsed-arc process is, by definition, a spray trans-
fer process wherein spray transfer occurs in pulses at
regularly spaced intervals. In the time between pulses,
the welding current is reduced and no metal transfer
occurs.
Pulsed-arc transfer is obtained by operating a power
source between low and high current levels. The high
current level or “pulse” forces an electrode drop to the
workpiece. The low current level or “background” main-
tains the arc between pulses. (See Figure B.3).
In GMAW-P mode, arc control adjusts the background
current and frequency of the wave. When arc control
goes up, the frequency increases thus increasing the
droplet transfer.
FIGURE B.3
EACH PULSE DELIVERS ONE DROPLET OF WELD MATERIAL
FREQUENCY
SPRAY TRANSITION
CURRENT
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B-9
B-9
OPERATION
PULSE WELDING
FIGURE B.3
CURRENT WAVE FORM (PULSE)
Pulse welding procedures are set by controlling an
overall "arc length" variable. When pulse welding, the
arc voltage is highly dependent upon the waveform.
The peak current, back ground current, rise time, fall
time and pulse frequency all affect the voltage. The
exact voltage for a given wire feed speed can only be
predicted when all the pulsing waveform parameters
are known. Using a preset voltage becomes impracti-
cal, and instead the arc length is set by adjusting
"trim".
Current
Time
Trim adjusts the arc length and ranges from 0.50 to
1.50, with a nominal value of 1.00. Trim values greater
than 1.00 increase the arc length, while values less
than 1.00 decrease the arc length.
All pulse welding programs are synergic. As the wire
feed speed is adjusted, the Power Wave will automati-
cally recalculate the waveform parameters to maintain
similar arc properties.
The Power Wave utilizes "adaptive control" to compen-
sate for changes in electrical stick out while welding.
(Contact to Work Distance is the distance from the
contact tip to the work piece.) The Power Wave wave
forms are optimized for a 0.75" (19mm) stick-out. The
adaptive behavior supports a range of stickouts from
0.50" (13mm) to 1.25" (32mm). At very low or high wire
feed speeds, the adaptive range may be less due to
reaching physical limitations of the welding process.
Arc Control, often referred to as wave control, in pulse
programs usually adjusts the focus or shape of the arc.
Wave control values greater than 0.0 increase the
pulse frequency while decreasing the background cur-
rent, resulting in a tight, stiff arc best for high speed
sheet metal welding. Wave control values less than 0.0
decrease the pulse frequency while increasing the
background current, for a soft arc good for out-of-posi-
tion welding.
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B-10
B-10
OPERATION
PULSE-ON-PULSE™ (GMAW-PP)
When Arc Control is used in the Pulse on Pulse
modes, it does the same things it does in the other
pulsed modes: decreasing the Arc Control decreases
the droplet transfer and weld deposition rate.
Increasing the Arc Control increases the droplet trans-
fer and weld deposition rate. Since Arc Control varies
weld droplet transfer rate, the Arc Control can be used
to vary the ripple spacing in the weld bead.
Pulse on Pulse™ is a Lincoln process specifically
designed for use in welding relatively thin (less than
1/4" thick) aluminum (See the table below). It gives
weld beads with very consistent uniform ripple.
In Pulse on Pulse modes, two distinct pulse types are
used, instead of the single pulse type normally used in
GMAW-P. A number of high energy pulses are used to
obtain spray transfer and transfer metal across the arc.
Such pulses are shown in the figure below. After a
number "N" of such pulses, depending on the wire feed
speed used, an identical number "N" of low energy
pulses are performed.These low energy pulses, shown
in the figure below, do not transfer any filler metal
across the arc and help to cool the arc and keep the
heat input low.
BENEFITS OF PULSE ON PULSE FROM
LINCOLN ELECTRIC
• Excellent appearance of the weld bead
• Improved cleaning action
• Reduced porosity
"N" PULSES
"N" PULSES
Table B.3 shows WFS and Trim settings for common
aluminum types and wire sizes when welding with
Pulse-on-Pulse. The welds made to obtain the values
in the table were fillet welds in the flat position.The val-
ues in the table can be helpful as a starting point to
establish a welding procedure. From there, adjust-
ments need to be made to set the proper procedure for
each specific application (out-of-position, other types
of joints, etc.).
HIGH HEAT
PULSES
LOW HEAT
PULSES
PEAK
AMPS
BACKGROUND
AMPS
TIME
The Peak Current, Background Current, and
Frequency are identical for the high energy and low
energy pulses. In addition to cooling the weld down, the
major effect of the low energy pulses is that they form
a weld ripple. Since they occur at very regular time
intervals, the weld bead obtained is very uniform with a
very consistent ripple pattern. In fact, the bead has its
best appearance if no oscillation of the welding gun
("whipping") is used.(See the figure below)
The comments on the table below show values of WFS
below which it is not recommended to weld. The rea-
son is, that below these values the weld transfer will
change from a spray arc to a short-arc, which is not
advisable when welding aluminum.
TABLE B.3
WELDING PROCEDURES FOR PULSE-ON-PULSE
MATERIAL
GAS
Aluminum 4043
100% Ar.
E4043
Aluminum 4043
100% Ar.
E4043
Aluminum 5356
100% Ar.
E5356
Aluminum 5356
100% Ar.
E5356
WIRE
WIRE SIZE
0.035
3/64
0.035
3/64
14 ga.
250 / 0
400 / 0
550 / 0
600 / 0
200 / 0
280 / 0
340 / 0
400 / 0
230 / 0
425 / 0
670 / 0
700 / 0
225 / 0
400 / 0
500 / 0
550 / 0
10 ga.
3/16
1/4
Not Recommended
below 200 WFS
Not Recommended
below 100 WFS
Not Recommended
below 200 WFS
Not Recommended
below 200 WFS
COMMENTS
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C-1
C-1
TABLE OF CONTENTS - ACCESSORIES SECTION
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-1
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C-2
C-2
ACCESSORIES
OPTIONAL EQUIPMENT
FACTORY INSTALLED
None Available.
FIELD INSTALLED
K940-Work Voltage Sense Lead Kit
K1764-1-Undercarriage*
K1838-1-Valet Style Undercarriage
K1796-Coaxial Welding Cable-(Requires Adapter K2176-1)
K2176-1 Twist-mate to Lug Adapters
* Dual Cylinder Kit for K1764-1 is K1702-1
K2436-1 Ethernet/Devicenet Communication Interface
Welding Cable Connectors:
K852-70 1/0-2/0 CABLE
K852-95 2/0-3/0 CABLE
COMPATIBLE LINCOLN EQUIPMENT
Any ARC Link compatible wire feeding equipment
PF10M, PF15M, PF25M series.
NOTE: No Linc-Net semi-automatic wire feeding equip-
ment is compatible. Specifically, the semi-automatic
Power Feed family (PF-10, PF-10X2, PF-11) will not
work with a PW355M/405M.
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D-1
D-1
TABLE OF CONTENTS - MAINTENANCE SECTION
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-1
Periodic Maintenance..................................................................................................................................D-2
Major Component Locations.......................................................................................................................D-3
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D-2
D-2
MAINTENANCE
VISUAL INSPECTION
WARNING
Clean interior of machine with a low pressure air
stream. Make a thorough inspection of all compo-
Have qualified personnel do the maintenance
work. Always use the greatest care when
working near moving parts.
nents. Look for signs of overheating, broken leads or
other obvious problems. Many problems can be
uncovered with a good visual inspection.
Do not put your hands near the cooling blower
fan. If a problem cannot be corrected by
following the instructions, take the machine to
the nearest Lincoln Field Service Shop.
ROUTINE MAINTENANCE
1. Every 6 months or so the machine should be
cleaned with a low pressure airstream. Keeping
the machine clean will result in cooler operation
and higher reliability. Be sure to clean these
areas:
-----------------------------------------------------------------------
ELECTRIC SHOCK can kill.
• Do not touch electrically live parts or
electrode with skin or wet clothing.
• Insulate yourself from work and
ground
• All printed circuit boards
• Power switch
• Main transformer
• Always wear dry insulating gloves.
------------------------------------------------------------------------
EXPLODING PARTS can cause
• Input rectifier
• Auxiliary Transformer
• Reconnect Switch Area
• Fan (Blow air through the rear louvers)
injury.
•
Failed parts can explode or cause other
parts to explode when power is applied.
2. Examine the sheet metal case for dents or breakage.
Repair the case as required. Keep the case in good
condition to insure that high voltage parts are protected
and correct spacings are maintained. All external sheet
metal screws must be in place to insure case strength
and electrical ground continuity.
•
Always wear a face shield and long sleeves
when servicing.
------------------------------------------------------------------------
See additional warning information
throughout this Manual.
------------------------------------------------------------------------
PERIODIC MAINTENANCE
Calibration of the POWER WAVE 355M/405M is critical
to its operation. Generally speaking the calibration will
not need adjustment. However, neglected or improper-
ly calibrated machines may not yield satisfactory weld
performance. To ensure optimal performance, the cali-
bration of output Voltage and Current should be
checked yearly.
CAPACITOR DISCHARGE PROCEDURE
1. Obtain a power resistor (25 ohms, 25 watts).
2. Hold resistor body with electrically insulated glove.
DO NOT TOUCH TERMINALS. Connect the resis-
tor terminals across the two studs in the position
shown. Hold in each position for 1 second. Repeat
for all four capacitors.
Calibration is accomplished with our Diagnostic Utility
software found on the Lincoln Electric Service
Navigator CD or on our web site at www.lincoln-
electric.com.
RESISTOR
If a welder has difficulty in being calibrated some things
to look for proper configuration of the sense leads.
Make sure your meter is measuring at the same point
as the power source - local (studs) or remote (feeder).
CAPACITOR
TERMINALS
All meters used for calibration checks must be calibrat-
ed and traceable to National Standards. Some digital
meters may not function properly with inverter sup-
plies. Try an analog type meter and calibrate around
300 amps @ 30V loading in all cases.
3. Use a DC voltmeter to check that voltage is not
present across the terminals on all four capaci-
tors.
POWER WAVE 355M/405M
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D-3
D-3
MAINTENANCE
FIGURE D.1 – MAJOR COMPONENT LOCATIONS
1. Center Panel
2. Case Back
3. Case Front
Use parts page exploded views to also help iso-
late and identify smaller parts. Parts page num-
bers can be found on the Master Table of
Contents in the front of this manual.
4. Base Assembly
5. Case Wraparound
!
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POWER WAVE 355M/405M
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D-4
D-4
NOTES
POWER WAVE 355M/405M
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E-1
E-1
TABLE OF CONTENTS-THEORY OF OPERATION SECTION
Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-1
Switch Board and Main Transformer.........................................................................................................E-3
DC Bus Board, Power board and Control Board......................................................................................E-4
Output Rectifier and Choke.......................................................................................................................E-5
Thermal Protection ...................................................................................................................................E-6
Over current Protection.......................................................................................................................E-6
Insulated Gate Bipolar Transistor (IGBT) Operation ..................................................................................E-7
FIGURE E.1 BLOCK LOGIC DIAGRAM
To Control
Main Switch Board
Board
Positive
Output
Terminal
Input
Rectifier
Primary
Current
Sensor
Input switch
Choke
Negative
Output
Terminal
Reconnect
Switch
Primary
Current
Sensor
Fan
Primary Current Feedback(2)
115VAC Fan Supply
Input Relay Control
Soft Start Control
V/F Capacitor Feedback (2)
Auxiliary
Transformer
P
o
w
e
r
220 VAC
Machine Control Supply
+15VDC, -15VDC, +5VDC
Yellow
Thermal
LED
W
a
40VDC
Power
Board
v
e
Control Board
Status
Red/Green
LED
RS232 Supply +5VDC
Can Supply +5VDC
42VAC
4
0
5
220
Receptacle
{
o
n
l
Arc
Link
DC
Bus
Board
Electrode
Sense
21 Lead
y
Wire
Feeder
Recp.
Voltage
Sense
Recp.
40VDC
R232
Connector
Thermostats
2
To
Feeder
POWER WAVE 355M/405M
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E-2
E-2
THEORY OF OPERATION
FIGURE E.2 - GENERAL DISCRIPTION
Main Switch Board
Board
Positive
Output
Terminal
Input
Rectifier
Primary
Current
Sensor
Input switch
Choke
Negative
Output
Terminal
Reconnect
Switch
Primary
Current
Sensor
Fan
Primary Current Feedback(2)
115VAC Fan Supply
Input Relay Control
Soft Start Control
V/F Capacitor Feedback (2)
Auxiliary
Transformer
P
o
w
e
r
220 VAC
Machine Control Supply
+15VDC, -15VDC, +5VDC
Yellow
Thermal
LED
W
a
40VDC
Power
Board
v
e
Control Board
Status
Red/Green
LED
RS232 Supply +5VDC
Can Supply +5VDC
42VAC
4
0
5
220
Receptacle
o
n
l
Arc
Link
DC
Bus
Board
Electrode
Sense
21 Lead
y
Wire
Feeder
Recp.
Voltage
Sense
Recp.
40VDC
R232
Connector
Thermostats
2
develops three different secondary voltages. The
115VAC is applied, via the main switch board, to the
fan motor. The 42VAC is rectified and filtered. The
65VDC produced by the Bus board rectifier is used by
the Bus board to provide 40VDC to the power board.
40VDC is also applied to the wire feeder receptacle.
PW405 models have an additional 220VAC winding
that is connected to a 220 AC receptacle.
GENERAL DESCRIPTION
The Power Wave semi-automatic power source is
designed to be a part of a modular, multi-process
welding system. Depending on configuration, it can
support constant current, constant voltage, and pulse
welding modes.
The Power Wave power source is designed to be used
with the semi-automatic family of power feed wire
feeders, operating as a system. Each component in
the system has special circuitry to “talk with” the other
system components, so each component (power
source, wire feeder, user interface) knows what the
other is doing at all times. These components com-
municate with Arc Link (a digital communications sys-
tem).
The input voltage is rectified by the input rectifier and
the resultant DC voltage is applied to the switch board
through the reconnect switch assembly located at the
rear of the machine. The reconnect switch connects
the two pairs of input capacitors either in a parallel
(lower voltage) or series (higher voltage) configuration
to accommodate the applied input voltage.
During the precharge time the DC input voltage is
applied to the input capacitors through a current limit-
ing circuit. The input capacitors are charged slowly
and current limited. A voltage to frequency converter
circuit located on the switch board monitors the
capacitor voltages. This signal is coupled to the con-
trol board. When the input capacitors have charged
to an acceptable level, the control board energizes the
input relays, that are located on the switch board,
making all of the input power, without current limiting,
available to the input capacitors. If the capacitors
become under or over voltage the control board will
de-energize the input relays and the 355M/405M out-
put will be disabled. Other possible faults may also
cause the input relays to drop out.
The POWER WAVE 355M/405M is a high performance,
digitally controlled inverter welding power source
capable of complex, high speed waveform control.
Properly equipped, it can support the GMAW, GMAW-
P, FCAW, SMAW, GTAW, and CAC-A processes. It car-
ries an output rating of 350 Amps, 34 Volts at 60%
duty cycle and 300 Amps, 32 volts at 100% duty cycle.
INPUT LINE VOLTAGE, AUXILIARY
TRANSFORMER, & PRECHARGE
The POWER WAVE 355M/405M can be connected for
a variety of three-phase or single-phase input volt-
ages. The initial power is applied to the 355M/405M
through a line switch located on the front of the
machine. Two phases of the input voltage are applied
to the auxiliary transformer. The auxiliary transformer
NOTE: Unshaded areas of Block Logic
Diagram are the subject of discussion
POWER WAVE 355M/405M
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E-3
E-3
THEORY OF OPERATION
FIGURE E.3 – SWITCH BOARD & MAIN TRANSFORMER
To Control
Main Switch Board
Board
Positive
Output
Terminal
Input
Rectifier
Primary
Current
Sensor
Input switch
Choke
Negative
Output
Terminal
Reconnect
Switch
Primary
Current
Sensor
Fan
Primary Current Feedback(2)
115VAC Fan Supply
Input Relay Control
Soft Start Control
V/F Capacitor Feedback (2)
Auxiliary
Transformer
P
o
w
e
r
220 VAC
Machine Control Supply
+15VDC, -15VDC, +5VDC
Yellow
Thermal
LED
W
a
40VDC
Power
Board
v
e
Control Board
Status
Red/Green
LED
RS232 Supply +5VDC
Can Supply +5VDC
42VAC
4
0
5
220
Receptacle
o
n
l
Arc
Link
DC
Bus
Board
Electrode
Sense
21 Lead
y
Wire
Feeder
Recp.
Voltage
Sense
Recp.
40VDC
R232
Connector
Thermostats
2
To
SWITCH BOARD &
MAIN TRANSFORMER
AC square wave output signal at the secondary of the
main transformer. The two current transformers (CT)
located on the switch board monitor these primary
currents. If the primary currents become abnormally
high the control board will shut off the IGBTs, thus dis-
abling the machine output. The DC current flow
through each primary winding is clamped back to
each respective input capacitor when the IGBTs are
turned off. This is needed due to the inductance of the
transformer primary winding. The firing of the two
switch boards occurs during halves of a 50 microsec-
ond interval, creating a constant 20 KHZ output. In
some low open circuit Tig modes the firing frequency
is reduced to 5KHZ.
There is one switch board in the POWER WAVE
355M/405M. This board incorporates two pairs of
input capacitors, two insulated gate bipolar transistor
(IGBT) switching circuits, a fan motor drive circuit, and
a voltage/frequency capacitor feedback circuit. The
two capacitors in a pair are always in series with each
other. When the reconnect switch is in the lower volt-
age position the capacitor pairs are in parallel - that is,
two series capacitors in parallel with two series capac-
itors. When the reconnect switch is in the high voltage
position the two capacitor pairs are in series or, four
capacitors in series. This is required to accommodate
the higher input voltages.
When the input capacitors are fully charged they act
as power supplies for the IGBT switching circuits.
When welding output is required the Insulated Gate
Bipolar Transistors switch the DC power from the input
capacitors, "on and off" thus supplying a pulsed DC
section. Each IGBT switching circuit feeds current to
a separate, oppositely wound primary winding in the
main transformer. The reverse directions of current
flow through the main transformer primaries and the
offset timing of the IGBT switching circuits induce an
The POWER WAVE 355M/405M has a F.A.N. (fan as
needed) circuit. The fan operates when the welding
output terminals are energized or when a thermal over
temperature condition exists. Once the fan is activat-
ed it will remain on for a minimum of five minutes. The
fan driver circuit is housed on the switch board but it
is activated by a signal from the control board.
NOTE: Unshaded areas of Block Logic
Diagram are the subject of discussion
POWER WAVE 355M/405M
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E-4
E-4
THEORY OF OPERATION
FIGURE E.4 – POWER BOARD, CONTROL BOARD AND SERIAL PERIPHERAL INTERFACE (SPI) COMMUNICATIONS
To Control
Main Switch Board
Board
Positive
Output
Terminal
Input
Rectifier
Primary
Current
Sensor
Input switch
Choke
Negative
Output
Terminal
Reconnect
Switch
Primary
Current
Sensor
Fan
Primary Current Feedback(2)
115VAC Fan Supply
Input Relay Control
Soft Start Control
V/F Capacitor Feedback (2)
Auxiliary
Transformer
P
o
w
e
r
220 VAC
Machine Control Supply
+15VDC, -15VDC, +5VDC
Yellow
Thermal
LED
W
a
40VDC
Power
Board
v
e
Control Board
Status
Red/Green
LED
RS232 Supply +5VDC
Can Supply +5VDC
42VAC
4
0
5
220
Receptacle
{
o
n
l
Arc
Link
DC
Bus
Board
Electrode
Sense
21 Lead
y
Wire
Feeder
Recp.
Voltage
Sense
Recp.
40VDC
R232
Connector
Thermostats
2
To
Feeder
DC BUS BOARD, POWER BOARD CONTROL BOARD
AND CONTROL BOARD
The Control Board performs the primary interfacing
functions to establish and maintain output control of
the POWER WAVE 355M/405M. The function genera-
tor and weld files exist within the Control Board hard-
ware and software. Digital command signals received
from the user interface/feed head and feedback infor-
mation received from the current sensor and output
voltage sensing leads, are processed at the control
board. Software within the control board processes
the command and feedback information and sends the
appropriate pulse width modulation (PWM) signals
the switch board IGBT’s. In this manner, the digitally
controlled high speed welding waveform is created.
DC BUS BOARD
The DC Bus Board receives approximately 65VDC
from the bus board rectifier. The DC Bus Board regu-
lates that 65VDC to a +40VDC supply. This regulated
40VDC is applied to the Power Board and the wire
feed receptacles.
POWER BOARD
The power board, utilizing a switching power supply,
processes the 40VDC input and develops several reg-
ulated positive and negative DC supplies. Three DC
supplies are fed to the control board for machine con-
trol supplies. A +5VDC is used for the RS232 connec-
tion supply. Another +5VDC supply is utilized by the
CAN digital communication circuitry. An over or under
input voltage detection and shutdown circuit is also
part of the power board’s circuitry.
In addition, the Control Board monitors the ther-
mostats, the main transformer primary currents and
input filter capacitor voltages. Depending on the fault
condition, the Control Board will activate the thermal
and/or the status light and will disable or reduce the
machine’s output.
NOTE: Unshaded areas of Block Logic
Diagram are the subject of discussion
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E-5
E-5
THEORY OF OPERATION
FIGURE E.5 – OUTPUT RECTIFIER AND CHOKE
To Control
Board
Main Switch Board
Positive
Output
Terminal
Input
Rectifier
Primary
Current
Sensor
Input switch
Choke
Negative
Output
Terminal
Reconnect
Switch
Primary
Current
Sensor
Fan
Primary Current Feedback(2)
Input Relay Control
115VAC Fan Supply
Soft Start Control
V/F Capacitor Feedback (2)
Auxiliary
Transformer
P
o
w
e
r
220 VAC
Machine Control Supply
+15VDC, -15VDC, +5VDC
Yellow
Thermal
LED
W
a
40VDC
Power
Board
v
e
Control Board
Status
Red/Green
LED
RS232 Supply +5VDC
Can Supply +5VDC
42VAC
4
0
5
220
Receptacle
{
o
n
l
Arc
Link
DC
Bus
Board
Electrode
Sense
21 Lead
y
Wire
Feeder
Recp.
Voltage
Sense
Recp.
40VDC
R232
Connector
Thermostats
2
To
Feeder
OUTPUT RECTIFIER AND CHOKE
The output rectifier receives the AC output from the
main transformer secondary and rectifies it to a DC
voltage level. Since the output choke is in series with
the negative leg of the output rectifier and also in
series with the welding load, a filtered DC output is
applied to the machine’s output terminals.
NOTE: Unshaded areas of Block Logic
Diagram are the subject of discussion
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E-6
E-6
THEORY OF OPERATION
THERMAL PROTECTION
OVER CURRENT PROTECTION
Three normally closed (NC) thermostats protect the
machine from excessive operating temperatures.
These thermostats are wired in series and are con-
nected to the control board. One of the thermostats is
located on the heat sink of the switch board, one is
located on the output choke and the third thermostat
is located on the DC Bus Board. Excessive tempera-
tures may be caused by a lack of cooling air or oper-
ating the machine beyond its duty cycle or output rat-
ing. 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 turn-
ing or the air intake louvers are obstructed, then the
power must be removed from the machine, and the
fan problem or air obstruction corrected.
If the average current exceeds 450 amps for one sec-
ond, then the output will be limited to 100 amps until
the load is removed. If the peak current exceeds 600
amps for 150 ms, the output will be limited to 100
amps until the load is removed.
UNDER/OVER VOLTAGE PROTECTION
Protective circuits are included on the switch and con-
trol boards to monitor the voltage across the input
capacitors. In the event that a capacitor pair voltage
is too high, or too low, the machine output will be dis-
abled. The protection circuits will prevent output if any
of the following conditions exist.
1. Voltage across a capacitor pair exceeds 467
volts. (High line surges or improper input voltage
connections.)
2. Voltage across a capacitor pair is under 190 volts.
(Due to improper input voltage connections.)
PROTECTIVE CIRCUITS
3. Any major internal component damage.
Protective circuits are designed into the POWER
WAVE 355M/405M to sense trouble and shut down
the machine before damage occurs to the machine's
internal components.
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E-7
E-7
THEORY OF OPERATION
capable of conducting current. A voltage supply con-
nected to the drain terminal will allow the IGBT to con-
duct and supply current to the circuit components
coupled to the source. Current will flow through the
conducting IGBT to downstream components as long
as the positive gate signal is present. This is similar to
turning ON a light switch.
INSULATED GATE BIPOLAR
TRANSISTOR (IGBT)
OPERATION
An IGBT is a type of transistor. IGBT are semiconduc-
tors well suited for high frequency switching and high
current applications.
Example A in Figure E.6 shows an IGBT in passive
mode. There is no gate signal, zero volts relative to the
source, and therefore, no current flow. The drain ter-
minal of the IGBT may be connected to a voltage sup-
ply; but since there is no conduction, the circuit will not
supply current to components connected to the
source. The circuit is turned OFF like a light switch.
Example B shows the IGBT in an active mode. When
the gate signal , a positive DC voltage relative to the
source, is applied to the gate terminal of the IGBT, it is
FIGURE E.6 – IGBT
POSITIVE
VOLTAGE
APPLIED
GATE
GATE
SOURCE
SOURCE
n +
n +
n +
n +
p
BODY REGION
p
BODY REGION
DRAIN DRIFT REGION
DRAIN DRIFT REGION
n -
n -
n +
p +
BUFFER LAYER
n +
p +
BUFFER LAYER
INJECTING LAYER
INJECTING LAYER
DRAIN
DRAIN
B. ACTIVE
A. PASSIVE
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E-8
E-8
THEORY OF OPERATION
FIGURE E.7 — TYPICAL IGBT OUTPUTS.
MAXIMUM OUTPUT
PULSE WIDTH
MODULATION
By holding the gate signal on for 24 microseconds
each, and allowing only two microseconds of dwell
time (off time) during the 50-microsecond cycle, the
output is maximized. The darkened area under the top
curve can be compared to the area under the bottom
curve. The more dark area that is under the curve indi-
cates that more power is present.
The term Pulse Width Modulation is used to describe
how much time is devoted to conduction in the posi-
tive and negative portions of the cycle. Changing the
pulse width is known as modulation. Pulse Width
Modulation (PWM) is the varying of the pulse width
over the allowed range of a cycle to affect the output
of the machine.
1
An IGBT group consists of two IGBT modules feed-
ing one transformer primary winding.
MINIMUM OUTPUT
By controlling the duration of the gate signal, the IGBT
is turned on and off for different durations during the
cycle. The top drawing in Figure E.7 shows the mini-
mum output signal possible over a 50-microsecond
time period.
The positive portion of the signal represents one IGBT
1
group conducting for one microsecond. The negative
1
portion is the other IGBT group . The dwell time (off
time) is 48 microseconds (both IGBT groups off). Since
only two microseconds of the 50-microsecond time
period is devoted to conducting, the output power is
minimized.
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F-1
F-1
TABLE OF CONTENTS - TROUBLESHOOTING AND REPAIR
Troubleshooting and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-1
How to Use Troubleshooting Guide..........................................................................................................F-2
PC Board Troubleshooting Procedures and Replacement.......................................................................F-3
Test Procedures
Input Filter Capacitor Discharge Procedure.....................................................................................F-13
Main Switch Board Test....................................................................................................................F-15
Input Rectifier Test............................................................................................................................F-19
Power Board Test .............................................................................................................................F-23
DC Bus Board Test...........................................................................................................................F-27
Output Rectifier Modules Test..........................................................................................................F-31
Auxiliary Transformer Test.................................................................................................................F-35
Current Transducer Test ...................................................................................................................F-39
Fan Control and Motor Test..............................................................................................................F-43
Replacement Procedures
DC Bus Board Removal and Replacement......................................................................................F-61
Output Rectifier Modules Removal and Replacement.....................................................................F-69
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F-2
F-2
TROUBLESHOOTING AND REPAIR
HOW TO USE TROUBLESHOOTING GUIDE
WARNING
Service and Repair should only be performed by Lincoln Electric Factory Trained
Personnel. Unauthorized repairs performed on this equipment may result in danger to
the technician and machine operator and will invalidate your factory warranty. For your
safety and to avoid Electrical Shock, please observe all safety notes and precautions
detailed throughout this manual.
---------------------------------------------------------------------------------------------------------------------------
Step 3. RECOMMENDED
COURSE OF ACTION
The last column labeled “Recommended
This Troubleshooting Guide is provided to
help you locate and repair possible machine
malfunctions. Simply follow the three-step
Course of Action” lists the most likely com-
procedure listed below.
ponents that may have failed in your
machine. It also specifies the appropriate
test procedure to verify that the subject com-
ponent 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.
Step 1. LOCATE PROBLEM (SYMPTOM).
Look under the column labeled “PROBLEM
(SYMPTOMS)”. This column describes pos-
sible symptoms that the machine may exhib-
it. Find the listing that best describes the
symptom that the machine is exhibiting.
Symptoms are grouped into the following
categories: output problems, function prob-
lems, wire feeding problems, and welding
problems.
All of the referenced test procedures referred
to in the Troubleshooting Guide are
described in detail at the end of this chapter.
Refer to the Troubleshooting and Repair
Table of Contents to locate each specific
Test Procedure. All of the specified test
points, components, terminal strips, etc. can
be found on the referenced electrical wiring
diagrams and schematics. Refer to the
Electrical Diagrams Section Table of
Contents to locate the appropriate diagram.
Step 2. PERFORM EXTERNAL TESTS.
The second column labeled “POSSIBLE
AREAS OF MISADJUSTMENT(S)” lists the
obvious external possibilities that may con-
tribute to the machine symptom. Perform
these tests/checks in the order listed. In
general, these tests can be conducted with-
out removing the case wrap-around cover.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the
tests/repairs safely, contact the Lincoln Electric Service Department for technical troubleshooting
assistance before you proceed. Call 1-888-935-3877.
-----------------------------------------------------------------------------------------------------------------------------------
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F-3
F-3
TROUBLESHOOTING AND REPAIR
PC BOARD TROUBLESHOOTING PROCEDURES
- Remove the PC board from the static-shielding bag
and place it directly into the equipment. Don’t set the
PC board on or near paper, plastic or cloth which
could have a static charge. If the PC board can’t be
installed immediately, put it back in the static-shield-
ing bag.
WARNING
ELECTRIC SHOCK
can kill.
•
Have an electrician install and
service this equipment. Turn the
input power OFF at the fuse box
before working on equipment. Do
not touch electrically hot parts.
- 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 prop-
er failure analysis.
CAUTION
Sometimes machine failures appear to be due to PC
board failures. These problems can sometimes be
traced to poor electrical connections. To avoid prob-
lems when troubleshooting and replacing PC boards,
please use the following procedure:
4. Test the machine to determine if the failure
symptom has been corrected by the
replacement PC board.
NOTE: It is desirable to have a spare (known good)
PC board available for PC board troubleshooting.
1. Determine to the best of your technical ability
that the PC board is the most likely component
causing the failure symptom.
NOTE: Allow the machine to heat up so that all
electrical components can reach their operating
temperature.
2. Check for loose connections at the PC board to
assure that the PC board is properly connected.
5. Remove the replacement PC board and
substitute it with the original PC board to
recreate the original problem.
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:
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.
PC board can be damaged by static electricity.
b. If the original problem is recreated by the
substitution of the original board, then the PC
board was the problem. Reinstall the
replacement PC board and test the machine.
- 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
6. Always indicate that this procedure was
followed when warranty reports are to be
submitted.
frame.
ATTENTION
Static-Sensitive
Devices
Handle only at
Static-Safe
- If you don’t have a wrist strap,
touch an un-painted, grounded,
part of the equipment frame. Keep
touching the frame to prevent
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.
Workstations
static build-up. Be sure not to
touch any electrically live parts at
the same time.
- Tools which come in contact with the PC board must
be either conductive, anti-static or static-dissipative.
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F-4
Observe Safety Guidelines detailed in the beginning of this manual.
F-4
TROUBLESHOOTING AND REPAIR
PROBLEMS
POSSIBLE AREAS OF
MISADJUSTMENT(S)
RECOMMENDED
(SYMPTOMS)
COURSE OF ACTION
OUTPUT PROBLEMS
Major physical or electrical damage 1. Contact your local authorized 1. Contact the Lincoln Electric
is evident when the sheet metal
cover is removed.
Lincoln Electric Field Service
Facility for technical assistance.
Service Department,
1-888-935-3877.
The machine is dead—no output— 1. Make sure the input line switch is 1. Perform the Auxiliary Trans-
no LED’s.
in the ON position.
2. Check the main input line fuses.
If open , replace.
3. Check the 15 amp circuit break-
er (CB1). Reset if tripped. Also
check CB3.
3. The Bus Board rectifier and or
associated filter capacitor (C5)
may be faulty.
replace as necessary.
Check and
4. Make sure the reconnect switch
and jumper lead is configured
correctly for the applied input
voltage.
4. The Control Board may be faulty.
5. If the machine is being operated
with single phase input voltage
make sure the correct lead is not
The main input fuses (or breaker) 1. Make certain the fuses or break- 1. Check the reconnect switches
repeatedly fail.
ers are sized properly.
and associated wiring. See the
Wiring Diagram.
2. Make sure the reconnect switch
and jumper lead is configured
correctly for the applied input
voltage.
3. Perform the Main Switch Board
3. The welding procedure may be
drawing too much input current
or the duty cycle may be too
high. Reduce the welding cur-
rent and /or reduce the duty
cycle.
5. The Input Filter Capacitors may
be faulty. Check, and if any are
faulty replace all four.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely,
contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed.
Call 1-888-935-3877.
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F-5
Observe Safety Guidelines detailed in the beginning of this manual.
F-5
TROUBLESHOOTING AND REPAIR
PROBLEMS
POSSIBLE AREAS OF
MISADJUSTMENT(S)
RECOMMENDED
(SYMPTOMS)
COURSE OF ACTION
OUTPUT PROBLEMS
The machine does not have weld-
ing output.
1. Make sure the reconnect switch 1. Check the reconnect switch and
is configured correctly for the
input voltage applied.
associated leads for loose or
faulty connections. See the
wiring diagram.
2. Primary current limit has been
exceeded. Possible short in
output circuit. Turn machine
off. Remove all loads from the
output of the machine. Turn
back on. If condition persists,
turn power off, and contact an
authorized Lincoln Electric Field
Service Facility.
2. Perform the DC Bus Board
3. This problem will normally be
accompanied by an error code.
Error codes are displayed as a
series of red and green flashes
by the status LED.
6. The control board may be faulty.
7. The input filter capacitors may
be faulty. Check and replace if
necessary.
4. If an error code is displayed
If thermal light is on, wait for
machine to cool.
The POWER WAVE 355M/405M
will not produce full output.
1. The input voltage may be too
low, limiting the output capabili-
ty of the machine. Make cer-
tain the input voltage is correct
for the machine and the recon-
nect switch and jumper lead
configuration are correct.
1. Perform the Output Rectifier
2. The output current or voltage
may not be calibrated correctly.
Check the values displayed on
the Power Feed 10/11 versus
readings on an external voltage
and ammeter.
5. The control board may be
faulty.
3. The welding current may be too
high . The machine will fold
back to 100 amps if the weld-
ing current exceeds 450 amps.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely,
contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed.
Call 1-888-935-3877.
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F-6
Observe Safety Guidelines detailed in the beginning of this manual.
F-6
TROUBLESHOOTING AND REPAIR
PROBLEMS
POSSIBLE AREAS OF
MISADJUSTMENT(S)
RECOMMENDED
(SYMPTOMS)
COURSE OF ACTION
FUNCTION PROBLEMS
The machine regularly overheats 1. The welding application may
and the yellow thermal light is ON
indicating a thermal overload.
1. The 115VAC fan motor is con-
trolled by the control board via
the main switch board. Perform
be exceeding the recommended
duty cycle of the POWER WAVE
355M/405M.
2. Dirt and dust may have clogged
the cooling channels inside the 1. A thermostat or associated cir-
machine.
cuitry may be faulty. See the
wiring diagram. One normally
closed thermostat is located on
the output choke, one on the DC
Bus Board and the other is
located on the main switch
board heat sink. See the wiring
diagram.
3. Air intake and exhaust louvers
may be blocked due to inade-
quate clearance around the
machine.
4. Make certain the fan as needed
(F.A.N.) is operating properly.
The fan should operate when
welding voltage is present
and/or when there is an over
temperature condition.
Note: The Main Switch Board
Removal Procedure will be
required to gain access to
the heat sink thermostat.
An attached wire feeder will not 1. Make certain the wire feeder 1. Check for 40 VDC on pin “D” (+)
function correctly. Apparently the
wire feeder is not being powered-
up.
control cable is connected to
the wire feeder receptacle. See
the Wiring Diagram.
and pin “E” (-) at the Power Wave
wire feeder receptacle. See
Wiring Diagram.
If 40 volts DC is Not present at
the Power Wave wire feeder
receptacle, perform the DC Bus
2. Check the two circuit breakers
located at the front of the
machine. Reset if tripped.
3. The wire feeder or control cable
may be faulty.
2. Check the DC Bus Board rectifi-
er. See Wiring Diagram.
3. Perform the T1 Auxiliary trans-
4. If the 40 volts DC is present at
the Power Wave wire feeder
receptacle, the problem is in the
control cable or the wire
drive/control box.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely,
contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed.
Call 1-888-935-3877.
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F-7
Observe Safety Guidelines detailed in the beginning of this manual.
F-7
TROUBLESHOOTING AND REPAIR
PROBLEMS
POSSIBLE AREAS OF
MISADJUSTMENT(S)
RECOMMENDED
(SYMPTOMS)
COURSE OF ACTION
FUNCTION PROBLEMS
The machine often “noodle welds” 1. The machine may be trying to 1. Perform
the
with a particular procedure. The
output is limited to approximately
100 amps.
deliver too much power. When
the average output current
exceeds a maximum limit, the 2. The control board may be faulty.
machine will “phase back” to
protect itself. Adjust the proce-
dure or reduce the load to lower
the current draw from the Power
Wave machine.
Excessively long and erratic arc.
1. Check for proper configuration 1. Check the connections between
and implementation of voltage
sensing circuits.
the voltage sense receptacle
and the control board. See the
Wiring Diagram.
2. The control board may be faulty.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely,
contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed.
Call 1-888-935-3877.
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F-8
Observe Safety Guidelines detailed in the beginning of this manual.
F-8
TROUBLESHOOTING AND REPAIR
PROBLEMS
POSSIBLE AREAS OF
MISADJUSTMENT(S)
RECOMMENDED
(SYMPTOMS)
COURSE OF ACTION
FUNCTION PROBLEMS
auxiliary voltage.
front) may have opened. Reset.
2. Circuit breaker CB3 (in recon-
nect area) may have opened.
Reset.
3. On PW 405 models, the circuit
breaker CB4 protects the
220VAC receptacle. Reset if
tripped.
A fault or error code is displayed.
1. See Fault Code Explanations.
1. See Fault Code Explanations.
General degradation of the weld 1. Check for feeding problems, 1. Perform the Voltage and
performance.
bad connections, excessive
loops in cabling, etc.
Current Calibration Procedure
using the Power Wave software
program.
2. Verify weld mode is correct for
processes.
3. The power source may require
calibration.
4. Check the actual current dis-
played on the Power Feed 10 5. The control board may be
vs. actual current measured via
external meter.
faulty.
5. Check the actual voltage dis-
played on the Power Feed 10
vs. actual voltage measured via
external meter.
6. Check the actual WFS displayed
on the Power Feed 10 vs. actual
WFS measured via external
meter.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely,
contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed.
Call 1-888-935-3877.
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F-9
F-9
TROUBLESHOOTING AND REPAIR
power source Status LED, and some basic trou-
USING THE STATUS LED TO
bleshooting charts for both machine and weld perfor-
mance.
TROUBLESHOOT SYSTEM PROBLEMS
The Power Wave / Power Feed are best diagnosed as
a system. Each component (power source, user
interface, and feed head) has a status light, and when
a problem occurs it is important to note the condition
of each. In addition, errors displayed on the user
interface in most cases indicate only that a problem
exists in the power source, not what the problem may
be. Therefore, prior to cycling power to the sys-
tem, check the power source status light for error
sequences as noted below. This is especially
important if the user interface displays “Err 006”
or “Err 100”.
The STATUS LIGHT is a two color light that indicates
system errors. Normal operation is a steady green
light. Error conditions are indicated in the following
chart.
NOTE: The POWER WAVE 355M/405M status light
will flash green, and sometimes red and green, for up
to one minute when the machine is first turned on.
This is a normal situation as the machine goes
through a self test at power up.
Included in this section is information about the
LIGHT CONDITION
INDICATION
Status LED is solid green (no blinking)
1. System OK. Power source communicating nor-
mally with wire feeder and its components.
Status LED is blinking green
2. Occurs during a reset, and indicates the
POWER WAVE 355M/405M is mapping (identi-
fying) each component in the system. Normal
for first 1-10 seconds after power is turned on,
or if the system configuration is changed during
operation.
Status LED is blinking red and green
3. Non-recoverable system fault. If the PS Status
light is flashing any combination of red and
green, errors are present in the POWER WAVE
355M/405M. Read the error code before the
machine is turned off.
Error Code interpretation through the Status
light is detailed in the Service Manual.
Individual code digits are flashed in red with a
long pause between digits. The codes will be
separated by a green light. There may be more
than one error code indicated.
To clear the error, turn power source off, and
back on to reset.
Status LED is solid red (no blinking).
Status LED is blinking red.
Non-recoverable hardware fault. Generally indi-
cates nothing is connected to the POWER
WAVE 355M/405M wire feeder receptacle. See
Not applicable
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F-10
F-10
TROUBLESHOOTING AND REPAIR
ERROR CODES FOR THE POWER WAVE
The following is a list of possible error codes that the POWER WAVE 355M/405M can output via the status light
If connected to a PF-10/11 these error codes will generally be accompanied by an “Err 006” or “Err 100” on the
user interface display.
Individual code digits are flashed in RED with a long pause between digits. Complete codes are seprated by one
GREEN light. There may be more than one error code indicated
Example: Error code 31
- Red, red, red pause, red, green.
Error codes 32 & 34 - Red, red, red, pause Red,red, Green, Red,red,red, pause
Red,red,red,red, Green. Sequence will repeat continuously.
STATUS LED ERROR CODE TABLE
11
12
CAN communication bus off.
User interface time out error.
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.
Unprogrammed weld mode.
Empty weld table.
21
22
Contact the service department for instructions on reloading
the Welding Software.
Contact the service department for instructions on reloading
the Welding Software.
Weld table checksum error.
Primary overcurrent error.
Capacitor “A” under voltage.
Capacitor “B” under voltage.
23
31
32
33
Excessive Primary current present. May be related to a
short in the main transformer or output rectifier.
Low voltage on the main capacitors. May be caused by
improper input configuration.
When accompanied by an overvoltage error on the same
side, it indicates no capacitor voltage present on that side,
and is usually the result of an open or short in the primary
side of the machine.
Capacitor “A” overvoltage.
Capacitor “B” overvoltage.
34
35
Excessive voltage on the main capacitors. May be caused
by improper input configuration.
When accompanied by an under voltage error on the same
side, it indicates no capacitor voltage present on that side,
and is usually the result of an open or short in the primary
side of the machine.
Indicates over temperature. Usually accompanied by ther-
mal LED. Check fan operation. Be sure process does not
exceed duty cycle limit of the machine.
36
Thermal error.
Capacitor precharge failed. Usually accompanied by codes
32-35.
37
41
Softstart error.
The secondary (weld) current limit has been exceeded.
When this occurs the machine output will phase back to
100 amps, typically resulting in a condition referred to as
“noodle welding”
Secondary overcurrent error
NOTE: The secondary limit is 570 for the standard stud, and
325 amps for all single phase operation.
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F-11
F-11
The maximum voltage difference between the main capaci-
TROUBLESHOOTING AND REPAIR
43
Capacitor delta error.
tors has been exceeded. May be accompanied by errors
32-35. Check the output diodes.
Error codes that contain three or four digits are defined as
fatal errors. These codes generally indicate internal errors
on the Control Board. If cycling the input power on the
machine does not clear the error, try reloading the operating
system. If this fails, replace the Control Board.
Other
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F-12
F-12
NOTES
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F-13
F-13
TROUBLESHOOTING AND REPAIR
INPUT FILTER CAPACITOR DISCHARGE PROCEDURE
WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician
or machine operator and will invalidate your factory warranty. For your safety and to avoid
electrical shock, please observe all safety notes and precautions detailed throughout this
manual.
If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou-
bleshooting assistance before you proceed. Call 1-888-935-3877.
TEST DESCRIPTION
This procedure will drain off any charge stored in the four large capacitors that are part
of the switch board assembly. This procedure MUST be performed, as a safety pre-
caution, before conducting any test or repair procedure that requires you to touch inter-
nal components of the machine.
MATERIALS NEEDED
5/16” Nut Driver
Insulated Pliers
Insulated Gloves
High Wattage Resistor (25-1000 ohms and 25 watts minimum)
DC Volt Meter
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F-14
F-14
TROUBLESHOOTING AND REPAIR
INPUT FILTER CAPACITOR DISCHARGE PROCEDURE (continued)
WARNING
4. Obtain a high resistance and high wattage resistor
(25-1000 ohms and 25 watts minimum). This
resistor is not with the machine. NEVER USE A
SHORTING STRAP FOR THIS PROCEDURE.
ELECTRIC SHOCK can kill.
• Have an electrician install and service
this equipment.
5. Locate the eight capacitor terminals shown in fig-
ure F.1.
• Turn the input power off at the fuse box
before working on equipment.
6. Using electrically insulated gloves and pliers, hold
the body of the resistor with the pliers and con-
nect the resistor leads across the two capacitor
terminals. Hold the resistor in place for 10 sec-
onds. DO NOT TOUCH CAPACITOR TERMINALS
WITH YOUR BARE HANDS.
• Do not touch electrically hot parts.
• Prior to performing preventative maintenance,
perform the following capacitor discharge procedure
to avoid electric shock.
7. Repeat the discharge procedure for the other
three capacitors.
DISCHARGE PROCEDURE
1. Remove the input power to the POWER WAVE
355M/405M.
8. Check the voltage across the terminals of all
capacitors with a DC voltmeter. Polarity of the
capacitor terminals is marked on the PC board
above the terminals. Voltage should be zero. If
any voltage remains, repeat this capacitor dis-
charge procedure.
2. Using the 5/16” wrench remove the screws from
the case wraparound cover.
3. Be careful not to make contact with the capacitor
terminals located at the top and bottom of the
switch board.
FIGURE F.1 – LOCATION OF INPUT FILTER CAPACITOR TERMINALS
EIGHT
CAPACITOR
TERMINALS
- +
- +
INSULATED
PLIERS
- +
- +
INSULATED
GLOVES
POWER
RESISTOR
POWER WAVE 355M/405M
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F-15
F-15
TROUBLESHOOTING AND REPAIR
MAIN SWITCH BOARD TEST
WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician
or machine operator and will invalidate your factory warranty. For your safety and to avoid
electrical shock, please observe all safety notes and precautions detailed throughout this
manual.
If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou-
bleshooting assistance before you proceed. Call 1-888-935-3877.
TEST DESCRIPTION
This test will help determine if the “power section” of the switch boards are functioning
correctly. This test will NOT indicate if the entire PC board is functional. This resistance
test is preferable to a voltage test with the machine energized because this board can be
damaged easily. In addition, it is dangerous to work on this board with the machine ener-
gized.
MATERIALS NEEDED
Analog Volt/Ohmmeter
5/16 in. Wrench
7/16 in. Wrench
POWER WAVE 355M/405M
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F-16
F-16
TROUBLESHOOTING AND REPAIR
MAIN SWITCH BOARD TEST (continued)
FIGURE F.2 MAIN SWITCH BOARD LEAD LOCATIONS
207
202
J22
- +
- +
209
201
204
208
205
J21
J20
- +
- +
206
203
TEST PROCEDURE
4. Using a 7/16” wrench locate, label and remove
leads 201, 202, 203, 204, 205, 206, 207 and
208 from the switch board. Note lead and
washer placement for reassembly. Clear
leads.
1. Remove input power to the POWER WAVE
355M/405M.
2. Using a 5/16” nut driver, remove the case
wraparound.
5. Using the Analog ohmmeter, perform the resis-
ure F.2 for test point locations. Note: Test
using an Analog ohmmeter on the Rx1 range.
Make sure the test probes are making electri-
cal contact with the conductor surfaces on the
PC board.
Procedure detailed earlier in this section.
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F-17
F-17
TROUBLESHOOTING AND REPAIR
MAIN SWITCH BOARD TEST (continued)
6. If any test fails replace the switch board. See
8. Reconnect leads 201, 202, 203, 204, 205, 206,
207, and 208 to the switch board. Ensure that the
leads are installed in their proper locations. Pre-
Torque all leads nuts to 25 inch lbs. before tight-
ening them to 44 inch lbs.
7. If the switch board resistance tests are OK, check
connections on plugs J20, J21, J22 and all asso-
ciated wiring. See wiring diagram.
9. Replace the case wraparound cover using a 5/16”
nut driver.
TABLE F.1. SWITCH BOARD RESISTANCE TEST
APPLY NEGATIVE TEST
PROBE TO TERMINAL
NORMAL
RESISTANCE READING
APPLY POSITIVE TEST
PROBE TO TERMINAL
+206
+208
+202
+201
+205
+203
+204
+207
-205
-203
-204
-207
-206
-208
-202
-201
Greater than 1000 ohms
Greater than 1000 ohms
Greater than 1000 ohms
Greater than 1000 ohms
Less than 100 ohms
Less than 100 ohms
Less than 100 ohms
Less than 100 ohms
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F-18
F-18
NOTES
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F-19
F-19
TROUBLESHOOTING AND REPAIR
INPUT RECTIFIER TEST
WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician
or machine operator and will invalidate your factory warranty. For your safety and to avoid
electrical shock, please observe all safety notes and precautions detailed throughout this
manual.
If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou-
bleshooting assistance before you proceed. Call 1-888-935-3877.
TEST DESCRIPTION
This test will help determine if the input rectifier has “shorted” or “open” diodes.
MATERIALS NEEDED
Analog Voltmeter/Ohmmeter (Multimeter)
5/16” Nut Driver
Phillips Head Screwdriver
Wiring Diagram
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F-20
F-20
TROUBLESHOOTING AND REPAIR
INPUT RECTIFIER TEST (CONTINUED)
TEST PROCEDURE
6. Using
a
phillips head screwdriver,
1. Remove input power to the POWER
WAVE 355M/405M machine.
remove leads 207, 207A, and 209 from
the input rectifier.
2. Using a 5/16” nut driver, remove the case
wraparound cover.
7. Use the analog ohmmeter to perform the
Wiring Diagram.
3. Perform the Capacitor Discharge
Procedure detailed earlier in this section.
8. Visually inspect the three MOV’S for
damage (TP1,TP2,TP3). Replace if nec-
essary.
4. Locate the input rectifier and associated
leads. See Figure F.3.
5. Carefully remove the silicone sealant
from leads 207, 207A, and 209.
Figure F.3 Input Rectifier
Small Lead "H1"
To Auxiliary Transformer
3/16" ALLEN
BOLTS
C
B
#207
#207A
A
#209
Small Lead "A"
To Circuit Breaker
FRONT
REAR
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F-21
F-21
TROUBLESHOOTING AND REPAIR
INPUT RECTIFIER TEST (CONTINUED)
Table F.2 Input Rectifier Test Points
ANALOG METER
X10 RANGE
TEST POINT TERMINALS
Acceptable Meter Readings
+ PROBE
- PROBE
207
207
207
Greater than 1000 ohms
Greater than 1000 ohms
Greater than 1000 ohms
A
B
C
207A
207A
207A
Greater than 1000 ohms
Greater than 1000 ohms
Greater than 1000 ohms
A
B
C
209
209
209
Less than 100 ohms
Less than 100 ohms
Less than 100 ohms
A
B
C
A
B
C
Less than 100 ohms
Less than 100 ohms
Less than 100 ohms
207
207
207
A
B
C
Less than 100 ohms
Less than 100 ohms
Less than 100 ohms
207A
207A
207A
A
B
C
Greater than 1000 ohms
Greater than 1000 ohms
Greater than 1000 ohms
209
209
209
9. If the input rectifier does not meet the
acceptable readings outlined in Table F.2
the component may be faulty. Replace
11. If the input rectifier is faulty, see the
Replacement procedure.
Note: Before replacing the input rectifier,
check the input power switch and recon-
nect switches. Perform the Main Switch
faulty filter capacitors.
12. Replace the case wraparound cover.
10. If the input rectifier is good, be sure to
reconnect leads 207, 207A, and 209 to
the correct terminals and torque to 31
inch lbs. Apply silicone sealant.
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F-22
F-22
NOTES
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F-23
F-23
TROUBLESHOOTING AND REPAIR
POWER BOARD TEST
WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician
or machine operator and will invalidate your factory warranty. For your safety and to avoid
electrical shock, please observe all safety notes and precautions detailed throughout this
manual.
If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou-
bleshooting assistance before you proceed. Call 1-888-935-3877.
TEST DESCRIPTION
This test will help determine if the power board is receiving the correct voltages and also
if the power board is regulating and producing the correct DC voltages.
MATERIALS NEEDED
Volt-Ohmmeter
3/8” Nut Driver
Wiring Diagram
POWER WAVE 355M/405M
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F-24
F-24
TROUBLESHOOTING AND REPAIR
FIGURE F.4 – POWER BOARD TEST
J42
J41
J43
4 3
6 5 4
12 11 10 9 8 7
3 2 1
6 5 4 3 2 1
2 1
J43
J42
J41
TEST PROCEDURE
6. Turn on the Power Wave 355M/405M.
Carefully test for the correct voltages at the
Power Board according to Table F.4.
1. Remove input power to the Power Wave
355M/405M.
2. Using the 3/8” nut driver, remove the case
top.
7. If either of the 40 VDC voltages is low or not
3. Perform
the
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.
8. If any of the DC voltages are low or not pre-
sent at plugs J42 and/or 43, the Power
Board may be faulty.
5. Carefully apply input power to the Power
Wave 355M/405M.
9. Install the case top using the 3/8” nut driver.
WARNING
ELECTRIC SHOCK can kill.
High voltage is present when
input power is applied to the
machine.
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F-25
F-25
TROUBLESHOOTING AND 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
NORMAL
ACCEPTABLE
VOLTAGE
READING
POWER BOARD
CONNECTOR
PLUG J41
CHECK 40VDC
INPUT FROM
DC BUS BOARD
2 (+)
1 (-)
38 – 42VDC
477 (+)
475 (-)
475
412
477
POWER BOARD
CONNECTOR
PLUG J42
CHECK +15
VDC SUPPLY FROM
POWER BOARD
1 (+)
5 (-)
+15VDC
412 (+)
410 (-)
410
POWER BOARD
CONNECTOR
PLUG J42
CHECK +5VDC
SUPPLY FROM
POWER BOARD
3 (+)
5 (-)
+5VDC
-15VDC
+5VDC
+5VDC
+5VDC
408 (+)
410 (-)
408
410
POWER BOARD
CONNECTOR
PLUG J42
CHECK -15VDC
SUPPLY FROM
POWER BOARD
2 (+)
5 (-)
411
410
411 (+)
410 (-)
CHECK +5VDC
ARCLINK SUPPLY
FROMPOWERBOARD
5 (+)
10 (-)
POWER BOARD
CONNECTOR
PLUG J43
1104 (+)
1103 (-)
1104
1103
4 (+)
9 (-)
POWER BOARD
CONNECTOR
PLUG J43
CHECK +5VDC
“RS-232” SUPPLY
FROMPOWERBOARD
406 (+)
405 (-)
406
405
3 (+)
403 (+)
401 (-)
POWER BOARD
CONNECTOR
PLUG J43
12 (-)
CHECK +5VDC
SPI SUPPLY FROM
POWER BOARD
403
401
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F-26
F-26
NOTES
POWER WAVE 355M/405M
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F-27
F-27
TROUBLESHOOTING AND REPAIR
DC BUS BOARD TEST
WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician
or machine operator and will invalidate your factory warranty. For your safety and to avoid
electrical shock, please observe all safety notes and precautions detailed throughout this
manual.
If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou-
bleshooting 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 process-
ing the proper voltages.
MATERIALS NEEDED
3/8” Nut driver
Volt/ohmmeter
Wiring Diagram
POWER WAVE 355M/405M
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F-28
F-28
TROUBLESHOOTING AND REPAIR
DC BUS BOARD TEST (CONTINUED)
FIGURE F.5 – DC BUS POWER SUPPLY POWER SUPPLY PC BOARD
DC BUS BOARD
S
T
A
T
U
S
T
H
E
R
M
A
L
L
I
N
C
O
L
E
N
T
L
E
C
R
I
C
W
A
R
N
I
N
G
R
E
M
O
T
E
P
O
W
E
R
O
N
TEST PROCEDURE
WARNING
ELECTRIC SHOCK can kill.
1. Remove input power to the machine.
2. Using the 3/8” nut driver, remove the wrap-
around cover.
High voltage is present when
input power is applied to the
machine.
3. Locate the DC Bus Board. See Figure F.5.
4. Carefully apply input power to the Power
Wave 355M/405M.
5. Turn on the Power Wave 355M/405M. The
LED on the DC Bus Power Supply PC Board
should light.
FIGURE F.6 – DC BUS POWER SUPPLY POWER SUPPLY PC BOARD
J47
J47
Bus
Rectifier
51
475
52
477
Thermostat
J46
66
65
J46
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F-29
F-29
TROUBLESHOOTING AND REPAIR
DC BUS BOARD TEST(CONTINUED)
6. Check the DC Bus Board input and output
7. If all the voltages are correct, the DC Bus
Board is operating properly.
8. If any of the output voltages are not correct
and the input voltage is correct, the DC Bus
Board may be faulty.
WARNING
ELECTRIC SHOCK can kill.
9. If the input voltage is not correct, check the
leads between the DC Bus Board and the
Bus Rectifier. See the Wiring Diagram.
High voltage is present at the ter-
minals of Capacitor C3 near
where testing is to be done.
10. When finished testing, replace the case
wraparound cover.
TABLE F.4 – DC BUS POWER SUPPLY PC BOARD VOLTAGE TABLE
Positive Meter Probe
Negative Meter Probe
Test Point
Approximate Voltage
Reading
Conditions/Comments
Test Point
Plug P46 – Pin 1
Lead 65
Plug P46 – Pin 3
Lead 66
65 – 75 VDC
Should be same as the
Bus Rectifier
Plug P47 – Pin 8(+)
Lead 52
Plug P47 – Pin 1(-)
Lead 51
38.0 – 42.0 VDC
38.0 – 42.0 VDC
Supply to the Wire
Feeder Receptacle
Plug P47 – Pin 3(+)
Lead 477
Plug P47 – Pin 6(-)
Lead 475
Supply to Power Board
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F-30
F-30
NOTES
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F-31
F-31
TROUBLESHOOTING AND REPAIR
OUTPUT RECTIFIER MODULES TEST
WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician
or machine operator and will invalidate your factory warranty. For your safety and to avoid
electrical shock, please observe all safety notes and precautions detailed throughout this
manual.
If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou-
bleshooting assistance before you proceed. Call 1-888-935-3877.
TEST DESCRIPTION
This test will help determine if any of the output diodes are “shorted”.
MATERIALS NEEDED
Analog Voltmeter/Ohmmeter
Wiring Diagram
POWER WAVE 355M/405M
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F-32
F-32
TROUBLESHOOTING AND REPAIR
OUTPUT RECTIFIER MODULES TEST (continued)
FIGURE F.7 Machine Output Terminals
STATUS
THERMAL
_
+
NEGATIVE
OUTPUT
POSITIVE
OUTPUT
TERMINAL
TERMINAL
TEST PROCEDURE
4. Using the analog ohmmeter test for more
than 200 ohms resistance between positive
and negative output terminals. Positive test
lead to the positive terminal; Negative test
1. Remove input power to the POWER WAVE
355M/405M.
2. Locate the output terminals on the front
panel of the machine. See Figure F.7.
3. Remove any output cables and load from the
output terminals.
NOTE: The polarity of the test leads is most
important. If the test leads polarity is not cor-
rect, the test will have erroneous results.
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F-33
F-33
TROUBLESHOOTING AND REPAIR
OUTPUT RECTIFIER MODULES TEST (continued)
Figure F.8 Terminal Probes
_
+
5. If 200 ohms is measured then the output
diodes are not “shorted”.
9. Test all output diode modules individually.
Test for open diodes also.
NOTE: There is a 250 ohm resistor across
the welding output terminals. See Wiring
Diagram
NOTE: This may require the disassembly of
the leads and the snubber board from the
diode modules.
Refer to the Output
6. If less than 200 ohms is measured, one or
more diodes or the snubber board may be
faulty.
Replacement Procedure for detailed
instructions.
Procedure detailed in the maintenance sec-
tion.
8. Locate the output diode modules and snub-
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F-35
F-35
TROUBLESHOOTING AND REPAIR
AUXILIARY TRANSFORMER TEST
WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician
or machine operator and will invalidate your factory warranty. For your safety and to avoid
electrical shock, please observe all safety notes and precautions detailed throughout this
manual.
If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou-
bleshooting assistance before you proceed. Call 1-888-935-3877.
TEST DESCRIPTION
This procedure will determine if the correct voltage is being applied to the primary of aux-
iliary transformer and also if the correct voltage is being induced on the secondary wind-
ings of the transformer.
MATERIALS NEEDED
Volt-ohmmeter (Multimeter)
5/16” Nut Driver
Wiring Diagram
POWER WAVE 355M/405M
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F-36
F-36
TROUBLESHOOTING AND REPAIR
AUXILIARY TRANSFORMER TEST (continued)
FIGURE F.10 Auxiliary Transformer
Auxiliary
Transformer
Secondary Lead
Plugs P52
S
T
A
T
U
S
T
H
E
R
M
A
L
L
I
N
C
O
L
E
N
T
L
E
C
R
I
C
W
A
R
N
I
N
G
R
E
M
O
T
E
P
O
W
E
R
O
N
TEST PROCEDURE
4. Locate the auxiliary transformer. See Figure
F.10.
1. Remove input power to the POWER WAVE
355M/405M.
5. Locate the secondary leads and plug P52.
See Figure F.10 and F.11.
2. Using a 5/16” nut driver, remove the case
wraparound cover.
Procedure detailed earlier in this section.
FIGURE F.11 Plug Lead Connections Viewed From Transformer Lead Side of Plug
PW405
Only
(220V)
532
(115V)
Plug P52
Com 2
(31)
POWER WAVE 355M/405M
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F-37
F-37
TROUBLESHOOTING AND REPAIR
AUXILIARY TRANSFORMER TEST (continued)
TABLE F.5
NORMAL EXPECTED VOLTAGE
LEAD IDENTIFICATION
COM 2 (31) TO 115V (532)
115 VAC
42 VAC
42 TO COM 1A (quick connects)
7. Carefully apply the correct input voltage to the
POWER WAVE 355M/405M and check for the
correct secondary voltages per table F.5.
Make sure the reconnect jumper lead and
switch are configured correctly for the input
voltage being applied. Make sure circuit
breaker (CB3) is functioning properly.
WARNING
High voltage is present at primary of
Auxiliary Transformer.
9. If the correct input voltage is applied to the
primary, and the secondary voltage(s) are not
correct, the auxiliary transformer may be
faulty.
NOTE: The secondary voltages will vary if the
input line voltage varies.
8. If the correct secondary voltages are present,
the auxiliary transformer is functioning proper-
ly. If any of the secondary voltages are miss-
ing or low, check to make certain the primary
is configured correctly for the input voltage
applied. See Wiring Diagram.
10. Remove the input power to the POWER WAVE
355M/405M.
11. Install the case wraparound cover using a
5/16” nut driver.
POWER WAVE 355M/405M
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F-38
F-38
NOTES
POWER WAVE 355M/405M
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F-39
F-39
TROUBLESHOOTING AND REPAIR
CURRENT TRANSDUCER TEST
WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician
or machine operator and will invalidate your factory warranty. For your safety and to avoid
electrical shock, please observe all safety notes and precautions detailed throughout this
manual.
If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou-
bleshooting assistance before you proceed. Call 1-888-935-3877.
TEST DESCRIPTION
This test will help determine if the current transducer and associated wiring are function-
ing correctly.
MATERIALS NEEDED
Volt-ohmmeter
5/16” Nut Driver
Grid Bank
External DC Ammeter
POWER WAVE 355M/405M
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F-40
F-40
TROUBLESHOOTING AND REPAIR
CURRENT TRANSDUCER TEST (continued)
FIGURE F.12 Metal Plate Removal & Plug J8 Location
S
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Plug J8
6. Check for the correct DC supply voltages to
the current transducer at plug J8. See Figure
F.12.
TEST PROCEDURE
1. Remove input power to the POWER WAVE
355M/405M.
A. Pin 2 (lead 802+) to pin 6 (lead 806-)
should read +15 VDC.
2. Using the 5/16” nut driver, remove the case
wraparound cover.
B. Pin 4 (lead 804+) to pin 6 (lead 806-)
should read -15 VDC.
7. If either of the supply voltages are low or miss-
ing, the control board may be faulty.
4. Locate plug J8 on the control board. Do not
remove the plug from the P.C. Board.
5. Apply the correct input power to the POWER
WAVE 355M/405M.
FIGURE F.13. Plug J8 Viewed From Lead Side of Plug
802
804
801
Plug J8
806
POWER WAVE 355M/405M
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F-41
F-41
TROUBLESHOOTING AND REPAIR
AUXILIARY TRANSFORMER TEST (continued)
TABLE F.6
EXPECTED TRANSDUCER FEEDBACK
OUTPUT LOAD CURRENT
VOLTAGE
300
250
2.4
2.0
200
150
100
1.6
1.2
0.8
8. Check the feedback voltage from the current
transducer using a resistive load bank and
with the POWER WAVE 355M/405M in mode
200. Mode 200 is a constant current test
mode. This mode can be accessed using a
wire feeder placed in mode 200 or a laptop
computer and the appropriate software. Apply
the grid load across the output of the POWER
WAVE 355M/405M. Set machine output to
300 amps and enable WELD TERMINALS.
Adjust the grid load to obtain 300 amps on the
external ammeter and check feedback volt-
ages per Table F.6.
Before replacing the current transducer, check
the leads and plugs between the control board
(J8) and the current transducer (J90). See The
Wiring Diagram. For access to plug J90 and
the current transducer refer to: Current
11. Remove input power to the POWER WAVE
355M/405M.
12. Replace the control box top and any cable ties
previously removed.
13. Install the case wraparound cover using the
5/16” nut driver.
A. Pin 1 (lead 801) to Pin 6 (lead 806) should
read 2.4 VDC (machine loaded to 300
amps).
9. If for any reason the machine cannot be
loaded to 300 amps, Table F.6. shows what
feedback voltage is produced at various cur-
rent loads.
10. If the correct supply voltages are applied to
the current transducer, and with the machine
loaded, the feedback voltage is missing or not
correct the current transducer may be faulty.
POWER WAVE 355M/405M
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F-42
F-42
NOTES
POWER WAVE 355M/405M
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F-43
F-43
TROUBLESHOOTING AND REPAIR
FAN CONTROL AND MOTOR TEST
WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician
or machine operator and will invalidate your factory warranty. For your safety and to avoid
electrical shock, please observe all safety notes and precautions detailed throughout this
manual.
If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou-
bleshooting assistance before you proceed. Call 1-888-935-3877.
TEST DESCRIPTION
This test will help determine if the fan motor, control board, switch board, or associated
leads and connectors are functioning correctly.
MATERIALS NEEDED
Voltmeter
5/16” Nut Driver
POWER WAVE 355M/405M
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F-44
F-44
TROUBLESHOOTING AND REPAIR
FAN CONTROL AND MOTOR TEST (continued)
TEST PROCEDURE
1. Remove the input power to the POWER WAVE
355M/405M machine.
4. Locate plug J22 on the main switch board. Do
not remove the plug from the board. See
Figure F.14.
2. Using the 5/16” nut driver, remove the case
wraparound cover.
FIGURE F.14 PLUG J22 LOCATION
J22
J21
J20
5. Carefully apply the correct input power to the
machine.
6. Carefully check for 115VAC at plug J22 pin-2
to J22 pin-3. (leads 32A to 31B(C) See Figure
F.15. WARNING: HIGH VOLTAGE IS PRE-
SENT AT THE MAIN SWITCH BOARD.
FIGURE F.15 PLUG J22
Fan Lead
2
1
3
Lead 32A
4
Fan Lead
Lead 31B(C)
Plug J22
POWER WAVE 355M/405M
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F-45
F-45
TROUBLESHOOTING AND REPAIR
FAN CONTROL AND MOTOR TEST (continued)
7. If the 115VAC is low or not present check cir-
1. Locate plug J20 on the switch board. Do not
cuit breaker CB2 located on the front panel. If
the circuit breaker is OK, perform The
circuit breaker CB2 and associated leads for
loose or faulty connections. See the Wiring
Diagram.
remove the plug from the switch board. See
2. Energize the weld output terminals (Select
Weld Terminals ON) and carefully check for
+15VDC at plug J20 pin-6+ to J20 pin-2-
(leads 715 to 716). See Figure F.16. If the
15VDC is present and the fan is not running
then the switch board may be faulty. If the
15VDC is not present when the weld terminals
are energized then the control board may be
faulty. Also check plugs J20, J7, and all asso-
ciated leads for loose or faulty connections.
See the Wiring Diagram.
8. Energize the weld output terminals with the
PW 355M/405M in mode 200. This mode can
be accessed using a wire feeder placed in
mode 200 or a laptop computer and the appro-
priate software. Carefully check for 115VAC at
fan is not running then the fan motor may be
faulty. Also check the associated leads
between plug J22 and the fan motor for loose
or faulty connections. See the Wiring Diagram.
WARNING: HIGH VOLTAGE IS PRESENT AT
THE SWITCH BOARD.
WARNING: HIGH VOLTAGE IS PRESENT AT
THE SWITCH BOARD.
3. Remove the input power to the POWER WAVE
355M/405M.
Note: The fan motor may be accessed by the
9. If the 115VAC is NOT present in the previous
step then proceed to the fan control test.
removal of the rear panel detailed in The
4. Replace the case wrap-around cover.
FAN CONTROL TEST PROCEDURE
FIGURE F.16 PLUG J20
Lead 716-
1 2 3 4
8
5 6 7
Plug J20
Lead 715+
POWER WAVE 355M/405M
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F-46
F-46
NOTES
POWER WAVE 355M/405M
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F-47
F-47
TROUBLESHOOTING AND REPAIR
CONTROL BOARD REMOVAL AND REPLACEMENT
WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician
or machine operator and will invalidate your factory warranty. For your safety and to avoid
electrical shock, please observe all safety notes and precautions detailed throughout this
manual.
If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou-
bleshooting assistance before you proceed. Call 1-888-935-3877.
DESCRIPTION
The following procedure will aid the technician in removing the control board for mainte-
nance or replacement.
MATERIALS NEEDED
5/16” Nut Driver
3/8” Nut Driver
Flathead Screwdriver
Phillips Head Screwdriver
POWER WAVE 355M/405M
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F-48
F-48
TROUBLESHOOTING AND REPAIR
CONTROL BOARD REMOVAL AND REPLACEMENT (continued)
FIGURE F.17 - CONTROL BOARD LOCATION
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Control Board
PROCEDURE
4. Locate the control board behind the front panel of
the machine. See Figure F.17.
1. Remove input power to the POWER WAVE
355M/405M.
5. Using a 5/16” nut driver remove the two screws
from the bottom of the front of the machine. See
Figure F.18.
2. Using a 5/16” nut driver remove the case wrap-
around cover.
Procedure detailed earlier in this section.
FIGURE F.18 CASE FRONT SCREW REMOVAL
STATUS
THERMAL
Phillips Head
Screws
Phillips Head
Screws
_
+
5/16"
Mounting Screws
POWER WAVE 355M/405M
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F-49
F-49
TROUBLESHOOTING AND REPAIR
CONTROL BOARD REMOVAL AND REPLACEMENT (continued)
FIGURE F.19 - CONTROL BOARD ALL PLUG LOCATIONS
J6
J7
J5
J8
J9
J4
J2
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J10B
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J10A
P
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8. The front of the machine may now gently be pulled
forward to gain access to the Control Board.
Note: The front of the machine cannot be removed
completely, only pulled forward a few inches.
CAUTION
Observe static precautions detailed in PC
beginning of this section.
9. Beginning at the right side of the control board
remove plugs J10A and J10B. Note: Be sure to
label each plugs position upon removal. See
Figure F.19.
10. Working your way across the top of the board
from right to left, label and remove plugs #J9, #J8,
#J7, #J6, and #J5. See Figure F.19.
6. Using a phillips head screwdriver remove the two
screws and their washers from above and below
11. Working your way down the left side of the board,
label and remove plugs #J4 and #J2. See Figure
F.19.
7. Using a phillips head screwdriver remove the four
screws from around the two welder output termi-
POWER WAVE 355M/405M
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F-50
F-50
TROUBLESHOOTING AND REPAIR
CONTROL BOARD REMOVAL AND REPLACEMENT (continued)
12. Using a 3/8” nut driver remove the two mounting
nuts from the top two corners of the control
board. See Figure F.20.
14. Replace the control board.
13. Cut any necessary cable ties.
FIGURE F.20 CONTROL BOARD MOUNTING SCREW LOCATION
Mounting
Nuts (3/8")
15. Replace the two 3/8” mounting nuts at the top
two corners of the control board.
19. Replace the four screws from around the two
welder output terminals on the front of the
machine.
16. Replace any previously removed cable ties.
20. Replace the two case front mounting screws at
the bottom of the front of the machine.
17. Replace plugs #J2, #J4, #J5, #J6, #J7, #J8, #J9,
#J10B, and #J10A previously removed.
21. Replace the case wraparound cover.
18. Replace the two screws and their washers from
above and below the input power switch.
POWER WAVE 355M/405M
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F-51
F-51
TROUBLESHOOTING AND REPAIR
MAIN SWITCH BOARD REMOVAL & REPLACEMENT
WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician
or machine operator and will invalidate your factory warranty. For your safety and to avoid
electrical shock, please observe all safety notes and precautions detailed throughout this
manual.
If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou-
bleshooting assistance before you proceed. Call 1-888-935-3877.
DESCRIPTION
The following procedure will aid the technician in removing the main switch board for
maintenance or replacement.
MATERIALS NEEDED
5/16” Nut Driver
Flathead Screwdriver
7/16” mm Socket
3/16” Allen Wrench
3/8” Nut Driver
POWER WAVE 355M/405M
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F-52
F-52
TROUBLESHOOTING AND REPAIR
MAIN SWITCH BOARD REMOVAL & REPLACEMENT (continued)
FIGURE F.21 – MAIN SWITCH BOARD LEAD LOCATIONS
207
202
J22
- +
- +
209
201
204
208
205
J21
J20
- +
- +
206
203
PROCEDURE
5. Using a 3/8” nut driver, remove the input lead
shield from the area at the bottom of the main
switch board.
1. Remove the input power to the POWER WAVE
355M/405M.
2. Using a 5/16” nut driver remove the case wrap-
around cover.
6. Using a 7/16” socket, remove leads 201, 202,
203, 204, 205, 206, 207, 208, 209 from the
switch board. Note lead terminal locations and
washer positions upon removal.
Procedure detailed earlier in this section.
7. Locate and disconnect the three harness plugs
associated with the main switch board. Plugs
#J20, #J21, #J22. See Figure F.21.
CAUTION
8. Locate the eight capacitor terminals and
remove the nuts using a 7/16” socket or nut
driver. Note the position of the washers behind
each nut for replacement.
Observe static precautions detailed in PC Board
Troubleshooting Procedures at the beginning of
this section. Failure to do so can result in perma-
nent damage to equipment.
4. Locate the main switch board and all associat-
ed plug and lead connections. See figure F.21.
See Wiring Diagram.
POWER WAVE 355M/405M
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F-53
F-53
TROUBLESHOOTING AND REPAIR
MAIN SWITCH BOARD REMOVAL & REPLACEMENT (continued)
FIGURE F.22 – 3/16” ALLEN BOLT LOCATION
- +
- +
3/16" ALLEN BOLTS
- +
- +
9. Using a 3/16” allen wrench remove four allen
bolts and washers as shown in Figure F.22.
At this point, the board is ready for removal.
15. Reconnect the nine leads (#201-#209) that
were previously removed.
16. Replace any necessary cable ties previously
removed.
10. Carefully maneuver the board out of the
machine.
17. Pre-torque all screws to 25 inch lbs. before
tightening to 44 inch lbs.
11. Apply a thin coat of Penetrox A-13 to the
IGBT heatsinks on the back of the new
switch boards mating surfaces. Note: Keep
compound away from the mounting holes.
18. Replace the input lead shield previously
removed.
12. Replace the four allen bolts and washers
previously removed.
19. Replace the case wraparound cover.
NOTE: Any instructions that are packaged with
the replacement board will supercede
these instructions.
13. Replace the eight capacitor terminal nuts,
washers, and necessary leads previously
removed.
14. Reconnect the three harness plugs previous-
ly removed.
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F-54
F-54
NOTES
POWER WAVE 355M/405M
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F-55
F-55
TROUBLESHOOTING AND REPAIR
SNUBBER BOARD REMOVAL AND REPLACEMENT
WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician
or machine operator and will invalidate your factory warranty. For your safety and to avoid
electrical shock, please observe all safety notes and precautions detailed throughout this
manual.
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 trou-
bleshooting assistance before you proceed. Call 1-888-935-3877.
DESCRIPTION
The following procedure will aid the technician in removing the snubber board for main-
tenance or replacement.
MATERIALS NEEDED
5/16” Nut Driver
7/16 Socket or Nut Driver
POWER WAVE 355M/405M
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F-56
F-56
TROUBLESHOOTING AND REPAIR
SNUBBER BOARD REMOVAL AND REPLACEMENT (continued)
PROCEDURE
1. Remove input power to the POWER WAVE
355M/405M.
Procedure detailed earlier in this section.
4. Locate the snubber board.. See Figure F.23.
2. Using a 5/16” nut driver remove the case wrap-
around cover.
FIGURE F.23 – SNUBBER BOARD LOCATION
Snubber
Board
LEFT SIDE
5. Remove small lead #B1 from the board. See
Figure F.24.
8. Replace the snubber board.
9. Replace the bolts, leads, and washers previously
removed. Torque bolt to 30-40 Inch Lbs.
6. Remove the four bolts using a 7/16” socket. Two
of these bolts have leads #30 and #10 connected
to them. Note the position of all leads and associ-
ated washers upon removal.
10. Reconnect small lead B1 previously removed.
11. Replace the case wraparound cover.
7. Carefully remove the snubber board.
FIGURE F.24 – SNUBBER BOARD LEADS (CLOSE UP)
Lead 30
Lead B1
Lead 10
POWER WAVE 355M/405M
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F-57
F-57
TROUBLESHOOTING AND REPAIR
POWER BOARD REMOVAL AND REPLACEMENT
WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician
or machine operator and will invalidate your factory warranty. For your safety and to avoid
electrical shock, please observe all safety notes and precautions detailed throughout this
manual.
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 trou-
bleshooting assistance before you proceed. Call 1-888-935-3877.
DESCRIPTION
The following procedure will aid the technician in removing the power board for mainte-
nance or replacement.
MATERIALS NEEDED
5/16” Nut Driver
3/8” Nut Driver
POWER WAVE 355M/405M
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F-58
F-58
TROUBLESHOOTING AND REPAIR
POWER BOARD REMOVAL AND REPLACEMENT (continued)
FIGURE F.25 POWER BOARD LOCATION
Power Board
LEFT SIDE
PROCEDURE
1. Remove input power to the POWER WAVE
355M/405M.
Procedure detailed earlier in this section.
4. Locate the power board. See Figure F.25.
2. Using a 5/16” nut driver remove the case wrap-
around cover.
POWER WAVE 355M/405M
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F-59
F-59
TROUBLESHOOTING AND REPAIR
POWER BOARD REMOVAL AND REPLACEMENT (continued)
7. Remove the three nuts at the corners of the board
using a 3/8” nut driver. Board is ready for removal.
CAUTION
8. Replace the power board.
Observe static precautions detailed in PC
beginning of this section.
9. Secure the new power board into its proper posi-
tion with the three 3/8” nuts previously removed.
10. Reconnect the three plugs previously removed.
Plugs J41, J42 and J43.
5. Locate the three plug connections. J41, J42 and
J43 on the Power Board. See figure F.26.
11. Replace the case wraparound cover.
6. Carefully disconnect the three plugs from the
Power Board.
FIGURE F.26 – POWER BOARD LEAD LOCATION
J43
J42
J41
POWER WAVE 355M/405M
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F-60
F-60
NOTES
POWER WAVE 355M/405M
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F-61
F-61
TROUBLESHOOTING AND REPAIR
DC BUS BOARD REMOVAL AND REPLACEMENT
WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician
or machine operator and will invalidate your factory warranty. For your safety and to avoid
electrical shock, please observe all safety notes and precautions detailed throughout this
manual.
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 trou-
bleshooting assistance before you proceed. Call 1-888-935-3877.
DESCRIPTION
The following procedure will aid the technician in removing the DC Bus Board for main-
tenance or replacement.
MATERIALS NEEDED
5/16” Nut Driver
3/8” Open End Wrench
Flat Head Screwdriver
Phillips Head Screwdriver
POWER WAVE 355M/405M
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F-62
F-62
TROUBLESHOOTING AND REPAIR
DC BUS BOARD REMOVAL AND REPLACEMENT (continued)
PROCEDURE
6. Using a phillips head screwdriver remove the two
screws and their washers from above and below
1. Remove input power to the POWER WAVE
355M/405M.
2. Using a 5/16” nut driver remove the case wrap-
around cover.
7. Using a phillips head screwdriver remove the four
screws mounting the two welder output terminals
Procedure detailed earlier in this section.
8. The front of the machine may now gently be pulled
forward to gain access to the DC Bus Board.
Note: The front of the machine cannot be removed
completely, only pulled forward a few inches.
4. Locate the DC Bus Board. See Figure F.27.
5. Using a 5/16” nut driver remove the two screws
from the bottom of the front of the machine. See
FIGURE F.27 DC BUS BOARD LOCATION
DC BUS BOARD
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POWER WAVE 355M/405M
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F-63
F-63
TROUBLESHOOTING AND REPAIR
DC BUS BOARD REMOVAL AND REPLACEMENT (continued)
FIGURE F.28 CASE FRONT SCREW REMOVAL
STATUS
THERMAL
Phillips Head
Screws
Phillips Head
Screws
_
+
5/16"
Mounting Screws
9. Label and remove two thermostat leads and four
leads from the bus rectifier.
13. Reconnect previously removed leads to their prop-
er locations.
10. Using a 3/8” open end wrench, remove the three
DC Bus Board mounting nuts. See Figure F.29.
14. Replace the four phillips head screws mounting
the two welder output terminals to the front of the
machine.
11. Replace the DC Bus Board.
15. Replace the two phillips head screws from above
and below the input power switch.
12. Secure the new DC Bus Board in its proper loca-
tion using the 3/8” mounting nuts.
FIGURE F.29 CASE FRONT SCREW REMOVAL
J47
Bus
Rectifier
3/8" Mounting
Nuts
Thermostat
J46
POWER WAVE 355M/405M
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F-64
F-64
TROUBLESHOOTING AND REPAIR
DC BUS BOARD REMOVAL AND REPLACEMENT (continued)
16. Replace the two 5/16” mounting screws to the
bottom of the case front.
17. Replace the case wraparound cover.
POWER WAVE 355M/405M
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F-65
F-65
TROUBLESHOOTING AND REPAIR
INPUT RECTIFIER REMOVAL AND REPLACEMENT
WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician
or machine operator and will invalidate your factory warranty. For your safety and to avoid
electrical shock, please observe all safety notes and precautions detailed throughout this
manual.
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 trou-
bleshooting assistance before you proceed. Call 1-888-935-3877.
DESCRIPTION
The following procedure will aid the technician in removing the input rectifier for mainte-
nance or replacement.
MATERIALS NEEDED
3/16” Allen wrench
5/16” Nut Driver
Flathead Screwdriver
Penetrox A-13 Heatsink Compound
Silicon Sealant
POWER WAVE 355M/405M
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F-66
F-66
TROUBLESHOOTING AND REPAIR
INPUT RECTIFIER REMOVAL AND REPLACEMENT (continued)
PROCEDURE
1. Remove input power to the POWER WAVE
355M/405M.
6. Remove the six screws from the terminals using a
flathead screwdriver. Carefully note the position of
2. Using a 5/16” nut driver remove the case
wraparound cover.
7. Using a 3/16”in. allen wrench remove the two
mounting screws and washers from the input
Procedure detailed earlier in this section.
4. Locate the input rectifier. See figure F.30.
8. Remove the input bridge.
5. Carefully remove the silicon sealant insulating the
six input rectifier terminals.
NOTE: Any instructions that are packaged with the
replacement board will supercede these
instructions.
FIGURE F.30 – INPUT RECTIFIER LOCATION
INPUT
RECTIFIER
S
T
A
T
U
S
T
H
E
R
M
A
L
L
I
N
C
O
L
E
N
L
E
C
T
R
I
C
W
A
R
N
I
N
G
R
E
M
O
T
E
P
O
W
E
R
O
N
POWER WAVE 355M/405M
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F-67
F-67
TROUBLESHOOTING AND REPAIR
INPUT RECTIFIER REMOVAL AND REPLACEMENT (continued)
9. Apply a thin coat of Penetrox A-13 heatsink com-
pound to the point of contact between the input
rectifier and the mounting surface.
11. Reconnect the previously removed leads to their
proper locations. Torque to 31 inch pounds.
12. Cover the input rectifier and its six terminals with
silicon sealant.
10. Secure the new input bridge into its proper posi-
tion with the two 3/16”in. allen mounting screws
previously removed. Torque to 44 inch pounds.
13. Replace the case wraparound cover.
FIGURE F.31 – INPUT RECTIFIER (CLOSE-UP)
Small Lead "H1"
To Auxiliary Transformer
3/16" ALLEN
BOLTS
C
B
#207
#207A
A
#209
Small Lead "A"
To Circuit Breaker
FRONT
REAR
POWER WAVE 355M/405M
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F-68
F-68
NOTES
POWER WAVE 355M/405M
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F-69
F-69
TROUBLESHOOTING AND REPAIR
OUTPUT RECTIFIER MODULES REMOVAL AND REPLACEMENT
WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician
or machine operator and will invalidate your factory warranty. For your safety and to avoid
electrical shock, please observe all safety notes and precautions detailed throughout this
manual.
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 trou-
bleshooting assistance before you proceed. Call 1-888-935-3877.
DESCRIPTION
The following procedure will aid the technician in removing the output rectifier modules
for maintenance or replacement.
MATERIALS NEEDED
3/16” Allen wrench
9/64” Allen wrench
5/16” Nut Driver
7/16” Wrench
Flathead Screwdriver
Penetrox A-13 Heatsink Compound
Thin Knife/Screwdriver
POWER WAVE 355M/405M
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F-70
F-70
TROUBLESHOOTING AND REPAIR
OUTPUT RECTIFIER MODULES REMOVAL AND REPLACEMENT (con’t)
PROCEDURE
6. After the snubber board is removed, remove the
1. Remove input power to the POWER WAVE
four leads connected to the modules using a 3/16”
allen wrench. These leads are #X4, #X2, #20, #40.
355M/405M.
2. Using a 5/16” nut driver remove the case wrap-
around cover.
7. Remove the copper plates from the tops of the
modules.
Procedure detailed earlier in this section.
NOTE: Any instructions that are packaged with the
4. Locate the output diode modules located behind
replacement part will supercede these instruc-
the snubber board. See figure F.32.
tions.
5. Before the output rectifier modules can be
reached, the Snubber Board Removal
Procedure must be performed.
FIGURE F.32 – OUTPUT RECTIFIER MODULE LEAD LOCATIONS
Output Diode
Modules
Snubber
Board
LEFT SIDE
POWER WAVE 355M/405M
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F-71
F-71
TROUBLESHOOTING AND REPAIR
OUTPUT RECTIFIER MODULES REMOVAL AND REPLACEMENT (con’t)
8. Under the copper plate previously removed, there
is an allen bolt. Remove it using a 9/64” allen
wrench. See Figure F.33.
13. The screw threads may catch on the threads of
the heat sink, so be sure to get the face of the
screw into contact with the surface of the module
(using just hand torque).
9. Using a 7/16” socket remove the mounting bolts at
the top and bottom of the modules. See Figure
F.33.
14. Using a 7/16” socket, tighten each mounting bolt
to between 5 and 10 inch pounds.
10. The output rectifier modules are ready for removal
and/or replacement.
15 Tighten the center allen screw to between 12 and
18 inch pounds.
11. Before replacing the diode module, apply a thin
even coat of Penetrox A-13 heatsink compound
to the bottom surface of the diode module. Note:
Keep the compound away from the mounting
holes.
16. Tighten each mounting bolt again (30 to 40 inch
pounds this time).
15. Replace leads #X2, #X4, #20, #40 to their original
terminals in their proper positions. Torque bolts to
30-40 Inch Pounds.
12. Press the module firmly against the sink while
aligning the mounting holes. Insert each outer
screw through a spring washer and then a plain
washer and into the holes. Start threading all
three screws into the heat sink (2 or 3 turns by
hand).
Procedure detailed earlier in this section.
17. Replace the case wraparound cover.
FIGURE F.33 – OUTPUT RECTIFIER MODULE MOUNTING BOLT LOCATIONS
Mounting
Bolts
40 20
X4
X2
3/16" Allen
Bolts
9/64" Allen
Bolts
Mounting
Bolts
POWER WAVE 355M/405M
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F-72
F-72
NOTES
POWER WAVE 355M/405M
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F-73
F-73
TROUBLESHOOTING AND REPAIR
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.
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 trou-
bleshooting assistance before you proceed. Call 1-888-935-3877.
DESCRIPTION
The following procedure will aid the technician in removing the current transducer for
maintenance or replacement.
MATERIALS NEEDED
5/16” Nut Driver
1/4” Nut Driver
1/2” Nut driver
3/8” Nut Driver
Channel Locks
Flathead Screwdriver
Phillips Head Screwdriver
Hammer
Crescent Wrench
Pliers
POWER WAVE 355M/405M
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F-74
F-74
TROUBLESHOOTING AND REPAIR
CURRENT TRANSDUCER REMOVAL AND REPLACEMENT (continued)
PROCEDURE
4. Using a 5/16” nut driver remove the four screws
1. Remove input power to the POWER WAVE
from the bottom and right side of the rear assem-
355M/405M.
bly. See Figure F.34.
2. Using a 5/16” nut driver remove the case wrap-
around cover.
Procedure detailed earlier in this section.
FIGURE F.34 – CASE BACK SCREW LOCATIONS
REAR
OFF
OFF
OFF
Plastic
Nut
5/16" Mounting Screws
POWER WAVE 355M/405M
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F-75
F-75
TROUBLESHOOTING AND REPAIR
CURRENT TRANSDUCER REMOVAL AND REPLACEMENT (continued)
5. Label and remove the four leads connected to the
reconnect panel. Pliers may be necessary.
9. Using a hammer and a flathead screwdriver, firmly
tap the metal nut from the bottom of one of its ribs.
This tapping will loosen the nut. Note: Be sure to
tap from the bottom so the nut loosens in a counter
clockwise fashion if viewed from the front of the
machine.
6. Label and remove the two leads connected to the
CB2 circuit breaker.
7. Using a crescent wrench, remove the large plastic
nut from around the input power line located at bot-
tom of the rear assembly. See Figure F.35.
10. Using a 3/8” nut driver label and remove leads
#202, #203, #206, #207A from the reconnect
switches. See Figure F.35.
8. Locate the steel nut located directly on the other
side of the rear assembly behind the plastic nut
that was previously removed. See Figure F.35.
FIGURE F.35 LEAD LOCATIONS
#206
#202
#207A
#203
S
T
A
T
U
S
T
H
E
R
M
A
L
L
I
N
C
O
L
E
N
L
E
C
T
R
I
C
W
A
R
N
I
N
G
R
E
M
O
T
E
P
O
W
E
R
O
N
POWER WAVE 355M/405M
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F-76
F-76
TROUBLESHOOTING AND REPAIR
CURRENT TRANSDUCER REMOVAL AND REPLACEMENT (continued)
11. The back of the machine may now gently be
pulled away to gain access to the current trans-
ducer. Note: The rear of the machine cannot be
removed completely.
16. Using a 3/8” wrench, remove the three mounting
screws from the output diode heatsink assembly.
Take note placement of insulation for reassembly.
See Figure F.36.
12. Carefully swing the rear of the machine open to
the left while facing the rear of the machine.
17. Cut any necessary cable ties and carefully remove
the heavy lead from the diode heatsink using a
1/2” nut driver.
18. Remove the output diode heatsink assembly
through the rear of the machine.
14. Remove leads #X2 and #20 from the output diode
module.
19. Remove plug #J90 from the current transducer.
15. Remove leads #X4 and #40 from the other output
diode module.
20. Using a 3/8” nut driver, remove the two mounting
nuts from the current transducer.
FIGURE F.36 – OUTPUT HEATSINK MOUNTING SCREW LOCATION
3/8"
MOUNTING
BOLTS
POWER WAVE 355M/405M
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F-77
F-77
TROUBLESHOOTING AND REPAIR
CURRENT TRANSDUCER REMOVAL AND REPLACEMENT (continued)
21. Replace the current transducer.
29. The rear of the machine may now be placed back
into its original position.
22. Replace the two 3/8” mounting nuts previously
removed.
30. Using a 3/8” wrench, replace leads #202, #203,
#206, and #207A previously removed from the
reconnect switches.
23. Reconnect plug #J90 to the current transducer.
24. Replace any necessary cable ties previously cut.
31. Tighten the metal nut previously removed from the
inside of the rear wall on the back of the machine.
Channel locks may be necessary.
25. From the rear of the machine, replace the heavy
flex lead to the bottom of the output diode
heatsink assembly using a 1/2” wrench. Note:
Don’t forget to include all washers.
32. Replace the large plastic nut from around input
power line located at the back of the machine.
26. Replace the output diode heatsink assembly pre-
viously removed using a 3/8” wrench.
33. Replace the four leads to the reconnect panel in
their proper locations.
Note: Be sure to place insulation in its original
34. Replace the two CB2 circuit breaker leads previ-
ously removed.
location.
27. Replace leads X2, #20, X4, #40 previously
removed from the two output diode modules.
Torque to 30-40 inch lbs.
35. Using a 5/16” nut driver, replace the four screws
from the rear assembly.
36. Replace the case wraparound cover.
POWER WAVE 355M/405M
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F-78
F-78
TROUBLESHOOTING AND 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
If you repair or replace any electrical components.
INPUT IDLE AMPS AND WATTS
Input Volts/Hertz
Maximum Idle Amps
Maximum Idle KW
208/60
230/60
400/60
460/60
575/60
4.0
3.3
2.1
2.0
1.8
0.45
0.45
0.45
0.45
0.45
MAXIMUM OUTPUT VOLTAGES
Input Volts/Hertz
Output Terminals
X1 - X2
115 Volt Receptacles
- No load
208/60
230/60
400/60
460/60
575/60
OCV
115 - 123 VAC
10 Amp Load
111 - 119 VAC
50-70 VDC
48.5 - 55 VDC
POWER WAVE 355M/405M
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G-1
G-1
TABLE OF CONTENTS - DIAGRAM SECTION
Electrical Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-1
Wiring Diagram (G4131) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-2
Entire Machine Schematic (G4132) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-3
Control PC Board Schematic #1 (G3789-1D0/1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-4
Control PC Board Schematic #2 (G3789-1D0/2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-5
Control PC Board Schematic #3 (G3789-1D0/3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-6
Control PC Board Schematic #4 (G3789-1D0/4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-7
Control PC Board Assembly (S25385-[ ]for 355, S25425-[ ] for 405) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .*
Digital Power Supply PC Board Schematic (G3631) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-8
Digital Power Supply PC Board Assembly (G3632-[ ]) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .*
Switch PC Board Schematic (L11487) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-9
Switch PC Board Assembly (G3830-[ ]) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-10
Snubber PC Board Schematic (S24761) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-11
Snubber PC Board Assembly (M19532-[ ]) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-12
40 VDC Buss PC Board Schematic (M19330) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-13
40 VDC Buss PC Board Assembly (L11832-[ ]) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .*
* NOTE: Many PC Board Assemblies are now totally encapsulated and are therefore considered to be
unserviceable. The Assembly drawings are provided for reference only.
POWER WAVE 355M/405M
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G-2
G-2
ELECTRICAL DIAGRAMS
WIRING DIAGRAM - POWERWAVE 355/405 - G4131
WIRING DIAGRAM - POWER WAVE 355/405
RIGHT SIDE OF MACHINE
}
INPUT
PER
N.A.
+ C1,C3
FLAT SIDE OF LED
ALIGNED WITH
BLACK LEAD
3200/300
206
205
203
208
SWITCH
J20
607
2 B
1010
1
2
3
4
THERMAL
YELLOW
LED
615
716
715
611
612
609
602
5
6
7
8
4
3
2
1
8
7
6
5
1020
610
1002 1020
209
53
1103
54
1104
605
1001
1010
J21
608
616
1
2
1
2
3
6
5
4
1
3
2
4
2 W
1W
1001
1002
903
N.D.
21
67
J9
2
J22
1
901
804
201
3200/300 207
1
2
204
504
505
J11
J10A J10B
3
4
201
4
3
8
7
6
5
STATUS
202
J8
205
RED/GREEN
LED
FAN
FAN
L6
+
2
802
806
801
32A
31B
C2,C4
1
B
CONTROL
BOARD
8
7
16
15
2 B
1B
6
2
716
715
J7
2 W
PRIMARY
X2
RECONNECT
FLAT SIDE OF LED
ALIGNED WITH
WHITE LEAD
3
20
204
7
FAN
FAN
4
3
1 B
L1
REACTOR
13
1
X3
25
14
30
1 W
208
X1
203
207A
J1
FAN
30
251
CHOKE
x x x x x x x
254
253
608
8
16
15
14
13
12
11
10
9
505
J6
10
616
506
607
615
7
6
206
A
503
202
MAIN
40
5
4
3
2
1
605
610
612
611
( 380-575VAC POSITION )
X4
L2
TRANSFORMER
401
REACTOR
10
A
CB3
INPUT
N.E.
TP3
A
A
BRIDGE
602
609
209
+
_
_
A
N.C.
R2
10
A
B
C
253
D
E
F
TP1
504
H4
H2
200-
208V
J2
380-
415V
2
1
4
3
502
503
J5
1
2
251
254
3
207A
207
B
403
403A
4
TP2
J3
9
J4
8
502
66C
65C
x x x x x x x
550-
575V
440-
220-
12 11 10
9
3
7
1
10
5
8
7
C
460V
230V
DC BUS
BOARD
H6
H5
H3
2
4
1
3
2
2
X2
20
65
66
6
5
4
4
3
X4
40
1
OUTPUT
RECTIFIER
H1
J46
5
401A
403A
406
WIRE FEEDER
RECEPTACLE
VOLTAGE SENSE
RECEPTACLE
1
51
408
402
405
410
407
475
J47
6
2
412
411
H1 H2 H3
H4 H5 H6
7
8
3
4
477
52
L3
E
A
1
53
AUXILIARY
TRANSFORMER
S
2
3
D
51
220V
COM2
115V
42V
N
U
B
B
E
R
B
54
4
COM1
C
( )COLORS FOR PW405
52
SNB
N.F.
41
67
10
G(G/Y)
R(B)
W(N)
B(U)
1103 1104
401A
L4
L5
W
V
U
~
1
5
8
-
65C
66C
C5
J52
405
403
401
402
65
66
407 410
412 411
477
R1
406
A
CB1
475
B
31 42 COM1A
532
408
C
~
903B
901B
66B
65B
J52-1
5201
J52-11
J52-3
532
1
3
2
8
41
2
5
3
6
2
4
3
9
4
5
6
1
4
1
7
31
CB2
_
10
CONTROL
RECTIFIER
11 12
42
32A
LEGEND
ALL MACHINES
J42
J43
903
J41
POWER
CB2
31B
CB4
32A
31B
OPTION
COMPONENT OUTLINE
31D
J90
2 3 4
CURRENT
TRANSDUCER
COLOR CODE:
FRONT VIEW OF MACHINE
1
PW355
MODEL
PW405
MODEL
B = BLACK
G = GREEN
R = RED
901
LEFT SIDE OF MACHINE
NOTES:
W = WHITE
U = BLUE
N.A. 1. FOR MACHINES WITH RED, BLACK AND WHITE POWER CORDS-
N = BROWN
N.B. SINCE COMPONENTS OR CIRCUITRY OF A PRINTED CIRCUIT BOARD MAY CHANGE WITHOUT AFFECTING
THE INTERCHANGEABILITY OF A COMPLETE BOARD, THIS DIAGRAM MAY NOT SHOW THE EXACT
COMPONENTS OR CIRCUITRY HAVING A COMMON CODE NUMBER.
N.C. PLACE "A" LEAD ON APPROPRIATE CONNECTION FOR INPUT VOLTAGE. CONNECTION SHOWN IS FOR
550-575V OPERATION (PW405ONLY GO TO 415VAC)
FOR SINGLE PHASE INPUT: CONNECT GREEN LEAD TO GROUND PER NATIONAL ELECTRICAL
CODE. CONNECT BLACK AND WHITE LEADS TO SUPPLY CIRCUIT. WRAP RED LEAD WITH TAPE
TO PROVIDE 600V. INSULATION.
FOR THREE PHASE INPUT; CONNECT GREEN LEAD TO GROUND PER NATIONAL ELECTRICAL
CODE. CONNECT BLACK, RED & WHITE LEADS TO SUPPLY CIRCUIT.
Y = YELLOW
J8,J20,
J21, J47
J2,J5,J11,
J10A,
J1,J6,J7
J52
N.D. INPUT POWER LINE FILTER IS PRESENT ONLY ON PW405.
N.E. ON PW405, MOV'S ARE IN THE INPUT POWER LINE FILTER.
N.F. 220VWINDING IS ONLY PRESENT ON PW405.
TOP CENTER
PANEL
J9, J42
1
2. FOR MACHINES WITH BROWN, BLACK AND BLUE POWER CORDS-
J4, J43
J22, J41, J46
J10B
1
9
8
2
4
5
1
6
1
1
3
1
7
1
FOR SINGLE PHASE INPUT: CONNECT GREEN/YELLOW LEAD TO GROUND PER NATIONAL
ELECTRICAL CODE. CONNECT BLUE AND BROWN LEADS TO SUPPLY CIRCUIT. WRAP BLACK
LEAD WITH TAPE TO PROVIDE 600V. INSULATION.
BASE
CASE FRONT
FAN SHROUD
PROTECTIVE BONDING CIRCUIT
8
6
3
4
5
12
10
16
4
6
2
FOR THREE PHASE INPUT: CONNECT GREEN/YELLOW GROUND PER NATIONAL ELECTRICAL
CODE. CONNECT BLUE, BLACK & BROWN LEADS TO SUPPLY CIRCUIT.
CONNECTOR CAVITY NUMBERING SEQUENCE
(VIEWEDFROM COMPONENT SIDE OF BOARD)
ELECTRICAL SYMBOLS PER E1537
A
G4131
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 355M/405M
Download from Www.Somanuals.com. All Manuals Search And Download.
G-3
G-3
ELECTRICAL DIAGRAMS
SCHEMATIC - COMPLETE MACHINE
2 1 3 G 4
ENGINEERING CONTROLLED
Released from "X"
CHANGE DETAIL:
MANUFACTURER:
No
+15
SWITCH BOARD
(Sch. L11487)
609
602
J20-4
J20-8
MAIN
INPUT
RELAY
CR1
CONTROL BOARD
(Sch. G3789)
209
+15V
J6-9
J6-2
609
602
MAIN RELAY CONTROL
RECONNECT SWITCH
CR1
616
VOLTAGE / FREQUENCY CONVERTER #1 (+)
VOLTAGE / FREQUENCY CONVERTER #1 (-)
PRIMARY CURRENT SENSE #1 (-)
PRIMARY CURRENT SENSE #1 (+)
J6-16
J6-8
205
206
N.C.
N.B.
608
1001
1002
SNUBBER
BOARD
J10A-1
J10A-2
(Sch. S24761)
4200 uF
J21-6 616
-
-
V/F CONVERTER # 1
REACTOR
J21-2
J21-1
J21-5
608
J8-1
OUTPUT
DIODES
CURRENTFEEDBACK ( 4V=500A )
I OUT
+15V
-15V
801
801
802
804
806
J90-3
J90-1
J90-2
J90-4
INPUT SWITCH
L1
1001
1002
+15V
802
804
806
J8-2
J8-4
J8-6
-15V
4200 uF
H1
FLAT SIDE OF LED
ALIGNED WITH BLACK LEAD
GND
POS
NEG
CONTROL BOARD COMMON
AC3
AC2
AC1
W
V
WHITE
(BROWN)
C
B
A
POSITIVE
203
202
J9-1
J9-3
(+) STUD VOLTAGE SENSE
(-) STUD VOLTAGE SENSE
208
204
901
903
+
TP3
TP2
901B
INPUT
LINES
L2
RED
CURRENT
TRANSDUCER
C1/TP1
.05uF
600V
320V
160J
R1
(BLACK)
TP1
L3
THERMAL
U
G
THERMAL LED
BLACK
(BLUE)
8J7
2B
TP3
YELLOW
LED
150V
4200 uF
GREEN
2W
-
THERMAL LED
A
80J
7J7
3J7
MAIN CHOKE
x x x x x x x
(GREEN/YELLOW)
J21-7
605
610
NEGATIVE
903B
V/F CONVERTER # 2
-
1W
1B
STATUS LED (HIFOR RED)
CB3
STATUS
GND
6.0A
J21-3
( ) COLOR FOR PW405
THERMOSTAT
C2/TP2
.05uF
600V
RED/GREEN
LED
320V
160J
J21-4
J21-8
4200 uF
REACTOR
506
Dashed lines represent
copper busconnections.
503
-
N.D.
207
B1
STATUS LED (HIFOR GREEN)
4J7
506
505
SNB
201
Shown connected for
200 - 240Volt InputVoltage
+15
1010
503
502
THERMOSTAT
THERMOSTAT
J5-3
J5-2
1020
SOFT
FLAT SIDE OF LED
ALIGNED WITH WHITE LEAD
START
(+)
(-)
505
504
605
610
J6-5
VOLTAGE / FREQUENCY CONVERTER #2 (+)
VOLTAGE / FREQUENCY CONVERTER #2 (-)
PRIMARY CURRENT SENSE #2 (-)
PRIMARY CURRENT SENSE #2 (+)
GND (a)
SOFT START CONTROL
PULSE TRANSFORMER GATE DRIVE
PULSE TRANSFORMER GATE DRIVE
+ 15 (a)
J6-10
J10B-1
J10B-2
J6-11
J6-12
AUXILIARY
1010
1020
611
TRANSFORMER
611
FAN
615
607
716
612
612
615
607
715
716
115 VAC
715
J6-15
FAN
FAN
J6-7
J7-15
FAN CONTROL
J7-16
32A
J4-7
J4-12
504
407
412
407
412
POWERDOWN SIGNAL (HIGH=RUN)
+15V (a)
J42-4
J42-1
POWER DOWN SIGNAL
31B
+15 (a)
POWER
BOARD
MACHINE
J4-8
+5 (a) J42-3
408
410
411
408
410
411
+5V (a)
GND (a)
-15V (a)
J46-1
65
(Sch. G3631)CONTROL
65B
42
502
POWER
J4-10
J4-11
GND (a)
-15 (a)
J42-5
J42-2
65C
J46-2
SUPPLY
C5
31
J46-3
J46-4
66
+5 SPI (b)
+15 SPI (b)
J4-3
J4-2
403
403A
402
+5V SPI (b)
J43-3
J43-6
J43-12
J43-4
66C
SPI
402
401
406
+15V SPI (b)
CB1
15A
66B
41
POWER
SUPPLY
SPI GND (b)
+5 RS232 (e)
R2
10 Ohms
401A
406
J4-1
J4-6
477
475
52
GND SPI (b)
+5V RS232 (e)
+40VDC POWER
COMMON
J47-3
J41-2
+40 VDC
J41-1
RS232
SUPPLY
31B
J47-6
J47-8
CB2
405
401A
405
J4-5
J43-9
J43-11
GND (e)
GND (e)
532
2.5A
32A
+40VDC
FEEDER
L3
+20 (c) J43-8
PW355
CHOPPER
GND (c)
+20 (d)
J43-2
J43-7
J43-1
POWER
SUPPLY
J47-1
51
COMMON
MODEL
SEE BELOW
FOR PW405
J2-1
251
253
254
21
67
54
53
1104
J9-6
J9-4
J11-1
J11-2
J11-4
GND (d)
VOLTAGE SENSE
LINCNET
LINCNET
J2-3
J2-4
DC BUS
BOARD
(Sch. M19330)
+5
J43-5
13
25
CAN
1103
J11-3
GND
J43-10
WIRE FEEDER
RECEPTACLE
L5
251
254
J52-11
31
J52-1
5201
J52-3
532
CB2
2.5A
LINCNET -
A
B
C
D
E
53
54
67
14
253
LINCNET +
1
32A
ELECTRODE SENSE
52
51
+40 VDC
0VDC
31B
CB4
2.5A
L4
VOLTAGE SENSE
RECEPTACLE
31D
J2,J5,J11,
J22,J41,J46
1
J8,J20,
J21,J47
NOTES :
J10A,
J10B
1
J1,J6,J7
1
J4, J43
J9,J42
2
3
4
8
N.A. PCBOARD COMPONENTS SHOWN FOR REFERENCE
ONLY. ALL COMPONENTS ARE NOT SHOWN.
N.B. INPUT POWER LINE FILTER IS PRESENT ONLY ON PW405.
J52
2
1
4
1
21
6
1
7
1
3
1
6
5
PW405
ELECTRICAL SYMBOLS PER E1537
MODEL
9
16
4
5
3
4
8
6
12
LEGEND
10
N.C. ON PW405, MOV's ARE IN THE INPUT POWER LINE FILTER.
2
ALL MACHINES
N.D. PLACE "A" LEAD ONAPPROPRIATE CONNECTIONFOR
INPUT VOLTAGE. CONNECTION SHOWN SI FOR 550-575V
OPERATION (PW405 ONLY GO TO 415 VAC).
OPTION
COMPONENT OUTLINE
CONNECTOR CAVITY NUMBERINGSEQUENCE
(VIEWED FROM COMPONENT SIDE OF BOARD)
THIS DOCUMENT CONTAINS PROPRIETARY INFORMATION OWNED BY LINCOLN GLOBAL, INC. AND MAY NOT BE DUPLICATED, COMMUNICATED
TO OTHER PARTIES OR USED FOR ANY PURPOSE WITHOUT THE EXPRESS WRITTEN PERMISSION OF LINCOLN GLOBAL, INC.
PROPRIETARY& CONFIDENTIAL:
UNLESS OTHERWISE SPECIFIED TOLERANCE
DESIGN INFORMATION
REFERENCE:
MANUFACTURING TOLERANCE PER E2056
EQUIPMENT TYPE:
SUBJECT:
PAGE _1__ OF ___
1
POWERWAVE 355/405
MACHINE SCHEMATIC
ON
2
PLACE DECIMALS IS .02
DRAWN BY: F.Valencic
L.Petrila
APPROVED: J.O'Connor
G4093
ON
3
PLACE DECIMALS IS .002
DOCUMENT
NUMBER:
DOCUMENT
REVISION:
ON ALL ANGLES IS .5 OF
A
DEGREE
") TO AGREE
MATERIAL TOLERANCE ("
t
ENGINEER:
SCALE:
WITH PUBLISHED STANDARDS.
MATERIAL
DISPOSITION:
APPROVAL
DATE:
PROJECT
NUMBER:
G4132
CRM33683
A
RW
7/15/02
NONE
DO NOT SCALE THIS DRAWING
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
POWER WAVE 355M/405M
Download from Www.Somanuals.com. All Manuals Search And Download.
G-4
G-4
ELECTRICAL DIAGRAMS
SCHEMATIC - DIGITAL CONTROL PC BOARD #1
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
POWER WAVE 355M/405M
Download from Www.Somanuals.com. All Manuals Search And Download.
G-5
G-5
ELECTRICAL DIAGRAMS
SCHEMATIC - DIGITAL CONTROL PC BOARD #2
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
POWER WAVE 355M/405M
Download from Www.Somanuals.com. All Manuals Search And Download.
G-6
G-6
ELECTRICAL DIAGRAMS
SCHEMATIC - DIGITAL CONTROL PC BOARD #3
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
POWER WAVE 355M/405M
Download from Www.Somanuals.com. All Manuals Search And Download.
G-7
G-7
ELECTRICAL DIAGRAMS
SCHEMATIC - DIGITAL CONTROL PC BOARD #4
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
POWER WAVE 355M/405M
Download from Www.Somanuals.com. All Manuals Search And Download.
G-8
G-8
ELECTRICAL DIAGRAMS
SCHEMATIC - POWER SUPPLY PRINTED CIRCUIT BOARD
+5V
Machine Control Power Supply
R50
.13
J42
D18
3
1
2
6A
200V
+
t
D4
6A
200V
60V
LED2
10
T1
+5Volts, .750 Amp
C43
100
16V
C41
100
16V
C39
0.1
50V
T1
C12
.0015
2000V
33.2
33.2
10-55 VDC
Operation
332
3
Vref
1
10.0K
10.0K
10.0K
R9
11
12
D22
10.0
1.0A
30V
R60
10.0
D
S
+15Volts
Q1
21A
G
R61
10.0
200V
.750 Amp
D24
C13
1
200V
7
6
VCC
OUT
1
5
Vref
1
J41
8
4
5
2
J42
D3
1A
600V
VREF
RT/CT
GND
VFB
D19
DZ8
18V
3W
Vfb1
OCI1
2
X8
1
DC Input (+)
1
IN
OUT
COMP
CS
3A
600V
CNY17-3
R10
R5
3
100K
100K
2
6
4
J41
4
X5
Vfb1
ADJ
9
+
t
7
D21
1.0A
30V
C11
22
35V
C14
0.1
50V
C47
1.0
35V
R55
1.21K
.33W
R52
221K
T1
1.82K
T1
OV1
475
Machine Control
Shut Down
Capacitor
4
6
C7
0.1
50V
C45
C6
4.7
35V
150p
R39
R12
5.62K
100V
56.2K
C8
820p
50V
3W
0.05
C42
R13
C32
2700p
50V
10p
10.0K
J41
3
100V
1
J41
8
X1
GND
1
5
DC Input (-)
REF
TL431
6
C44
0.1
50V
C38
4.7
35V
C40
1.0
35V
-15Volts, .100Amp
T1
1.21K
.33W
5
6
J42
J42
8
ADJ
J42
2
IN
OUT
DZ1
24V
3W
X9
14
D8
1A
600V
gnd_mcps
T2
+5V
Operation
30-55 VDC
1
D25
1.00K
Undervoltage
Detect
<30VDC
C31
.0015
2000V
D2
1A
600V
D23
1.0A
30V
5
1
OCI2
CNY17-3
D10
X3
D
Q2
J42
4
4
6
2
21A
J43
G
7
6
200V
VCC
OUT
R32
15.0
6
S
IN
OUT
Vref
2
8
4
5
2
VREF
RT/CT
GND
VFB
D9
DZ2
27V
.5W
C49
.022
R34
221K
1A
DZ7
18V
3W
1
COMP
CS
R31
75K
Vfb2
600V
ADJ
3
3
C53
.1
R29
X4
C27
C23
1.0
35V
100K
C25
0.1
50V
OV2
C24
4.7
35V
C26
1
200V
1.21K
.33W
T2
12
150p
100V
D20
1.0A
30V
C52
150p
DZ3
27V
.5W
15Volts, .250Amps
SPI
gnd_mcps
C2
0.1
50V
C3
4.7
35V
R38
R28
5.62K
56.2K
C4
820p
50V
3W
0.05
Overvoltage
Shutdown
> 55 VDC
C28
249
10p
J43
100V
R40
3
+
t
D16
16A
.13
200V
60V
OV2
OV1
LED1
2
+5Volts, 3 Amps
SPI
D14
D17
C37
100
16V
C36
100
16V
C35
100
16V
C34
0.1
50V
T2
13
150
.33W
150
.33W
150
.33W
D13
Vref
2
332
DZ4
3.3V
3W
C33
4.7
35V
15
J43
D15
X7
5
IN
OUT
1A
600V
4
1
5
GND
J43
OCI3
CNY17-3
R17
C5
0.1
50V
C1
4.7
35V
C30
1.0
35V
+5Volts, .100 Amp
CAN
8
T2
11
150
.33W
+
t
D7
2
6
4
1A
.24
Vfb2
6
600V
J43
10
+20Volts
.200 Amps
Gate Drive
475K
R21
C21
0.1
50V
C17
4.7
35V
C18
4.7
35V
T2
9
2.49K
.33W
C46
150p
100V
J43
2
D12
1.82K
C16
R22
J43
7
R24
.24
2700p
50V
10.0K
J43
4
D1
+
t
D6
1A
X6
1
IN
OUT
7
600V
1A
600V
X2
8
5
+20Volts
.200 Amps
Gate Drive
GND
REF
TL431
6
C22
0.1
50V
C20
4.7
35V
C19
4.7
35V
T2
8
C9
0.1
50V
2.49K
.33W
C10
4.7
35V
C29
+5Volts, .100 Amp
RS232
T2
10
1.0
150
.33W
35V
J43
11
J43
9
J43
1
J43
12
FILENAME: G3631-2D2
GENERAL INFORMATION
ELECTRICAL SYMBOLS PER E1537
LAST NO. USED
R-
C-
D-
CAPACITORS
RESISTORS
DIODES
=
MFD
(
.022/50V
UNLESS OTHERWISE SPECIFIED)
NOTES
:
LABELS
=
Ohms
(
1/4W UNLESS OTHERWISE SPECIFIED)
(UNLESS OTHERWISE SPECIFIED)
N.A. SINCE COMPONENTS OR CIRCUITRY ON
A
PRINTED CIRCUIT BOARD MAY CHANGE
=
1A, 400V
WITHOUT AFFECTING THE INTERCHANGEABILITY OF COMPLETE BOARD, THIS DIAGRAM MAY
A
SUPPLY VOLTAGE NET
POWER SUPPLY SOURCE POINT
COMMON CONNECTION
NOT SHOW THE EXACT COMPONENTS OR CIRCUITRY OF CONTROLS HAVING
NUMBER.
A
COMMON CODE
FRAME CONNECTION
EARTH GROUND CONNECTION
THIS SHEET CONTAINS PROPRIETARY INFORMATION OWNED BY THE LINCOLN ELECTRIC COMPANY AND IS NOT TO BE REPRODUCED, DISCLOSED OR USED WITHOUT THE EXPRESS WRITTEN PERMISSION OF THE LINCOLN ELECTRIC COMPANY, CLEVELAND, OHIO U.S.A.
UNLESS OTHERWISE SPECIFIED TOLERANCE
"X" INFO.
Chg. Sheet No.
6-2-2000A
DESIGN INFORMATION
REFERENCE:
MANUFACTURING TOLERANCE PER E2056
EQUIPMENT TYPE:
Digital Systems
Schematic, Digital Power Supply
ON
2
PLACE DECIMALS IS .02
DRAWN BY: JP\TK
ON
3
PLACE DECIMALS IS .002
ON ALL ANGLES IS .5 OF
A
DEGREE
10-27-2000E
SUBJECT:
MATERIAL TOLERANCE ("
WITH PUBLISHED STANDARDS.
t
") TO AGREE
ENGINEER:
SUPERSEDING:
11-30-98
DRAWING No.:
APPROVED:
SCALE:
NONE
DATE:
G 3631
DO NOT SCALE THIS DRAWING
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
POWER WAVE 355M/405M
Download from Www.Somanuals.com. All Manuals Search And Download.
G-9
G-9
ELECTRICAL DIAGRAMS
SCHEMATIC - SWITCH PC BOARD
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
POWER WAVE 355M/405M
Download from Www.Somanuals.com. All Manuals Search And Download.
G-10
G-10
ELECTRICAL DIAGRAMS
PC BOARD ASSEMBLY - SWITCH PC BOARD
ITEM
REQ'D
PART NO.
IDENTIFICATION
2
2
2
2
2
2
2
4
9
C1,C23
C10,C11
C2,C24
C25,C26
C3,C18
C31,C32
C4,C21
C5,C6,C15,C16
C7,C12,C13,C14,C20,C27,C28
C29,C30
S20500-4
S13490-130
S20500-7
T11577-57
S13490-93
S16668-7
S20500-1
S16668-6
S16668-5
CAPACITOR,PPMF,.0047,1000V,BOX
CAPACITOR,PCF,0.27,50V,5%
CAPACITOR,PPMF,.047,1600V,BOX,10%
CAPACITOR,PEF,0.1,400V,10%
CAPACITOR,TAEL,27,35V,10%
CAPACITOR,CEMO,820p,50V,5%
CAPACITOR,PPMF,0.1,1000V,10%,BOX
CAPACITOR,CEMO,4700p,50V,10%
CAPACITOR,CEMO,.022, 50V,20%
C8,C9,C22
CR1,CR2
D1,D4,D16,D17
D7,D8,D9,D12,D14,D18,D19
D20,D21
3
2
4
9
S16668-9
S14293-18
T12705-59
T12199-1
CAPACITOR,CEMO,150p, 100V,5%
RELAY,DPST,12VDC,AG-CDO
DIODE,AXLDS,3A,600V,UFR
DIODE,AXLDS,1A,400V
DZ1,DZ2,DZ3,DZ5,DZ6,DZ15
DZ16,DZ18,DZ19,DZ23
DZ11,DZ22
DZ4,DZ7,DZ17,DZ20
DZ8
DZ9,DZ10,DZ12,DZ13
J20,J21
J22
10 T12702-29
ZENER DIODE, 1W,15V,5% 1N4744A
N.E., N.F.
R2
R1
R126
R127
J21
2
4
1
4
2
1
3
1
1
4
1
T12702-4
T12702-40
T12702-19
T12702-45
S24016-8
S24016-4
S15000-22
S15000-29
T12704-75
T12704-73
T12704-69
ZENER DIODE, 1W,20V,5% 1N4747A
ZENER DIODE, 1W,6.2V,5% 1N4735A
ZENER DIODE, 1W,12V,5% 1N4742A
ZENER DIODE, 1W,18V,5% 1N4746A
CONNECTOR,MOLEX,MINI,PCB,RT-L,8-PIN
CONNECTOR,MOLEX,MINI,PCB,RT-L,4-PIN
OPTOCOUPLER,PHOTO-Q,70V,CNY17-3/VDE
OPTOCOUPLER,TRIAC,DRV,RANDOM,600V
TRANSISTOR,NMF,T247,4A,900V(SS)
MOSFET,4-PIN DIP,1A,100V,RFD110(SS)
TRANSISTOR,PNP,TO226,0.5A, 40V,2N4403
RESISTOR,WW,5W,3.3K,5%,SQ
6
7
2
1
2
1
R122
DZ22
R83
DZ11
R123
C22
R37
C9
.275
.285
X1
X4
R .045
∅
OCI3
OCI1,OCI2,OCI3
OCI4
Q1
C3
C18
MAX.
R65
OCI2
.105
CRIMP
HEIGHT
R135
R72
N.A.
D21
C32
R39
R38
N.A. Q2,Q3,Q4,Q5
5
NON-COMPONENT
SIDE
Q6
X2
R1,R2,R3,R4,R7,R8,R9,R10
16 T14648-5
R124,R125,R126,R127,R130
R131,R132,R133
R11,R12,R30,R31
R13,R39,R43,R60,R81,R92
R137
R138
R139
R14,R107
R140
R15,R20,R21,R22,R27,R28
R97,R98,R99,R100,R101,R106
R29,R83,R122,R141
R32,R33,R34,R48,R49,R50
R51,R62,R63,R74,R75,R85
R86,R87,R134,R135
R35,R52,R73,R84
R36,R37,R123
R38,R40,R42,R45,R53,R59
R66,R69,R70,R72,R80,R82
R142,R143
R15
4
B203
B207
EYELET DETAIL
R19
C5
C12
R41
R99
4
6
1
1
1
2
1
S19400-1503 RESISTOR,MF,1/4W,150K,1%
S19400-3321 RESISTOR,MF,1/4W,3.32K,1%
R43
D9
R20
R93
C15
R78
B218
B211
DZ9
S19400-3570 RESISTOR,MF,1/4W,357,1%
S19400-1500 RESISTOR,MF,1/4W,150,1%
S19400-4750 RESISTOR,MF,1/4W,475,1%
S19400-1652 RESISTOR,MF,1/4W,16.5K,1%
S19400-39R2 RESISTOR,MF,1/4W,39.2,1%
R97
N.C.
B213
B217
D1
D16
N.J.
(8 PLACES)
C31
R35
R60
12 S19400-10R0 RESISTOR,MF,1/4W,10.0,1%
C1
C23
C13
C20
4
S19400-1000 RESISTOR,MF,1/4W,100,1%
R5
R128
DZ23
R129
16 S19400-1003 RESISTOR,MF,1/4W,100K,1%
DZ1
R6
X3
C2
C24
4
3
S19400-6191 RESISTOR,MF,1/4W,6.19K,1%
S19400-2213 RESISTOR,MF,1/4W,221K,1%
R82
R53
14 S19400-1002 RESISTOR,MF,1/4W,10.0K,1%
B216
B212
R52
B205
B204
R22
R69
R41,R67
R44,R68
R46,R76
R47,R64
R5,R6,R19,R26,R93,R105
R109,R128,R129
R55,R56,R57,R58
R61,R77
R65,R120
R78,R79
T1
T2,T3
TP1
TRI1
X1,X4
X2,X3
2
2
2
2
9
S19400-4752 RESISTOR,MF,1/4W,47.5K ,1%
T12300-79 RESISTOR,WW, 1W,1.0,1%
S19400-3322 RESISTOR,MF,1/4W,33.2K,1%
S19400-2000 RESISTOR,MF,1/4W,200,1%
S19400-1001 RESISTOR,MF,1/4W,1.00K,1%
R70
R26
C6
DZ13
N.D.
3
D4
D17
(16 PLACES)
R106
R27
N.B., N.G., N.M.
(5 PLACES)
R105
C16
B206
B202
R101
1
4
2
2
2
1
2
1
1
2
2
S24376-3
RESISTOR,WW,10W,100,5%
R133
S19400-8251 RESISTOR,MF,1/4W,8.25K,1%
S19400-2001 RESISTOR,MF,1/4W,2.00K,1%
R130
S16296-5
S13000-46
M19612
T13640-24
S15161-27
S15128-10
S15128-18
TRIMMER,MT,1/2W,10K, 10%,LINEAR
TRANSFORMER,PCB;
CURRENT-TRANSDUCER,125-TURN
MOV,175VRMS,120J,20MM
TRIAC,T220,8A,800V
VOLTAGE REF,ADJ, PRECISION,431I
OP-AMP,QUAD, HIGH-PERF,33074
R8
R9
MANUFACTURED AS:
G3830-1B1
R131
R132
N.K.
(4 PLACES)
R7
R10
N.K.
TRI1
(4 PLACES)
R11
J22
IDENTIFICATION CODE
B209
T1
R138
R140
PART NO.
R137
R139
OCI1
NOTES:
N.A.
N.L.
CR2
CR1
C25
THIS DEVICE IS SUBJECT TO DAMAGE BY
STATIC ELECTRICITY. LINCOLN ELECTRIC TO SEE E2454
CAUTION:
CAPACITORS = MFD/VOLTS
INDUCTANCE = HENRIES
RESISTOR = OHMS
BEFORE HANDLING.
J20
C26
N.B. SNAP POWER TERMINALS INTO COMPONENT SIDE OF BOARD.
N.C. THIS AREA TO BE COVERED ON BOTH SIDES OF BOARD (WHERE
POSSIBLE) WITH SEALANT PRIOR TO ENCAPSULATION.
N.D. INJECT SEALANT ITEM 8 THROUGH THE PC BOARD TO SEAL MODULE LEADS
(16 PLACES), AND ALL COMPONENT LEADS ON THE NONO-COMPONENT
SIDE OF THE BOARD, THAT ARE COVERED BY MODULE CASE.
N.E. FEMALE EYELET TO BE AGAINST THE NON-COMPONENT SIDE AS SHOWN
EYELET MUST NOT SPIN AFTER CLINCHING.
N.F. SOLDER EYELET SO THAT SOLDER COVERS ENTIRE EYELET
AND ALL AROUND EYELET ON COPPER SIDE ONLY.
ITEM PART NO.
DESCRIPTION
QTY
1
2
3
4
5
6
7
8
G3831-B
M16100-44
S23006
M19612
S24866
P.C. BOARD BLANK
1
ELECTRONIC MODULE (A1, A2)
TERMINAL (B211,B218,B204,B205,B209)
CURRENT TRANSDUCER (T2, T3)
POWER TERMINAL (B201, B208)
EYELET-FEMALE
2
N.A.
5
2
NO ICICLES OR SOLDER BLOBS PERMITTED.
2
8
N.G. AFTER SOLDERING, INSPECT POWER TERMINAL CONNECTIONS
TO ENSURE SOLDER HAS PROPERLY WET COMPONENT SIDE PAD
ON A MINIMUM OF 3 OF THE 4 LEGS OF THE POWER TERMINAL.
N.H. BAR MUST BE FREE OF ENCAPSULATION MATERIAL ON BOTH SURFACES
AROUND MOUNTING HOLES AND ENTIRE LENGTH OF MOUNTING SURFACE.
ENCAPSULATION MATERIAL MUST NOT EXTEND BEYOND THE MOUNTING
SURFACE PLANE. (2 PLACES)
T9147-11
T9147-15
E2861
EYELET-MALE
8
SEALANT
5.0oz
N.P.
2
N.J. DO NOT COAT WITH ENCAPSULATION MATERIAL, TOP AND BOTTOM, .80 +/- .05” DIA.
N.K. PC BOARD HOLES TO BE FREE OF ENCAPSULATION MATERIAL AND SEALANT
FOR A DIAMETER OF .50” FOR THE LARGER HOLES, AND .25 FOR THE SMALLER
HOLES, BOTH SIDES OF BOARD. (4 PLACES).
N.L. THIS AREA TO BE COVERED ON COMPONENT SIDE OF BOARD WITH SEALANT
PRIOR TO ENCAPSULATION. MATERIAL MUST BE APPLIED FROM TOP TO
COMPLETELY FILL TO UNDERSIDE OF DEVICE. THEN APPLY SEALANT AROUND
BASE OF DEVICE.
MAKE PER E1911
ENCAPSULATE WITH E1844, 3 COATS
N.N.
(2 PLACES)
N.H.
(2 PLACES)
TEST PER E3817-SW
N.M. THIS AREA TO BE COVERED ON OPPOSITE COMPONENT SIDE OF BOARD WITH
ITEM 8 PRIOR TO ENCAPSULATION. DO NOT COAT WITH ENCAPSULATION
MATERIAL ON THE TOP SURFACES NOR THE THREADS.
N.N. THESE SURFACES MUST BE MAINTAINEDCO-PLANAR WITHIN .010” THROUGH
ENTIRE SOLDERING AND SEALING PROCESS.
N.P. SEALANT HEIGHT BETWEEN MODULES NOT TO EXCEED .17” MAX.
THIS SHEET CONTAINS PROPRIETARY INFORMATION OWNED BY THE LINCOLN ELECTRIC COMPANY AND IS NOT TO BE REPRODUCED, DISCLOSED OR USED WITHOUT THE EXPRESS WRITTEN PERMISSION OF THE LINCOLN ELECTRIC COMPANY, CLEVELAND, OHIO U.S.A.
UNLESS OTHERWISE SPECIFIED TOLERANCE
Chg. Sheet No.
6-2-2000A
"X" INFO.
XM5626
XA
DESIGN INFORMATION
REFERENCE:
MANUFACTURING TOLERANCE PER E2056
ON 2 PLACE DECIMALS IS .02
EQUIPMENT TYPE:
INVERTER WELDERS
SWITCH P.C. BOARD ASSEMBLY
DRAWN BY: F.V./JB
ENGINEER:
ON 3 PLACE DECIMALS IS .002
ON ALL ANGLES IS .5 OF A DEGREE
SUBJECT:
MATERIAL TOLERANCE (" ") TO AGREE
t
SUPERSEDING:
WITH PUBLISHED STANDARDS.
APPROVED:
SCALE:
FULL
DATE:5-11-2000 DRAWING No.:
3830-1B1
G
DO NOT SCALE THIS DRAWING
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 pro-
vided for reference only. Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician. Improper PC board repairs could result in damage to the
machine.
POWER WAVE 355M/405M
Download from Www.Somanuals.com. All Manuals Search And Download.
G-11
G-11
ELECTRICAL DIAGRAMS
SCHEMATIC - SNUBBER PC BOARD
6-2-2000
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
POWER WAVE 355M/405M
Download from Www.Somanuals.com. All Manuals Search And Download.
G-12
G-12
ELECTRICAL DIAGRAMS
PC BOARD ASSEMBLY - SNUBBER PC BOARD
ITEM
C1,C2,C3,C4
R1,R3
REQ'D
PART NO.
DESCRIPTION
4
2
2
S20500-4 CAPACITOR,PPMF,.0047,1000V,BOX
1
RESISTOR,WW,5W,150,5%,SQ
RESISTOR,WW,5W,10,5%,SQ
T14648-20
T14648-25
R2,R4
N.A., N.B.
+.04
2.90
3
ITEM PART NO. DESCRIPTION
QTY
4
C3
1
2
3
4
M19532-A
T13157-16 TAB TERMINAL
EYELET-FEMALE
1
1
4
4
P.C. BOARD BLANK
B O X C P 4
C1
T9147-11
T9147-15 EYELET-MALE
B O X C P 4
R3
R1
B10
1.92
B1
6
1
Q C
.275
.285
NOTES:
R .045
∅
N.A. FEMALE EYELET TO BE AGAINST THE COPPER SIDE AS SHOWN
BOXCP4
C4
EYELET MUST NOT SPIN AFTER CLINCHING.
.105 MAX.
CRIMP
C2
B O X C P 4
N.B. SOLDER EYELET SO THAT SOLDER COVERS ENTIRE EYELET
AND ALL AROUND EYELET ON COPPER SIDE ONLY.
NO ICICLES OR SOLDER BLOBS PERMITTED.
2
R2
R4
COPPER
SIDE
HEIGHT
B20
B30
B40
.55
EYELET DETAIL
MANUFACTURED AS:
0
0
MAKE PER E1911
ENCAPSULATE WITH E1844, 2 COATS
TEST PER E3817-SN
M19532-1A0
+.04
.60
1.75
2.90
3.50
IDENTIFICATION CODE
THIS SHEET CONTAINS PROPRIETARY INFORMATION OWNED BY THE LINCOLN ELECTRIC COMPANY AND IS NOT TO BE REPRODUCED, DISCLOSED OR USED WITHOUT THE EXPRESS WRITTEN PERMISSION OF THE LINCOLN ELECTRIC COMPANY, CLEVELAND, OHIO U.S.A.
UNLESS OTHERWISE SPECIFIED TOLERANCE
Chg. Sheet No.
"X" INFO.
XM5626
XC-UF
DESIGN INFORMATION
REFERENCE:
MANUFACTURING TOLERANCE PER E2056
ON 2 PLACE DECIMALS IS .02
EQUIPMENT TYPE:
INVERTER WELDERS
SNUBBER P.C. BOARD ASSEMBLY
6-2-2000
DRAWN BY:
ENGINEER:
APPROVED:
F.V.
ON 3 PLACE DECIMALS IS .002
ON ALL ANGLES IS .5 OF A DEGREE
SUBJECT:
SUPERSEDING:
MATERIAL TOLERANCE (" ") TO AGREE
t
WITH PUBLISHED STANDARDS.
10-6-99
SCALE:
NONE
DRAWING No.:
DATE:
19532-1
M
DO NOT SCALE THIS DRAWING
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 pro-
vided for reference only. Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician. Improper PC board repairs could result in damage to the
machine.
POWER WAVE 355M/405M
Download from Www.Somanuals.com. All Manuals Search And Download.
G-13
G-13
ELECTRICAL DIAGRAMS
SCHEMATIC - 40 VDC BUSS PC BOARD
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
POWER WAVE 355M/405M
Download from Www.Somanuals.com. All Manuals Search And Download.
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